by Engr. Kh. Mashiur Rahman | Apr 19, 2019 | Blog
Garment quality control checklist
- Garment quality control checklist – Any type of final inspection problem (Recheck) Quality dept. become responsible not production. Read more about Top 100 QC Tools & Quality Tools …
- All recheck done by QC not others (final /internal)
- For skip / broken stitch – production people not take proper and prompt action.( reply that quality will check after that production will take necessary action)
- Any problem find out by QC – if supervisor not capable to correct it then QC will go to solve it by senior management.
- For defect (shade) – supervisor ask to go to senior management for solving the problem.
- Daily rolling inspection Report
- Daily in process Report
- End table Report
- Measurement inspection Report
- Hourly lot pass Report
- Daily Alter analysis Report
- Pre-Final & Final inspection Report
- 100% finished goods measurement record key point
- Fusing Test Report
- Button pull test Report
- Metal Detaction calibaration Report
- Rejection Fabric Report &Re-processing Report
- Reject Goods Keeping Report
- Maintenance wants tolerance for skip stitch 100/2 but who will ensure it.
- Supervisors work as helper not supervises the problems and sewing line.
- Hourly full quantity garments not supply to output
- Label mistake not solve permanently
- Any garment quality control checklist problem find out by QC, supervisor call to operator for continuing production.
- A, B & C shade – production continue for hoping pack separately.
- Held up garments in QC box – supervisor not care of it on time to repair.
- Tendency of supervisor that responsibility shouldering to QC for defect.
- Bundle not controlling in sewing line.
- Tang top piping not match as per cutting / summery not maintained.
- Traffic light system – Red flag problem not solve immediately.
- After identify defect – production transfer it to front without rectification.
- Operator always negligence about defect and tell to talk with supervisor.
- For reject – responsibility goes to production and QC not maintenance.
- R&D persons give importance about production not quality.
- Any garment quality control checklist problem – production people tell my responsibility is to do production not quality.
- More defects occurred but no one care of it.
- Fabric 4 point system Procedure
- Fabric Relaxation (S.O.P)
- Cutting Section Bundling (S.O.P)
- Cutting Spreading (S.o.p)
- Cutting Rejection Goods (Parts) Replacement (S.o.p)
- Cutting Parts number matching at sewing line( S.o.p)
- Care Label Main Label & any Decoration Label (S.O.P)
- Accessories Inspection Procedure
- Problem of operator not communicate to supervisor but only communicate to QC.
- Knowledge of styling very poor of supervisor cannot identify the problem.
- Relationship between production and QC very unfortunate.
- Finishing area defect not care by production and depend on finishing solving operator.
- Supervisor tendency is to pas s with defect as a result operator will occurs same defect.
- Defect not solve on time (garments kept in bag and solve end of the day)
- Inventory Report
- Accessories Inspection Report
- Fabric shrinkage Report
- Lab test Report
- Fabric inspection Report
- Fabric relaxation Report
- Marker check Report
- Spreading Layer Report
- Cut panel inspection Report (3 pcs system)
- 100% cut panel inspection Report
- 100%cut panel Quality check Report
- Cutting defect analysis Report
- Label issue register not maintain properly.
- Huge defect occurring due to style change.
- Create more defects due to operator change frequently.
- Any type of garment quality control checklist problem not solve on time but check with other floors.
- During any confrontation, supervisor call to QC – get out from my line.
- No headache about spot defect by production concern.
by Engr. Kh. Mashiur Rahman | Apr 19, 2019 | Blog
Sewing Production
- Quality department should responsible for production like as production concern. Read more about Inexpensive Sewing Machine
- Quality problem should communicate as per chain of command
- Defect should solve immediately but not keep long time for communicating with top management.
- New workers (Operator) migration is occurring due to over monitoring by Quality Inspector.
- M/C servicing problem – not keep long time to solve.
- Needle hole problem
- Any problem should not hold long time by . Mechanic for repairing.
- Take more time for new style layout
- Due to over documentary work, R&D officer not giving more time in production floor.
- SMV readjustment is required if more manpower included.
- Garments keep long time, if production concerns ask for it then QC find out more defect to avoid this.
- Major problem in finishing by quality & annoyance to operators.
- Keep garments in Custom Sewing Production line long time by in line quality without decision
- Same defect presented to several persons.
- Senior mechanic not come on time if call by supervisor and shown various excuse.
- Mechanic gives wrong decision without going to place.
- Oil leakage find out by production but not take proper action.
- During M/C problem if call mechanic for problem solve then mechanics negatively answer how pcs problem till now may.
- Problematic M/C keep long time but not sign by mechanic and show excuse to tell his boss.
- If M/C problem and request to change M/C but it will be changed after a long time
- Any type problem arise, if APM call QC then they replay that I do not ork under of you.
- Loose thread found over 5”-6” then maintenance accept it but QC not accepts this.
- Skip stitch and others M/C problem, responsibility goes to production concern not to maintenance.
- Inside’s small size uncut thread get out by QC.
- Need expert person o
- Proactive action required for critical area if have any probability of major defect.
- Layout giving delay by IE for new style.
- End of Custom Sewing Production
by Engr. Kh. Mashiur Rahman | Apr 19, 2019 | Blog
Non Compliance Report
- There are no Non compliance report and control of popper process for babies products. To know more Personal Protective Equipment for a Compliance Factory
- Metal tacks/nails/staples are being used on Tesco products or found on a production line/track manufacturing Tesco products
- There is no Effluent Treatment Plant for denim, dyeing, printing
- No Needle Control process within the factory as non compliance report
- There is complete failure of metal detector process – this could include: no metal detector or the metal detector is not working, being deliberately by-passed or is not being used on all products.
- Child Labour
- Fire Procedure – this could include no procedure in place, no fire exits, insufficient number of fire exits or blocked fire exits
Major non-compliances
- Un-controlled visitor access to site. Contractors working un-supervised/un-aware of requirements
- Waste management is insufficient or not in place
- No Chemical segregation
- Machine guards not in place throughout factory
- No PPE (gloves, eye guards) in use
- No Pest control program in place or is not sufficient enough or managed in a way as to prevent pest infestation
- No evidence of risk assessment carried out on childrenswear
- Raw materials do not go through a positive release system. There is no inspection carried out.
- No calibrated Light Box present for colour approval or shade batching
- Light box present but not calibrated in a minor
- Leather not 100% inspected
- Un-organised raw material warehouse where raw materials are not identified by quality and status and not stored in an organised manner
- Un-organised trim and packaging area. Products not inspected, identified or stored in an organised manner
- No metal detection on in take of children’s metal trims
- No structured product care label process in both the issuing and control of the labels within the production area
- Any manufacturing process being carried out by an external secondary site without Tesco approval.
- No guard around Band knife machine
- Fusing machine and/or fusing process has not got records to demonstrate required process control tests are carried out. Specifically applies to a tailoring or shirt manufacturer.
- Incorrect machinery for the attachment of buttons, poppers, bows etc on childrens products.
- Not using correct nominated poppers on childrens products non compliance report
- No pinch testing on poppers on childrens products
- No pneumatic or electric popper machines
- No “pull tests” carried out on Childrens products
- Non-segregation or classification of rejected products at examination processes
- Correct audit lighting – inspection tables only
- Un-controlled access to the secure, metal free zone where finished goods are stored awaiting shipment.
- Isolated incidents where the needle control requirements are not been managed correctly
- The majority of Scissors/clippers not ties to machines
- Isolated incidents where the metal detection requirements are not been managed correctly
- Metal free zone – has loose metal object found
- Unsafe electrical area
- One or two fire doors locked or some are blocked as non compliance report
by Engr. Kh. Mashiur Rahman | Apr 19, 2019 | Blog
Meeting Minute Rules
Meeting Minute Rules -During giving speech in the meeting minute rules you MUST take care that the listener does not get absent minded. No thoughts of the outside world should be in the meeting because the activity is the work of the ‘Darbar’. It is a very dangerous act. We sale Meeting Room Booking System for Buyer and Customers
Everybody MUST give full concentration on the meeting. Good quality of papers, pens etc. (stationary items) MUST be used in the meeting minute rules. There should be RED, BLUE and BLACK pen for marking different points differently. RED means mistakes, BLUE means need discussion etc.
Individual file MUST be maintained.We need to discuss about the mistakes which we did in the
earlier sessions in the meeting. We have to overcome the mistakes within next 24h
time. The same mistakes should not happen in future.
Everybody MUST be in a good, decent fashionable dressing.
Gorgeous cloths MUST be wearing during summer session. In winter formal
official dress (suite, tie and shoe) is preferable.
All attendees MUST use body deodorant and per need to conduct/arrange some kind of training to those who are fume before coming to the meeting. Lots of OTHER people are present in the meeting and so all attendees MUST be in holy/pure state of mind. Many important person observe our meeting.
‘Colored Stick’ (made of ‘Gozeri’ tree) will be there in the
meeting room when ‘Baba’ is present in the meeting.If anybody feel asleep, he/she MUST be punished either in
monetary or physical form (hitting by punch).
Business related discussion will be in a separate session. Need to establish the business proposal. Wrist watch is not allowed in the meeting. Mobile phone MUST be switched off. In case of emergency one may use by taking permission and going outside the room.
Actions
All communications in the meeting should be in English. Fluency in spoken & written English is a MUST. We need to conduct/arrange some kind of training to those who are lacking in English. Writing pad and pen with the Spiritualizer foundation logo should be prepared. Flowers should be there in the meeting room.
As our organization is profit based so we all legal papers should be prepared in proper ways. As this government is very strict in paper works that’s why we need to take extra precautions about the works. One person will lead a lot of other people, so we need to know how to instruct/lead. All need to know and practice 4 types of Tie-Knotting
techniques.
We need to add some Yoga related to the physical fitness of the attendees. Need to make donation to the SIDR victim to ‘Prothom Alo’ in the name of the Foundation to make our good activities (the foundation) visible. We need to organize blood donation program so that we can
help our ‘Zaker’ brothers.
All needs to take Yoga and also needs to show medical check-up report in every 6 months. We need to listen to the children about any misbehave/torture etc. they faced. Need to arrange special training about the meeting (Rules, Principles etc.) for the age-wise meeting attendees.
Need to arrange training on Cooking, ‘Hostoshilpo’ etc. for those who are educated but not engaged in formal jobs. Need to prepare visiting card after finalization of the foundation. Everybody will be designated by posts so that no questions will be asked by outside world.
Principles
Meeting attendees should be more responsible on their works.
Every task will be time bounded.
We need to concentrate more on the Meeting room environment. Without proper/good environment meeting will not be effective. That’s why we need a formal place not the home for meeting. Our own music (light instrumental music and the sound of flowing water) should be played during the meeting… …it has some psychological effect on our mind. The sound of flowing water will refresh our ‘Kolb’. Fresh flower should be present and also we need to concentrate on the cleanliness of the meeting room environment .With this meeting, all our problems will be solved. Both our social & spiritual problems will be solved by this meeting minute rules activity. Everybody should have different responsibilities. ‘Gagotik’ problem, Private problem should be discussed separately. If anybody feels shy then problem can be written to ‘Baba’ in letters also.
1st and main objective of this meeting minute rules is to get the satisfaction of Allah and His Rasul (SM). Those who work for themselves are the fools. Betrayers will be punished. Punishment is for his/her safety in the future. The age group (minimum/maximum age) of the children team will be decided by the Seniors.
by Engr. Kh. Mashiur Rahman | Apr 14, 2019 | Blog
Child Labor Policy
Child Labor Policy -All Vendors shall comply with all applicable laws of the countries in which the Vendors are doing business, including (but not limited to) laws and regulations relating to prison or other forced labor, child labor, freedom of association, pay and compensation, employment discrimination, the environment, health and safety, the apparel industry and any related fields. Read more about Attendance & Overtime Management ….
- The Vendor should encourage and allow eligible workers to participate in work-study or apprenticeship programs, and other government-sponsored educational programs. Auto Fashion Ltd. does not recruit any worker under age of 18 years.
- In case if required to recruit adolescent workers, i.e. under 18 years and above 14 years of age, will follow following procedure:
- The Vendor shall follow all applicable laws concerning employment of persons between the ages of 16 and 18 . Work hour not more than 5 hours a day.
- Will not work between the hours of 7 p.m & 7 a.m
- The Vendor shall not use forced or involuntary labor of any kind, including prison labor, debt bondage, forced labor, or labor that is required as a means of political coercion or as punishment for holding, or for peacefully expressing, political views.
- Will require certificate of fitness from civil surgeon.
- Will require written consent from parents.
- Employees are free to choose whether or not to lawfully organize and join associations. Auto will seek business partners that share its commitment to the right of employees to establish and join organizations of their own choosing.. Will keep separate register.
- Auto requires that its foreign Vendors and its U.S. Vendors of imported merchandise supply a manufacturer’s certificate for each shipment of foreign-produced merchandise . Some laws may restrict such employees from working overtime, in a hazardous environment or during school hours. Will carry a token
- The manufacturer’s certificate will verify that the merchandise was manufactured at a specific factory, identified by name, location and country, and that neither prison labor, forced labor, indentured labor, nor child labor was employed in the manufacture of the merchandise.Will not work in any machines that are in motion.
- Will get annual leave based on one day for every fifteen days of work.
- factory does not have written child labour policy
- age verification system not in place
- factory has no written child remediation policy – young workers have no health examination & registration approval from local labour bureau not obtained
- Auto will not knowingly utilize or purchase materials and/or products manufactured by prison, forced or involuntary labor.
Conclusion
Child Labor Policy -In case if mistakenly a child labor (Under 14 years of age is recruited), immediately Company will discontinue the service of that worker and will arrange and bear the cost of education, and will also give guarantee that on completion of education and achieving the age of 18 years will give priority and will offer him / her job in this company.
by Engr. Kh. Mashiur Rahman | Apr 14, 2019 | Blog
Security Audit Check List
Security Audit – Insufficient Security Audit seating arrangement due to yarn storage in the dining room of the workers was discussed with due importance and Mr. ggg express his utter dissatisfaction for the mismanagement. It was recommended that the dining space for the workers should be free for taking food conveniently. We sale electronic document management system …
Sufficient seating arrangement is to be provided in the owrkers dining room. Decision has taken that nothing to be kept in the workers dining room. It should be always free from any obstacle. All concerned persons are informed to take necessary measures.\
Factory management has not yet implemented the new Labour Law
Management Representative said at this moment all types of law and regulations have been implemented in the factory. Ms. Vice gggemphasis on this issue and she proposed to appointment a Law Consultant for the company. Manager, GS & Compliance, Corporate Head Office will be monitoring the legal requirement of the factory and a Law consultant to be appointed as soon as possible.
- Hiring procedure.
- Termination policy.
- Employee training manual (related to security).
- Incident reports.
- Copy of background check.
- Copy of employment verification.
- Security meeting minutes (attendees list).
- Security training program/schedule (type of training).
- Invoice from alarm Company and surveillance camera(s) (or maintenance bill).
- Documentation of internal Security Audit.
- Employee identification badges.
- Crisis management plan.
- Certificate of Incorporation
- Company Income Tax Clearance Certificate
- VAT Clearance Certificate
- Building Approval
- Environment Certificate
- Trade License
- Export License
- Import License
- Visitor’s log book.
- Incoming vehicle registration log.
- Vehicle release slip.
- Visitor passes/identification badges.
- Security guard patrol log.
- Factory License
- Export Promotion Bureau Certificate (EPB)
- Bond License
- Fire License
- Permission for Generator From the Legal Authority
- Certificate from the Ministry of Power, Electricity & Mineral Resources for the
- Bill of lading, if any (copy)
- Commercial invoice, if any (copy)
- Packing List (copy)
- Other related shipping manifest, if any (copy)
- Any other documentation related to shipments
- Electric Sub. Station.
- Boiler License & Competency Certificate for Boiler Operator Certificate for Electrician
- Latest Drinking Water Test Report
- Group Insurance Records
- BGMEA/ BKMEA Membership Certificate.
- M/C List
- Manpower Status (Total: Male, Female: Present (Male & Female)
- No of Security Guards
- Name, address and phone no of subcontractors.
- Fire Drill Register
- Broken Needle Register
- List of Trained Fire Fighters
- List of Trained First Aides
- Fire Equipment List (Floor wise)
- Accident & Injury Register
- Waste Water Test Record
- Training Record on fire, PPE, M/C operation, First Aid
- Worker’s Service Book
- Personnel files
- ID Cards/ Appointment Letter
- Attendance Records
- Time Cards
- Payroll Sheets & Overtime Payment Records Last 03 Months
- Maternity Benefit Payment Documents & Register
- Leave Documents & Register
- Leave encashment Docs for the Resigned Worker’s/ Final Settlement Records
- Festival Holiday List
- Copy of Pay Slips / Copy of Overtime Slips
- Labor Union Agreements/ Workers Participation Committee minutes/ Worker’s Welfare Committee.
Conclusion
The Management reiterated the importance of Health and Safety Management System. Manager GS & Compliance, Corporate Head Office pointed out that it is deeply associated with the matter of health and safety. All types of chemical containers those are using in the production process and ETP the Labels and MSDS have to be prepared and attached in the container if there is missing any Manufacturer Security Audit & Document Check List
