To ensure that only an acceptable quality of fabric and childrenswear accessories are used for producing garments and proper quantity of shipment is received from the supplier. All incoming fabric and accessories of Auto Garments Limited.Store Manager and QC Manager is responsible for fabric and accessories inspection and proper reporting to the Director (Marketing & QC) or Merchandiser. Merchandiser/Director (Marketing & QC) is responsible for informing and negotiating with buyer regarding any non-conformity issues. Director (Marketing & QC) and Merchandiser is responsible for giving disposition decision.
Procedure
Store Manager will receive incoming fabric and accessories and store them with YELLOW MARKED BOARD signifying the QUARANTINE status.
Store Officer will check the received fabric with the reported length, color and type of fabric with the stated shipment document quantity and the actual order quantity.
The findings will be recorded in Fabric Receive report (No. F/ST/10) and Accessories Receive Report (F/ST/01) as applicable. Discrepancy will be notified to the Director using Non-Conforming Material/Product Report (F/QC/20)
QC Inspector (Fabric) will check 10% of received fabric (shall include all colors and dyelots received) for quality using the fabric inspection machine. He will identity any defect, hole or stain and shade variation in the fabric and make calculation as given in the following page.
If the initial Inspection on 10% fabric fails, an additional 15% of fabric shall be checked. If the second check also shows high fault point, the shipment shall be either rejected or checked for 100%.
If point grade is 28 or below, the fabric is accepted.
The maximum penalty for any running yard (36″ X fabric width) must not be more than 4 points
If result is more then 28 points the Director (Marketing & QC) or the Merchandiser shall be informed and the Fabric identified with ORANGE color board representing non-conforming status.
The fabric is also visually checked for shading defects in side by side and length during fabric inspection and by cutting 6″ full width of fabric from each roll.
The defect and inspection result is recorded in Pre-Cutting Fabric Inspection Report (Form No. F/QC/17). Any non-conformity and abnormal shading will be notified using Non-Conforming Material/Product Report (F/QC/20). Roll wise Color continuity card is maintained for identification of shade variations.
Director (Marketing and QC)/Merchandiser shall make required communication with buyer and supplier for action to be taken. Director (Marketing & QC) shall review all decisions taken for the reported non-conformities.
During the fabric inspection if the yardage of any roll is reported more or less by the Fabric Inspection Machine than the one specified in the roll, the roll will be measured manually using measurement tapes. Only calibrated measurement tapes shall be used.
The result of manual measurement will be accepted as final. Any major discrepancy in roll length shall be notified to the Director (Marketing & QC) or the respective Merchandiser for that buyer.
For washable garments, Fabric shrinkage and color fastness is tested by QC inspector (Fabric) on roll of fabric. A sample is cut into 15 sq. centimeters block and washed. After wash it is rechecked for shrinkage. Fastness of color/color bleed is checked after ironing he washed sample and comparing with the buyer approved sample. The record shall be made in Fabric Shrinkage and Color Fastness test Report (Form no. F/QC/18)
Store Officer (Accessories) shall receive all accessories and check the received quantity for color wise and size wise break-up against suppliers commercial invoice/Packing list/work order & challan.
Accessories carton will be weighted and checked against the stated weight.
If the actual weight is found in accordance to the weight mentioned in shipping documents, packages will be opened for counting.
If the weight is not found proper store Manager will be notified of the findings and the packet will not be opened.
Store In-charge will record the non-conformity in Non-Conforming Material/Product Report (F/QC/20) and inform Director (Marketing and QC) or respective Merchandiser. Director 9Marketing & QC) / Merchandiser will give decision on that packet/lot of accessories after communicating with the supplier.
10% of Accessories of each type of every style shall be physically checked as per criteria specified by the buyer. The applicable sample size, inspection criteria and test method is available in Reference for Accessories Checking. The record (Pass/Fail) shall be maintained in Accessories Receive report (Form no. F/ST/01)
Non-Conforming Material/Product Report (F/QC/20) will be used for recording of any non-conformity identified. Director (Marketing & QC) or respective merchandiser will be notified of any non-conformity in quality of accessories.
If the accessories are found bearing acceptable quality and stated quantity, these will be stored in proper place in the stores with Identification and Quality passed status.
Non-conforming Accessories shall be identified with “ORANGE” board representing non-conforming status. After decision from the Director (Marketing and QC) or the respective Merchandiser, Rejected accessories shall be stored with “RED” board showing Rejected status.
Accessories Requirements
There should be no sharp edges that could result in injury to the wearer.
For childrenswear, all non-detachable components such as buttons, zips, sliders, studs, buckles and cords must withstand a specified pull force, which is customer specific. Buyer will mention relevant requirements in our make sheets.
All components for childrenswear must be either:
Too large to pass through a cylinder 32mm in diameter, or
Small enough to pass straight through the cylinder.
In other words, they must not stick in the cylinder and thus be capable of sticking in a child’s throat.
Generally, it states that any materials used must be designed and manufactured to meet the requirements of hygiene and cleanliness, avoiding risk of infection, sickness or contamination. Materials must in particular be visually clean and free from contamination.
Components must not rust or corrode, so be steel free as well as nickel & lead free.
All components used on childrenswear must be non-ferrous.
All zips must have no scratch top-stops.
Open-end zips must have top stops to prevent the slider being pulled off when the garment is unfastened.
Autolock sliders for zips must be used for all principle fastening applications for all garments.
With regard to childrenswear specifically:
Metal/Claw top or bottom stops must not be used. Plastic top stops must be used whenever available in the country of manufacture.
Coil zips must not be used on garments intended for children under 36 months.
On closed end coil zips, plastic bottom stops must be used whenever possible.
Metal zips are not suitable for children under 36 months.
A placket is required behind all zips on garments for children aged 36 months or under.
Pullers can be metal provided they meet all criteria and are non-ferrous and nickel free.
All zippers must have plastic moulded stoppers top and bottom.
Buttons must conform to all aspects of British Standard and must not contain toxic elements in excess of the limits.
All buttons and other trims must be lockstitch attached with a minimum of 10 stitches.
Any handsewing required must be discussed with the technical department buyer prior to production start.
Buttons and any other components must be able to withstand a pull test force of 90N, so thread used and the design of the button must support the required security of the attachment of the button.
Buttons made from glass, wood, mother of pearl, two-part or fabric covered buttons must not be used for childrenswear unless agreed with the customer.
All buckles whether sewn on or riveted must be checked for sharp edges or burrs before attached.
PU belts must be phthalate free, sides to be painted and ends rounded
Any metal used must be strong enough not to bend or break, in accordance with BS5665.
Eyelets & Metal fasteners must be cleanly clenched over to prevent sharp edges.
Prong studs must be at least 15 lignes (9.53mm) in size.
Stud buttons have arrow head fitment. Staple/prong attachments are unacceptable.
Waste punched from the eyelet hole must be removed and the item checked thoroughly prior to packing, to ensure that no waste remains.
Eyelets & Metal fasteners must be applied securely (with backing washer) according to the instructions of a signed data sheet and using the correct & recommended machinery (for press fastener attachment ratchet machines should be used). For childrenswear in particular, foot pressure machinery is not allowed.
Roll setting eyelets (opposed to split setting eyelets) must be used on all products.
All machines must be checked with sample pieces 2 – 4 hourly to ensure correct pinch is achieved.
Facings should be made wide enough to accommodate the press fastener easily.
They should not be positioned over seams or stitching.
They should not be applied to a single layer of fabric. On knitted fabrics woven interlinings should be used as a backing.
On garment wash items buttons/press fasteners etc. must only be attached after the washing process.
Garments should be turned inside out before attaching press fasteners. Then turned the correct way at inspection to ensure no loose press fasteners remain.
Supervisors and inspectors must have been trained on how to carry out daily random checks and document those (i.e. using a micrometer to check foundation depths on garments and a Vernier caliper to check correct pinch).
All accessories to be BHT free and of at least 100 gauge thickness.
All polybags must have at least 2 punched through airholes (so 4 holes in total) at least 150mm apart, of a ventilation area of 300mm per hole, to avoid accidental suffocation of children.
All polybags to carry a “child safety” warning. Please see the required wording below. Font size to be a minimum of 14 pt.
100% Polyester thread must be used on products with low-flammability requirements.
Monofilament thread must not be used in the production of auto garments
Harsh or rough threads must not be used where they will come into direct contact with the skin.
Where the back of a stitch, with heavy construction, may cause irritation to skin on any age, there must be a non-woven fusible interlining applied to prevent irritation
Chain stitch must not be used with heavy thread counts to reduce abrasion
For external decorative features, bulk thread double high twist thread products should be used
Cable ties must be no longer/wider than 14 cm x 4mm.
The materials those are used in clothing companies to create a garment beautiful for sale and packing other than fabrics and trims are called garments accessories.
Medicine was missing according the medicine list in the first aid box.
Workers not using ID card during the working time
Machine safety cover was missing the ROLAND 200
Hand gloves. Ear plug & Safety goggles were missing this area.
Die Cutting.
Fire Extinguisher not available
Evacuation plan was missing
Smoke detector not functional & not available
Fire alarm was missing
Fire alarm switch was missing
Auto
Worker not using PPE
Fire Extinguisher was blocked
Chemical container here & there
Smoke detector not available in this area
Manual
Worker not using PPE ( Ear plug, Hand gloves, Safety gloves , Musk)
Carton stored is so much sky-scraping
Emergency Light not available in the all premises
Need to installed Smoke Detector
Expose
Workers not using PPE
Need to installed Exhaust fan
Need to installed PA system in the hole premises
Store
Bin Card is missing in the store
MSDS was missing the store
Accessories stored in the excess level
Generator:
Chemical Container not using ion the second containment area
MSDS not available
Generator Operator not using Ear muff
Documents:
Fire fighter Certificate was missing
All training not updated since 2 months
Fire Fighter team was missing
Fire fighter list wasn’t update
Health & safety committee wasn’t update
Additional Garments Accessories :
Must be suitable for the material/ product/ treatment and wash
Must be correctly positioned, according to instructions
Must be colour fast
Must not damage the product when attached
Must if loose, e.g. belt, decoration, be attached with a pin tag/ stitches
Garments Accessories – Beads And Pearls for Children
Beads, and pearls must be checked for sharp edges and sharp points.
Beads, and pearls must never break or disassemble.
Styles with beads and pearls need to be wash tested 5 times to ensure that all decorations are intact and not sharp after wash.
Where hand stitched, the stitching should be locked off after every 10th stitch.
Additional requirements for size 44 up to and including size 98
Beads and pearls are small parts and can be a choking risk. Due to their small size they cannot be tested for 90/70N pull force, and are thus not allowed.
For bigger beads threaded on straps, the strap should withstand 90 N pull force test.
Garments Accessories – Decorations for Children
Studs and decorations must be checked for sharp edges and sharp points.
Studs and decorations must never break or disassemble.
Styles with glued on studs need to be wash tested 5 times to ensure that all studs/decorations are intact after wash.
Additional requirement for size 44 up to and including size 98
Glued on studs, decorations or diamantées are not allowed since they cannot be tested for 90/70 N pull force.
Decorations for Children
Garments Accessories – Touch and Close Fasteners for Children
It is recommended that soft qualities of touch and close fasteners are used on garments for baby and children.
The male part (scratchy part with hooks) should be directed away from the body of the child to avoid skin abrasion.
Touch and close fasteners used on garments must have trimmed corners, preferably rounded, or sewn with no exposed edges. No sharp edges allowed.
Garments Accessories – Liquid Filled Components
Liquid filled accessories shall be avoided as much as possible, but if in any exceptional case we need to use that
Global Quality Department must approve the product and liquid.
We always have to ask for a MSDS (material safety data sheet) and when needed also a full description of the content of the fluid.
Liquid Filled Components
Garments Accessories –Fringes
Fringes could be an entanglement hazard. Fringes that are loops are at higher risk, and for these the maximum allowed length is 7,5 cm in circumference (where fringes are allowed). Fringes that are a series of attached tassels must in addition to the below requirement be assessed as small parts.
Head, neck and upper chest area
44-134
No fringes allowed on hood or back of the neck. Other parts of neck and upper chest fringes are allowed with maximum length 7,5 cm.
No knots or 3D embellishment allowed.
Not from elastic material.
140-170
Maximum length 7,5 cm.
Knot or 3D embellishment is allowed.
Not from elastic material.
Chest & Waist
Maximum length 14 cm.
Knots or 3D embellishment only allowed on garments worn from waist down, such as trousers, shorts, skirts.
Lower edge (hem) of garments which end below crotch
Maximum length 14 cm.
Fringe must not hang below lower edge (hem).
Garments that finish at ankle: no fringe at lower edge, even if ending above hem.
Back area
Maximum length 7,5 cm.
No knots or 3D embellishment allowed.
Sleeves
Long sleeves
Maximum length 7,5 cm
Fringe must not hang below lower edge (hem).
No fringe at lower edge, even if ending above hem.
No knots or 3D embellishment allowed.
Short sleeves 44-134
Maximum length 7,5 cm
Knot or 3D embellishment is allowed.
Short sleeves 140-170
Maximum length 14 cm
Knot or 3D embellishment is allowed IF length of fringe is maximum 7,5 cm.
Garments Accessories Inspection
In order to ensure the best quality of Auto knit wear Ltd of Auto Group, each item (Garments Accessories) of every Order & Style must be inspected by following the below systems. At first, the responsible QC inspectors will be collected all kinds of necessary documents including approval from responsible concern person against that accessories before starting the inspection in any Receiving accessories. Then as per AQL those goods should be inspected randomly according to 10 % of receiving qty. During the inspection if the defect qty is more than 01 %, the inspection result will be failed. After that, the non-conformity report against problematic goods will be submitted to the concern persons for reviewing. Then those accessories (failed qty) have to dispose according to the written decision by authorized persons for segregating the defective goods.
Pls note, if is found doing a few pcs such problem-wrong information goods, mixed colors & mixed sizes in a delivery pack it must be informed to the concern persons through the non-conformity report for reviewing. As there is no acceptable quality level in this kind of problem.
Inspection Failed Qty: The inspection failed qty shall be re-inspected as per 15 % of receiving qty after checking by the supplier people. If the result of re-inspection is failed it should be 100 % inspected for bulk.
Accessories inspection Reports: It must be reported both pass & fail all kinds of accessories inspection as a record in daily & thus all accessories inspection reports of each order must be kept to save at least in one year as a record for showing as presentation.
Control of non- conforming accessories: All non-conformity accessories will be stored either in rejected zone or sent back to the supplier for replacement. Of course, this should be done as per the disposition decision of authority.
Replacement qty or short qty: Every time the replacement qty or short qty must be checked as per AQL & shall be reported both pass & fail of inspection as a record. If the inspection result is failed it has to inform to concern persons through the non-conformity report for the disposition decision. All kinds of accessories will be inspecting as per the above – mentioned instructions until
Garments Accessories – Buckles, Toggles, Hook & Eye for Children
Buckles, toggles and hook & eye must be checked for sharp edges and sharp points.
Buckles, toggles and hook & eye must never break or disassemble
Additional requirements for size 44 up to and including size 98
Buckles, toggles and hook & eye fitting completely within the small parts testing cylinder are considered small parts and must withstand 90 N pull force test.
Both the attachment of the detail, and all parts of the detail itself should be tested.
Buckles, Toggles, Hook & Eye for Children
Fabric trim is the related term of garments accessories
[1] S. M. Bappy Rana, B.Sc.in Textile Engineering, BUBT
