What is Abrasion and Pilling Tester and Methods?

What is Abrasion and Pilling Tester and Methods?

Abrasion and Pilling Tester

Abrasion and Pilling tester machine is used to determine the resistance of the textiles fabric after rubbing against a standard abradant (a special woven worsted fabric) that is assessed by visual comparison after predetermined no. of cycles.

  • Machine name: Abrasion and Pilling tester.
  • Model number: Nu-Martindale 404
  • Machine origin: England
  • Brand name: James H. Heal & Co. Ltd
  • Test Name : Random Pilling

Apparatus

  • Random Pilling Tester .
  • Cork cylinder Liner about 146mm wide by 452mm long cut from 1.5mm thick flat surface .
  • Air Injection Device to give 14-21 kpa (2-3psi)air pressure in each chamber
  • Adhesive White all Purpose for sealing edges specimen
  • Vacuum cleaner
  • Cotton Sliver 4301tex fine American
  • A set of five photographs, 105-mm square (4.13 in.), numbered 1 to 5 illustrating varying degrees of pilling from “very severe pilling” to “no pilling” such as Adjunct The photos should have a dull matte finish and Be of the same size as the tested specimen.

Pre-Treatment

Samples may be washed or dry cleaned before cutting the test
specimens, using conditions appropriate for the fabric end use
or conditions agreed upon by all interested parties.

ICI PILLING TESTER (2)
ICI PILLING TESTER (2)

No of Specimen/Specimen Size

Sample = 4 Pcs (105mm×105mm) 45° Diagonally

Testing Procedure

  • Seal the edges of all specimens to a width not exceeding 3 mm (.13 in.) on the face of the fabric with adhesive. Hang the specimens on racks until dry, and in any case for at least 2 h
  • After every hour of machine running time, remove theliner and clean the impeller by wiping with a cloth wetted in a solution of detergent and water. Allow the chamber to
    dry

Evaluation

Turn on the light of the viewing cabinet , Place the tested specimen and Original(Left Tested & Right Original) one onto the viewing cabinet ,
Using the viewing apparatus and option selected from and either
suitable fabric or photographic standards subjectively rate
the appearance of the face (as indicated by the markings and after the respective tumbling times)
of each specimen, using the following scale
5—no pilling
4—slight pilling
3—moderate pilling
2—severe pilling
1—very severe pilling
Average the ratings for the three specimens from each laboratory
sampling unit and the average for the lot.Check the pilled
specimens for non uniformity of pilling

Reporting

  • Number Of Complete Washing & Drying Cycle ,
  • Number Of Revolution
  • Average Grade Numerical
  • Detail of Any Deviation

Test Name : Martindale Pilling

Scope
To determine of the resistance to pilling and surface change of textile fabric using a modified Martindale Method.
Apparatus
Martindale Abrasion Tester.
Specimen Holder Guide Plate/ Plastic Ring.
Pilling Specimen Mounting Weight
Auxiliary device for Specimen Mounting
Viewing Cabinet
Loading Pieces

Pre Treatment
Unless Otherwise agreed Launder or Dry-clean The Sample Using a Method agreed between the interested parties.

Specimen Size

Sample = 3 Pair’s of 140±mm diameter Alternative size 150cm²
Felt = 90 ±1mm diameter for Top
Felt = 140 ±1mm diameter for Top

Washing and Drying Procedure :
As Agreed between the interested parties
Testing Procedure
Clean The Martindale abrasion tester fit one specimen onto the mounting table with one felt of 140±1mm diameter beneath the specimen. and other specimen of set mount on top specimen holder with 90±1mm diameter felt .and set the desired revolution Start the machine .
Evaluation

Turn on the light of the viewing cabinet, Place the tested specimen and Original (Left Tested & Right Original) one onto the viewing cabinet, Viewing distance may be 30cm-50cm . Grade each specimen according to Table 1, Half grade may be given, More than 1 observer grade each specimen and average them.

Reporting

Washing And Drying Procedure,
Number Of Complete Washing & Drying Cycle,
Number Of Revolution
Average Grade Numerical
Detail of Any Deviation

Test Name : ICI PILLING TEST

ICI PILLING TEST
ICI PILLING TEST

Scope
To determine of the resistance to pilling and surface change of textile fabric.

Apparatus
Polyurethane Tube : Length = 140mm± 1mm Outside Diameter = 31.5 ± 1mm Wall Thickness = 3.2 ±0.5mm,Weight = 52.25.± 1mm
Mounting Zig.
Self Adhesive Polyvinyl Chloride Tape(PVC) 19mm Wide
Sewing Machine
Viewing Cabinet
ICI Pilling Tester

Pre Treatment

Unless Otherwise agreed Launder or Dry-clean The Sample Using a Method agreed between the interested parties.
Condition
16 Hrs (Temperature 20°C ± 2° C, Relative humidity 65% ± 4%
Specimen Size
125×125mm (Length & Width)

Specimen Preparation
Sew The Two Specimen Lengthwise (Face side inside) at the 12 mm From The Edge of Specimen And Two Width Wise Direction. Turn Inside Out and cut 6mm of each end to remove
sewing distortion .Mount 4 specimen with Mounting Zig so that the specimen are an equal distance from the Polyurethane Tube. Apply PVC Tape around the each of the cut end So that The Tape fixes onto the tube and 6 mm leave from the end of tube.

Testing Procedure

Clean The Box with Vacuum Cleaner , Insert four specimen mounted tube into the box , Set the desired revolution and run the machine

Evaluation

Turn on the light of the viewing cabinet, Place the tested specimen and Original (Left Tested & Right Original) one onto the viewing cabinet , Viewing distance may be 30cm-50cm . Grade each specimen according to Table 1, Half grade may be given, More than 1 observer grade each specimen and average them .

Reporting

Washing And Drying Procedure ,
Number Of Complete Washing & Drying Cycle ,
Number Of Revolution
Average Grade Numerical
Detail of Any Deviation

PILLING RESISTANCE (POLAR FLEECE ONLY)

1 SCOPE:
This In House Test Method describes the method of test in order to determine the resistance of a knitted or woven fabric to pilling or change in surface appearance.

2. PRINCIPLE
The correct number of test specimens are to be prepared and tested as specified within this test method in order to achieve a performance assessment of the product/fabric as described within the scope.
3. EQUIPMENT:
3.1 WASCATOR Washing Machine
3.2 Drying Racks
3.3 Viewing cabinet from which external light is excluded.
4. CONDITIONING

The test specimens are to be conditioned in the standard atmosphere of 65% Relative
Humidity (RH) +/- 2% and 20°C +/- 2°C for a minimum of 16 hours. All tests should also
be carried out in this atmosphere. (after wash/dry process – before grading)

5. HEALTH & SAFETY

Not applicable.

6. PREPARATION OF TEST SPECIMENS/MATERIALS

Not applicable.
7. TEST PROCEDURE

7.1 Wash a fabric sample (in accordance with the Care Label instructions), Retain some original fabric for final comparison.
7.2 Dry flat on plastic mesh trays.
8. ASSESSMENT/RESULTS OF TESTED SPECIMENS
8.1 Mount the tested specimen with piece of untested fabric.
8.2 Grade the sample in the viewing cabinet, rate the sample according to the following table of assessment: (Half grades may be given).
Grade Descriptive Method
5 No Visual Change
4 Slight Surface Fuzzing
3 Moderate Surface change/matting or isolated pills
2 Significant surface change and/or matting
1 Distinct surface change and/or matting.

9. REPORTING OF RESULTS
9.1 The washing process
9.2 The average grade from two assessors to the nearest ½ grade.

This is the end report of Abrasion and Pilling Tester

Written By - Jony Ahmed, Lab Technologist, Osaka Japan
What is PPE? We Make Personal Protective Equipment

What is PPE? We Make Personal Protective Equipment

What is PPE

PPE is stand for Personal Protective Equipment. We are top class PPE manufacturer and garments company in Bangladesh. We have high skilled workers to make it well. We receive order from Buyer.

Purpose

The purpose of this procedure is to provide guidelines that ensure adequate provision, enforcement of use of PPE for SMI and its subcontractor personnel.

The use of personal protective equipment is one of the control options available for controlling hazards in the workplace and not substitutes for effective engineering controls, safe work conditions or sound work practices, but can play an essential part in the protection of the worker.

Its use does neither eliminate the hazard nor does it prevent incidents but helps to reduce the impact or adverse health effects, if used correctly.

Scope

This procedure provides guidelines for Contractors on the requirements for conducting a hazard assessment of the workplace to determine the need for appropriate personal protective equipment (PPE), communicating the assessment results to employees, eliminating defective PPE, and training employees in the proper use of PPE.

Objectives

  • To ensure all personal protective equipment requirements of SMI and its subcontractor employees involved in the project are identified.
  • To ensure the use of properly fitted and effective PPE for specific jobs.
  • To establish a procedure detailing accountability for selection, use, inspection, and to evaluate the effectiveness of the PPE program.
  • To regulate the standard of PPE supplied to all employees irrespective of their employer.

RESPONSIBILITIES

Project Manager is responsible for the provision of suitable types and quantity of PPE and ensures proper use in line with the project PPE requirements. Additional PPE for more hazardous tasks shall also be provided when required.

HSE Manager is responsible for the selection and issue of relevant PPE in conformance with applicable international standards at all times. See attachments 1, 2, 3.

Has responsibility to replace bad, worn or expired PPE on return of the original issue.

Supervisor is responsible and shall be held accountable for ineffective use of the PPE provided for workers under his control. He must set an example by using his PPE as appropriate and ensure its use by others as required. Assessing the risks to employees in relation to the performance of particular items of PPE and choosing from products already available through master agreement suppliers.

HSE Supervisor shall carry out routine checks and from time to time inspect PPE to ensure that the agreed procedures are appropriate and are being followed using the attached checklist (see attachment 4).

Shall provide information to employees on the use, maintenance, storage, effect on employee’s health as well as limitations of all PPE provided for their use.

Subcontractor Site Manager is responsible for the provision of all necessary safety equipment and the procedures required maintaining and affecting the use in accordance with this procedure, in order that all tasks will be completed safely.

Employees have responsibility for signing for any personal protective equipment issued to them and shall ensure that it is used as required. Employees are responsible for maintaining and using the correct PPE while performing their task and complying with HSE rules and regulations

PPE GUIDELINES

  • Basic PPE to be worn by all site employees shall be safety helmet, safety glasses with side protections, steel toe capped safety footwear, gloves, overalls or long sleeve shirt and trousers of cotton or poly-cotton.
  • Types of PPE issued shall be detailed in the Work Method Statement.
  • SMI shall ensure that PPE are properly maintained in good order and replaced at no charge when defective, or lost to the employee.
  • SMI employees shall wear the personal protective equipment required, a failure in compliance will result in disciplinary action against the offender employees and where appropriate, their line supervision.
  • All PPE shall conform to BS, DIN, AS or ANSI standard or approved by the Client is fit for purpose and is comfortable.

PERSONAL PROTECTIVE EQUIPMENT

HEAD PROTECTION

General Duties (Safety Helmet)

The helmet gives some protection against splashing by liquids. It should be manufactured from plastics.

Note: 1 Helmets are required to be replaced if subjected to severe impact.

Note: 2 Local regulations may require helmets not to be worn in the vicinity or helicopter operations, except for Firemen’s helmets worn during fire fighting duties.

Note: 3 The use of paint (aerosol type) and certain adhesive stickers may affect the integrity of the helmet and should not be allowed.

Note: 4 Metal safety helmets shall not be worn.

Specific Safety Helmets

Air Supplied Helmets should be worn when working with chemical sprays or grit blasting.

Welding Helmets/Caps, which give protection against dangerous arc radiation and hot particles of weld metal, shall be worn when engaged in welding operations.

Care and Maintenance

Safety helmets must be properly cared for and maintained by:

  • Storing them in a safe place when not in use, for example on a peg or in a cupboard.
  • Visually examining them regularly for signs of damage or deterioration.
  • Replacing defective harness components.
  • Regularly cleaning or replacing the sweat band.
  • All safety helmets are susceptible to loss of strength and impact resistance from ultraviolet light, temperature extremes and chemical degradation. An inspection and maintenance program that includes provision for replacement should be established. The service life of a safety helmet can be extended by cleaning both the shell and harness as part of the maintenance program. These parts can be scrubbed with a mild detergent (not soap) to remove dirt and stains, rinsed thoroughly with warm water (400 C), wiped dry and then inspected for any signs of damage. This should also be carried out before issuing a used safety helmet to another person.

Eye Protection

General Duties (Clear Lens Non-prescription Safety Spectacles)

Eyes require to be protected against injury from wind blown debris, and from impact against various fixtures, fittings or loose items which the wearer may inadvertently knock into by nature of working in close confines of plant or equipment.

Eye protection shall be worn in specific areas, or for specific activities, on all onshore/offshore operational sites.

Note: 1 For prescription and non-prescription spectacles incorporating side shields, removal of these shields invalidates the Standards.

Contact Lenses

Personnel wearing contact lenses require the same level of eye protection as those without contact lenses, but an additional potential hazard associated with contact lenses should be noted. In the event of a foreign body or chemical splash into the eye, it may be difficult to remove the lens in order to effect satisfactory irrigation; medical assistance should be sought.

Welding Operations (Eye, Face and Neck Protection}

Welding operations require special eye, face and neck protection for the operator. Assistants, Firewatchers will also require protection against ultra-violet radiation.

Hazardous Operations (Full View Goggles/Face Shields}

Certain operations are significantly more hazardous to the eyes, and the eye protection selected must be suitable against particular hazard in question. For operations including grinding, scraping, chipping etc, the handling of chemicals and solvents, sample taking, etc, advice should be sought from the Safety and Environmental Protection Division. Full-view goggles/face shields may be required and they should be suitable for dust or chemical protection.

Eye First Aid (Eye-Baths and Bottles}

Suitable first aid equipment for the treatment of eye injuries will be maintained on all sites and installations, as specified by the Medical Services.

Care and Maintenance

The lenses of eye and face protectors must be kept clean as dirty lenses restrict vision, causing eye fatigue and leading to accidents. There are two methods for cleaning eye and face protectors:

  • Glass, polycarbonate and other plastic materials can be cleaned by thoroughly wetting both sides of the lens or shield and drying with wet strength absorbent paper. Anti-static and anti-fog, cleaning fluids may be used if static or misting is a problem.
  • Materials can be “dry” cleaned by removing grit and dust with a brush and using silicon treated non-woven cloth. Plastic and polycarbonate material, however, should not be “dry” cleaned as the cloth used in this method may scratch it.

Eye protectors should be issued on a personal basis and used only by the person to whom they are issued. If eye protectors are reissued they must be thoroughly cleaned and disinfected. Eye protectors should be kept in a case or pouch when not in use. Eye protector headbands are to be replaced when worn out or damaged.

Scratched or pitted lenses should be replaced as they may impair vision and their resistance to impact may be impaired. Transparent face shields should be replaced when warped, scratched or brittle with age.

Hand Protection

General Purpose Gloves

General purpose gloves should only be used to protect against minimal risks to health and safety (i.e. resist cuts and abrasions, repel some liquids and offer a good grip).

Care should be taken in the donning, use, removal and storage of protective gloves. They should be maintained in good condition, checked regularly and discarded if worn and deteriorated.

Gloves should always be cleaned (if applicable) according to manufacturer’s instructions (i.e. repeated washing may remove fungal and bacterial inhibitors from the lining of the glove, possibly leading to skin irritation).

Care and Maintenance

Where tests show that penetration through a glove can occur, a control system of regular glove checking, cleaning and replacement must be put in place.

Gloves are to be regularly examined for cuts, punctures, abrasion, cracks, contamination, etc. Areas between the fingers and other flex points must be carefully examined. They may be tested for leaks by inflating with low-pressure air (200 kPa) and immersing in a water bath while still under pressure. Although it may be practical to decontaminate and re-use gloves in certain situations, the cleaning process usually does not remove all the toxic material, thus reducing breakthrough time for subsequent use. Discarded and contaminated gloves are to be destroyed in order to prevent unauthorized retrieval and use (this is especially important for gloves that may have been in contact with very toxic substances.)

Gloves should be stored at ambient temperatures away from light, moisture, solvents and chemicals. Each person should be issued with protective gloves on a personal basis to prevent the spread of contagious skin infections.

If rubber gloves for electrical work become dirty or soiled, they can be cleaned by washing with soap and water at a temperature not exceeding the glove manufacturer’s recommended limit, then thoroughly dried and dusted with talcum powder. If insulating compounds such as mastic or paint continue to stick to the gloves, the affected parts should be sparingly wiped with a suitable solvent and re-c1eaned. They may then be returned to their storage box or pouch.

Specific Hazards (Approved Safety Gloves)

Approved safety gloves must be worn for specific types of exposure:

Leather Rigger Gloves

Leather rigger gloves are required to be carried by all members of the crew, carrying out heavy duty lifting work. Fire fighting gloves provide better protection against heat and flame.

Chemical Handling (PVC/Neoprene Gloves)

Particular care should be used when handling chemicals, which must not come into contact with the skin. PVC gloves for handling acids/alkalis should be worn. Special gloves are available (Nitrile) for handling solvents. Handle and remove gloves carefully to avoid contamination of hands and inside the gloves. Wash hands and arms frequently, dry them

carefully and use a hand cream to prevent dryness of the skin through loss of natural oils. Keep cuts and abrasions covered with waterproof plasters.

Electrical Work (Rubber Gloves)

Rubber gloves shall be worn during electrical work (refer to Regulation No 19 Working with Electricity (Offshore)).

Foot Protection

Safety footwear protects against hazards ranging from dermatitis to crushing injuries. Within this broad range of hazards, consideration needs to be given to the possibility of contact with chemicals, extremes of heat, slippery surfaces, punctures from nails or other sharps objects, and electrical hazards both live and static. All personnel working in, or visiting, potentially hazardous areas such as construction sites, workshops, process areas, etc. must wear safety footwear at all times while in the area. Safety footwear in general use SMI operations includes:

Boots and Shoes

These are the most common types of safety footwear and normally comprise rubber soles and leather uppers with integrated steel toecaps. They may also have features such as slip resistant soles and steel mid-soles.

Note: 1 Footwear incorporating external steel toecap, hob nails, steel toe plates or heel plates are forbidden.

Note: 2 Boots shall be replaced when damage exposes the toecap, or when the sole is worn smooth.

Wellington Boots

These protect against water and wet conditions and are useful in jobs where the footwear needs to be washed and disinfected for hygienic reasons, such as in food handling. Usually made from rubber, they are also made from polyurethane and PVC that have greater chemical resistance. Wellington boots are available with steel toecaps and instep guards.

Selection

The selection of protective footwear depends primarily on the hazard(s) but comfort and durability must also be considered. The choice is therefore made on the basis of suitability for protection, compatibility with the work and the requirements of the user.

Generally, safety footwear must be flexible, wet resistant and absorb perspiration. Boots should be selected where ankle protection is required. The ability to resist corrosion, abrasion and industrial wear and tear should also be considered. Manufacturers’ instructions and markings for appropriate use and level of protection must always be observed.

Specific requirements for protective footwear are as follows:

Soles

Boots and shoes to have treaded soles for slip resistance. Soles can be heat and oil resistant, shock resistant, anti-static or conductive, as required for the work being carried out. Footwear intended to protect against oils, solvents or liquids to have soles that are molded or bonded to
the upper. Footwear with steel mid-soles to be used where there is a risk of the sole being pierced by nails and similar objects. The soles of footwear used for abseiling work to have a substantial instep to enable a firm footing when climbing.

Steel toecaps

These to be capable of resisting a heavy sharp object falling from a considerable height.

Burn protection

Footwear made of leather to be used to protect against burning by sparks and slag.

Waterproofing

People working in places where it is wet underfoot to wear safety footwear impervious to water. Rubber and PVC are suitable waterproof materials for footwear but are not permeable and prevent the escape of perspiration. For people whose work requires prolonged wearing of waterproof footwear, items made of ‘breathable’ material to be considered.

Anti-static

Anti-static footwear offers protection against the hazard of static electricity and gives some protection against mains electric shock. Anti-static footwear to be worn where there is both a hazard from static build up and the possibility of contact with mains electricity. The soles to have a resistance low enough to allow static electricity to leak slowly away while maintaining enough resistance to protect against a 240 V mains electric shock.

Care and Maintenance

Safety footwear must be maintained in good condition, checked regularly and discarded if worn or deteriorated. Bootlaces are to be checked and replaced if necessary. Materials lodged in the sole tread should be removed without further damaging the tread. Stitching should be checked for loose, worn or cut seams.

Protective silicone sprays or waxes may be used to give protection against wet conditions.

Body Protection

General Duties (Coveralls)

Coveralls give protection to the wearer against general dirt. The garments shall be manufactured from cotton material.

The coveralls should be of color that is easily seen, namely orange yellow or red (offshore). If dark color material is used, a light-reflective strip should be incorporated across the shoulders of the garment.

Foul Weather Duties (Jacket and Over-Trousers)

These garments give protection against wind, and rain, and some protection against splashing from liquids. The clothing will offer a degree of protection if the wearer is inadvertently exposed to a fire situation.

The garment shall be manufactured from approved materials.

Note:   Personnel employed in the production of hydrocarbons – including drilling operations – should be issued with a jacket and over-trousers.

Chemical Handling (Protective Clothing)

Personnel handling bulk chemicals may require whole body protection against splashes. If necessary, they shall wear impervious suits or aprons.

Handling Low Specific Activity Scale

Personnel handling equipment contaminated by radioactive low specific activity (LSA) scale need special protective equipment. For example:

  • Impermeable, disposable one-piece protective coverall.
  • Waterproof gloves.
  • Hard hat.
  • Eye protection (goggles).

Contaminated coveralls should be disposed of along with the LSA scale.

Decontamination (Emergency Showers}

In all places where acids or corrosive liquids are used or handled, emergency water showers shall be provided.

Emergency showers should be tested once per shift and before any work involving the handling of acids or corrosive liquids.

Water feed lines to emergency showers which are exposed to direct sunlight should be lagged.

Care and Maintenance

All types of body protective clothing and equipment must be maintained in good condition and checked regularly. It must be repaired or discarded if damaged. General-purpose coveralls should be regularly laundered to prevent irritation and the spread of skin infections. Coveralls that are damaged or torn must be repaired or replaced.

Chemical suits should be washed in warm water and a mild soap whenever they have come into contact with chemicals. Suits should be hung up to dry before being stored in cases or hung on hangers. Chemical suits have a life expectancy of three to four years and must be inspected and tested every three months, even if not in use. The inspection and testing must include an air test with examination of all seams for leakage. Vapor suits must be air tested, after use and cleaning, with the manufacturers test kit before being stored in a protective case. Where available and when necessary, the manufacturer’s testing and repair services should be used.

HEARING PROTECTION

General Duties

Hearing conversation programmes should be established in all locations where employees are exposed to noise levels above 85dBA for 8 hours.

It is necessary to take special precautions to prevent damage to hearing by exposure to excessive or prolonged noise.

Wear hearing protection in all areas where noise levels exceed 85dBA for an 8-hour shift shall be designated as Hearing Protection Areas.

No exposure to continuous or intermittent noise levels in excess of 115dBA is allowed.

Noise Exposure Dose

To find the average amount of exposure, a person can be subjected to in a period of time, the time weighted average (TWA) is used, based on an 8-hour shift.

Noise exposure should be reduced to as low as reasonably practicable. Everyone entering a designated hearing protection area must wear suitable hearing protection.

Types of Hearing Protection

There are three basic types of hearing protection which are widely used:

  • Aural insert protectors (earplugs).
  • Semi-aural protectors (canal caps).
  • Circum-aural protectors (earmuffs).
  1. Earplugs

Earplugs fit into the ear canal. For them to be effective they must be properly inserted. If the plugs are of the disposable type, they must be disposed of every time they are removed.

Non-disposable earplugs must be cleaned regularly to ensure that they do not cause a possible ear infection, both bacterial and fungal. Earplugs worn by one person must never be worn by another.

  1. Canal Caps

Canal caps are individually moulded to an individual’s ear. If worn properly, canal caps can reduce noise exposure between 10-30dBA.

  1. Earmuffs

Earmuffs can be worn independently or as attachments to a hard hat in addition to earplugs. If worn properly, earmuffs can reduce noise exposure by 15-25 dBA.

Care and Maintenance

Ear plugs are intended to be disposable and although they can be cleaned and reused, it is not recommended.

Ear muffs must be regularly examined for signs of damage or deterioration to the shells, linings and headband, and defective parts replaced. Regular cleaning of the contact seals with a damp cloth will prevent discomfort and ear infection. Ear muffs should be stored in a cool, dry place when not in use.

Respiratory Protection

Introduction

Personnel may be exposed to harmful vapors, dust and other airborne contaminants by the design or operating procedures of the worksite, in these circumstances it will be necessary to provide respiratory protective equipment (RPE) to personnel. This will be identified as one or more of the control measures after conducting a task risk assessment (Information Material Safety Data Sheet).          .

It will be necessary to correctly identify the respiratory hazards, smokes, the product of combustion, dust, abrasion material, liquids, gases, vapors from chemicals, solvents, etc. The concentration and combination of the harmful substances should be assessed for their degree of toxicity. Advice the selection of RPE for particular applications can be sought from HSE Section.

Prior to the selection of suitable RPE, due consideration should be given to potential face-fit problems, including the wearing of facial hair. Full beards are not permitted for staff that may be required to wear respiratory protection during their normal working day, in particular, self contained breathing apparatus for fire fighting, rescue or H2S escape.

Respiratory protection may be required for normal working conditions or emergency conditions and fall into two general categories:

  • Those providing air which must pass through a filtering mechanism (referred to as respirators).
  • Those providing an air supply from an uncontaminated source (referred to as breathing apparatus).

Note:   It is important to remember that filtration respirators are unsuitable for atmospheres which are deficient in oxygen.

Dust and Fumes (Filter Respirators)

Respirators range in type from a simple disposable dust mask to a high performance full-face mask with filters suitable for organic vapor, acid gas and dust.

It must be emphasized that respirators are only designed to afford protection against relatively low concentrations of toxic substances, and if there is a doubt as to correct level of protection that is required, then the higher level of protection will be selected. This may mean that in certain circumstances a respirator is deemed to be inadequate and breathing apparatus is required. Where doubt arises, advice should be obtained from the HSE Department.

7.7.3   Oxygen Deficiency (Breathing Apparatus}

Where the level of airborne contaminants is beyond the filtration capability of a respirator, or where there is an oxygen deficiency, then breathing apparatus (SA) must be used.

Note:   Portable air compressors may only be used when sited in an unpolluted atmosphere.

Self-contained Compressed Air Breathing Apparatus

  • These sets are provided for emergency use where a portable supply of air is required for a short period of time.
  • The air for this apparatus is supplied under pressure either from compressed air cylinders carried by wearer, or from trolley sets.
  • Self-contained compressed air breathing apparatus (SCABA) shall be located in the control room and at strategic points within hazardous areas. The apparatus is housed in easily distinguishable boxes, or in wall-mounted containers, painted green.
  • SCABA shall be inspected and the air pressure checked on a weekly basis, where practicable (inspection, minimum of once a month). Minimum acceptable pressures are specified, depending on the type of equipment being used. The checks shall be recorded and faults reported to the HSE Department. These checks are in addition to specified maintenance schedules.
  • After use, a breathing apparatus set shall be serviced and fitted with a fully-charged cylinder before being re-sited. The servicing shall include the cleaning and decontamination of the face piece. On Das Island this will be carried out by the Fire and Rescue Services and offshore by specialized personnel
  • All persons required to use breathing apparatus must receive initial training and refresher training at intervals not exceeding 6 months. The training shall be recorded.

7.8       Fall Protection

Use equipment to reduce personal injury when crew may be exposed to:

  • A fall of 2 meters.
  • Work over the side.
  • Work on a vent stack.
  • Work in enclosed areas of oxygen deficiency/contamination.

The equipment is to consist of:

  • Full body harness.
  • Shock absorbing lanyard or approved equipment.
  • Connecting hook.

The label should indicate the year and standard of manufacture.

7.8.1   Types of Harness

Waist belts and chest harnesses may be used only for work positioning purposes, i.e. may be used to prevent a person from reaching position where all the risk of a fall exists. The waist belts or chest harnesses are not to be used as fall-arrested equipment.

Fall-arrest equipment requires a full body harness. Such a harness incorporates buttock straps designed to absorb the forces on a falling person. Use a harness in conjunction with shock-absorbing equipment.

7.8.2    Types of Shock-Absorbing Equipment

A lanyard from the harness incorporating a shock-absorbing or break-out device must be attached to a secure anchor point. The maximum length of the lanyard is 2 meters including any connecting hooks.

Shock-absorbing equipment of the dynamic type (e.g. inertia reel) must be directly attached to the body harness, the other end being secured to a suitable anchor point. For convenience, a short lanyard of up to 400 mm may be utilized between the harness attachment point and the hook of the inertia reel.

7.8.3    Connecting Hook

The connecting hook or shackle used in conjunction with the fall-arrest equipment requires to be of an auto-locking or double action type.

7.8.4    Safety Belt and Life Line

When the safety belt and life line are used, prearranged signals shall be used with the member outside the hazardous area (refer to Table below)

7.9       Fire Fighting Personnel Protective Equipments

7.9.1    Standards for Fire Fighting PPE

The minimum requirement calls for whole body protection, i.e. neck, torso, arms and legs; it excludes the head, hands and feet.

The specification for the clothing allows for a degree of flexibility in design and the garment may either be:

  • A single garment.
  • A two-piece suit consisting of a jacket and trousers with a specified minimum overlap.
  • A series of outlet and under garments designed to be worn together. In such a case, this must be declared on the labels of all the garments involved, and instruction is required to ensure that the requirement of this clause is met on every occasion.

With respect to this particular type of risk, such PPE must possess thermal insulation capacity and mechanical strength appropriate to the conditions of use amongst other requirements, for example, a good quality three-layered garment.

7.9.2    Fire Fighting (Fireman’s Helmet)

The conventional rig safety helmet is not suitable for helideck use and should not be worn during helicopter operations. The thermo-plastic material used to form the shell of the helmet has poor heat resistance properties, and the helmet will readily deform if subjected to a fire situation.

Firemen’s helmets complete with appropriate visors are required for fire fighting duties.

7.9.3    Fire Fighting (Suit, Underclothing and Flash Hoods)

Fireman’s Suit (Whole Body Protection)

The Company should assess the level of risk that firefighters are likely to be exposed to, taking into account all duties carried out, prior to selecting an appropriate level of protection in accordance with Standards for Fire fighting PPE.

Underclothing

It should be recognized that ‘adequate clothing’ should be worn beneath fire tunics/over trousers etc at all times of year. This is necessary to ensure good insulation against the high levels of radiated heat which can be expected from any liquid hydrocarbon fire.

‘Adequate clothing’ would include cotton/tool shirt and trousers and/or coveralls.

Flash Hoods

The provision of flash hoods is recommended in order to provide full body protection.

7.10    Working Over Water (Life Jackets And Work Vest)

When work is being carried out where there is a risk of falling in to the water, a life jacket shall be worn. When the wearing of a Iifejackets is impractical, a Work Vest/Buoyancy Aid shall be worn.

Approved lifejackets must be worn by all personnel travelling on or over water. Aircraft and Boat Captains have complete authority on the need to wear lifejackets, and their instructions must be obeyed.

Lifejackets must be secured in the approved fashion.

Lifejackets and work vests must comply with an appropriate standard, be inspected regularly and before use, and maintained in good condition.

8. SELECTION OF PPE

Before selecting an item of PPE, an assessment should be undertaken which should be carried out along the following lines:

  • Identification of the risk with respect to a job or particular circumstances.
  • Characteristics and standards of the proposed PPE.
  • Comparison between (a) and (b) to establish the suitability of the equipment for the risks involved and for the personal characteristics of the use.

8.1       Compatibility

Ensure that where a combination of PPE is to be worn, the items are compatible and do not interfere with the effective use of the other items of PPE.

8.2       Primary Assessment

In many cases, the assessment will be simple and obvious, and an initial assessment of equipment suitable for a particular risk, or group risks, will be sufficient.

8.3       Secondary Assessment

In more complex cases, however, an assessment shall be performed by an individual with a thorough knowledge of the risks involved in a particular task. The results of the assessment will require to be recorded, and information made readily available to others who may be involved in the selection of appropriate protective equipment to match particular jobs.

9. STANDARDS I MAINTENANCE & STORAGE OF PPE

9.1       Minimum Standards

Protective clothing shall be issued which is suitable for an individual site. As a minimum when on a production, process, construction or drilling worksite, personnel would normally be required to wear safety helmet, coveralls and safety boots.

Personnel, who work inside e.g. in galleys or kitchens, cleaning accommodation, in workshops or maintaining office equipment etc., must also be provided with suitable PPE. Local rules will state the areas in which this equipment is required to be worn. Shorts and other similar sports wear should not be worn at operational sites.

The minimum standards set by the Company for protective clothing or equipment shall apply, as appropriate, to all persons on site, including visitors and contractor’s personnel. PPE shall comply with relevant standards.

9.2       Maintenance of PPE

  • PPE must be maintained in an efficient state. The level of inspection or maintenance with respect to PPE will be determined by the type of equipment used and the conditions in which it is used.
  • With simple equipment, an inspection by the user immediately before use may suffice, and maintenance may be in the form of cleaning or laundering, with the item being replaced when worn out.
  • Protective clothing and equipment should be used properly, and any defects in the equipment shall be reported to the supervisor.
  • Do not wear clothing or equipment that is contaminated (e.g. oil, grease or other substances), return it for cleaning or replacement.
  • Where appropriate, a record of inspection and maintenance will be necessary, and manufacturer’s maintenance schedules should be followed.

9.3       Storage of PPE

PPE must be stored correctly. The Company shall make appropriate arrangements for the storage of PPE:

  • The storage shall be adequate to protect the equipment from damage or contamination.
  • Items of PPE shall be adequate to protect the equipment from damage or contamination.
  1. TRAINING IN THE USE AND MAINTENANCE OF PPE

Those involved in the use of PPE shall be given suitable instruction and training in the use of particular equipment as follows:

  • ‘Everyday’ equipment which is simple to use will require only basic instructions.

Personnel involvement in the use, maintenance, repairs or testing of more complex equipment will require formal training, and such training may be both theoretical and practical. In such cases, refresher training may be required, as an appropriate, and records of ppe- Personal Protective Equipment

Written By - Davie Burner, Compliance Manager, Auko Text China Co Ltd.
How Chromatography Filter Paper Works?

How Chromatography Filter Paper Works?

Chromatography Filter Paper

By simple chromatography filter paper the levelling properties of a product for direct or reactive dyes  can be checked in a very short time.

Preparation of the test :

A circular glass, i.e. a watch glass, (A) is filled up to the half with the same composition as the dye bath, but without the dyes.

The dyes (Yellow, Red and Blue plus a combination of Y, R and B ) are drawn on a quarter of a circle at about 2 cm. from the center (C) of a filter paper with 15 cm. * (B).

A piece of filter paper is twisted and inserted into the center (C) of the filter paper (A). The dyeing bath is then coming up by capillary through the center of the filter paper.

Dye selection   

Reactive Red 195

Reactive Blue 19

Reactive Blue 21

Reactive Navy 1

The solutions are prepared at 10 %)

Auxiliary             

0 – 0,5. – 1 g/l of the tested product

Temperature    

Room temperature

Time for chromatography

From the moment the dyeing bath enters the center of the filter paper A at the point C the chromatography should run 20 minutes before taking away the filter paper C.

Evaluation         

The first evaluation is visual but it is possible to prepare a diagram by measuring the distance from the center to the last ring observed on the Chromatography filter paper.

Written By - Dr. Stef, CTO, Lorel Chemical co. Ltd, New York, USA
How Fabric Examining Machine Works with 4 Point System?

How Fabric Examining Machine Works with 4 Point System?

Fabric Examining Machine

Fabric examining machine with variable speed control, overhead lighting  and yardage counter. The machine must be clean with no excess oil and no sharp edges to damage the fabric. The garment making process should inspect 10% of rolls from each delivery AT RANDOM – this should include all colours and dye lots within a delivery. If the results show a high fault rate, an additional 15% of the rolls should be inspected. A high fault rate is defined as an average fault rate in excess of 29 points per 100 square yards.

Fabric examining machine procedure:

Auto as a standard for design, colour and handle. The process needs to check against this cutting as follows:

Design, Colour, Handle, Shading

At the beginning of each roll, a 6” full width cutting should be taken as a design & colour reference and checked against the approved bulk cutting for the following:

  • design
  • colour
  • handle
  • side to centre and side to side shading

This full width cutting must be labelled with the order number, fabric reference number or name, batch number, piece number, colour name, colour number, date and whether it was acceptable to the approved bulk cutting or not.

Width

The width of the fabric between the stenter pins must be measured and compared with the given minimum usable width.

Shading & Width

Each roll checked, should be stopped at least 3 times during inspection. At these stops design, colour, handle and side to centre and side to side shading should be assessed. End to End shading must be checked by comparing the full width cutting to this point in the roll. Also the cuttable width (between stenter pins) should be measured.

The cuttable width should be recorded on the inspection report, as should any design, colour or handle variability detected.

Length

The garment making process should check the fabric length stated on the piece ticket against the actual length of roll for variance. Both values should be recorded on the inspection report.

Defects

During the inspection, the fabric needs to be checked for defects which are rated on the 4 point system, as follows:

– Flaws up to 3” in length = 1 point

– Flaws up to 6” in length = 2 points

– Flaws up to 9” in length = 3 points

– Flaws over 9” in length = 4 points

* The maximum penalty for any running yard (36” x fabric width) must not be more than 4 points.

* Flaws in both warp and weft receive equal points.

* All holes, regardless of size, must be penalised 4 points.

* No more than 2 joins per fabric roll are allowed.

* The average point value per shipment should not exceed 28 points per 100 square yards.

* Individual rolls exceeding 40 points per 100 sq. yards must be rejected.

How to calculate points per 100 square yard:

Actual points counted   x           36”            x 100 = points / 100 sq. yards

Actual roll length            Actual width

e.g.     25       x      36”     x 100 = 28 points / 100 sq.yards

75 yds           43”

After the inspection is completed, calculate the average point value per 100 sq. yards by totalling the points and dividing by the number of pieces inspected.

This will be the final points total for this inspection.

All defect points must be recorded in the inspection report. In addition, the location of all defects must be marked at the right selvedge of the piece.

Bowing & Skewing

Any bowing or skewing needs to be mentioned on the inspection form as a percentage.

Colour Continuity

The process needs to prepare a colour continuity card which shows a 10cm wide x 20cm long (minimum) cutting of each roll. These need to be mounted onto a card by folding them in half (lengthwise) and overlapping each other. The continuity card should then be assessed in the light box under the requested light source against the approved bulk fabric cutting sent by Auto. See light box guide below.

If any shading is found that is not commercial, the process needs to send roll cuttings to Auto immediately for their approval. A roll cutting is a 20cm long x full width cutting of each roll.

Please ensure that any shading found is marked on the inspection form, by stating how many different shades in total were found.

Washing Shrinkage

In order to assess washing shrinkage the process needs to wash piece(s) of the bulk fabric for every order/colour, picked from rolls at random and 1 piece per 1000yds, mark an area of 50cm x 50cm and wash & dry according to the advised washcare on the make sheet. Then gently smooth out the fabric by hand (do not iron it) and please enter the found shrinkage/extension on the inspection form.

Please also press half of the washed cutting (if pressing is required for the order) to assess the look after pressing and confirm that it is acceptable i.e. that the fabric lays straight and true and has no degree of pucker. Please confirm the outcome on the fabric inspection report.

For any fabrics that are woven on 2 beams we require you to send half of the washed and half of the pressed cutting attn. to our fabric technologist immediately for our reference. Please note that you can identify any 2 beam fabrics by the wording ‘dobby’ added to the fabric sheet.

How to measure correctly?

In order to get accurate figures on shrinkage/extension that are fully representative of bulk, please follow the below steps:

  • Take ¾ to 1 yard full width of fabric.
  • Any measurement taken should be taken from markers at least 6 inches away from the selvedge or piece end.
  • The length/width measured should be 50cm (warp) x 50cm (weft) and should be measured using a fine ball point marker, so that no deviation occurs.
  • All measuring should be carried out using a ruler with each centimeter subdivided into 10 parts.
  • The sample should be washed at the required temperature (see washcare on make sheet) and dried (if required on the washcare). Straighten the fabric out after it has dried and measure in the unironed state.
  • Any shrinkage/extension figures should be specified with 1 decimal, e.g. -1.6%

Steaming Shrinkage

In order to assess steaming shrinkage the process needs to take piece(s) of the bulk fabric for every order/colour, picked from rolls at random and 1 piece per 1000yds, mark an area of 50cm (warp) x 50cm (weft) and iron according to the advised care instructions on the make sheet. Please enter the found shrinkage/extension on the inspection form.

How to measure correctly?

In order to get accurate figures on shrinkage/extension that are fully representative of bulk, please follow the below steps:

  • Take ¾ to 1 yard full width of fabric.
  • Any measurement taken should be taken from markers at least 6 inches away from the selvedge or piece end.
  • The length/width measured should be 50cm (warp) x 50cm (weft) and should be measured using a fine ball point marker, so that no deviation occurs.
  • All measuring should be carried out using a ruler with each centimeter subdivided into 10 parts.
  • The sample should be ironed at the required temperature (see care instructions on make sheet).
  • Any shrinkage/extension figures should be specified with 1 decimal, e.g. -1.6%

Contamination

On any yarn dyed orders where the design has a light ground and where any parts of the garment will be fused or if comments on contamination are made in sample approval comments (only applicable for samples made from correct bulk fabric), please fuse 4 pieces of fabric (representing collars/cuffs/plackets) picked randomly from different roles to assess whether there is any fabric contamination that will show up after fusing.

If you do not find the cuttings commercially acceptable or if you are not sure, please send them through to the fabric technologist at Auto Ltd. for approval

Standard Operation Procedure

A – Unloading

Perform By – Store Keeper

Report to – Store Manager

Must check and be ready with all relevant documents from commercial manager sending by mail of the goods before unloading. Then store manager will be responsible inform to GMP / GMA for their reference by mail.

  • Packing list
  • Invoice
  • Challan

I f above documents is ok store manager will allow to unloading goods in unloading area ( quarantine area ) and inform to QA Manager to do the inspection of fabric and trims.

Also when the unloading is start bellow responsible peoples must be present at unloading area.

  • Store Manager
  • Senior in charge
  • Security Officer

And count accordingly to the packing list and make sure goods are tally with the packing list submitted by commercial manager. If there is a any shortage store manager must update the by mail commercial manager and GMP/GMA for the further action

B – Fabric Inspection

Perform By – Fabric Inspector

Report to – QAM

Purpose

The purpose of this procedure is to inspect the quality of the fabric as per buyer’s requirement &take the necessary corrective &preventive action to rectify all the failures.

Scope

This procedure covers all fabric the is to be used for production at Auto Garment in Fabric Inspection Machine

Responsibility

Fabric inspector will be responsible to do fabric inspection as per the 4 point system under supervision by quality manager

Sample selection criteria for inspection random selected 10% of the bulk lot wise.

Procedure

  1. Fabric inspector must check 10 % from received quantity as per lot wise.
  2. Uncover the fabric roll & lead into the inspection machine.
  3. Fabric color standard has to be maintained at the inspection machine during inspection.
  4. in case of buyer approved sample is unavailable factory QAM approved sample will be present at inspection machine.
  5. Color standards should contain as follows.
  • customer
  • season
  • color name
  • shade group
  1. Must doing inspection against supply inspection report.

Inspection of fabric should be done as per the following

  1. Correct side of the garment should be considered as the face side of the fabric for inspection.
  2. Length of the fabric roll should be checked against the quantity mentioned in the supplier roll tag any variation in the length should be informed to supplier through the merchandiser.
  3. Usable width if fabric should be checked at 3-5 different places at equal lengths of the roll and compared against the purchased width .if the width is less the purchased width, need to inform fabric supplier with evidence. A mini marker for the actual with should be drawn to the new consumption. The supplier is liable to replace the fabric for extra consumption.
  4. Weight of the fabric will be checked at the three different areas across the width. Average of the three areas should be within +/- 5% of the specification weight.
  5. Fabric defect should be checked according to the 4 point system and marked with a defect sticker highlighting the defect, any approval required, need to arrange the defect sample for approvals & get the approval before pp meeting·
  6. Selvedge of the fabric should be inspected for defect, cutting, waviness etc.
  7. Within the roll color shading will be checked at start, middle end of the roll .if nay variation identified a full width stripe (approximately 6″ width) from start. Middle and end. of the roll will be taken and a blanket will be made to assess the color shading
  8. Above findings shell be marked on the inspection report .sample shell be kept as evidence for any major defect .issue. Point 100 Square and predicted garment fall out to be calculated on above information.
  9. If the point count is greater the 28 point per 100 square need another 10% of the batch is inspected. Still the point count is 28 point per 100 square yards goods cannot pass without 100 % inspection.
  10. If 100 % inspection also found over mark will inform the merchandiser and reject the fabric and do the necessary action.
  11. Sample of the reject goods have to submitted to the relevant merchandiser for getting approval from the buyer
  12. Based on the NRC – Non conformity report must have initiated and the reject goods should be store in a separate rejection area with the clear identification and mark.
  13. After that store manager should be inform to relevant merchandiser with correct quantity as rejected during trims inspection by mail.
  14. Rejected quantity must be sent through the challan to supplier after getting confirmation from respective merchant
  15. Store manager must be follow up status regarding replacement of returns trims and update records accordingly
  16. Replacement fabric must do 100% inspection again.

B – 01: Shade Band procedure

  1. Need to cut 5 pcs of blanket from each roll the measurement of 8″x 8″
  2. Make role wise blanket 1yard X 1 yard 5 sets and sent to washing plant.
  3. It’s should be separate with 3 set of wash and two set of non wash and make shade band.
  4. Wash blanket one set will be handover to washing and another set will be keep as a factory reference, another set should keep as a shade segregation,
  5. Non wash blanket one for washing plant and one should be kept in garment factory reference.
  6. One wash blanket will cut and segregate shade group and will make the report.
  7. Re wash the blanket if shad not within range and get the approval by merchandiser accordingly.

B – 02: Shrinkage Test

[:or shrinkage purpose from each roll will be cut and sent as follows

As sawn above fabric inspector will be responsible to cut pcs from each roll and mark by permanent marker pen with measurement of 50 cm X 50 cm.

  1. After the measurement mark will be sent to washing plant for wash.
  2. Wash shrinkage pcs separately measure for shrinkage and roll will be segregate as per shrinkage.
  3. The same inspector will be responsible to update in a format and hand over to each copy to all relevant department ( store’s/cutting/production/quality)

4 POINT STYSTEM

.        DEFECTI. UP FO-0-3″IN LENGTH OR WIDT                            =       01 POINT
I.        DEFECF UP TO-3′ – 6″ IN LENGTH OR WIDTH                        =      02POINT
II.     DEFECT UP TO-6′- 9″ IN LENGTH OR WIDTH                          =     03 POINT
III.  DEFECT MORE THEN9’IN LENGTH OR WIDTH                       =     04 POINT
IV.  ALL HOLES,COLUR SHADING,SELVEDGE DAMAGE,TEAR MARKS = 04 POINT
V.

C – Trims Inspection

Perform By – Trims Auditor

Report to – QAM

Purpose

 To inspect the quality of the trims as per buyer requirement and take the necessary corrective / preventive action to rectify all defects

Procedure

  • Trims inspector must have approved trim card sign by merchandiser before start the inspection
  • Before start the inspection must pass through the metal detection machine for identify the fault .if any metal including in inspected trims report update and inform to QAM for further action.
  • Should maintain the register with details style/goods received date/color/qty and inspection information (fail/pass)
  • Inspection shall be done 10% from order quantity. Shall select random sample quantity as per A.Q.L. sample chart
  • In the event of inspection fail another inspection must be carried out as per the authorization by QAM.
  • Sample of the reject goods have to submitted to the relevant merchandiser for getting approval from the buyer
  • Based on the NRC – Non conformity report must have initiated and the reject goods should be store in a separate rejection area with the clear identification and mark.
  • After that store manager should be inform to relevant merchandiser with correct quantity as rejected during trims inspection by mail.
  • Rejected quantity must be sent through the challan to supplier after getting confirmation from respective merchant
  • Store manager must be follow up status regarding replacement of returns trims and update records accordingly
  • Will do the 100 % inspection for replacement trim’s

D – Fabric and Trims storing

Perform By – Store Keeper

Report to – Store In charge

  1. After inspection pass fabric storing will be done buyer wise and bin card update accordingly under supervision by store keeper
  2. Also trims will be store as per the buyer wise and bin card update accordingly
  3. Also very same time register must be maintain by store keeper

E – Issuing Fabric to cutting

Perform By – Store Keeper

Report to – Store In charge

  1. Before performing this process store keeper must have fabric inspection report/shrinkage / shade report in hand.
  2. Cutting Manager will prepare store challan and sent through the cutting servicer to get required fabric as per shade/shrinkage / width and lot.
  3. Servicer will be present store requisition to store manager and will get approval
  4. After that cutting servicer will submit to store keeper and store keeper will be responsible to issue fabric according to SR.
  5. After issuing store keeper must be responsible to update challan/ register/ bin card according to issuing quantity.
  6. If anything excess cutting manager will be responsible to prepare Meterial Return Challan and sent excess goods to Store Manager

F – Issuing Trims to production line

Perform By- Store Keeper

Report to – Store In charge

  1. Before performing this process store keeper must have Approved trim card in hand.
  2. As per the input quantity sewing servicer will prepare trims requisition form and submitted to store keeper after sign by production manager
  3. Store keeper must cross check with cutting report and line requisition report to re confirm quantity and size ratio to be ok and get approval from store manager
  4. If figures are match store keeper have authority to issue trims according to challan and update register/bin card.
  5. If anything excess Production manager / Finishing Manager will be responsible to prepare Left over Hanover sheet and sent excess goods to Store Manager. It’s should be received by Store Keeper.

G – Prepare Monthly Shipment Status

Perform By – Store Manager

Report to – GMA

  1. Shipment sent as per the commercial invoice and packing list under supervision by store manager / Finishing Manager / Security in charge.
  2. After sending the goods store keeper will be responsible to update the shipment status
  3. End of the month store keeper must complete the shipment status
  4. This report should be checked and forward to respective concern (GMP / GMA/Head IE / Accounts and finance) after approved by GMA

H – Style Reconciliation Report

Perform By – Store Keeper

Report to – Store Manager

  1. Finishing Manager will prepared finishing reconciliation report and sent to Store Department for prepare the style reconciliation report.
  2. Store Keeper left over will be responsible to prepare the style reconciliation report and submit to store manager further checked and sign.
  3. After complete the report and sign by Merchandising department / Head IE / GMP/GMA store manager will be responsible to hand over copy to all concern.

I – Left over stock Report.

Perform By – Store Keeper

Report to – Store Manage

  1. After shipment complete left over store keeper will be prepared the Left over stock report.
  2. This report should be checked and sign by Store manager and GMA.
  3. GMA will be responsible to share this Report with Managing Director
  4. Left over store keeper will be responsible to remove label and sent all left over garments to outside warehouse under FC.

This is the berife description of Fabric Examining Machine Works with 4 Point System

Written By - P.K Roy, GM, Esan Fabric Mills Ltd, Chennay, India
What is Carton. Describe its Specification.

What is Carton. Describe its Specification.

 What is Carton

  • Carton strapping is permitted but use of staples is NOT permitted.
  • Cartons are not to exceed 15kg GW
  • All cartons should be 3 ply grade cardboard.
  • All cartons should have a cardboard insert on top of the contents to protect the goods when we open the carton
  • All cartons must be H sealed with Pelmark tape – see diagram
  • The following carton markings are required on all four sides and will be printed directly on to the cartons:

Supplier Name:         Pelmark Direct

Item No:                     (Refer to matrix below for details)

Product Code:          (Refer to matrix below for details)

PD Product Code:    (Refer to matrix below for details)

TML PO Number:       (Refer to matrix below for details)

KB PO Number:         (Refer to matrix below for details)

PO Number:              (Insert Pelmark PO number here)

Quantity:

Size:                            (Insert size for item in carton)

Colour:                       (Refer to matrix below for details)

NW:

GW:

Carton Dims:

SOP for Garments Carton Process
SOP for Garments Carton Process

SOP for Garments Carton Process

 A)      AIM:   To identify packaging and labeling standards for carton box marking and carton box content of products manufactured by Carton Machine

B)    SCOPE: This procedure covers all products manufactured domestically and internationally for Tema Mağazacılık.

  1. DEFINITIONS:

 Polybag: A plastic bag used for packaging products individually.

Blister bag: A bag used for packaging together assorted products which are already packaged individually in polybags.

  Solid colour-solid size:  One size of each colour of a product.

Assortment: Size distribution of a product (E.g. S/1, M/2, L/2, XL/1).

Lot: A packaged assortment.

Solid colour-solid size Packaging: Packaging only solid colour-solid size products in one box.  (E.g. 30 pieces in a box, Style: CITY, Colour: Navy, Size: S)

  Single Lot Packaging: Packaging only one lot in one box.

Multiple Lot Packaging: Packaging two or more lots in one box.

  Mixed Size Box: Packaging same-colour different-size products, which are not included to the order, in one box.

 CARTON BOX CONTENT STANDARDS:

  • Products in one lot should be layered tidily on top of each other. Products should not be placed side-by-side in one lot.
  • A Lot Label should be attached to each lot package in a box. Please refer to Example-1 to see how the label is placed. The lot label should not be a thermal label.
  • Lot packages in a box should be firmly taped with a 4.5 cm-wide transparent tape. The lot label should not be on the same side as the tape. It should be attached on the opposite side.
  • All products in a box should have price hangtags. Price hangtag details should be visible; if there are any additional hangtags, they should be layered under price hangtags. Barcode IDs on price hangtags should definitely be visible.  Product price hangtag, product inner barcode label, lot label and carton box marking barcode label should all have matching information.
  • The assortment distribution and the packaging should be made according to the assortment agreed for the order. Products which are not included in assortments should be boxed as solid colour-solid size.
  • Different sizes or styles, which do not match with the information on the lot label or box label, should NEVER be added to the package simply to complete missing sizes or colours.
  • Carton Separators should be put at bottom and top side of inner carton boxes, to avoid the possible damages to the garments when opening the boxes by knife, scissors etc.
  • Barcode coding system should be good. It is forbidden to use any other barcode coding system for labeling.

 POLYBAG STANDARDS

  • The polybag quality should be 7-8 micron Polypropylene (PP).
  • The blister bag quality should be 9-10 micron Polyethylene (PE).
  • Polyethylene (PE) and Polypropylene (PP) based bags should not contain
  • The size of the polybag (product bag) should be selected correctly according to the product type.
  • The safety warning label given below should be attached to each product bag.Safety warning should be printed at backside of the polybag (which is the same side with sticker tape)

CARTON BOX MARKING STANDARDS

Carton boxes prepared for shipment should comply with the packaging standards given belowCarton Box Standards:

  • The size of the box should be selected correctly according to the type of the product. (Table.1) The same box size should be used for ALL orders of a particular style/option.
  • Please look the Table.2 for the products cannot be folded  and  placed in smaller size boxes (coats, jackets etc).
  • Carton box quality should be: “K/F/F/F/K” Kraft Fluting (doppel), 140 g/m2.
  • A full box should be maximum 15 kg.
  • There should not be any empty space in the carton boxes after packing. The empty space in the carton causes possible damages, crushing and tearing of the boxes on the storage, and it harms the garments.  There should be neither empty space in the carton boxes  nor tumescent boxes (squeezed garments) while packing

Carton Box Short Side Label:

  • The external box label should not be a thermal label; the barcode scanner should be able to scan the label; it should not be erased, worn-out or multiplied with photocopy.
  • Carton Box Short Side Label should be attached on the middle of both short-side surfaces of the box.
  • The height of the carton box short side label should be 10cm, and its length should be 15cm.
  • Carton Box Short Side Labels of Solid colour-solid size and 2nd Quality products should be as shown in and they should all contain accurate information.
  • Since solid colour-solid size products are not assorted, they will not have “Assortment Total” and Lot quantity given in a circle on the top righthand side of the label.
  • Seperators should be used between different sizes when mixed-size products are boxed.
  • Carton box short side label given in should be used for mixed-size boxes.
  • There should be a “Mix Sizes” sign in a circle on the right bottom side of the label.
  • There is no barcode info on mixed-size box labels, as it is not defined.

Carton Box Long Side Label:

  • In addition to carton box short side label, a carton box long side label is used as well. The long side label includes the following information:
  • Name and address of our company
  • Special Code 1
  • Carton box gross and net weight
  • Carton box size measurements
  • Carton box number
  • Product – country of origin
  • These details should be present in the middle of both long side surfaces of boxes. The template for the carton box long side label can be printed in advance on the box. If printed boxes are not used, label information given in should be provided.
  • A printed box prepared for a particular style or colour should definitely not be used for another style or colour.
  • The size of the label (or the print) should be as follows: height 12 cm, width 20 cm.

Box Tape:

  • Boxes should be taped with suppliers’ colourful logo-printed special tapes. If supplier does not have a logo-printed tape, any tape with a logo or print (without any brand name) can be used.
  • The same type of tape should be used for the whole order. Tapes with different logos are not allowed for the same order shipment.
  • Boxes that are opened at the customs should be taped with the logo-printed tape of the related customs clearance company

Sticker:

  • Coloured stickers should be attached on boxes according to the product packaging type.

Depending on the packaging, the sticker should be as follow:

  • Solid colour-solid size : Blue
  • Single Lot Packaging : Yellow
  • Multiple Lot Packaging : Red
  • Mixed Size Box : Black 
  • Carton Box Packaging for Air Shipments;

Boxes prepared for air shipment should be wrapped with naylon one-by-one and they should be strapped.

Carton Number:

Product DescriptionItem NumberPD Product CodeProduct CodeTML PO NumberKB PO NumberBarcode
McLaren Team T-Shirt Baby – Small (1-2yrs)TM2036TM152009157685KBOW2589/0001175054130595627
McLaren Team T-Shirt Baby – Medium (2-3yrs)TM2036TM152009157685KBOW2589/0001175054130595634
McLaren Official Team Set Up T-Shirt – XSmallTM2061TM152020157695KBOW2589/0001185054130596174
McLaren Official Team Set Up T-Shirt – SmallTM2061TM152020157695KBOW2589/0001185054130596150
McLaren Official Team Set Up T-Shirt – MediumTM2061TM152020157695KBOW2589/0001185054130596143
McLaren Official Team Set Up T-Shirt – LargeTM2061TM152020157695KBOW2589/0001185054130596136
McLaren Official Team Set Up T-Shirt – XLargeTM2061TM152020157695KBOW2589/0001185054130596167
McLaren Official Team Set Up T-Shirt – XXLargeTM2061TM152020157695KBOW2589/0001185054130596181
McLaren Official Team Set Up T-Shirt – XXXLargeTM2061TM152020157695KBOW2589/0001185054130596198
McLaren Team Driver T-Shirt Male – XSmallTM3050TM152013157698KBOW2589/0001195054130596327
McLaren Team Driver T-Shirt Male – SmallTM3050TM152013157698KBOW2589/0001195054130596303
McLaren Team Driver T-Shirt Male – MediumTM3050TM152013157698KBOW2589/0001195054130596297
McLaren Team Driver T-Shirt Male – LargeTM3050TM152013157698KBOW2589/0001195054130596280
McLaren Team Driver T-Shirt Male – XLargeTM3050TM152013157698KBOW2589/0001195054130596310
McLaren Team Driver T-Shirt Male – XXLargeTM3050TM152013157698KBOW2589/0001195054130596334
McLaren Team Driver T-Shirt Male – XXXLargeTM3050TM152013157698KBOW2589/0001195054130596341
McLaren Team Driver T-Shirt Female – XSmallTM3051TM152014157699KBOW2589/0001195054130596396
McLaren Team Driver T-Shirt Female – SmallTM3051TM152014157699KBOW2589/0001195054130596372
McLaren Team Driver T-Shirt Female – MediumTM3051TM152014157699KBOW2589/0001195054130596365
McLaren Team Driver T-Shirt Female – LargeTM3051TM152014157699KBOW2589/0001195054130596358
McLaren Team Driver T-Shirt Female – XLargeTM3051TM152014157699KBOW2589/0001195054130596389
McLaren Team Driver T-Shirt Kids – SmallTM3052TM152015157700KBOW2589/0001205054130596426
McLaren Team Driver T-Shirt Kids – MediumTM3052TM152015157700KBOW2589/0001205054130596419
McLaren Team Driver T-Shirt Kids – LargeTM3052TM152015157700KBOW2589/0001205054130596402
McLaren Team Driver T-Shirt Kids – XLargeTM3052TM152015157700KBOW2589/0001205054130596433
McLaren Team Driver T-Shirt Kids – XXLargeTM3052TM152015157700KBOW2589/0001205054130596440
Written By - Robert Dkay, Manager, Golder Accessories Ltd. Narayangoang