After 3 days new style output , need get capacity in each operator to find out the line bottle neck areas and each bottleneck operations need to have a plan to improve by using method and time study tools. By using this capacity studies and technique of Engineered Garments line has to re-balance to solve the bottle necks. Required monitoring of each individual operator efficiency till the line reached their plan targets. Production account team will monitoring the hourly production in each line and will update progress in hourly basic. Line R&D officer will update the line blanching graph as per actual output so that easy to identify the fall back operation and can take the action fast , Also Line balancing graphs of Garments Worker required to get sign by PM/Factory Manager/GM.
What Is Line Balancing Preparation?
Study the Operation Bulleting along with the sample
Selecting the correct workers for each process by analyzing their past records.
Call up a meeting for Supervisors & Operators to make them understand of the new style and also new Targets, incentive, build up & Delivery date.
Skill requirement to be given to HR department for arranging additional Manpower.
Anticipate & emphasize on providing training on operations which can be a bottlenecks. Identification of the Line as per the Production Plan.
Instructions & Guidance given to COT by the Unit Head.
Stitching 2 pcs of Sample by, Line supervisor and Sr. Line Supervisor, and Line Quality Supervisor will follow up the quality points.
Target rates been considered & verified while the sample is been made.
A meeting called by the Unit Head to review the PP Sample.
All the points are discussed, clarified & understood by the COT.
Any construction, method or attachment issue will be cleared.
What Is Line Balancing With Engineered Garments?
Every engineered garments process officers need to involve for the improvements their own line.
Need to keep records of old and new method etc..Photos/video clips.
Engineered garments need involved of the cost Saving activities to get the best productivity for the company
Every Line of engineered garments need to do 3 improvements per week for the Goal
Operator skill monitoring & update need to done daily basic
Fabric & Operation analysis.
Mock up making in critical operation with using correct folder/gauge and attachments
Method studies
Machine, gauge, folder & Manpower requirement and availability
Understand the Operation Bulletin and Machine Layout
Review the Production plan
Training start if required in critical operations
Garment Manufacturing Process – Review Meeting
Required study closely the new Style Construction with Sketch or Sample
Highlight the area that Construction need to be Changed for the photo ( development ) sample
Compare with similar styles construction & finalized easy methods with available machinery
R&D manager , Maintenance manager , Technical head, concern Merchandiser, Sample Head , Unit head , Quality Manager need to be attend the style review meeting
Comments & suggestions need to apply for the new style & if required need to send the mock up for Buyer to get it approval through Merchandiser,
Need to keep the records of SMV saving.
First initial Bulletin need garment manufacturing process within 2 days of Review meeting.
Once we received the approved Sample, will finalize the bulletin. Final bulletin need to get approved from Factory Manager/ GM.
Line Target has to go to the R&D Dept. machine, manpower, work station, special machine with attachment & critical operation need to be identified and calculate.
If any Construction changes required, it has to be taken in -writing for change the bulletin.
Machinery / Attachments / Gauge/ Manpower requirements need to calculate for next 3 months. If any Special Machine/Gauge/attachment/folders required, it has to be address well in advance to Factory Manager/GM.
Garment Manufacturing Process – Special Foot Arrangements
Every new style Folder requirement need to submit after fit approval sample received.
If required special pressure foots, gauge or attachment will advise to the maintenance department before 30 days of bulk.
New Styles Sticker/Cage placement need to mark in mini marker and will confirm the placement after discussed with PM, IE and Cutting manager ( before size set or pilot run cut)
This Sticker placements will be given to CAD dept after having proper signatures by Technical / Cutting Manager / Quality manager /R&D /Factory Manager/GM
After analysis pilot run, if required to change any sticker/cage placements it should be informed in proper in writing to the CAD dept
Checklist for Pilot run before 15 days to input
Operation bulleting and Machine Layout Availability of Fabrics & Trims
Size set approval
PP sample approval
Mock up making for Critical operations
Technical File & PP Approved Sample
Folder and Attachments in-house
Micro Mc planning for pilot line
Garment Manufacturing Process
Garment Manufacturing Process – PP Meeting
Meeting with complete production Factory Manager/ PM /Line Chief / Supervisor/QA/ Maintenance / R&D need to be discuss.
All Process Parameters, Special precaution in the process, Process check list with responsibility
Quality Plan with responsibility.
Trims & Accessories in house status.
Critical operation need to discuss and quality points.
Complete changing the first 40% of operations within the first day.
Change up to 70 % within 2 days.
Get the first Line output by 3rd day
Engineered Garments – Change Over Team
Team Leader – Sr. Line Supervisor
Front, Back & Assembly Supervisor.
R&D officer
Quality Supervisor
Mechanic In-charge & Assistant
Electrician
Minimize the wastage during garment manufacturing process
Wastage of material:
Thread
Stationery utensils &
Fabric
Minimizing way:
By reducing rejection.
By reducing alteration.
By reducing consumption &
By creating consciousness.
Wastage of Human Hour:
By Motivation.
By developing working method.
By reducing unnecessary use of Man/Machine.
By ensuring available supply of materials.
By reducing the material handling (by keeping them in the minimum distance)
By reducing unnecessary movement.
By grow up consciousness
Importance of garment manufacturing process
To reduce unnecessary work or excessive work.
Maximum utilization of resources.
Reduced additional expenditures.
Time reduced.
Productivity increase.
To find the best method.
Effective production planning & controlling.
Method Study: Method Study is the systematic recording and critical examination of existing & proposed ways of doing work, as a means of developing & applying easier & more effective methods & reducing costs.
Objectives of Method Study:
Improvement of process & procedure.
Improvement in the design of plant & equipment.
Improvement of layout.
Improvement in the use of men, materials & machines.
Economy in human effort & reduction of unnecessary fatigue.
Improvement in safety standards.
Development of better working environment.
Method Study Procedure: SREDDIM is key word of Method study procedure.
Steps:
Select
Record
Examine
Develop
Define
Install
Maintain
Work Measurement: Work Measurement is an application of techniques designed to establish the time for a qualified worker to carry out a specified job at a defined level of performance.
Techniques of Work Measurement
Techniques of Work Measurement:
Time study.
PMTS
Work Sampling.
Synthesis from standard data.
(Analytical Estimating & Comparative Estimating.)
IE Tools, Terms & Techniques:
SMV & Efficiency: It is the time required to complete one piece of garment by a qualified(standard) operator at standard condition.
Efficiency: Efficiency is a ratio of produce minute & spent minute.
Efficiency Formula:
(Production *SMV)/(M/P*Hour*60)*100
Bottleneck & Line balancing:
Bottleneck: Minimum Production capacity work station of a line is called “Bottleneck Position.”
Result of Bottleneck:
Production Loss.
Productivity Fail.
Bad Quality.
Increase cost of manufacturing.
Reason of stain(dirty, oil).
Indiscipline work station.
Long lead time.
Line balancing: Equal distribution of workloads in each work station of a working line is called line balancing.
Objective of Line balancing:
Everyone is doing the same amount of work.
No one is overloaded.
No one is waiting.
Everyone working together in a BALANCED fashion.
Techniques of Line balancing:
Split the task.
Share the task.
Use Parallel work station.
Improving Non-bottleneck Process.
Production & Productivity:
Production: Production may simply be defined as the function of acquiring inputs and transforming them into outputs desired by customer.
Productivity: Productivity is a ratio to measure how well an organization converts input resources into goods & services.
Different types of Productivity measures:
Single factor Productivity.
Multi factor productivity.
Total factor productivity
Operation Bulletin/ M/C Breakdown: Operation bulletin is a listing of the content of a job by elements. A garment consists of some parts & some group of operations. Operation bulletin means to writing down all parts & all process/operation after one another lying with the complete garment according to process sequence. It is a must to write down the estimated SMV & type of machine beside each & every process.
Allocate the M/P & Job design:Product type wise M/P allocation & Proper job design is most important thing for better Productivity. Job design involves specifying the content & methods of jobs. Job design focus on:
What will be done in a job ?
Who will do the job ?
How the job will done ?
Where the job will be done ?
Tools for job design:
Job Enlargement.
Job Rotation.
Job Enrichment.
Data base maintain:
SMV data bank.
Skill Matrix.
Operation Bulletin Bank etc.
VSM: Value Stream Mapping is a method of visually mapping a product’s production path (Material & Information) from door to door.
The Steps-VSM
Product Family of engineered garments
Current State Drawing
Future State Drawing
Plan & Implementation
Benefits of VSM
VSM helps to:
Visualize the product flow.
Show links between information, material & process.
Identify source of waste.
Establish clear future vision for the value stream.
Prioritize improvement activities.
Focus attention on key activities that will improve the lead time.
And reduce the total cost of product.
OEE: OEE is a best practices way to monitor & improve the effectiveness of your manufacturing process. OEE helps to:
Availability
Performance
Quality
Calculation of OEE: OEE=Availability*Performance*Quality
Where,
# Availability=(Planned Production Time-Down Time)/Planned Production Time
# Performance= (Total Production*SMV)/Total Operating Time
# Quality= Good Pieces/Total Pieces
The Goal & Benefits of OEE Measurement
Awareness of losses.
Verification that established objectives have been achieved.
Comparison of results in time.
Better Productivity & Profitability.
Wastage :Waste is anything that does not contribute to transforming a part to the customers needs.
Two types of actions for WASTE
Waste= can be 100% eliminated.
Waste= can be reduced of simplified.
Waste has major effect on……….
Labor utilization………to maximize labor working time.
M/C utilization……….to maximize NDT (needle down time).
Space utilization……….to reduce cost related to WIP, Inventories etc.
Type of Wastage: TIMUWOOD is the key word of 8 Wastage.
Underutilizing people.
Over production.
Over processing.
Lean Manufacturing: A systematic approach to identifying and eliminating or reducing waste (non-value added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection. Lean Benefits
Cost
Defects
Lead time
Inventory
Space
Waste
Productivity
Customer satisfaction
Profit
Customer respnsiveness
Capacity
Quality
Cash flow
On time delivery
Lean Tools & Techniques:
5s (Workplace Organization)
Visual control system
Quick changeover
Cellular manufacturing(Team work)
TPM(Total Productive Maintenance)
Kanban(Instruction card)
Kaizen
Standardization
Mistake Proofing
Jikoda
The work study Practitioner: The work study practitioner should be wel-behaved & expert to relation buildup.He should be always overall qualified-
Honesty & Perseverance.
Creative & Indoustrious.
Highly intersted to work.
Desire to self-improvement.
Time management practice.
Situation controlling power.
Attractive Personlity &
Finaly he should be CONFIDENT.
Engineered Garments – Avoid Startup Losses
Study the Technical File & PP approved Sample with the TEAM prior to Pilot Run
Understand critical areas need special attention
Necessary Pattern adjustment before bulk cut.
Identification of critical operations
Required skill level
Training time if needed
Ensure the approval of pattern
Change the pattern in advance if needed
Ensure both cuts & Trims are available before start inputs.
Selecting operators with the correct skill
Educate & Motivate If need to change another operator
Encourage to achieve the set Target of the operation
Arrangement of folder, Templates & guides prior to the Pilot Run
Avoid Startup Losses
Setting of all required machines with attachments as per Machine lay-Out prior to start inputs.
All information regarding quality check points & standards made available.
Train the QCs on the above.
Avoid/minimize changes once sewing started.
Line Chief has to named list for the operators for each operation engineered garments
Engr. Kh. Mashiur Rahman, Garments Auto Machine Technologist, Web: www.autogarment.com, Please contact us by submitting a comment below on Leave a Reply box, Cell: +88 017 92 52 53 54
Ensure that all budgeted positions in the area filled with proper trained and equipped Engineers with technique. Ensure all relevant area of the manufacturing management receive proper support from industrial engineering. Participating in product development process to ensure effective start up of new styles. Assistant the managers in critical areas with work method, evaluate with tools , that will help to perform the line. Monitoring daily routing work of industrial engineering officer’s and production accounting. The other responsibility are listed below –
Finalize the operation bulletins, line targets, line balancing build up , for the new styles.
Close Follow up “ change over plan and COT “ for new styles.
Train operators for particular operation as needed for specific steps.
Continue to look for opportunity to implement work aids to reduce steps , time and cost
Ensure the department in management is consistency looking for method to reduce the cost and improve the efficiency
Labor utilization and line balancing follow up.
Method study activities in cutting ,sewing, finishing
Setting of Standard Minute Value for new operations.
Confirming of Standard Minute Value and line target.
Pre planning of man, machine and attachment requirements
Ensure to balance the skill in each sewing lines and factory workers grading, this will help to get operator skill ( history ) with their height archived target. This data will helps to HR to upgrade the operators in end of the year factory workers Skill analysis card
Factory Workers
Every operators are having individual skill card and slot to keep/her card in each line
This skill card will update operator skill operation wise by industrial engineering team
Each operator picture required to paste on the card
Operator required to sign on skill card to confirm his/her achieved high target
09 lines will be 09 clouds card
This card will use as KPI to evaluate each operator performance at the end of the year
line Supervisor is fully responsible to keep these card safe
If any operator achieved his/her operation highest target ( than before) ,this needs to update in back of the skill card
When factory workers up grade been done, dates to be written on the back of the skill card with op signature
Execute Of Commando Factory Workers Concept:
To balance the daily absenteeism/new style changeover/critical operations/machine breakdown. We are having 6 teams (1 team leader with 5 commando operators) and all factory workers will report to the GM and follow up by IE manager, each team leader are fully responsible to fill the “ pro card “ for each commando operators and daily required to get this card sign from IE Manager.
IE Procedure:
Help to production people for manpower balancing
Be present by 7.55 AM in the sewing floor.
Check line wise manpower.
Try to balance within the line & discuss with seniors & supervisor/APM.
If not possible to balance within the line, then line balance within the section but must discuss with seniors before balance.
If not possible to balance the line within the section, then R& D Officer discuss with seniors & others section R& D Officer & APM for balancing line.
If not possible to balance the line properly, you try to balance output area of the particular line to get the output of first hour and inform it to R & D manager within 9.00 AM.
Must observe the capacity & quality of new operator, if running operator absent.
Procedure of making Miss-use manpower report
Find out “Operator works as a helper” daily basis.
Make miss-use manpower report.
Miss-use manpower report sends to production manager.
Put star mark when operator works as a helper continuous basis (above 3 days).
Discuss with production people about reducing “Miss-use manpower” (daily/ weekly basis).
Procedure of making Un-authorized manpower report
Find out “Un-authorized manpower / idle manpower” daily basis.
Make Un-authorized manpower report.
Un-authorized manpower report sends to production manager.
Discuss with production people about reducing Un-authorized manpower.
Try to make Zero Un-authorized manpower & it’s considering KPI of RND officers.
Check plan, input, washing status etc.
Check production plans (If plan not clear then must discuss with RND manager).
Check input status (If input are not available according to sewing demand then need root cause against that problem).
Check washing status.
Collect data about shipment schedule, difficulties against shipment.
Meeting preparation
Set daily work plan according to JD & practical situation.
Set plan for performing weekly & monthly task according to your JD which is given by RND manager.
Noted problem, if you faced any problem or difficulties at sewing floor.
Attend IE meeting & approve your daily jobs
Attend IE meeting with daily work plan.
Approve your daily work plan by IE manager according to job load.
Analyze previous day efficiency report.
Collect efficiency ticket & provide to supervisor as soon as possible.
NPT report collect & SQDC board follow up.
NPT report collect form supervisor & ensure signature of all responsible personnel.
Manage production, quality & maintenance responsible personnel for fill up visual (SQDC) board. Check accuracy of visual board.
Discuss with senior floor management about the importance of SQDC, about sustainability, discuss & take action for improving efficiency, reducing DHU, reducing NPT, reducing hazard.
Check hourly production sheet according to their capacity (at least 2 times/ day).
Identify the actual bottle neck operation.
Perform basic work study (workplace engineering, motion study, motivation, etc.)
Find out line wise deviation between target & production.
Create check points for production monitoring.
Perform production study, if actual production is bellow than capacity.
Find out root cause, if actual output is bellow than target.
Firstly discuss with supervisor about this issue, then discuss with APM & IE manager then finally discuss with factory manager sir.
Calculate accurate NPT from sewing floor
Help to supervisor for calculate accurate NPT.
Provide on the job training to supervisor about NPT calculation system, importance for NPT calculation with documentation.
NPT data analysis & conduct meeting with supervisor & APM for reducing NPT.
Attend Evening meeting
Discuss about daily achievement & share with others people.
Learn from seniors (Layout, Operation standardization, Method study)
Discuss about next day plan
Make skill matrix
Make skill matrix (collect operator picture & operation capacity).
Skill matrix update weekly basis.
Skill matrix provides to supervisor monthly basis & visualize skill matrix monthly basis with record.
Perform capacity study & Make capacity graph & line balancing through capacity study
Perform capacity study, if allocated quantity is above than 4000 pieces but sometimes it depends on FM & IE
1st capacity study perform within 2nd
Identify below capacity operation.
Perform basic work study (Do the critical examination, develop material handling, reduce motion or share motion with nearest operation, etc.)
If motion reducing not possible, then try to balance with other operation.
Introducing new system to Supervisor, QC, APM & AQM.
Make capacity graph & submit to supervisor, APM & visualize.
Capacity graph updated, when you make change anything & again capacity graph submit to supervisor, APM & again update visual board.
Perform production study
After check capacity, if production is not up to the target level, it demands to do the production study.
Identify ineffective time & try to eliminate it.
If operator could achieve the production target, needs to get the signatures from operator & supervisor.
Fill up hourly sheet according to production of production study.
If production is not up to the target level then try to balance with others operations.
Give one copy of production study sheet to production manager.
Record of production study sheet for future reference.
Style change over record & analyze the way of reducing style changeover
Ensure Approved layout & flow chart copy sent to mechanics, production & quality department before feeding the line.
Allocate manpower with name & pin according to skill matrix.
Before line feeding RND officer must collect layout, flow chart, work instruction & measurement chart.
Define layout start time & date.
Write down machine preparation time & quality achieves time.
Perform basic work study (practice RFT, Material handling, Method, check estimated SMV, Right operator right place, individual efficiency, workplace engineering)
If operational time taken more than standard then write down root cause behind excess time.
If needed, to change any operation in the layout should be informed to the immediate senior of the IE
Check layout paper & make flow chart
Collect production plan from planner.
Collect sample from sample department as planned.
Collect operation breakdown & layout paper with SMV.
Check the layout paper according to skill matrix & actual floor situation.
If found any discrepancy, it needs discussion with the seniors & select the most suitable way to do layout.
Confirm the layout with discuss with production technical & finally confirm by IE manager with signature.
Send it to mechanics, production & quality department ASAP.
Compile a copy of the layout in the IE department for reference.
Make flow chart according to approved layout.
Perform PP meeting
You must collect layout paper before attend PP meeting.
Collect work instruction & measurement sheet from PP meeting & discuss about CTQ point.
Make Video library
Identify bottleneck operation & operation to be developed.
Record all present details (by video, drawing, capacity, production study, hourly production sheet).
Do the critical examination.
Develop the operation by engineering the workplace & improving motion.
Compare it with existing methods.
Introducing new method to supervisor & APM.
Establish the new methods.
Maintain it by regular routine checkup.
Ensure the quality level up to the standard.
Calculate financial advantage of this operation standardization.
Take video for department for future reference.
Provide training to supervisor & worker
Provide on the job training to supervisor & worker monthly basis.
Provide off the job training to supervisor & worker.
Training topics (off the job) must be approved by FM, HR & RND manager.
Documentation (take picture & attendance).
Worker assessment & record
Take informal viva about work experience, operational knowledge, observe attitude etc.
Verifying operation name which is fill up by supervisor.
Take cycle time.
Define grade according to company policy.
Send to production in charge for salary negotiation.
Audit 5S & make presentation
Audit sewing floor according to audit check list (3rd Week of every month)
Take picture, if found any discrepancy.
Make presentation by inserting picture at define presentation format.
Monthly present to supervisor & top management & give award to good supervisor according to 5S score.
Special jobs:
LPR update daily basis (8.30 to 9.30)
Make efficiency report by taking data from LPR, DHU & others report.
Report to RND manager(hard copy) within 9.30 am
Report to FM (hard copy) & mail to RND manager within 10.00 am.
Report to FM (hard copy) & RND manager (Hard copy & mail) within 11.30 am.
Report (hard copy) to all production managers by respective floor RND in-charge.
Make proposal for reducing miss-use & unauthorized manpower.
Miss-use manpower report (Individual floor IE in charge responsible)
Analysis miss-use manpower report (report to HR department when any operator or helper miss-use from 10 days) & report to RND manager of 1st week of every month.
Action taken against miss-use manpower with Production & HRD department.
Record all documents for future reference.
Un-authorized manpower report (Individual floor IE in charge responsible)
Summarized un-authorized (idle) manpower report monthly basis & report to IE Manager according to department policy.
SQDC board (Individual floor IE in charge responsible)
Ensure SQDC board completely fills up according to policy.
Take picture of SQDC board monthly basis & record for future reference.
Fill up hourly output monitoring sheet by supervisor/IE
Fill up others relevant information according to policy.
Take picture of hourly output monitoring sheet & record for future reference.
Skill matrix (Individual floor IE in charge responsible)
Visualize skill matrix to sewing floor & provide to supervisor monthly basis.
Record of all monthly updated skill matrixes for future reference.
Capacity study/graph (Individual floor IE in charge responsible).
Record all capacity (1st graph, 2nd graph…) sequentially.
Compare capacity improvement & productivity gap.
Production study (Individual floor IE in charge responsible).
Record production study status.
Take picture of hourly production sheet when you mention the improvement after performing production study.
Supervisor assessment
Assess supervisor monthly basis.
Visualize best supervisor to visual board.
Give award to best supervisor according to assessment.
Take picture of visual board & record all others relevant documents for future reference.
LPR update
LPR update daily basis (8.30 to 9.30).
Make efficiency report by taking data from LPR, DHU & others report.
Report to RND manager (hard copy) within 9.30 am.
Report to FM (hard copy) & mail to RND manager within 10.00 am.
Make monthly production summary report according to department format.
NPT report make
Make NPT report daily basis.
Summarize NPT report for weekly & monthly presentation.
Update NPT database.
Video presentation makes for standard operation.
Make awareness & help for operation standardization
Collect video & practically check the procedure of operation standardization.
Make video presentation according to defined format & update database.
Arrange monthly presentation.
CSR activities
Update blood donate status.
Internship data update.
5S Audit (Individual floor IE in charge)
Audit sewing floor according to audit check list (3rd Week of every month)
Take picture, if found any discrepancy.
Make presentation by inserting picture at define presentation format.
Monthly present to supervisor & top management & give award to good supervisor according to 5S score.
Training (Individual floor IE in charge)
Provide on the job training to supervisor & worker monthly basis.
Provide off the job training to supervisor & worker (How to calculate NPT, Efficiency, Productivity, Balancing technique, Layout paper, SMV, Operation chart, Motion reducing technique etc.).
Training topics (off the job) must be approved by FM, HR & RND manager.
Documentation (take picture & attendance).
Factory Workers Training & Up Date For The Special Operations.
Make sure to Monitor the skill level of the line for special operation,
Need to highlight in advance for the training in critical operations
These training needs to start at least 15 days before new style Input.
Those factory workers daily monitoring required till new style comes to the line.
Engr. Kh. Mashiur Rahman, Garments Auto Machine Technologist, Web: www.autogarment.com, Please contact us by submitting a comment below on Leave a Reply box, Cell: +88 017 92 52 53 54
Fusing machine for garments is very much important to maintain the quality of the products.Fusing press machine for garments is very much important to maintain the quality of the products. The press machine carries out fusing by holding the fabric & the interlining between the conveyor belts while heating. The pieces are then pressed by rollers at the outlet. The required fusing temperature is achieved by bringing the belt into contact with the heating elements
Each day before start of production, the pressure on the left, rihgt and center of the rollers shall be checked by means of the light weight woven fabric strips. One of the strip shall be passed through the T Shirt Heat Press Machine for garments while holding the other and tight. When the end passes out of the press, the strip will be pull to feel the pressure of the rollers.
When we start any order in the sewing floor. We make sure fusing machine parts of the garments. At first we collect the data sheet from the supplier. According to data sheet (like: pressure time: temperature) we adjust the m/c. After adjusting the m/c we check the m/c (1) thermo paper (2) thermo meter. We check the fusing m/c by thermo meter two times in a day that means after lunch and before lunch against every order according to data sheet. 3.bond strength test machine: we doing bond test when test the machine (after lunch before lunch)
Follow the machine direction or warp direction cut the interlining 17 cm x 7 cm.
1 kg = 9.81 newton.
1 kg = 1000 gram
Check Point Fusing Machine
Check Point Fusing Machine
check the physical condition of the pressure roller.
check the set temperature of the heater, by using a thermal strip at different areas of the rubber roller.
check the pressure exerted by the pressure roller of fusing machine for garments
for a flat bed fusing m/c check the bed at different zones.
check for all electrical connections.
check the solid state relay switch
Proper personal protective equipment i.e. gloves, visors, and aprons must be used.
This machine is used in high temperature, so pay attention to your hands and clothes not to be burned.
Always wait until the machine is fully stationary.
Do not push finger/ hand through the heated chamber.
Avoid wearing loose wears.
First aid equipment such as first aid kit, stretcher, and dressing material box must be stationed in the vicinity.
Carefully observe announce location and operation of fire extinguishers.
Do not operate the equipment in the presence of flammable gases or fumes.
Switch off the fusing machine.
After maintenance work always tighten released screw, nut-bolt connections.
Do not use compressed air on electric and electronic parts directly.
Confirm that the power plug is properly connected.
Pay sufficient attention not to make contact with the belt and the upper cover whose temperature rises high nor mount things on them.
Don’t put anything to the main unit of the press except the materials to be inserted.
Classification of fusing:
Top fusing
Semi fusing
Non fused
Corrective Action For Fusing Machine
if the roller is found too hard of bubble inside the roller, repair it or replace it.
if the obtained temperature varies beyond 10 c check the thermocouple of the m/c also the magnetic contractor.
Clean the whole machine.
Check and clean the belt with a dried floor cloth when the operation is over.
Raise the scraper three or four times a day in order to clean.
Inspect the belt cleaner.
Wipe off dusts using a dry floor mat, before inserting the material.
Clean and oil the guides and bearings.
Check all the screw & nut & Bolt.
Check and put oil if necessary on the upper and lower belt.
Check the electrical wiring system.
Check the machine for visual damages.
pass a long fabric between two rollers and pull the fabric by hand & feel the pressure.
if the bed becomes defored, change the bed cushion / foam of the m/c.
take necessary actions for loose connections of wirngs etc.
if the solid state relay does not work take n/a and maintain the fusing machine
Some common fusing problem:
Gum at collar, cuff, Flap, etc.
Crease mark
Fabric fault
Dust / Stain Mark
Foreign Thread
Bauble at collar, cuff, flap, etc
Fusing Machine Operating Procedure
Each day before start of production, the pressure on the left, right and center of the rollers shall be checked by means of the lightweight woven fabric strips. One of the strip shall be passed through the fusing press and while holding the other end tight. When the end passes out of the press, the strip will be pull to feel the pressure of the rollers.
The Fusing machine will be set to conditions recommended for Fusing of the fabric type.
The conveyor belts shall be checked. If there is any adhesive residue contaminating the belts, it will rub off with a soft cloth.
The cover of the cleaning bars will be Turn or changed, depending on how dirty they are. The scraper blades will be cleaned with a cloth.
Once the Fusing machine is ready for operation, the inter-lining will be set in proper position of the fabric, the appropriate time will be set and a test run through the machine will be made.
Fusing Machine Operating Procedure
After the test run, the fabric will be checked for proper fusing by the QC manager. If the proper fusing condition has been achieved, The QC manager will approve the fused part with signature and temperature setting and the process will continue, otherwise adjustments shall be made to temperature and timing to obtain proper fusing. After that, upon approval of the QC manager the fusing shall commence.
Fusing: Fusing is the process of joining interlining with the fabric. The interlining contains adhesive, which melts at a specific temperature (Glue Line Temperature) and Pressure to make bond with the Fabric.
Importance of Fusing: Fusing is one of the most important processes involved in apparel manufacturing which affects the appearance of the garment. It also provides support and strength to the specific parts of the garment.
Parameters for Fusing: There are three parameters involved in the fusing process:
Fusing Temperature
Fusing Pressure
Fusing Time
Initial Procedure: In the Tech Pack, buyer provides the details about the type of interlining to be used and also the quality standards to be maintained.
As per the details mentioned in the Tech Pack, the respective merchandiser communicates with the suppliers for getting the interlining.
The supplier provides the details of the interlining along with Test Report. This Test Report contains the details of the M/C in which the test was done along with the Temperature, Pressure and Time to achieve the Glue Line temperature.
The Technical GM goes through the Test Report along with the details provided in the Tech Pack. He provides the instructions to the Cutting Department to follow during fusing.
Fusing Procedure: The temperature, pressure and time of the Fusing M/C is set as per the instructions received during the Technical Meeting.
Thermo-strip is inserted in the M/C to achieve the Glue Line Temperature (Actual Fusing Temperature). This process is done twice a day; once in the morning 8:10 AM after starting the M/C and once in the afternoon (45 min after lunch).
Once the Glue Line temperature is achieved, Fusing for 10 Pcs (Mock Ups) is done.
2 Pcs are sent to the Lab for testing the Bond strength. This test is done by the Lab In-charge using the following M/C: OHBA SIKI JAPAN.
8 Pcs are sent to the Washing Department, to observe the effects after wash. The after wash Pcs are checked for bubbling, stain marks and strength.
The results from Lab and Washing is sent to the Technical GM. If the results are OK, approval for Bulk Fusing is given. If any deviation is observed, the Technical GM finalizes the correction for the temperature, pressure and time and communicates to the respective GM.
The cutting department follows the instructions provided by the Technical GM to achieve the Buyer Required Standards.
Requirements of Temperature, Pressure and Time for Commonly Used Interlinings:
M/C Type Temperature Pressure Time
OLD Machines 150 Degrees C 2 Kg 15 Sec
New M/C (HASHIMA HP900LC) 120 Degrees C 1.5 Kg 12.5 Sec
Requirements of Temperature and Pressure for KOHLS VT 20SP Interlining:
M/C Type Temperature Pressure Time
New M/C (HASHIMA HP900LC) 100 Degrees C 2.5 Kg 12 Sec
Reports in Fusing Section: Two reports are being made in the Fusing Section:
Fusing M/C Temp & Pressure Checking Report:
This report contains Thermostrip along with Fabric swatch. This report needs to be filled up two times a day (before starting fusing in morning & before starting fusing after lunch).
Fusing M/C Clean Report:
This report is filled up 3 times a day (10:00 AM, 1:00 PM and 4:00 PM).
Classification of Interlining Fabric
jersey
paper fused / paper non fused
cotton fused / cotton non fused
polyester fused / polyester non fused
Tc interlining (non fused)
Features of the interlining fabric
Features of the Interlining Fabric
It’s used for front fuse.
The excellent hand feel and appearancewill keep good sharp.
Hard hand feeling, superior elastic resilience used For high quality men’s suits
Shrink-resistant, good stretch ability and very comfortable.
Can be washed in any condition:
Water-washing and dry washing.
soft hand feeling, best water and oil
Selection of Interlining Fabric
Selection of Interlining Fabric
Right Interlining for right fabric
Fabric thickness, GSM, Construction, Composition
Fusible, Non fusible, Woven, Non Woven doted etc
Product category
Fusing test-Bonding
Bond strength – or the sturdiness of the seal between the fusible interlining and the fabric – should be evaluated after fusing, and after washing or dry cleaning, depending on the recommended care of the garment
A basic idea about fusing:
Cuff, Collar, Flap, Epulate, Band
Fabric Description
Lining Description
Required temperature
Required speed/ time
Required presser
100 % Cotton
Cotton
160-170
10-12
2-2.5 Kg
100 % Cotton
Paper
130-140
10-12
1 Kg
100% Polyester
Paper
Adjust able in test
10-12
Adjust able in test
100% Polyester
Cotton
Adjust able in test
10-12
Adjust able in test
68% Cotton,
27% polyester,
5% Elaston
paper
130-140
10-12
1 Kg
Note: – * if lining is thick then it needs to adjust less heat and time.
* If lining is thin then it needs to adjust more heat and time.
Fabric Description
Lining Description
Required temperature
Required speed/ time
Required presser
100 % Cotton
Cotton
180-185
18-22
8-10 Kg
100% Polyester
Cotton
Adjust able in test
Adjust able in test
Adjust able in test
Almost of order at front placket lining is used cotton lining.
Note: – These above information always not correct but this is a basic idea that can follow. After testing according to fabric and lining nature speed, temperature, presser should be set up.
Preparation for Fusing Press Machine
Fusing Press Machine
Select right fusing press machine
Fusing press machine Calibration
Find require temperature, pressure, speed & time
Test for bonding test, Thermal paper test, & wash test
Interlining shouldn’t be bigger than fabric to avoid the gluing
These accelerated laundry clothing tests are to evaluate the color fastness to washing of fabrics and garments. The fabric or garment color loses and surface changes are resulting by this test. Method we use: FOR USA / CANADA: AATCC 135 and FOR EUROPE: ISO 105 …
Specifications of Launder Tester:
Specifications Name
Specifications Value
Product Category
Lab
Machine Category
Launder Tester
Product Name
Launder Tester
Product Model
According to Manufacturer
Product Class
New
Origin
Made in China
Brand/ Manufacturer
Name of Manufacturer
Agent in Bangladesh
No/Yes
Power
380v
Temperature
Normal
Certification
SGS/Others
Production Capacity
NA
Compressor
France taikang
Delivery
in stock, prompt ship
temp.accuracy
<+-1 degree
OEM/ODM
Available
Temp range
0-100 degree
humidity range
35%RH-95%RH
Time range
1-99.99 hour
rotating holder
0-10rpm/min
circulating air
0.02-0.5m/s
heating power
1500w
dimension
50*50*60cm
weight
157kg
Description
For cotton, wool, silk, hemp for laundry clothing
How To Wash Laundry :
Heat the waterbath at Digiwash to 40°C
Digiwash to 40°C
Prepare 150 ml sol. ECE dtgnt at 40°C, 10 steelballs and specimen inside containier
Prepare 150 ml sol
Put inside Digiwash and process for 30 min
Inside Digiwash
Take out the specimen, then dry
Evaluation process
Evaluation process
Dry rubbing
Wet rubbing laundry clothing
Customer Wash Evaluation to Insure Quality –CWIQ
The CWIQ program is to ensure that the after wash performance of apparel or textile products meets the customer expectations. The factory conducts this evaluation after the 1st 1200 pieces per color are complete. The CWIQ evaluation is performed on the 1st shipment only of a style. Agent/Vendor QA will review and confirm the results as part of their Final Random Inspection (FRI). Evaluations are conducted at the factory’s facility in American washers and dryers.
Two apparels or textile products in each color way are to be pulled for analysis . One product in each color way is to be washed 3 times and dried 3 times , according to the care label instructions approved for that product. The after laundry clothing appearance of that product is then compared to the unwashed product.
Reqired Materials to complete testing
American washer and dryer- it is recommended that AATCC approved brand names such as Whirlpool or Kenmore is used.
Gray scale.
Pilling Standard.
Overall Smoothness Appearance Standard.
Seam Smoothness Board.
Viewing board.
Household Detergent -American Label Tide.
Procedure
Two apparel or textile products in each way are to be pulled for analysis. Read the care label instructions carefully. Compare the apparel or textile products to each other , to confirm that they are identical, including specification measurements. Measure one apparel or textile product in length and width as indicated by the point of measure used on the technical specification. Record these measurements on the CWIQ worksheet , under dimensional stability , unwashed . Tops – the measurements should be body length and chest width. Bottoms – the measurements should be waist and inseam/skirt length. An exception to this is full elastic bottoms , the width measurement should be the hip, low hip if applicable, instead of waist.
Washing laundry clothing procedure
Launder the measured apparel or textile product according to the care label instructions , using household detergent. Include a twin size mark sheet , in 100% white cotton , to help balance the wash and dry load. Use 1 twin flat sheet to reduce the potential of excessive wrinkling sometimes caused by a fitted sheet. The sheet may be used on multiple evaluations, as long as no color transfer has occurred . Multiple garments may be included in a laundry clothing or dry cycle as long as the color family is complementary and there are no ‘wash separately’ instructions included in the care label. Repeat the wash and dry process three times, according to care label instructions.
Drying Procedure
When care instructions call for ‘tumble dry low’, the temperature should be 137 degree Fahrenheit, +/- 5 degrees.
Tumble dry low – set heat temperature low
Time setting- Knits- approx. 45 min
Woven- approx. 25 min
Sweaters- approx. 35 min
After the product has been completed the laundry clothing and dry requirements, lay flat and allow to condition for a minimum of 4 hrs. Follow all care label instructions , including any ironing. If no ironing instructions are included , no ironing should be done. Care instructions ‘when needed’ means whenever the average consumer would find it necessary to iron in order to be satisfied with the overall appearance or specifically if the garment is a woven fabric. Hand iron weight is not to exceed 3 pounds.
With product flat, measure the length and width as indicated by the point of measure used on the technical specification. Record these measurements on the CWIQ worksheet , dimensional stability , washed. Calculate the shrinkage percentage and record on the CWIQ worksheet , dimensional stability and shrinkage.
After measuring , hang both products on the viewing board. Standing 4 feet from the board, compare the after wash product appearance to the unwashed product, using the appearance performance requirements. Both front and back appearance is to be compared.
The overall rating of satisfactory or unsatisfactory is based upon all the observations, both shrinkage and appearance requirements.
Appearance requirements
The following appearance requirements are to be compared between the washed and unwashed product. Where appropriate , the performance requirement has been given. The performance rating observed using a standard, such as the grey scale or a visual observation, must be entered on the CWIQ worksheet on the line in front of each appearance requirement. All observations are to be made by comparing the washed and unwashed product and using the performance standard indicated.
Appliqués , buttons or trim items securely attached. This is a visual observation that all appliqués, buttons, or trim items are securely attached after wash .Observation results are pass or fail
Needle cuts or chews. This is a visual observation for any evidence of needle cuts or chews after wash. Observation results are Pass or fail.
Color bleeding /Self Staining. This is a visual observation of colour transfer to another color or portion of the product, using the grey scale for evaluating staining to verify that customer requirement of 4.5 or better has been met. Observation results are the grey scale reading.
Raveled edges. This is a visual observation for any evidence of ravelled edges after wash. Observation results are pass or fail.
Seam Pucker. Seam smoothness standard is compared to the product to verify that customer requirement has been met. This includes seam puckering on all split fronts , such as snap fronts, Zipper fronts and button front products. This appearance requirement is applicable. for all products evaluated using the CWIQ test, including raised fiber and washed garment treatments(enzyme washed ,stone washed, etc). Observation results are pass or fail .
Torque/ Skew. The side seam and AATCC 179-2001 inverted T methods are used to verify that customer requirement s have been met. Wovens-3% max. Garment Indigo Dyed Wovens-4% max. Woven swimwear- 4% max. Knits and sweaters-5% max. 100% cotton jacquard and garment dyed knits-7% max. Down filled -3% max .See for all products evaluated using CWIQ test including knits and sweaters. Observation results are pass or fail.
Excessive color change. This is a visual observation comparing the washed product to the unwashed product. Use the Gray scale for evaluating change in color to verify that customer requirement of 4 or better has been met. Observation results are the gray scale reading.
Excessive wrinkling. Overall smoothness appearance standard is compared to the product to verify that customer requirement has been met. This appearance requirement is applicable for all products evaluated using the CWIQ test, including sweaters. It has no relation to a product that may be labeled as wrinkle-free. Observation results are pass or fail.
Excessive Pilling. Pilling standard is compared to the product to verify that customer requirement has been met. This appearance requirement is applicable procedure below. Observation results are indicated in %. (one decimal place, ex.3.4% 2.4%)
Holes or other signs of excessive abrasion. This is a visual observation for any evidence of holes or other signs of excessive abrasion after wash .Observation results are pass or fail.
Zippers or other trims items functioning properly. This is a visual observation for any evidence of holes or other signs of excessive abrasion after wash. Observation results are pass or fail.
Hand feel. This is a physical inspection to determine whether if the hand feel is the same as before wash sample. Observation results are pass or fail.
Torque
Procedure for using side seam method
After washing and drying, align the shoulder of a top or waist of a bottom. Lay flat and allow to condition for a minimum of 4 hrs. The product should be gently smoothed and free of large wrinkles or creases. Begin smoothing at the top of the garment and work down.
Using a marker pen, one skewing mark should be placed at the uppermost point of the product folded edge- point E and the other skewing mark should be placed at the lower most point of the same folded edge-point G.
Measure the distance from point F across to the nearest fold edge- point G.
Calculate the percentage of torque after wash as follows:
Line FG/Line EG* 100
If torque is more than 3% then garment will fail the test.
Torque
Skew
Procedure for using the AATCC test method 179-2001/ invented T method 2, Option 3
After washing and drying, align the shoulder of a top or waist of a bottom. Lay flat and allow to condition for a minimum of 4 hrs. The product should be gently smoothed and free of large wrinkles or creases. Begin smoothing at the top of garment and work down.
Using a marker pen, draw a reference line YZ across the width of the panel, above the bottom edge and hem. Draw a benchmark A perpendicular to end and in the middle of YZ. Draw benchmark B, both perpendicular to YZ and parallel to A.
Draw a line from B to line YZ, following the grain line. Mark this intersection as C.
Measure the distance from A to C. Measure the distance from A to B .
Conclusion:
Skew is not measured with those garments that have a horizontal engineered stripe or wide horizontal stripes, over 3” in width. The horizontal stripe is the predominant element of the garment and the fabric must be cut and sewn with stripe on the horizontal. This is the procedure of laundry clothing which is described above.
A model garment is doing all products to be checked 100% with a industrial metal detector prior to shipment after all manufacturing operations have been completed. This check is being carried out after the final examination and packaging of the garment (incl. attachment of swing tickets) but before packing/boxing the goods in the metal free zone and are being the part of the final quality control procedure. Industrial metal detectors are an aid to prevent metal contamination and are the best way to ensure that needle control procedures are effective, but are not to being used to replace an effective needle replacement policy. Metal detection are being implemented within the production process and used in conjunction with the broken needle procedure.
Metal Detector Calibration Procedure:
Machines are being calibrated every working day with this test card, at the beginning and at thend of each inspection lot, as well as when the machine is started up, then every hour and at the end of a working day as well as after any electricity cuts.
If an issue is found with the machine at the next calibration, the goods that were done since the last successful calibration need re-checking, so the smaller the gap between calibrations checks the smaller the quantity of goods that are being re-checked.
If the machine is to be found out of order after a check, it is being arranged for urgent repair and a replacement to cover for the time the machine will be out of order. This is being done through a static metal detector. It is being ensured though, that no orders leave the factory, that is not been checked, especially in case of children swears.
The following metal detector calibration procedure are being adhered to when checking the machine. Please see below diagram for the width across the belt of the metal detector and where the test card should sit when tested at the bottom, center and top position:
CROSS SECTION TUNNEL NEEDLE DETECTOR
TOP A7 A8 A9
CENTRE A4 A5 A6
BOTTOM A1 A2 A3
Metal Detector Calibration Checklist:
Switch on the machine and set the sensitivity level to less than 1.2mm sphere.
Position the test card directly onto the conveyor belt at position A1.
Let the card pass through the search head.
The metal detector is being activated and the alarm is sound.
Repeat the above steps 1-3 with the test card in positions A2 and A3.
Again the detector is being activated and the alarm is sound.
The test card is putting through on its own, we are not put it on a paper or put it through with a garment.
Repeat steps 1-3 with the test card positioned in the middle of a stand (7-8cm high) or on top of a stand that is around 3-4cm high (depending on the height of the gap between conveyor belt and top of machine) at positions A4, A5, A6.
Again the metal detector is being activated and the alarm is in sound. The stand are being a non-detectable block made of plastic material.
Repeat steps 1-3 with the test card on the top of a stand (7-8cm high or as high as the gap allows for) at positions A7, A8, A9 and again the metal detector calibration procedure are being activated and the alarm are in sound.
Records are being kept of all of these checks by using the prescribe form.
In case the machine fails to pass the calibration test, it is immediately being turned off and re-calibrated by an authorised technician. All goods checked after the last calibration is being re-checked once normal operations of the detector have been re-established.
Machines are being calibrated at least every 6 months by the manufacturer.
Calibration certificates are being obtained and being kept for auditing purposes.
If for any reason the detector are being relocated, it is being re-calibrated by the supplier’s authorised technical service.
Regular maintenance (at least annually) of the detector is being carried out by the supplier’s authorised technical service based on the periods set up by them. Records for maintenance and any re-calibration made by the supplier are being kept, in case these need to be provided during any audits.
Metal detection:
When performing the metal detection it is being ensured that products are placed on the moving conveyor belt one by one with sufficient space in between products, so that there is no overlap.
If goods are being shipped e.g. on hangers that are ferrous and cannot be passed through the metal detector, the goods are being taken off the hanger, passed through the metal detector and then re-hung. It is permitted for the hangers to be moved through the metal via a door. This process are controlling by the authorised person and only the correct amount of hangers per order are to be held at any one time, no spare hangers to be stored.
As a general guideline though garments be metal detected as last as possible in the production process and any ferrous metal items are being attached in the metal free zone, such as security tags, hangers etc.
The metal free zone are not being used for general storage and are being tidy. Once product is boxed or hung is to be taken to dispatch.
In case of stone washing the garments are being metal checked prior to washing as the pumice dust contains small metal particles that have an adverse effect to metal detection.
Any garments or part of a garment that are being outsourced for the application of a print, embroidery or any other process are being metal detected upon receipt back into the factory, prior to continuing production. This is to ensure that no whole or broken needle pieces, staples, other stray metals or sharp objects are in the returned pieces.
The factory are making sure that procedures are in place to ensure that all garments including repaired and re-inspected do not go to packing without being checked by the detector.
Clear separation and identification of the garments that are waiting to be checked and that are being checked to be strictly made.
Records are being kept for all garments that are passing through the metal detector and are being completed as product passes through the machine to verify compliance with this requirement.
If the alarm sounds, all garments on the halted conveyor belt are being put into a sealed bag, segregated and locked in a secure rejection box, to be located near the metal detector.
The rejection bin are being taken to a clearly marked area and thoroughly checked for contamination by the assigned person.
If the metal parts are found and the garment passes through the conveyor industrial metal detectors successfully, the garment can be returned to the bulk.
If the metal part cannot be found, the contaminated product are being put into a polybag with details clearly marked on it and then placed inside the rejection bin (s. photo) locked away from the factory floor and THE GARMENT ARE BEING DESTROYED after authorised sign off by the factory manager.
Under NO circumstances can it be returned to stock for shipment.
If a product is metal detected in its packaging, remove the packaging and detect the product and packaging separately as some packaging can contain traces of metal, especially if recycled, e.g. card, therefore may prevent the product being rejected.
The rejection bin are being locked with a designated person holding the key. The bin is having a slit at the top through which the garment can be passed through. The slit is being big enough to let the garment fit through, but small enough to avoid a hand fitting through it.
Any action is being recorded accordingly and any found metal parts are being taped securely to the metal detection failure record by sticky tape confirming source of contaminant and action taken to prevent future contamination.
Records of garment destruction are being kept for a minimum of 5 years for auditing purposes.
After the tested products are packed in a carton, the carton are being marked with a stamp stating date and ‘tested’.
Any products that are being returned from the storage area / warehouse to the sewing/finishing floor are being checked again with the industrial metal detector and the cartons must be re-stamped with date and ‘tested’.
Requirements on the metal detector machine and accessories:
There are 2 types of conveyor metal detectors:
General Purpose Metal Detectors, which detect all metals (use them for garments that do not have any metal components such as zippers, press studs, buckles etc.)
Ferrous Only Metal Detectors (use them to inspect garments that contain approved non-ferrous, non-magnetic components).
We recommend to use metal detectors that detect ferrous metals only, so that garments can be passed through the detector with metal components on such as zippers, press studs, buckles etc.
Please specify when ordering components that they need to be non-ferrous and non-magnetic.
A complete metal detection system comprises of a digital metal detector, conveyor belt, alarm reject system and test warning signal.
Any new metal detectors purchased must have a printer or production data recording facility to record calibration checks, the style numbers of product detected and contaminants detected.
The metal detector should be able to detect a metal part which is equivalent to a diameter of 1.2mm ferrous sphere at any point of the metal detector aperture at the supplied belt speed.
The sphere should be chrome steel of AISI 52100 grade with AFBMA GD 10 size tolerance mounted on a test card. Please only use approved test cards from nominated suppliers/manufacturers, do not make up your own! The test card must be available at all times with the metal detector it belongs to.
In case of garments with accessories, the metal detector must be capable of ignoring a representative sample of non-ferrous accessories and allowing it to pass undetected. In case of garments without accessories, the needle detector must at least ignore a non-ferrous test coin.
A sample to test your machine can be obtained from the machine manufacturer.
When passing the 1.2mm test card with the accessories or the test coin, the needle detector must detect the 1.2mm ferrous test card.
Machines must have an audible alarm with automatic belt stop in case any metal is detected. The conveyor belt must not be able to operate when the detector is faulty or switched off.
The audible alarm and conveyor belt should only be capable of being re-set by a key switch.
Metal detectors must be installed to the manufacturer’s guidelines and the manufacturer must approve the sitting of metal detectors.
Power fluctuation causes false alarms. Therefore the installation of a regulator will minimise the problem.
All metal components must be non-ferrous to pass through a ferrous metal detector.
Non-ferrous (non-detectable) and nickel free metal components (such as snaps, rivets, zippers etc.) should be used at all times and are mandatory for childrenswear to avoid false alarm during the detection. A special coating is applied to these components making them non-ferrous. Therefore it must be ensured that the trim supplier is alerted to deliver non-ferrous components for such garments.
The factory should check that this is the case by checking incoming items with a ferrous detector prior to attaching them in bulk.
Machine Location and Set-up:
The metal detector should be placed at the end of production (after all sewing operations, attachment of swing tickets and packing) in a so called airport system.
The detection machine should be positioned half into the packing area, then shielded and separated by a solid panel/wall (fence is not sufficient, as items can be passed through it), so the product ends on the other side through the machine in an isolated metal free zone/area. This is to eliminate any external interference and to avoid that goods can bypass the metal detection by mistake.
Please see photo for airport system:
Industrial metal detector location
The detector must be installed in a permanent location free of other metal objects like metal frames, doors, shelves etc. to avoid electrical interference.
It is recommended that the factory has at least 2 conveyor metal detectors at all times, to be able to carry on checking in case the one of them breaks down. It needs to be ensured though that any spare detector is in good working order and able to detect a metal part of 1.2mm ferrous sphere.
Best practice can be found in using 2 metal detectors placed at 90 degrees or even through a twin head metal detector. Position across the conveyor belt in a 9 point check.
Only authorised personnel should have a key that controls set-up and calibration of the machine. The key must not be left in the machine.
Only authorised and trained personnel should be operating and maintaining the metal detector. The training should be held by the manufacturer or an approved agent and trained staff should be able to make minor adjustments when needed. Records must be kept of all training, maintenance, servicing and repairs.
The operating personnel should be professionalised as full time workers.
An organisation chart with the names of people in charge and their photograph must be posted at this area (incl. the person in charge of the process as well as any other operators).
The metal detection policy must be translated into the local language, displayed where applicable and the management must ensure that workers fully understand the policy.
The policy should be part of your induction programme for new workers.
Cellular phones and other electronic devices must be kept away from the detector during operation. The supervisor should ensure that the assigned personnel must not wear clothing with pockets and should not wear items of metallic origin (e.g. wrist watches, rings, mobile phones, belts etc.) or carry a cellular phone while operating the machine.
Uniforms for the authorised workers working in the metal free zone should have a different colour to the rest of the factory.
The area the metal checked goods are going into, has to be a secured ‘metal free zone’ (so e.g. no clippers or scissors for cutting gum tape allowed), that is not too open and segregated/separated/isolated to avoid any possible contamination with the ongoing production.
The zone has to be declared and clearly marked as metal free and only authorised personnel should be allowed into the zone. This again should be clearly marked and communicated to everybody and personnel should be identified as authorised, e.g. through different coloured uniforms or ID cards.
The fencing of this zone should be solid, so that it can be avoided that metal objects can be passed through the fence and cause contamination.
Entry to this area must be restricted and monitored. No one should be allowed access carrying any metal tool, e.g. scissors, blades, clippers, needle, stapler and or spare metal components. Unauthorised personnel are prohibited from accessing the metal free area.
Anybody entering the metal free zone should be recorded with name, signature, in-time, out-time, purpose and signatures by person in charge & manager and again when leaving the area.
The entrance to the metal free zone should be locked during breaks and at the end of the day after ensuring that no one is left behind.
All product must pass through the metal detector into the secured ‘metal free zone’.
Once the product has passed through the metal detector, it must be placed in a designated quarantine area within the metal free zone until the following calibration check has been successfully completed, only then can the product be released from the quarantine area for further packing.
Packing can take place in this metal free zone, but no kimbal/tag guns should be used. Hangers can be inserted into garments and or put into the cartons in this area.
Tools which are used in the metal free zone should be numbered, recorded and kept at fixed places. The manager should check quantities of these tools before and after working.
Goods should be stored and kept in a metal free environment after the check is done and cartons are sealed.
Metal detection machine suppliers:
All the below suppliers are recommended and offer full calibration and maintenance service:
Conclusion:
In summary, records that are being kept to support the operation of the metal detector are: – Calibration checks of industrial metal detectors, – Style number, date and time of products metal detected – Contaminants detected and follow-up action taken. These records are being retained for 03 years after shipment in case of any legal claims. Furthermore Personnel Training Records are being kept, listing the responsible people who have received training in needle control and metal detector calibration procedure procedures. All records are fully completed at all times.
