All industrial sewing machine needles or parts of damaged/broken needles are controlled effectively and accounted for during the production process and throughout the whole manufacturing unit. This means that when a new needle is issued it is cross referenced with stock levels of the particular needle and size to ensure full traceability at all times. This includes janome sewing machine needles (machine and hand sewing), and any ticketing or kimbal/tag gun needles and the policy is covering all areas of manufacturing e.g. the sample room, embroidery and appliqué machines, machines that are positioned out of the main flow of manufacture and operations that are performed outside the factory premises. You can visit more about different types of needles mechanism.
The sample room is keeping a separate needle record, rather than having the record amalgamated with the production area.
All records are keeping away from the production floor to avoid contamination. Old records are being destroyed safely and off the factory premises.
For guidelines on how long to keep certain records please see individual sections below.
A person is nominated to hold a restricted supply of a pre-determined number of needles in a permanently locked & clearly marked facility. This facility is only be accessed by the nominated person responsible for managing the total process.
Replacement is only be issued if the store officer returns the equivalent number of used needles to the relevant manager/section (e.g. store).
Stock of industrial sewing machine needles is being controlled by a designated member of the management (e.g. production manager, warehouse manager etc.). The good needle releasing quantity is fully traceable according to the ‘One in/one out’ policy in the sewing workshop, i.e. needle stock match needle balance record.
Spare needles are being stored in a secure and locked position away from the production floor.
There is a recorded needle inventory, so that the amount of needles coming into the factory is accounted for with the records kept for needle distribution and broken needle records.
Control of sewing needles in use:
Workers are not being allowed to have any spare needles in their possession.
A person nominated as safety officer e.g. responsible for health & safety and internal auditing is checking compliance to this policy on a regular basis by carrying out audits and random checks.
New needles are being distributed by a store officer.
The nominated person to exchange needles, is ensuring that they receive all parts of the old needle before issuing a new one. A new needle can only be issued if all parts of the old one have been returned.
New industrial sewing machine needles are keeping in a secure, locked, clearly marked and safe environment with restricted access. The key to the storage place is held by the authorized person at all times and are not being available to machine operators.
The needle record is kept for all types of needles and are include the bend or broken needle fragments taped to the record.
To identify trends of breakage the broken needle record is reviewed on a daily basis which will lead the factory to be proactive in preventing excessive
Needle breakage. Worn out, out of alignment machine parts or operator handling may cause breakage.
Change of a needle during production:
To avoid needle breakage, damaged or worn points, needles & their points is being checked on a daily basis. The checks and any needle changes are recorded mentioning the needle ref. that needle got exchanged.
Machines including their needles are checked on a daily basis in the morning prior to work commencing by the worker.
Any damage to the needles and changes are recorded on a Replacement Needle Record.
If any inline or final QC inspectors find any needle damage, the relevant machine is checked immediately and needles changed.
All broken or bent needles are securely attached to the needle replacement form with a clear adhesive tape and all parts need to be accounted for. Store officer is responsible for the record keeping.
Any old/blunt needles are collected by the mechanic/s, recorded, kept in a sealed container in a separate area from the sewing floor and sent externally for recycling.
Broken needle/calibration records is keeping for a minimum of 06 years from shipment date for auditing purposes and disposed off safely thereafter.
At no times are records being stored near the factory floor as this can be cause possible contamination.
A broken or damaged needle are being always be replaced with a brand new needle and all parts of the old one is accounted for. So the exchange is on a one for one basis.
Mechanics are ensuring that no needles are left behind on the machines after any needle maintenance work carried out.
Unused/spare machines are having the industrial sewing machine needles removed.
Requirements for broken needle control:
When a needle breaks the worker call the line supervisor for the process and find all fragments of the broken needle and handover them to the store officer.
The needle or needle pieces are being placed in a small sealed container, in order to reduce risk of loss and taken to the needle control area where the new needles are being issued.
Ideally this is a small self contained sub store on the production floor one full time employee situated inside, who only has access.
Store officer is keeping the needle log is check that all pieces have been submitted, by aligning the pieces and comparing them to an intact needle of the sample chart with the following columns:
All pieces of the broken/bent needle are then be taped to the needle replacement form by sticky tape ensuring that all parts are securely kept in place. Broken needles are not be disposed of in any other manner.
This record are kept for a minimum of 06 years as proof of due diligence in case of any legal claims.
If any parts of the broken needle cannot be found, the machine operator with the supervisor present search the area around the machine, including looking in the oil bed inside the machine throat plate, feed dogs and bobbin case.
The bundles that the worker was working on as well as any bundles in surrounding areas of the workstation (within 2 metres) is being isolated, moved to a separate location in a wooden container clearly labeled and checked with a metal detector (conveyor belt).
If all the parts of the broken needle cannot be found, all work in progress at the workstation should be removed to a specifically designated metal free area and checked thoroughly with a metal detector.
As per system, one bundle of previous operation and one bundle of next operation have to be inspected by metal detector in case of any occurrence of broken needle.
After checking the garment is clear, it should be processed as normal. If however, metal is detected it must be found and removed before the garment is processed. But if metal detected and cannot be found, the garment must be destroyed.
The Operator will approach the nominated person with all the parts of the broken needles.
The concerned person should notify the production in charge and mechanic.
Check the garment or panels being stitched.
Uncover the machines oil tanks by mechanics for checking
Check the working area with a magnet to ensure that broken fragments are not fallen into the ready garments / panels.
If the broken fragments are still not found after the said searching procedure, the in charge is allowed to write onto the reports that “confirm garments are free from needle fragments”
Only the nominated/authorized persons should reissue the new needle to the operator.
Any found fragments are being added to the needle replacement form:
If any parts of the broken needle still cannot be found, then these bundles are placed in a locked container and later on destroyed after authorization has been obtained by the production or factory manager. Records of the complete procedure are being kept for a minimum of 06 years after production to be available for auditing purposes.
Under NO circumstances the product being returned to stock.
If all parts have been found the components/garments are being returned to the workstation.
Only once the janome sewing machine needles replacement form has been fully completed the machinist is being issued with a new needle.
Medical needle (surgery, minimally invasive surgical needles, acupuncture, medical America)
Instrument with a needle (flute, saxophone with a needle )
Electronic semiconductor with a needle (air filters, discharge needle, probe)
Nonwoven (needles)
And finishing with a needle
Hand stitches
Needle arts (ceramics, quilting)
Bur
Computerized embroidery
Schiffli lace with a needle
Costume with a needle (underwear, jeans, knitted …)
Leather (footwear) with a needle
Bindings with a needle
Needle Policy
Needles stock should be placed in the maintenance stores and locked away.
Small stock of needles would be transferred to production floor to a designated person in charge.
All records must be maintained for 01 month and records of 06 months are kept packed in stocked boxes.
Boxes carrying needles should be kept in lock and key.
All operators must carry broken needle parts in designated Needle carry boxes provided in each line.
Person in charge of needles procedures (production floor) should carried an inventory card identifying the stock.
Movement in and out per type of needle. The in process stock locked in all timeIn charge of needles procedures (production floor) should have in possession one file per production line that contains the following information
In charge should carry all damage needles in a transparent box similar to the box
Of the needles in order to transport the damaged or replaced needle to the person in charge of the needles procedure
In charge of needles procedures (production floor) should have in possession one file per production line that contains the following information
Samples of each type of needle
Copy of needles procedures
Report identifying the time, and the employee required the new needle
Or a needle replacement and the reason signed by the in charge.
Kimbal/Tag janome sewing machine needles control policy:
All janome sewing machine needles are being accounted for in each factory: this means when a new needle is issued it cross references with stock levels of the particular needle and size is ensuring full traceability at all times.
Kimbal/tag gun needles are holding by the nominated person in a locked cupboard, which is only accessible by the person responsible for issuing new needles.
One in, one out’ distribution system – All kimbal/tag guns are being handed out to the workers by a nominated person at the beginning of each shift and are being collected at the end of each shift.
This distribution system is being recorded (s. attached daily in/out log), detailing workers names and numbers of kimbal/tag guns issued/returned and records are being kept for a minimum of 3 years from shipment date in case of a legal claim.
The number of workers with access to kimbal/tag guns are limited.
All kimbal/tag guns are being kept on cord secured to the workstation table.
The procedure as well as record keeping for any broken/bend/lost kimbal/tag gun needles is the same as described above for machine sewing needles.
Kimbal/ Tag gun logs as well as kimbal/tag gun needle control logs are fully completed each time before the new janome sewing machine needles are issued and records are being kept for 03 year as proof of due diligence in case they are required for any legal claims.
Product are not being kimballed in the metal free zone, after passing through the tunnel conveyor belt detector.
Examples of sharp tools are – Scissors, Clippers, Kimball/Tag guns, Knives, Drill hole spikes, Notch punchers, Tweezers, Cutting pins (if used on stripes, plaids and checks). All sharp tools are accounted for and issuing to the workforce by store officer with a cross reference to stock levels of that particular tool to ensure full traceability at all times. If any of the below are found in a garment, they can cause serious injury or a potential hazard to the ultimate customer, result in customer complaints as well as a possible serious fine, which can amount to thousands of money.
A garments Group is fully responsible to ensure that effective measures are in place to prevent any metal contamination such as:
Hardware from machinery, such as nuts, bolts, screws etc.
personal effects or jewellery parts
Standard Operating Procedures for Sharp Tool Control
Sharp Tools:Sharp tools refers to metal and non metal components having sharp edge which may lead to injury or uneasiness/itching/irritation on contact.
Garment industry uses Sharp tools extensively and thus it is very important to control the issue, movement and disposal of Sharp Tools properly and maintain the accountability for the same.
Various Sharp Tools being used in Garment Industry: Following are various sharp tools which are extensively used in the garment industry:
Sewing Needles
Thread Cutter
Scissor
Cutting Pins/ Notchers/ M/C Knife
Cutting Clamps
Loose Metal M/C Parts
Sharp Tool Control Practices:Below mentioned are set of industrial practices which need to be followed strictly to avoid any injury to any person (this includes both the categories of people; who are involved in manufacturing of the product and also the consumers who shall be purchasing and using/wearing the garment) and to avoid any chances of Sharp Objects being shipped.
Usage of Sharp tools
All the cutters and scissors must be tied with a string and must not be kept loose on machine, table or in surroundings of work place. They can injure any individual or can cause damage to garments. Cutter/Scissors must be tied by using string of length that after hanging down from work place the distance from floor is 01 foot above the ground level.
All the M/C’s should be equipped with Eye Guard and Needle Guard to avoid any injuries to the workers.
Cutter man should always use metal gloves while using the straight knife machines.
Storage of Sharp Tools
All the usable sharp tool items must be stored in Red Box provided in each cutting, sewing line and finishing line with lock and key arrangement. While those are not in use, no sharp tool can be kept at any other place other than defined Red Box.
At the time of use sharp tools must be tied and not to keep loose.
Record of Issue and Receipt
Line manager has to keep a daily record of issuing sharp tools to individual and receiving those back. He must issue and receive against name and card of person.
This is applicable to cutters, scissors, cutting pins, metal clamps and hand gloves in cutting.
Control on Issue and Receipt of Machine Parts
All the machine parts will be issued on exchange basis from main maintenance store.
No mechanic is authorized to keep any kind of machine part with him/her.
Issue of machine parts must be executed with requisition properly signed by factory GM.
Needle Policy and Broken Needle control
Needles stock should be placed in the trims stores and locked away
Small stock of needles would be transferred to production floor to a designated person in charge.
All records must be maintained for six months
Replacement against broken needles has to be provided only after receiving all the parts of the broken needle.
Accountability
The physically used needle should match our account whatever we issue in the production floor.
All the use needle should be keep in our record & maintain the quantity
Metal Detection Control
Metal detection machine should be calibration two time morning & evening before start the production & keep the proper record.
All the garment should be checked detector machine before ship the garments, if found any garment not passed in our detector machine this garments should be kept & log as evidence in Red Box properly.
Prevention of Sharptools:
Means taking all reasonable steps to avoid any metal contamination in the first place.
In sample room and any manufacturing operation pins and wires are not being used. This includes securing, bundling, tacking components or packing of any products.
No pins may be used for bulletin/notice boards in the sewing plant.
In cases where metal components need to be to be used such as check fabric laying, the control of the use is ensured maintaining record.
Scissors/clippers and any other sharptools is securely fastened to the sewing machines and inspection tables/workstations.
It is ensured that the production plant is free of dangerous items such as broken glass, splinters etc., since these cannot be detected by the needle detection unit.
Prevention of Sharptools
Maintaining a metal free environment.
To avoid stray metal and other components, small components (such as loose poppers, studs, rivets, zips etc.) are kept in appropriate containers.
Workers and mechanics are complying with the policy and products are being removed from an area if risk of contamination exists.
Any goods entering the factory are ensured as contaminant-free. It is therefore ensuring that the policy is passed up the supply chain to other suppliers. Trims and components are often secured with pins and suppliers of those raw materials are being asked to use an alternative such as tape.
Check that bulk trims ‘pass’ through the metal detector prior to use in production.
Any packaging is removing from outer packaging outside production areas to eliminate risks of product contamination.
Worksharptools Detection:
Worksharptools means to put additional checks in place to ensure the products are safe when shipped.
At final inspection garments are being turned inside out and pockets checked to avoid any loose components being trapped in them.
We require metal detection for all our products and it is mandatory for all children’s or kids wear orders, any nightwear, underwear or lingerie.
Worksharptools Detection
Control of Sharp Machine Tools:
Factory is following A ‘One in, one out’ distribution system to minimize the loss of tools, potential injury to employee’s and the risk of tools being boxed in cartons and shipped and or lost in product presentation boxes and or pockets or lining of product.
All sharp tools are handing out to the workers by a nominated person (store officer) at the beginning of each shift and are collecting at the end of each shift. Counting and signed for by the store officer.
Kimball/Tag guns are individually numbered and named per worker.
This distribution system is being recorded (s. attached daily in/out log); detailing workers names, their signature and numbers of tool issued/returned and records are keeping for a minimum of 03 years for verification.
All tools are being securely attached to the workstation (machines, tables, benches and inspection areas) by cord or string as possible to tool type, but holes are being drilled through wooden handles and location and condition is being verified daily.
Scissors and clippers are not being worn around the neck or wrist as this is a safety hazard for the employee’s in case they trip and injure themselves.
we are following a documented control system for the issuing and collecting of scissors and clippers.
Machine Tools
The employees will not remove their tools at break, lunch or dinner times in order to avoid them becoming lost or leaving the factory premises.
The floor supervisors are checking at least twice a day that they have not been removed without permission and keep a record of how many pairs have been issued, as per the count in/out log process.
Any blades or other sharp cutting tools are using within the factory floor maintaining proper sharp machine tools control policy. Snap blades are not permitted as they can break easily, cause injury and get lost in product, packaging and or cartons.
Metal is not using as sewing guides and or templates for pressing around to manage a shape, e.g. pockets. If guides are required thick card and or plastic is using. Cut thin metal can cause injury, split and break off into a small piece and become lost in product, packaging and or cartons, which may damage a product: or injure employees at our customer’s warehouse, stores or a customer.
The use of pins is not acceptable in any products of the and it is being avoided throughout the factory (incl. sample room, cutting, sewing, inspection, metal free zone, packaging or any other areas where garments/components are being handled).
Where pins are being using in packaging for meet up the requirement of a customer this is done in a separate area quarantined from any other production and the issue of pins is being controlled.
Pins/staples are not being using to assemble cartons.
The use of staples and staplers is being avoided in the factory environment. This includes incoming goods area, cutting room, sample room, metal free zone, and packing and is not being using on any paperwork used on the factory floor.
Threading wires are kept by the mechanic and if they are needed by the worker again they are kept in a controlled environment and counted in and out at the beginning and end of a working day by a nominated person.
Machinists is not being allowed to keep screw drivers or any other tool for altering machine settings in their machine draws, its are being kept at all times by the mechanic and or supervisor in charge authorized to amend machine settings.
Tools collected at the end of the day and spare parts (e.g. cutting blades) are always being kept away from the factory floor in a safe and secure environment, i.e. locked away in designated cupboards which only the store officer has access to. The record log of tool/spare part issue is being kept in the designated cup board.
The management is ensuring this sharp machine tools policy applied to embroidery, appliqué, printing etc. operations whether in house or at another site.
The unit of cloth measuring tape is listed in this article. A cloth measuring tape has 60 inch or 150 cm. A measurement tape has 1.5 mitres. 1 mitre = 100 cm. 1 cm = 10 m.m. 1 ligne = o.635. 1 mm = 1574 ligne. 1 cm = 15.74 ligne . 1 inch = 40 ligne. Objective is to ensure that all measurement tapes are calibrated to give zero defect targets. Defected measurement tapes are replaced with proper record.
Standard Operating Procedure for cloth Tape Measure Calibration
Procedure: To establish a system/ policy to control:
All measurement tapes are calibrated after 06 months.
Measurement tapes are issued from central point lab only.
Measurement tapes are calibrated against steel pre-calibrated scale.
Pre-calibrated steel tape is attested by third party every year.
After 06 months each measurement is checked with tolerance of 1/8” against each 32” and recorded in lab.
Cloth Tape Measure Divisions:
If we divide 1 inch into 32 divisions for cloth tape measure –
1/32” = 0.793 MM
17/32” = 13.493 MM
2/32” = 1/16” = 1.587 MM
18/32” = 9/16” = 14.267 MM
3/32 = 2.381 MM
19/32 = 15.051 MM
4/32” = 1/8” = 3.175 MM
20/32” = 5/8” = 15.875 MM
5/32” = 3.968 MM
21/32” = 16.863 MM
6/32” = 3/16” = 4.762 MM
22/32” = 11/16” = 17.462 MM
7/32” = 5.556 MM
23/32” = 18.236 MM
8/32” = ¼” = 6.350 MM
24/32” = 3/8” = 19.050 MM
9/32” = 7.143 MM
25/32” = 19.843 MM
10/32” = 5/16” = 7.937 MM
26/32” = 13/16” = 20.637 MM
11/32” = 8.731 MM
27/32” = 21.431 MM
12/32” = 3/8 = 9.525 MM
28/32” = 7/8 = 22.225 MM
13/32” = 10.318 MM
29/32” = 23.018 MM
14/32” = 7/16” = 11.112 MM
30/32” = 15/16” = 23.812 MM
15/32” = 11.906 MM
31/32” = 24.606 MM
16/32”= ½’’ = 12.906 MM
32/32”=1’’ = 25.656 MM
If we divide 1 inch into 16 equal divisions for cloth tape measur
1/16”
2/16” = 1/8”
3/16
4/16” = ¼”
5/16” ”
6/16” = 3/8
7/16”
8/16” = ½”
9/16”
10/16” = 5/8”
11/16”
12/16” = ¾”
13/16”
14/16” = 7/8”
15/16”
16/16” = 1”
If we divide a cloth measuring tape 1 inch into 8 equal division
The product is also called puff-print paste or foamboard printing and are clarified according to different foam multiplier, BF-200 is low multiplier foam. BF-200 is low multiplier foam, could be foam with temperature of 80-120℃. It is used for screen printing environment. BF-200 is washing resistance type, specially designed for burning flower printing. Mix a little water or harder to lower down the viscosity. But please use higher viscosity to print, thus printing materials is not easy to infiltrate to cloth bottom, and have a better hand-touch(softness). If the foam multiplier is too high, add BW-S or BR-S to ajust it, add BW-S for white degree requirement, add elastic transparent paste BR-S for colour requirement. Add BW-768M or BR-768G serial for hand-printing.
After Foamboard Printing:
Add colour paste after foamboard printing and add colour paste directly, after mixing up, add some water to adjust the viscosity if needed, as different colour paste has different viscosity.
Foamboard Printing
Could be use temperature to foam directly, but the printing surface will be rough.
Could be use heat-presser to foam with temperature of 125℃ for 5 second, in this way, the printing surface will be better smooth.
The above information is based on our own company’s test result, please have a test with small quantity before manufaturing with big quantity.
According to international consuetude of chemical product , we are not obligated to any guarantee about foamboard printing.
JIANGMEN SINOBLE PIGMENT CO., LTD.
ADD: Douwei Chongnan, Meige, Shadui, Xinhui, Jiangmen, Guangdong, China
C Tpat means Customs Trade Partnership Against Terrorism. Security practices that help to mitigate the risk of loss, theft, and contraband smuggling that could potentially introduce acts of terrorism in the global supply chain. Please be prepared to respond to each question during the audit. Only c tpat audit checklist and IT security guideline is described here. You can visit more about c tpat audit security.
