To ensure that only an acceptable quality of fabric and childrenswear accessories are used for producing garments and proper quantity of shipment is received from the supplier. All incoming fabric and accessories of Auto Garments Limited.Store Manager and QC Manager is responsible for fabric and accessories inspection and proper reporting to the Director (Marketing & QC) or Merchandiser. Merchandiser/Director (Marketing & QC) is responsible for informing and negotiating with buyer regarding any non-conformity issues. Director (Marketing & QC) and Merchandiser is responsible for giving disposition decision.
Procedure
Store Manager will receive incoming fabric and accessories and store them with YELLOW MARKED BOARD signifying the QUARANTINE status.
Store Officer will check the received fabric with the reported length, color and type of fabric with the stated shipment document quantity and the actual order quantity.
The findings will be recorded in Fabric Receive report (No. F/ST/10) and Accessories Receive Report (F/ST/01) as applicable. Discrepancy will be notified to the Director using Non-Conforming Material/Product Report (F/QC/20)
QC Inspector (Fabric) will check 10% of received fabric (shall include all colors and dyelots received) for quality using the fabric inspection machine. He will identity any defect, hole or stain and shade variation in the fabric and make calculation as given in the following page.
If the initial Inspection on 10% fabric fails, an additional 15% of fabric shall be checked. If the second check also shows high fault point, the shipment shall be either rejected or checked for 100%.
If point grade is 28 or below, the fabric is accepted.
The maximum penalty for any running yard (36″ X fabric width) must not be more than 4 points
If result is more then 28 points the Director (Marketing & QC) or the Merchandiser shall be informed and the Fabric identified with ORANGE color board representing non-conforming status.
The fabric is also visually checked for shading defects in side by side and length during fabric inspection and by cutting 6″ full width of fabric from each roll.
The defect and inspection result is recorded in Pre-Cutting Fabric Inspection Report (Form No. F/QC/17). Any non-conformity and abnormal shading will be notified using Non-Conforming Material/Product Report (F/QC/20). Roll wise Color continuity card is maintained for identification of shade variations.
Director (Marketing and QC)/Merchandiser shall make required communication with buyer and supplier for action to be taken. Director (Marketing & QC) shall review all decisions taken for the reported non-conformities.
During the fabric inspection if the yardage of any roll is reported more or less by the Fabric Inspection Machine than the one specified in the roll, the roll will be measured manually using measurement tapes. Only calibrated measurement tapes shall be used.
The result of manual measurement will be accepted as final. Any major discrepancy in roll length shall be notified to the Director (Marketing & QC) or the respective Merchandiser for that buyer.
For washable garments, Fabric shrinkage and color fastness is tested by QC inspector (Fabric) on roll of fabric. A sample is cut into 15 sq. centimeters block and washed. After wash it is rechecked for shrinkage. Fastness of color/color bleed is checked after ironing he washed sample and comparing with the buyer approved sample. The record shall be made in Fabric Shrinkage and Color Fastness test Report (Form no. F/QC/18)
Store Officer (Accessories) shall receive all accessories and check the received quantity for color wise and size wise break-up against suppliers commercial invoice/Packing list/work order & challan.
Accessories carton will be weighted and checked against the stated weight.
If the actual weight is found in accordance to the weight mentioned in shipping documents, packages will be opened for counting.
If the weight is not found proper store Manager will be notified of the findings and the packet will not be opened.
Store In-charge will record the non-conformity in Non-Conforming Material/Product Report (F/QC/20) and inform Director (Marketing and QC) or respective Merchandiser. Director 9Marketing & QC) / Merchandiser will give decision on that packet/lot of accessories after communicating with the supplier.
10% of Accessories of each type of every style shall be physically checked as per criteria specified by the buyer. The applicable sample size, inspection criteria and test method is available in Reference for Accessories Checking. The record (Pass/Fail) shall be maintained in Accessories Receive report (Form no. F/ST/01)
Non-Conforming Material/Product Report (F/QC/20) will be used for recording of any non-conformity identified. Director (Marketing & QC) or respective merchandiser will be notified of any non-conformity in quality of accessories.
If the accessories are found bearing acceptable quality and stated quantity, these will be stored in proper place in the stores with Identification and Quality passed status.
Non-conforming Accessories shall be identified with “ORANGE” board representing non-conforming status. After decision from the Director (Marketing and QC) or the respective Merchandiser, Rejected accessories shall be stored with “RED” board showing Rejected status.
Accessories Requirements
There should be no sharp edges that could result in injury to the wearer.
For childrenswear, all non-detachable components such as buttons, zips, sliders, studs, buckles and cords must withstand a specified pull force, which is customer specific. Buyer will mention relevant requirements in our make sheets.
All components for childrenswear must be either:
Too large to pass through a cylinder 32mm in diameter, or
Small enough to pass straight through the cylinder.
In other words, they must not stick in the cylinder and thus be capable of sticking in a child’s throat.
Generally, it states that any materials used must be designed and manufactured to meet the requirements of hygiene and cleanliness, avoiding risk of infection, sickness or contamination. Materials must in particular be visually clean and free from contamination.
Components must not rust or corrode, so be steel free as well as nickel & lead free.
All components used on childrenswear must be non-ferrous.
All zips must have no scratch top-stops.
Open-end zips must have top stops to prevent the slider being pulled off when the garment is unfastened.
Autolock sliders for zips must be used for all principle fastening applications for all garments.
With regard to childrenswear specifically:
Metal/Claw top or bottom stops must not be used. Plastic top stops must be used whenever available in the country of manufacture.
Coil zips must not be used on garments intended for children under 36 months.
On closed end coil zips, plastic bottom stops must be used whenever possible.
Metal zips are not suitable for children under 36 months.
A placket is required behind all zips on garments for children aged 36 months or under.
Pullers can be metal provided they meet all criteria and are non-ferrous and nickel free.
All zippers must have plastic moulded stoppers top and bottom.
Buttons must conform to all aspects of British Standard and must not contain toxic elements in excess of the limits.
All buttons and other trims must be lockstitch attached with a minimum of 10 stitches.
Any handsewing required must be discussed with the technical department buyer prior to production start.
Buttons and any other components must be able to withstand a pull test force of 90N, so thread used and the design of the button must support the required security of the attachment of the button.
Buttons made from glass, wood, mother of pearl, two-part or fabric covered buttons must not be used for childrenswear unless agreed with the customer.
All buckles whether sewn on or riveted must be checked for sharp edges or burrs before attached.
PU belts must be phthalate free, sides to be painted and ends rounded
Any metal used must be strong enough not to bend or break, in accordance with BS5665.
Eyelets & Metal fasteners must be cleanly clenched over to prevent sharp edges.
Prong studs must be at least 15 lignes (9.53mm) in size.
Stud buttons have arrow head fitment. Staple/prong attachments are unacceptable.
Waste punched from the eyelet hole must be removed and the item checked thoroughly prior to packing, to ensure that no waste remains.
Eyelets & Metal fasteners must be applied securely (with backing washer) according to the instructions of a signed data sheet and using the correct & recommended machinery (for press fastener attachment ratchet machines should be used). For childrenswear in particular, foot pressure machinery is not allowed.
Roll setting eyelets (opposed to split setting eyelets) must be used on all products.
All machines must be checked with sample pieces 2 – 4 hourly to ensure correct pinch is achieved.
Facings should be made wide enough to accommodate the press fastener easily.
They should not be positioned over seams or stitching.
They should not be applied to a single layer of fabric. On knitted fabrics woven interlinings should be used as a backing.
On garment wash items buttons/press fasteners etc. must only be attached after the washing process.
Garments should be turned inside out before attaching press fasteners. Then turned the correct way at inspection to ensure no loose press fasteners remain.
Supervisors and inspectors must have been trained on how to carry out daily random checks and document those (i.e. using a micrometer to check foundation depths on garments and a Vernier caliper to check correct pinch).
All accessories to be BHT free and of at least 100 gauge thickness.
All polybags must have at least 2 punched through airholes (so 4 holes in total) at least 150mm apart, of a ventilation area of 300mm per hole, to avoid accidental suffocation of children.
All polybags to carry a “child safety” warning. Please see the required wording below. Font size to be a minimum of 14 pt.
100% Polyester thread must be used on products with low-flammability requirements.
Monofilament thread must not be used in the production of auto garments
Harsh or rough threads must not be used where they will come into direct contact with the skin.
Where the back of a stitch, with heavy construction, may cause irritation to skin on any age, there must be a non-woven fusible interlining applied to prevent irritation
Chain stitch must not be used with heavy thread counts to reduce abrasion
For external decorative features, bulk thread double high twist thread products should be used
Cable ties must be no longer/wider than 14 cm x 4mm.
I Manager Software is used for Lectra Plotter setting and for HPGL viewer. If you install I manager than you will get plotter list in start menu otherwise you don’t get this menu. I manager is used for printer creation. Please remember, Imanager is very sensitive. If you do any wrong configuration than your will face trouble again and again. to overcome it you will need to setup windows again and install again I manager freshly. If you don’t go for formant than you can configure in different profile. If you configure it in separate profile than you need not to setup windows again. Below we are showing how to configure Plotter for marker, pattern and mini printer with the help of I manager. We are sole agent of all Garment and Textile ERP Software companies. We will forward you to the best ERP software company based on your requirements. We are trouble shooter of fashion industrial software like Willcom, Barudan, Lectra, Gerber, iEcho, Datacolor, Shedomaster, Batch, Qc etc
First Click Start Button –Then click All Program – Then click Lectra– Then click IManager– Then click LectraPlotter List – Than click File– Than create New Plotter– Then HPGL Generator from combo box- Then click Next– Then assign printer name/ peripheral name – Then select default for Yes or no option button- Then click next button – Then click next button- Then click Plot test button –Then HPGL Generate directly. Now you need to create same name of assign printer name/ peripheral name in any drive of your computer. If you want to print mini print for buyer than select Windows printer instead of HPGL Generate directly – Then click OK– Then click Finish
I Manager Software Finish
We should install three plotter stated below-
Marker
Lectra Plotter
Miniprint
Setting and Format Change
First Click Start Button –Then click All Program – Then click Lectra– Then click IManager– Then click again IManager for setting and format change. If you click format button than you can change the page setting and other setting. After setting paper type click Ok button to fix it.
TextLib Configuration for Lectra Plotter
MARKER.LAB, PATERN.LAB, TEXT.LAB should be crated previously. There is some rules to create this 3 .LAB file. We will show you, how to create this types of files. Now we are showing the configuration path of MARKER.LAB, PATERN.LAB, TEXT.LAB in C directory below.
First go to C drive. Then go to Lectra Folder. Then go to TextLib Folder. From Here MARKER.LAB, PATERN.LAB, TEXT.LAB etc should be preserved for future use.
To describe the smooth generation, transmission, distribution and preventive maintenance procedure of electrical system for SFL-2. This guideline is applicable for SFL-2 factory, Electrical Engineering personnel who involve in this sector and have a large experience in operation and maintenance of Garments Factory Building. Process: Depend on machine wise.
Safety:
Personal safety: Please don’t carry water, fire/fire box, salt, dust, inflammable materials, chemical and a biological agent at substation that could cause fire hazard or illness. The Engineer/Electrician should wear protective safety gear such as boots, gloves, apron, electrical safety glasses and earplugs to protect him or her from Electric shocks and other environmental hazards.
Machine safety: Please follow the installation/operational manual for particular machine and Locking/unlocking and tagging/un-tagging policy.
Energy Management:
Examples of how it is possible to save energy and costs with the help of maintenance:
Switching to electronic ballast and LED light. Use Energy star product with label.
Load management at launch time. Switching to servo motors machines.
Energy efficient motors to be used with synchronous belt instead of V-belt.
Motor input voltage shall be balanced, well lubrication & ventilation, right alignment, checks motor temperature and ventilation, appropriate load consideration need to be maintained. Use VVVF or VFD at motor for speed control & soft starting. Avoid idle running of any machine and motor.
Insulate pipes, valves and flanges correctly and use steam traps at steam line. Repair steam and compressed air pipe leakage.
Electrical Waste Management:
Place the fluorescent lights/CFL/Battery back into their original containers or the package provided by the recycling company or waste disposal company. Label the box with “CFL/Fluorescent light/battery: hazardous waste.”
Tell everyone to leave the room; open windows, allowing the room to air out for about 15 minutes. Turn off any air conditioning or heat units in the storage area.
Deliver the fluorescent lights/CFL/Battery to Engineering Store/SFL-1 or Call your local recycling company or local hazardous waste Disposal Company and ask if they offer any fluorescent light disposal or recycling programs.
Inquire as to what kinds of fluorescent bulbs they take, as some will only accept bulbs that have burned out. Ask if there are any special boxes or labels you need to turn in your fluorescent tubes.
Methods of Electrical Maintenance:
Electrical Drawing: Update factory’s single line diagram including earthing system, Electrical Drawing of HT, LT, PFI, MDB, SDB & SB. And machine layout drawing with proper dimension for the factory to be update as a when required.
Lightning Protection System: Update & check Lightning Protection system diagram with earth pit after a year.
Earthing System: Ensure only one type of earthing system and also ensure separate earthing connection for Transformer, Generator, and Electrical System for your factory. Check & register earth resistance half yearly for all earth pits.
Electrical Preventive maintenance Log: Keep updating your preventive maintenance log i.g. Emergency & Exit light check monthly, Ceiling fan checking after 04months.
Cables loading: Ensure electrical cable is loaded not more than 75% of its loading capacity and prepare DB schedule half yearly.
Cable Connection/termination: Ensure that all the cable terminations/connections are tightened firmly. LT/MDB/SDB check quarterly. SDB, MDB, LT, HT, PFI, Cable rench/Tray/ladder: keep clean from dust and spider net. Cable trench/Tray/ladder check quarterly.
Electrical tools & Instruments: Ensure calibrated instruments and proper insulation for all the electrical tools used by factory electricians.
Insulation Resistance: Insulation resistance test of all the cables must be performed once every two years cycle and recorded.
Thermo graphic scanning: for entire electrical system must be performed on a biannual basis and recorded
This hiv policy in the workplace is applicable for all the employees of Auto Group ranging from workers to staff of different level in side of the organization. Auto recognizes the magnitude and severity of the development of hiv aids policy in the workplace epidemic worldwide. Auto is committed to develop safe and co-operative workplace where affected persons are not marginalized or shunned. Even in this age people are not that much aware about the HIV/ AIDS. To make a non-discriminating and harassment free work place along with appropriate awareness and prevention support, this policy has been formulated.
HIV Aids Policy in The Workplace
Auto will not and does not discriminate against employees or applicants having, perceived as having, living with or otherwise affected by hiv aids policy in the workplace
Company will treat HIV/ AIDS the same as other illnesses in terms of all the existing employee policies and benefits, including health and life insurance, disability benefits and leaves of absence.
All employees must adhere to the non-discrimination policy. Employees who refuse to work with, withhold services from, harass or otherwise discriminate against another employee because of his/her having HIV/ AIDS, being perceived as having, living with HIV/ AIDS, or being otherwise affected by hiv aids policy in the workplace, will be subject to discipline and/or other corrective actions.
Company will include sessions on HIV presentation awareness programs in its orientation training for workers and staff and will also touch upon the subject in refresher courses
Company will ensure that its welfare officers and doctors and nurses are trained in counseling HIV patients or those who are apprehending having been affected.
Regulations & Procedures
There will be no questions orally or in any application forms to be filled by applicants, through which it can be identified that the persona may be suffering from HIV/ AIDS.
Company will not have any separate category for hiv aids policy in the workplace in any of its formats, for any records needed for providing of any of the company benefits.
Responsible Parties
The Head of HR will be responsible for introduction or modification of this policy and the HR Department and welfare Department will be responsible for implementation of the policy. This is related with first aid policy
Conclusion
Exceptions to this policy require endorsement by the Head of HR and/ or MD. Hiv policy in the workplace is very essential for the apparel industries.
To establish a hard plastic glasses Control Program in organization or outside at the side disposal side, to prevent serious physical hazards to employees of organization or human society outside or product and that could cause injury or death to the customer. The following procedures shall be adhered to by all company personnel to prevent possible hard plastic glasses safety hazards.
Program Requirements of Hard Plastic Glasses
No glass items or broken sharp hard plastic should be kept in open or undisclosed inside or outside at the disposal site.
No glass bottles allowed on production floors.
Wherever possible, try to use substitute product made of hard plastic glasses materials.
On all Glass doors, proper alert signs should be there.
Control on issuing and receipt of Tube lights.
Tube lights must be properly secured to holders. All holders must be inspected by electrician every month.
Inspection of Windows must be done every month.
Tube lights are installed with Safety control in case of loose holder.
All employees must be trained to handle the situation if tube light falls off down.
All used tube lights must be kept in quarantine area segregated clearly away from other disposable waste and must be disposed off with proper record.
All the garments contaminated with glass must be rejected and disposed burnt off.
To ensure that disposed tube lights are being recycled and not being disposed off in HAZARDOUS way to environment.
Every month a management audit to be conducted for all above clauses and top management to be updated on findings.
In case of any non compliance to any of above point, a proper corrective action plan has to prepare with involvement of senior management.
Certificate from Disposal supplier that tube lights recycled and not being disposed in a Hazardous manner to environment and society.
All the office and inspection room glass walls must be covered with curtains so that in case of glass breakage, the particles are not too much scattered.
Immediately quarantine the area with a rope and take account of physical condition of person involved in accident and fabric/garments in quarantine area.
Use hand gloves to collect glass waste.
Use medical assistance if required immediately.
Fabric/garments involved in accident area must be rejected and recorded in Glass Accident Register.
Collected hard plastic glasses must be disposed off as per disposal policy.
