Raw Material Sourcing – One copy of purchase order / Proforma Invoice (P.I) must be sent to the store authority which must be match with Buyer’s order sheet.
The purchasing goods to be checked at the gate during arrival to the factory by the security personnel.
The goods must be checked as per challan by the security personnel and that is to be informed to the store authority for being realization about the arrival goods are pAuto r noticed or not.
After checking by the security personnel it is required to take permission from Admin authority for entrance the cargo vehicles.
According to production requirements supervisor will make a requisition slip.
The requisition must be placed to the production manager / Asst. Production Manager or competent authority who will give the permission after verifying of requirements.
All entrance gate, building, goods receiving and loading area, parking area, packing section will be monitored and observed by C.C TV system.
Minimum 45 days record will be preserved by D.V.R.
The recorded cassette will be preserved for minimum 6 month for requirements.
This C.C TV system will be controlled by one well trained security inspector under security in-charge by the guidance of the admin manager.
Previous incidents or occurrence will be detected by the recorded cassette.
After ensuring production manager’s / APM or competent authority the Raw Material Sourcing to be supplied as per requisition by the store authority.
Store authority must follow up & required to ensure about the utilization of goods.
The cargo vehicle is to be escorted to the predetermined unloaded area where the goods to be unloaded with the presence of store authority.
Store authority must check the goods according to Proforma Invoice (P.I) and to be stored properly in a secured place.
Raw Material Sourcing store authority must maintain a register for received goods according to details information like supplier name, quantity, date of receiving, place of stored, name of goods etc.
Fabric is the key raw material in garment it will take about 80% of the total cost. Auto Textile has special care of their main raw material before goes into production.
This point production (fabric) or stores will provide complete shade band to the quality department. Once out source fabrics comes to stores or in house fabrics before comes to stores will conduct 10% inspection and will accept or reject lot based on 4-point system. More Raw Materials
GSM & Lab test reports
Initially with the shade band GSM of the each roll will be check by the QC against buyer standard. QC is responsible for the getting lab test report for each lot as per the customers’ requirements such as color fastness, shrinkage, ph value, bowing etc. If GSM and lab test is pass then will go for the 10% fabric inspection to analyze visual defect level.
In the case of failure of the above for in house fabric will send into to the mill for re-processing, but in the case of out source quality manager and merchandiser will take final decision after discussion with buyer and the supplier.
Shade variation checking
Fabric rolls are feed into the fabric machine face side up and cut approximately 6” panel across width to asses the within roll shade variation. 6” wide panel must mark their left & right just after cutting it. While conducting visual inspection start, middle and end of the roll will check for shade deviation by placing 6” cut band left, middle & right alternatively.
Visual inspection of defects
After the fabric been load to inspection machine start inspection. Machine speed should be set to the 10 to 15 m/min. When fabric is moving on the machine inspector will observe possible defects and mark them on his inspection report
After completion of the inspection result will be compute as per 4-ponit system
4-point system (Reject length point system)
Length of defect Penalty Points
Less than 3” 1
3” to 6” 2
6” to 9” 3
9” above 4
Finally calculate the total point per 100 yards or meters. Depend on the different customer number of points allow will be differ and Auto standard is 40 point above will be fail. If the inspection “passes” whole fabric lot will be releasing to the production.
If the inspections “fail” QC will conduct 100% fabric inspection and accept good rolls for the production. For reject rolls quality manager will advise the corrective action.
For in house fabric 10% inspection fail will return to the fabric department for re-processing.
No
Document
Section
Responsibility
Supervision
1
10% Fabric Inspection Report
Fabric inspection
Quality Inspector
Quality Officer
2
Swatch Card-GSM
Fabric inspection
Quality Inspector
Quality Officer
3
Lab test report
Laboratory
Trims & Accessory inspection
Trims and accessories inspection will conduct in lot wise. Initially 10% of the material will be inspected. Decision of the acceptance or rejection will be done as bellow;
a. If lot has less than 2% defect it will be accept
b. If lot contains above 2% and less than 15% take another lot for the second inspection.
c. If more than 15% defect found will conduct 100% inspection and replace the damage quantity.
QC will conduct the inspection and test trims & accessories against the buyer standard.
Hook & Eye section
Before goes in to the production QC will ensure the shade of the fabric as per the buyers’ standard. Once the production start first out put will check and approve by the quality team for production. In first out put will check the shade (again), measurement, hook and eye strength. Further for the first out put will conduct lab test as per customer’s requirement.
During production QC will conduct 100% inspection.
