GOUS UPDATE SOP MANUAL
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This document outlines the standard operating procedures for document control at Gous Fashion Industries Ltd. It details the document coding system used to identify documents, the process for authorization and approval of new/revised documents, and responsibilities for document control. Key personnel are authorized to control documents for their departments. A document controller is responsible for collecting obsolete documents, organizing the document control room, and retaining/disposing of documents according to policy.
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All revisions to forms must be made after consultation with the heads of the relevant
departments.
All running production related documents must be kept in their specific area with the
identification and after completion of an order [final shipment] all documents should be
shifted to Documents Control Room.
GFILemploys responsible personsbearing the designation ofDocuments Controllerswho
are responsible to collect the obsolete documents, organize the entire Documents
Control Room, which is located on the 3rd floor besides the Managing Director’s room.
The designated room is identified by a signage as ‘Documents Control Room’.
Persons authorized toaccess and use the Document Control Room are listed andvisibly
posted at theentry gate of the room.
The Document Controller will retain the documents, maintain the records and dispose the
documents with evidence maintaining the relevant company policy and procedures.
Manager, Technical Compliance & Auditis responsible to make sure the policies and
procedures are implemented and controlled. If any non-compliance issues arise in any
area the Manager, Technical Compliance & Auditwill issue a Non Conformance slip and
report the same to the Factory COO and the Managing Director.
Controlled documents are found as mentioned in the master list of controlled document.
4. Document Control:
4.1 Document Coding:
4.1.1 The documents are numbered in the form of GFIL.AAA.BBB.##, where:
4.1.1.1 GFIL stands for Gous Fashion Industries Ltd.
4.1.1.2 AAA is the department code.
• DDC Document & Date Control
• MKT Marketing
• MER Merchandising
• HRM Human Resources
• TCA Technical Compliance & Audit
• SCP Social Compliance
• QMS Quality Management
• QAS Quality Assurance
• QCS Quality Control
• ICQ Incoming Quality Control
• PQT Pre-final Quality Team
• SPL Sample
• SEW Sewing
• CUT Cutting
• FIN Finishing
• TST Testing
• IVS Inventory & Stores
• MNT Maintenance](https://image.slidesharecdn.com/f75eb694-abd5-4034-a115-75a010de2484-170202112535/85/GOUS-UPDATE-SOP-MANUAL-8-320.jpg)
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If there is a new version of a document, it is distributed following the Revision of
Documents procedure. At the same time the obsolete document is removed from
use.
The Manager TC&A is responsible to ensure the management of obsolete
documents as per the above procedure.
4.4 Revision [amendment] of Documents:
4.4.1 The Authorised Document Controller is responsible to identify the need for any
change required in any document and initiate process of revision.
4.4.2 The document number is given an extension with “ – “followed by the change
number.
4.4.3 Revised document is prepared by Authorised Document Controller and submitted
to Manager TC&A for approval.
4.4.4 All the revised / amended documents are distributed according to the Clause # 4.5.
4.5 Document Distribution:
Authorised personnel can only initiate distribution of new or revised documents
after acquiring approval from Manager TC&A and the Managing Director as stated
in 4.3.
Once the Managing Director has approved the new or revised document the
Manager TC&A will hand it over to the respective Authorised Document Controller
who shall then conduct the distribution process.
The Authorised Document Controller must acquire acknowledgment from any
personnel the document is provided to and maintain such record at his own and
provide a copy of such acknowledgement to the Manager TC&A for record in the
document control system.
4.6 Closing, Storing, Disposal & Retention Period of Document:
4.6.1 When the last shipment of a Style is completed all related documents (SIP/PVP &
SOP files) and samples are collected and the file is closed for that Style. And It will
be OBSOLETE, Once the document is closed, it cannot be retrieved without the
approval of the Managing Director.
4.6.2 All Production Documents and Samples are gathered together and stored in
document control room. There will be a check list posted in document control room
for the identification to find details of style, production start date, last shipment
date, document retentions period and disposal date of the document. The same
information will be mentioned on the file as well.
4.6.3 All documents are to be disposed after the retention period as per local disposal
law.
4.6.4 Hardcopy of documents shall be shredded after they have been retained until the
end of the Document Retention Schedule. Digital copies will be destroyed by
formatting the hard-drive/ storage media. Stored Media such as CDs, DVDs, etc
will be destroyed by proven means to destroy such media after they have been
retained until the end of the Document Retention Schedule.
we will designate any disaster area, documents – will be sold at Paper mill for
recycling purpose or will burn for maintaining the local environment law and take a
digital images for evidence and all disposing items name should be enclosed at
Documents destruction form with time period.
4.6.5 A designated area shall be provided in the Store to store documents that shall be
disposed or destroyed eventually.
4.6.6 Paper documents maybe sold to the local paper mills or its representatives for
recycle purpose maintaining local and environmental laws.](https://image.slidesharecdn.com/f75eb694-abd5-4034-a115-75a010de2484-170202112535/85/GOUS-UPDATE-SOP-MANUAL-11-320.jpg)
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06. In house testing procedure (Shrinkage test, GSM test, button pull test etc.) are executed to
ensure the meet quality safety rules and regulations.
07. To allocate the inline checking procedure at finishing stage for confirm the packed goods
are meet the customers quality level.
Backup Quality Procedure:
Overview:
The factory keeps extra quality inspector trained on various process of several work. In the
event of shortage in QC coverage in any department, these QC’s are assigned as
replacements in any respective departments.
Purpose:
The purpose of this procedure is to establish and process for ensuring 100% quality coverage
for every production unit in every shift.
Scope:
In case of any emergency / migration, GFIL maintains a backup QC team to smoothly support
the regular work. Back up QC are mostly used in Sewing Quality and Cutting Quality. These
departments must always be facilitated by backup QC at all times.
Responsibility:
Floor Sewing Quality Controller / In Charge will be responsible to maintain attendance register
for QCs. In any absentees floor sewing quality controller need to follow the backup QC
procedure. Similarly cutting, store and finishing QC In Charge need to maintain QC attendance
registers and follow the procedure in case of any absentees. Quality manager has the
responsibility to ensure the procedure is followed.
Number of Backup QCs:
GFIL maintains a total of five [5] well trained Backup QCs, who are assigned to work under the
Finishing .
Backup QC Procedure:
1. A Backup QC register with name and ID no of the personnel must be maintained daily
by floor QC In Charge, Cutting QC In Chare, Store QC In Charge, Finishing QC In
Charge for the permanent station QCs.
2. Another register is maintained to record status of presence for the Backup QCs.
3. If any permanent assigned QC is on leave or absent than a Backup QC will be allotted
for the coverage of that shift.
Record of Revisions:
Version
Number
Date Section(s) Page(s) Summary of Changes Signature](https://image.slidesharecdn.com/f75eb694-abd5-4034-a115-75a010de2484-170202112535/85/GOUS-UPDATE-SOP-MANUAL-21-320.jpg)
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GFIL.MER.PRO.03
Version # 3
Issue Date : Feb02, 2013
Revision Date : March20, 2014
11. Product Test Plan [PTP]
Purpose:
1. To develop and implement the Product Test Plan [PTP] as appropriate to the product and the
process involved to manufacture the product in order to validate product quality, safety and
compliance with rules, bans, standards & regulations.
2. To meet the Consumer Product Safety & Improvement Act (CPSIA) rules and regulations.
3. To avoid customer compliant regarding any safety issue in future.
Scope:
This procedure is applicable to all the products being manufactured at and/or for all the
production units of GFIL.
Responsibilities:
The respective Merchandiser and Manager – Technical Compliance and auditare responsible
to develop the PTP and COO is responsible to approve the PTP
Procedure:
1. PTP is a documented plan for validating product quality, safety and compliance with rules,
standards and regulations.
2. PTP guides all the concerns about:
2.1 The types of testing and inspections for the product
2.2 The process monitoring stages and requirements
2.3 The frequency to conduct 4.2.1 & 4.2.2
2.4 The criteria to conduct 4.2.1 & 4.2.2
2.5 Covered section and respective concern person with designation.
2.6 Clearly defined the tolerance level.
2.7 Measurement method, reaction and documents control id are including at PTP.
3. Respective Merchandisers and Manager Technical Compliance & Audit are assigned to
prepare the PTP appropriate to product & process with following considerations:
3.1 Category of the product
3.2 Product risk level
3.3 Product regulations
3.4 Manufacturing processes
3.5 Raw Material used
3.6 Factory capabilities](https://image.slidesharecdn.com/f75eb694-abd5-4034-a115-75a010de2484-170202112535/85/GOUS-UPDATE-SOP-MANUAL-32-320.jpg)
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GFIL.QCS.PRO.01
Version # 3
Issue Date : Feb02, 2013
Revision Date : March20, 2014
16.Procedure for Fabric Inspection
1.0 Purpose & Scope
To identify and determine the extent of fabric defects, the different width and other quality level of fabric lot
received so as to ensure the fabrics confirms to the required standard before spreading.
2.0 Responsibilities
2.1 The IQC In-charge is responsible for the monitoring and the implementation of the fabric inspection
system and to verify the authenticity of the fabric inspection report.
2.2 The Fabric Inspectors [QA] are assigned to carry out the fabric inspection and to maintain the
inspection reports.
3.0 Procedures
4 point system fabric inspection:
1. Sampling: For the inspection, a minimum of 10% of the fabric covering each color and each dye lot and
different width of fabric is covered based on the fabric lot size.
1.1 Shipment of 1,000 yards or less - 100% inspection
1.2 Shipment of 1,001 yards or more - 10% inspection (minimum 1000 yards)
2. The inspection is carried out major fabric defects
2.1 Major woven fabric defects are slubs, hole, missing yarn, conspicuous yarn variation,
end out, soiled yarn etc
2.2 Major knitted fabric defects are mixed yarn, yarn variation, runner, needle line, bare,
slub, holes, press off etc
2.3 Major dye or printing defects are out of register, dye spot, machine stop, color out,
color smear or shading.
3. Points are allocated to every fault as per the point’s table listed below:
Size of defects (in inches – length wise) Penalty points
Up to 3 inch 1 Point
3 inch to 6 inch 2 Points
6 inch to 9 inch 3 Points
Over 9 inch to 36 inch 4 Points](https://image.slidesharecdn.com/f75eb694-abd5-4034-a115-75a010de2484-170202112535/85/GOUS-UPDATE-SOP-MANUAL-47-320.jpg)
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GFIL.QMS.CRT.02
Version # 01
Issue Date: 20 March 2014
Revision Date: N/A
26. GFIL AQL [Acceptable Quality Level]Charts:](https://image.slidesharecdn.com/f75eb694-abd5-4034-a115-75a010de2484-170202112535/85/GOUS-UPDATE-SOP-MANUAL-72-320.jpg)
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GFIL.FIN.PRO.01
Version # 03
Issue Date: 04 February 2014
Revision Date: 20 March 2014
32. Finishing Department
Purpose:
To develop, implement and maintain the procedures for the functions under the Finishing Department to validate
accuracy of the product quality, track every product with record in the department for packing accuracy and in time
shipments.
Scope:
This procedure is applicable to all concerned handling the products manufactured at Gous Fashion Industries Ltd,
pertinently in the Finishing department.
Responsibilities:
The Finishing Manager is responsible to implement and maintain the procedures and relevant records in the
department.
Procedure:
1.0 Input of Garments:
All goods coming in must be checked for quantity
All goods must be segregated as per PO, Style, Color & Size
All goods must be stored in a clean area before processing
All incoming goods must be separated from goods that are being worked upon.
2.0 Shade Checking:
All Shades must be sorted and segregated as per approved shade band
3.0 Loop Cutting:
Loops must be trimmed as per clients requirement and as per approved sample
Care must be taken not to damage the garment while cutting the loop tolerance
4.0 Size-wise Sorting:
All goods must be sorted size-wise
5.0 Pocket Cleaning [for washed garments & if required only]:
Pockets are checked inside out and cleaned of all dust particles manually and through thread sucker
machine.](https://image.slidesharecdn.com/f75eb694-abd5-4034-a115-75a010de2484-170202112535/85/GOUS-UPDATE-SOP-MANUAL-81-320.jpg)
GOUS UPDATE SOP MANUAL
- 1. Gous Fashion Industries Ltd. Standard Operating Procedure. 1 SOP – gfil property GFIL.ORG.01 Version # 3 Issue Date : Feb02, 2013 Revision Date : March20, 2014 Organization Chart
- 2. Gous Fashion Industries Ltd. Standard Operating Procedure. 2 SOP – gfil property GFIL.WFD.01 Version # 3 Issue Date : Feb02, 2013 Revision Date : March20, 2014 GFIL Work Flow Diagram
- 3. Gous Fashion Industries Ltd. Standard Operating Procedure. 3 SOP – gfil property
- 4. Gous Fashion Industries Ltd. Standard Operating Procedure. 4 SOP – gfil property GFIL.QMS.ORG.01 Version # 3 Issue Date : Feb02, 2013 Revision Date : March20, 2014 GFIL QA Organ gram Chart
- 5. Gous Fashion Industries Ltd. Standard Operating Procedure. 5 SOP – gfil property GFIL.QMS.WFD.01 Version # 3 Issue Date : Feb02, 2013 Revision Date : March20, 2014 GFIL QA Work Flow Diagram Fabric Inspection Department. 01.Fabric inspection ,10% 02.Fabric Shrinkage Test, 10% 03.Fabric Weight Test, 10% 04.Fabric Shade & Grade Separation, 100% w ash blanket Inventory Accessories Inspection Department. 01.Acc. Inspection , 10% 02.Carton Inspection, 10% 03.Barcode Scanning Report.Test, 10% Inventory Cutting Department 01.Fabric Relax 02. Marker Checking , 100% 03.Spreading Inspection 04.Cutting Marking Check, 05.Cut Panel & Bundle Inspection. 100% For Big parts
- 6. Gous Fashion Industries Ltd. Standard Operating Procedure. 6 SOP – gfil property Sewing Department 01.Process Check- Front & Back Part Inspection. 02.Final End Table Inspection 03. Measurement 04.Hourly Lot Pass Inspection- A.Q.L-1.5. 05.Daily Defect Analysis 06.Daily Wash Repo, 10%rts 07.Weekly Quality Goals 08. Traffic Light Chart w ith Process Mock-up 09.Stitch Monitoring P.P. Meeting / 1st output Meeting / Pilot Run Meeting Finishing Department 01.Process Inspection. 02.Final End Table Inspection 03.Hourly Lot Pass Inspection- A.Q.L-1.5 04.Daily Iron Defect Identification 05.Weekly Quality Goals 06.Daily Carton Audit – A.Q.L.- 2.5,Level-1 07.Pre-Final Inspection- A.Q.L-.2.5,Level- 1 08. Key Point Measurement
- 7. Gous Fashion Industries Ltd. Standard Operating Procedure. 7 SOP – gfil property GFIL.DDC.PRO.01 Version # 3 Issue Date : Feb02, 2013 Revision Date : March20, 2014 5. Documents, Samples& Data Control 1. Purpose & Scope: To give a clear guideline to the concerned personnel to use and control the documents used in each department. This procedure is a “controlled” document and authorized for use. Before using a printed copy of this document, it should be ensured that it is the most up to date version by checking the date and version numbers with the Document Control Department. Unauthorized changes to the document and overwriting or using fluid are strictly prohibited. This policy specifies how important documents (hardcopy, online or other media) should be controlled, distributed, retained, protected and disposed. The policy also ensures that: a) Necessary and important documents are preserved for future reference b) Documents that are not necessary are destroyed to avoid any confusion c) Documents are easily accessible d) Documents are of current version, executed, controlled and clearly defined how, where and who will be responsible to control and dispose the documents 2. To successfully implement the operational procedures the Factory HR and FE Departments must assure the following: a) Implement the policy in correct way and ensure its functional activities. b) Educate all concerned persons about the policy and organize the training for all respective departments to execute the policy at all stagesfully and efficiently. c) Regularly monitor to ensure the documents are segregated, retained and disposed as per the policy. d) Regularly monitor the Document destruction procedure (must be maintained as per the local law) and Collect the destruction form with evidence from the respective departments. e) That the retained documents are easily accessible. f) Any need to change or modifyany of the procedure and related documents must be approved through a meeting with the presence of the Managing Director. g) Conductat least one yearly meeting including Managing Director to review the implementation and execution of the procedures. 3. Responsibilities: Each department head and other relevant personnel are responsible for the control, distribution (if applicable) and handling of their respective departments’ documents. The Managing Director of in consultation with individual department heads will categorize the types of documents/records that need to be maintained and will assign retention periods upon periodic review of company policies and procedures. All forms used in the day to day activities must be controlled as per the general document control policy, however the authorized person to make changes will be the Chief Operating Officer after consulting with the Department Heads.
- 8. Gous Fashion Industries Ltd. Standard Operating Procedure. 8 SOP – gfil property All revisions to forms must be made after consultation with the heads of the relevant departments. All running production related documents must be kept in their specific area with the identification and after completion of an order [final shipment] all documents should be shifted to Documents Control Room. GFILemploys responsible personsbearing the designation ofDocuments Controllerswho are responsible to collect the obsolete documents, organize the entire Documents Control Room, which is located on the 3rd floor besides the Managing Director’s room. The designated room is identified by a signage as ‘Documents Control Room’. Persons authorized toaccess and use the Document Control Room are listed andvisibly posted at theentry gate of the room. The Document Controller will retain the documents, maintain the records and dispose the documents with evidence maintaining the relevant company policy and procedures. Manager, Technical Compliance & Auditis responsible to make sure the policies and procedures are implemented and controlled. If any non-compliance issues arise in any area the Manager, Technical Compliance & Auditwill issue a Non Conformance slip and report the same to the Factory COO and the Managing Director. Controlled documents are found as mentioned in the master list of controlled document. 4. Document Control: 4.1 Document Coding: 4.1.1 The documents are numbered in the form of GFIL.AAA.BBB.##, where: 4.1.1.1 GFIL stands for Gous Fashion Industries Ltd. 4.1.1.2 AAA is the department code. • DDC Document & Date Control • MKT Marketing • MER Merchandising • HRM Human Resources • TCA Technical Compliance & Audit • SCP Social Compliance • QMS Quality Management • QAS Quality Assurance • QCS Quality Control • ICQ Incoming Quality Control • PQT Pre-final Quality Team • SPL Sample • SEW Sewing • CUT Cutting • FIN Finishing • TST Testing • IVS Inventory & Stores • MNT Maintenance
- 9. Gous Fashion Industries Ltd. Standard Operating Procedure. 9 SOP – gfil property • IEP Industrial Engineering & Planning • TCT Technical Team • ICT Information Technology & Communication • FAD Finance & Accounts • CCA Cost Control & Internal Audit • COM Commercial • CLA Corporate & Legal Affairs 4.1.1.3 BBB is the document level, represented by 2 or 3 letters. • ORG Organization charts • WFD Work flow diagrams • PRO Procedure • WI Work Instruction • QP Quality Plan • FRM Format • LST List • FL File • MNC Memos & Notices • MMT Meeting Minutes • NCM Non Conforming material record • NCS Non Conformance Slip • CLB Calibration documents • CAP Corrective action plan • SNG Digital printed signage 4.1.1.4 ## is the individual document number, starting from 01. 4.1.1.5 Revision of document: Whenever a new document is first created it is identified as version 1. As changes are made to the same document when any update or correction is implemented by Managing Director or by a buyer, the document version changes incrementally. For example, after a change is made to the first document, the version changes to 2 and will continue incrementally. 4.2 Document Authorization and Approval: GFIL has approved certain personnel who are authorized signatories and also responsible to initiate anddistribute related documents in their respective departments and as appropriate. They are called Authorised Document Controllers. Any new or revision requirement of any document must be prepared in consultation with the Manager TC&A.
- 10. Gous Fashion Industries Ltd. Standard Operating Procedure. 10 SOP – gfil property All new or revised documents must be crossed checked thoroughly, signed, dated, the version number must be included by the authorized personnel as stated in the list of AuthorisedDocument Controllers below. For revised documents the old versions must be recalled and made obsolete as per the Control of Obsolete Documents procedure for ensuring the use of current and up to date versions only. All new or revised documents must be submitted to the Manager TC&A who will review, sign and acquire final approval from the Managing Director prior to distribution. In case of emergency and in absence of the Managing Director the COO may provide temporary approval but the final approval must be acquired by the Managing Director as soon he / she is available. Please see the list of AuthorisedDocument Controllers below. Sl. No. Section Name Authorised Documents Controller Designation 01. Information & Technology(IT) SM Shameem Iqbal Managing Director 02. Finance & Accountants (FAD) 03. CostControl & Internal Audit (CCA) 04. Commercial (COM) 05. Corporate & Legal Affairs (CLA) 06. Marketing (MKT) Khurshid Alam COO 07. Merchandising (MER) 08. Cutting (CUT) Mokter Ahmmed GM 09. Sewing (SEW) 10. Finishing (FIN) 11. Maintenance (MNT) 12. Inventory & Stores (IVS) 13. Human Resources (HRM) Nurul Huq Manager – HR & Admin14. Social Compliance (SCP) 15. Technical Compliance & Audit (TCA) Sujan Barua Manager – Technical Compliance & Audit 16. Quality ManagementSystem (QMS) Sarwar Kamal Sr. Manager – Quality Assurance17. Quality Assurance (QAS) 18. Quality Control (QCS) 4.3 Control of Obsolete Document: Whenever a document is revised or becomes obsolete as notified by the Authorised Document Controllers or any relevant authority as maybe appropriate it must be ntified to the Manager of TC&A. The Manager TC&A will recall the document from relevantsections of the operation and make it obsolete by putting an OBSOLETE stamp on it.
- 11. Gous Fashion Industries Ltd. Standard Operating Procedure. 11 SOP – gfil property If there is a new version of a document, it is distributed following the Revision of Documents procedure. At the same time the obsolete document is removed from use. The Manager TC&A is responsible to ensure the management of obsolete documents as per the above procedure. 4.4 Revision [amendment] of Documents: 4.4.1 The Authorised Document Controller is responsible to identify the need for any change required in any document and initiate process of revision. 4.4.2 The document number is given an extension with “ – “followed by the change number. 4.4.3 Revised document is prepared by Authorised Document Controller and submitted to Manager TC&A for approval. 4.4.4 All the revised / amended documents are distributed according to the Clause # 4.5. 4.5 Document Distribution: Authorised personnel can only initiate distribution of new or revised documents after acquiring approval from Manager TC&A and the Managing Director as stated in 4.3. Once the Managing Director has approved the new or revised document the Manager TC&A will hand it over to the respective Authorised Document Controller who shall then conduct the distribution process. The Authorised Document Controller must acquire acknowledgment from any personnel the document is provided to and maintain such record at his own and provide a copy of such acknowledgement to the Manager TC&A for record in the document control system. 4.6 Closing, Storing, Disposal & Retention Period of Document: 4.6.1 When the last shipment of a Style is completed all related documents (SIP/PVP & SOP files) and samples are collected and the file is closed for that Style. And It will be OBSOLETE, Once the document is closed, it cannot be retrieved without the approval of the Managing Director. 4.6.2 All Production Documents and Samples are gathered together and stored in document control room. There will be a check list posted in document control room for the identification to find details of style, production start date, last shipment date, document retentions period and disposal date of the document. The same information will be mentioned on the file as well. 4.6.3 All documents are to be disposed after the retention period as per local disposal law. 4.6.4 Hardcopy of documents shall be shredded after they have been retained until the end of the Document Retention Schedule. Digital copies will be destroyed by formatting the hard-drive/ storage media. Stored Media such as CDs, DVDs, etc will be destroyed by proven means to destroy such media after they have been retained until the end of the Document Retention Schedule. we will designate any disaster area, documents – will be sold at Paper mill for recycling purpose or will burn for maintaining the local environment law and take a digital images for evidence and all disposing items name should be enclosed at Documents destruction form with time period. 4.6.5 A designated area shall be provided in the Store to store documents that shall be disposed or destroyed eventually. 4.6.6 Paper documents maybe sold to the local paper mills or its representatives for recycle purpose maintaining local and environmental laws.
- 12. Gous Fashion Industries Ltd. Standard Operating Procedure. 12 SOP – gfil property 4.6.7 Digital image shall be taken and updated on the Document Destruction Form for all disposal and destruction activities of documents. 4.6.8 Any document being disposed must be updated and listed in the Documents Destruction Form.All such forms shall be filed and kept in theDocuments Control Room. 4.6.9 The Manager TC&A is authorized to conduct the destruction of any document and may seek the assistance of Inventory & Store personnel besides his / her own team for the task. 4.6.10 Relevant Document: Documents Destruction Form – GFIL.DDC.FRM.01 4.7. Accessibility of Documents: 4.7.1 The current and updated version of all documents must be readily available at the Document Control Room in custody of the Manager TC&A. The TC&A shall provide such documents when requested by the Authorised Document Controller for his / her respective department. 4.7.2. All documents shall be printed, implemented, distributed and retained according to the Master List of Documents. The Manager TC&A must ensure that the Master List of Documents is always updated and current and none of the old or revised documents are found anywhere in the company once the new or revised version has been circulated / distributed. 4.7.3 A copy of any unused, old and modified documents shall be kept in Documents Control Room for record but clearly marked and stampedas OBSOLETE Documents.
- 13. Gous Fashion Industries Ltd. Standard Operating Procedure. 13 SOP – gfil property GFIL.DDC.MLD.01 Version # 3 Issue Date: 02 Feb 2013 Revision Date: 20 March 2014 6. Master List of Controlled Documents: Sl. No. Section Documents Types Documents Types Version Documents ID Issue Id Retention Period 1 Merchandising Pvp / Sip / Master File Including All Testing Results Master file 1 GFIL.MER.FL. 01 16.02.2014 Five (05) Years 2 Monthly Shipment Tracking Sheet Form 1 GFIL.MER.FRM. 02 16.02.2014 Tw o (02) Years 3 Suppliers Performance Evaluation Form Form 1 GFIL.MER.FRM. 03 16.02.2014 Tw o (02) Years 4 ApprovalSample Sample 1 GFIL.MER.SPL 04 16.02.2014 Five (05) Years 5 Vendor Recertification Notices Certificate 1 GFIL.MER.CR. 05 16.02.2014 Five (05) Years 6 Production Test Plan Form 2 GFIL.MER.FRM 06 10.03.2014 Five (05) Years 7 Stores Requisition Form 1 GFIL.IVS.FRM.01 01.03.2013 One (01) Year 8 Blunt/Broken Needle Log Book Form 3 GFIL.IVS.FRM.02 12.2.2014 One (01) Year 9 Needle Exchange Log Book Register 2 GFIL.IVS.FRM.03 12.2.2014 One (01) Year 10 Needle Exchange Request Form Form 2 GFIL.IVS.FRM.04 12.2.2014 One (01) Year 11 Needle Stock Register Register 1 GFIL.IVS.REG.05 01.03.2013 One (01) Year 12 Needle StockRecord Form 2 GFIL.IVS.FRM.05A 12/2/2014 One (01) Year 13 Fabric Register Book Register 1 GFIL.IVS.REG.06 01.03.2013 One (01) Year 14 Accessories Register Book Register 1 GFIL.IVS.REG.07 01.03.2013 One (01) Year 15 Bin Card Form 2 GFIL.IVS.FRM.08 20.03.2014 One (01) Year 16 Inventory Card Form 1 GFIL.IVS.FRM.09 01.03.2013 Tw o (02) Years 17 Purchase Requisition Form 1 GFIL.IVS.FRM.10 01.03.2013 One (01) Year
- 14. Gous Fashion Industries Ltd. Standard Operating Procedure. 14 SOP – gfil property 18 Delivery Challan/ Gate Pass Form 1 GFIL.IVS.FRM.12 01.03.2013 One (01) Year 19 Re-Issue Form For Missing Broken Needle Form 3 GFIL.IVS.FRM.14A 12.2.2014 One (01) Year 20 Inventory Report Form 2 GFIL.IVS.FRM.15 16.07.2013 Tw o (02) Years 21 Non Confirming Item Receive Register Register 1 GFIL.IVS.REG.16 01.03.2013 One (01) Year 22 Security register for Out Bound Goods Form 2 GFIL.IVS.REG.17 1.7.2013 Tw o (02) Years 23 Shipment Register Register 1 GFIL.IVS.REG.18 01.03.2013 Tw o (02) Years 24 Spare Parts Register Book Register 1 GFIL.IVS.REG.19 01.03.2013 One (01) Year 25 Stationary Register Book Register 1 GFIL.IVS.REG.20 01.03.2013 One (01) Year 26 Electrical Register Book Register 1 GFIL.IVS.REG .21 01.03.2013 One (01) Year 27 Bolt Seal Register Register 1 GFIL.IVS.REG.22 01.03.2013 One (01) Year 28 Wash Send & Rcv Report Form 1 GFIL.IVS.FRM.26 01.03.2013 One (01) Year 29 Thread Recvd & Issue Register Register 1 GFIL.IVS.REG.24 01.03.2013 One (01) Year 30 Finishing Accessories Rcvd & Issue Reg Register 1 GFIL.IVS.REG.23 01.03.2013 One (01) Year 31 Needle Display Display 2 GFIL.IVS.DPL.01 03.07.2014 One (01) Year 32 Fabrics and Accessories Inspection Fabric Shrinkage Test Report Form 1 GFIL.QCS.FRM.02 3/2/2013 Five (05) Years 33 Fabric Inspection Report(4 Point System) Form 1 GFIL.QCS.FRM.01 3/2/2013 Five (05) Years 34 Fabric Weight Report Form 1 GFIL.QCS.FRM.03 3/2/2013 Five (05) Years 35 Measurement Tape Calibration Report Form 1 GFIL.CLB.FRM.08 3/2/2013 Tw o (02) Years 36 Non-Conforming Fabric Records Form 2 GFIL.NCM.FRM.07 3/2/2013 Tw o (02) Years 37 Accessories Inspection Report Form 1 GFIL.QCS.FRM.05 1/3/2013 Five (05) Years 38 10% Inspection Reject Trims Register . Form 1 GFIL.QCS.FRM.28 1/3/2013 Tw o (02) Years
- 15. Gous Fashion Industries Ltd. Standard Operating Procedure. 15 SOP – gfil property 39 Light Box Log Register Form 2 GFIL.QCS.FRM.06 01.03.2014 Tw o (02) Years 40 Shade Analyze Report Form 2 GFIL.QCS.FRM.04 03.02.2013 Five(05) Years 41 Barcode Scanning Report Form 1 GFIL.QCS.FRM.29 11.03.2014 Five(05) Years 42 Cutting Section Spreading Report Cutting Section Form 1 GFIL.CUT.FRM.01 01.03.2013 One (01) Year 43 Cutting Number Sheet Form 1 GFIL.CUT.FRM.02 01.03.2013 One (01) Year 44 Po Size Wise Cutting Details Form 2 GFIL.CUT.FRM.03 04.02.2014 One (01) Year 45 Po Size/ Po Wise Input Details Form 2 GFIL.CUT.FRM.04 04.02.2014 One (01) Year 46 Cutting Report Form 1 GFIL.CUT.FRM.05 01.03.2013 One (01) Year 47 Fusing Machine Test Report Form 2 GFIL.TST.FRM.06 15.04.2014 Five (05) Years 48 Non Conforming Materials Form 1 GFIL.NCM.FRM.07 05.03.2013 Tw o (02) Years 49 Line w ise Daily input register Reg 1 GFIL.CUT.REG.02 20.03.2014 One (01) Year 50 PO / SIZE w ise cutting plan and consumption Form 1 GFIL.CUT.FRM.06 08.07.2014 One (01) Year 51 Cutting QC Qc Attendance Register Register 1 GFIL.QCS.REG.10 05.03.2013 One (01) Year 52 Spreading Quality Control Report Form 1 GFIL.QCS.FRM.11 05.03.2013 Five (05) Years 53 100% Cutting Inspection Report Form 1 GFIL.QCS.FRM.12 05.03.2013 Five (05) Years 54 Cutting Spare Parts Issue Register Register 1 GFIL.CUT.REG.11 05.03.2013 One (01) Year 55 Sharp Tools Control Records Register 1 GFIL.SPT.REG. 01 05.03.2013 One (01) Year 56 Fabric Relaxation Report Form 2 GFIL.CUT.FRM.13 12.02.2014 Tw o (02) Years 57 Marker Inspection Report Form 1 GFIL.QCS.FRM.13A 05.03.2013 One (01) Year 58 Cutting Quality Control Report 100% Form 1 GFIL.QCS.FRM.14 05.03.2013 Five (05) Years 59 Cutting Register Register 1 GFIL.CUT.REG.16 05.03.2013 One (01) Year 60 Cutting Machine And Hand Gloves Register 1 GFIL.CUT.REG.18 05.03.2013 One (01) Year
- 16. Gous Fashion Industries Ltd. Standard Operating Procedure. 16 SOP – gfil property Register 61 Reject Part Replacement Register Register 1 GFIL.CUT.REG.19 05.03.2013 One (01) Year 62 Sew ing Input Output Register Form 1 GFIL.SEW.REG.01 01.07.2013 One (01) Year 63 Flagging Records Form 1 GFIL.SEW.FRM.02 01.07.2013 One (01) Year 64 Line Wise Production Status Form 1 GFIL.SEW.FRM.03 20.03.2014 One (01) Year 65 Daily Reject Report Form 1 GFIL.SEW.FRM.05 01.07.2013 One (01) Year 66 Hourly Production Report. Form 1 GFIL.SEW.FRM.06 01.07.2013 One (01) Year 67 Sharp Tools Control Records Form 1 GFIL.SPT.REG. 01 01.03.2013 One (01) Year 68 Sew ing Quality Measurement Spec Sheet Form 2 GFIL.QCS.FRM.15 08.03.2014 Five (05) Years 69 Quality Measurement Checking Report Form 2 GFIL.QCS.FRM.15A 08.03.2014 Five (05) Years 70 Pre-Production Meeting Report Form 3 GFIL.PPE.FRM.16 10.03.2014 Five (05) Years 71 First Piece Bulk Production Review With Sample Form 3 GFIL.PPE.FRM.17 08.03.2014 Five (05) Years 72 Pilot Run Form 1 GFIL.PPE.FRM.17A 15.02.2014 Five (05) Years 73 Inline Process Quality Reports/End line Quality Reports Form 3 GFIL.QCS.FRM.18 08.03.2014 Five (05) Years 74 Traffic Light System Report Form 1 GFIL.QMS.FRM.19 18.02.2014 One (01) Year 75 Lot Pass Form 3 GFIL.QCS.FRM.20 08.03.2014 Five (05) Years 76 Sew ing Quality Daily Inline Goals/Quality Meeting And Cap Form 2 GFIL.QMS.FRM.21 16.2.2014 One (01) Year 77 Daily And Weekly Quality Defects Analysis And Goals Dg board 2 GFIL.QMS.DG. 21A 16.2.2014 One (01) Year 78 Weekly Defects Trend Analysis Form 1 GFIL.QMS.FRM. 22 15.03.2014 One (01) Year 79 Weekly Quality Goals Meeting Attendance Sheet Form 2 GFIL.QMS.FRM. 22A 16.02.2014 One (01) Year
- 17. Gous Fashion Industries Ltd. Standard Operating Procedure. 17 SOP – gfil property 80 Machine Setting Report Form 2 GFIL.SEW.FRM.11 15.2.2014 One (01) Year 81 Stitch Monitoring Records On Daily Basis Form 2 GFIL.QMS.FRM. 23 15.2.2014 One (01) Year 82 Production Stop Report Due To Quality Nonconformity Form 2 GFIL.QCS.FRM.24 20.2.2014 One (01) Year 83 Weekly Quality Goals Form 1 GFIL.QCS.FRM.22B 20.03.2014 One (01) Year 84 Defects Classification List 2 GFIL.QCS.DCL.25 01.03.2013 Five(05) Years 86 Sew ing Quality Style Start up check list activities Check List 1 GFIL.QCS.CL.26 20.03.2014 One (01) Year 87 Daily Machine Check Report Form 1 GFIL.QCS.FRM.27 28.05.2014 One (01) Year 88 Process Mock -up Mock-up 1 GFIL.QMS.MOCK.01 20.03.2014 One (01) Year 89 Finishing Daily Thread Cutting Report Form 1 GFIL.FIN.FRM.01 1/3/2013 One (01) Year 90 Daily Alter Repairing For Line Report Reg 1 GFIL.FIN.REG.02 1/3/2013 One (01) Year 91 Daily Alter Repairing For Finishing Report Reg 1 GFIL.FIN.REG. 03 1/3/2013 One (01) Year 92 Daily Reject Report Reg 1 GFIL.FIN.REG..04 1/3/2013 One (01) Year 93 Daily Bar tack Alter Report Form 1 GFIL.FIN.FRM.05 1/3/2013 One (01) Year 94 Daily Iron Section Production & Alter Report Form 1 GFIL.FIN.FRM.06 1/3/2013 One (01) Year 95 Daily Button Attaching Production & Alter Checking Report Form 1 GFIL.FIN.FRM.07 1/3/2013 One (01) Year 96 Daily Poly Report Form 1 GFIL.FIN.FRM.08 1/3/2013 One (01) Year 97 Daily Finishing Production Report Form 1 GFIL.FIN.FRM.09 1/3/2013 One (01) Year 98 Hourly Production Report Form 1 GFIL.FIN.FRM.09A 20.03.32014 One (01) Year 99 Sharp Tools Control Records Form 1 GFIL.SPT.REG. 01 1/3/2013 One (01) Year 100 Daily Spot Removing Register Form 1 GFIL.FIN.FRM.10 20.03.2014 One (01) Year
- 18. Gous Fashion Industries Ltd. Standard Operating Procedure. 18 SOP – gfil property 101 Broken Button Register Reg 1 GFILFIN.REG.05 07.07.2014 One (01) Year 102 Finishing QC Factory Quality Audit Report Form 1 GFIL.QCS.FRM.25 01.03.2013 Five (05) Years 103 Button / Snap Button Pull Test Reports Form 2 GFIL.TST.FRM. 02 09.03.2014 Five (05) Years 104 Prefinal And Fri Reports Form 2 GFIL.QMS.FRM.01A 20.03.2014 Five (05) Years 105 Metal Detector Scanning Report Form 2 GFIL.PSD.FRM.O3 03.02.2013 Five (05) Years 106 Needle detector calibration log Form 3 GFIL.PSD.FRM.03A 20.03.2014 Five (05) Years 107 Daily Spec Defects Tally Form 1 GFIL.QMS.FRM.27 03.02.2013 One (01) Year 108 Process Checking Defects Tally Form 1 GFIL.QMS.FRM.28 03.02.2013 One (01) Year 109 Daily Wash Check Report Form 2 GFIL.QCS.FRM.31 10.03.2014 One (01) Year 110 Hourly Lot Audit Form 1 GFIL.QCS.FRM.32 10.03.2014 One (01) Year 111 Inside Process Checking records and repair register Form 1 GFIL.QCS.FRM.33 01.03.2013 One (01) Year 112 Weekly Defects Trend Analysis Form 1 GFIL.QMS.FRM.22C 15.03.2014 One (01) Year 113 Finishing Accessories AccuracyCheck Form 1 GFIL.QCS.FRM.34 20.03.2014 Tw o (02) Years 114 Maintenance Machine Stock Register Register 1 GFIL.MNT.REG.01 01.03.2014 Tw o (02) Years 115 Machine Servicing Register Register 2 GFIL.MNT.REG.02 20.03.2014 Tw o (02) Years 116 Machine Servicing Card Card 1 GFIL.MNT.CRD.01 01.03.2014 Tw o (02) Years 117 Daily Machine Check list Form 1 GFIL.MNT.FRM.04 01.03.2014 One (01) Year 118 Monthly Machine Servicing Schedule Form 1 GFIL.MNT.REG. 03 01.03.2014 One (01) Year 119 Folder and tools register Reg 1 GFIL.MNT.REG.04 20.03.2014 One (01) Year 120 Machine Rent approval Form 1 GFIL.MNT.FRM.06 20.03.2014 One (01) Year 121 Machine Transfer Form Form 2 GFIL.MNT.FRM.05 12.06.2014 One (01) Year
- 19. Gous Fashion Industries Ltd. Standard Operating Procedure. 19 SOP – gfil property 122 Documents Control Documents Destruction Form Form 1 GFIL.DDC.FRM. 01 10.03.2014 Five (05) Years 123 Documents Receiving Confirmation Form 2 GFIL.DCP.FRM.01 10.06.2014 One (01) Year 124 Documents Check List Form 1 GFIL..DDC.CL.01 20.03.2014 Subject to the documents retention period 125 Documents Control Register Reg 1 GFIL.DDC.REG.01 20.03.2014 One (01) Year 126 Training Operator Training Records Form 1 GFIL.TRN.FRM.03 09.03.2014 One (01) Year 127 Quality Training Records Form 1 GFIL.TRN.FRM. 04 09.03.2014 One (01) Year 128 Maintenance Training Records Form 1 GFIL.TRN .FRM.05 09.03.2014 One (01) Year 129 CARA Corrective And Remedial Action Format 2 GFIL.CAP.FRM. 01 10.03.2014 Tw o (02) Years 130 CNCM All Sections CNCM Records Form 1 GFIL.NCM.FRM.07 05.03.2013 Tw o (02) Years 131 LEFT OVER AT ALL SECTION Left Over Register Reg 1 GFIL.IVS.REG.25 01.03.2014 Tw o (02) Years 132 SWATCH CARD Trims Card Card 1 GFIL/SWC.01 15.03.2014 Five (05) Years 133 Fabrics Shade Card Card 1 GFIL.MER .SWC.02 01.03.2014 Five (05) Years 134 Process Mock- up Process mock-up Card 1 GFIL.QMS.MOCK.01 20.03.2014 One (01) Year 135 SAMPLE Sample Distribution Register Reg 1 GFIL.SPL.REG.01 01.03.2014 Five (05) Years 136 Pattern & Marking Distribution Register Reg 1 GFIL.SPL.REG.02 01.03.2014 Five (05) Years 137 First Fit/Second fit approvalreport Form 1 GFIL.SPL.FRM.03 01.03.2014 Five (05) Years 138 Meeting Minutes Meeting minutes Form 1 GFIL.MMT.FRM.01 20.03.2014 One (01) Year 139 List Approved Suppliers list Form 1 GFIL.MER.LST.01 16.02.2014 One (01) Year 140 Subcontractor List Form 1 GFIL.MER.LST.02 16.02.2014 One (01) Year 141 PVP checklist Form 1 GFIL.MER.LST.03 20.03.2014 One (01) Year 142 PP File Check List Form 1 GFIL.MER.LST.04 20.03.2014 One (01) Year
- 20. Gous Fashion Industries Ltd. Standard Operating Procedure. 20 SOP – gfil property 143 Plan Monthly Master Plan Form 1 GFIL.MER.PLN.01 01.03.2014 Five (05) Years 144 Style w ise Plan Form 1 GFIL.MER.PLN.01A 01.03.2014 Five (05) Years 145 Layout Machine layout Form 2 GFIL.MER.LYT.01 20.03.2014 Five (05) Years 146 Washing Wash send and receive register Reg 1 GFIL.IVS.REG.26 01.03.2013 One (01) Year 147 Floor w ise wash garments receive register Reg 1 GFIL.IVS.REG.26A 01.03.2013 One (01) Year 148 Wash garments hand over register Reg 1 GFIL.IVS.REG.26B 01.03.2013 One (01) Year GFIL.QMS.PRO.01 Version # 3 Issue Date : Feb02, 2013 Revision Date : March20, 2014 7. Quality Management Purpose: GFIL uses a quality management system that can be used by the top management to guide the organization towards improved performance. GFIL quality policy is to achieve sustained, profitable growth by providing services that consistently satisfy the needs and expectations of its customers. This level of quality is achieved through adoption of a system of procedures that reflect the competence of our company to existing customers, potential customers, and independent auditing authorities. Responsibilities: To achieve and maintain the required level of assurance the Managing Director retains responsibility for the Quality Management System with routine operations controlled by the Quality Manager. Procedure: 01. Assure all incoming raw materials are meet the safety rules and regulations . GFIL has established the in house inspection system for all incoming raw materials before to start production. 02. Organizing a Pre-production meeting and review the production test plan , sample, testing results at P.P. meeting and meeting notes are communicate with all concern person for reference. 03. Implementing the cutting inline inspection to control the defects rate at sewing. 04. Establish the Quality layout at sewing section such as In process and end line checking procedure based on products it may be vary. 05. Provide the checking instruction to all inline check point and implement the Traffic light system to control the defects rate and improve the quality level.
- 21. Gous Fashion Industries Ltd. Standard Operating Procedure. 21 SOP – gfil property 06. In house testing procedure (Shrinkage test, GSM test, button pull test etc.) are executed to ensure the meet quality safety rules and regulations. 07. To allocate the inline checking procedure at finishing stage for confirm the packed goods are meet the customers quality level. Backup Quality Procedure: Overview: The factory keeps extra quality inspector trained on various process of several work. In the event of shortage in QC coverage in any department, these QC’s are assigned as replacements in any respective departments. Purpose: The purpose of this procedure is to establish and process for ensuring 100% quality coverage for every production unit in every shift. Scope: In case of any emergency / migration, GFIL maintains a backup QC team to smoothly support the regular work. Back up QC are mostly used in Sewing Quality and Cutting Quality. These departments must always be facilitated by backup QC at all times. Responsibility: Floor Sewing Quality Controller / In Charge will be responsible to maintain attendance register for QCs. In any absentees floor sewing quality controller need to follow the backup QC procedure. Similarly cutting, store and finishing QC In Charge need to maintain QC attendance registers and follow the procedure in case of any absentees. Quality manager has the responsibility to ensure the procedure is followed. Number of Backup QCs: GFIL maintains a total of five [5] well trained Backup QCs, who are assigned to work under the Finishing . Backup QC Procedure: 1. A Backup QC register with name and ID no of the personnel must be maintained daily by floor QC In Charge, Cutting QC In Chare, Store QC In Charge, Finishing QC In Charge for the permanent station QCs. 2. Another register is maintained to record status of presence for the Backup QCs. 3. If any permanent assigned QC is on leave or absent than a Backup QC will be allotted for the coverage of that shift. Record of Revisions: Version Number Date Section(s) Page(s) Summary of Changes Signature
- 22. Gous Fashion Industries Ltd. Standard Operating Procedure. 22 SOP – gfil property GFIL.TRN.PRO.01 Version # 3 Issue Date : Feb02, 2013 Revision Date : March20, 2014 Employee Training Procedure Purpose: GFIL recognizes that to realize the vision of the company by pursuing its mission to ‘strive to earn customer delight & trust by exceeding the quality and timeliness of our business commitments’ it needs high quality human resources engaged at the various functions of the company. Therefore GFIL is committed to continuously develop its human resources through training and coaching at all levels of the structure to meet its goals. This procedure outlines the methods of the training programs to improve the efficiency and productivity of the employees of the company by focusing on the following: Develop and maintain a friendly working environment Freedom for all to be able to share opinions with their respective superiors without any hesitation or apprehension of any kind Firm intent to increase the working skills of all concerned Building a strong team spirit Respect for the individual Striving for excellence Awareness of company policies and procedures and respectfully adhering to them Reduction of cost by eliminating waste at all aspects of operation Scope: This training and development procedure is particularly for the workers of GFIL. Responsibility: All training initiatives are from the HRD. The head of HRD is responsible to ensure that all its resources are aligned toward achieving the goals of the company. He will thus identify all training needs in consultation with department heads and design and administer all training programs through his department and team. Procedure: The skill levels of workers from the production, quality and mechanical departments are particularly assessed on a regular basis. During the hiring process the initial skill levels are at first determined. This is done by testing the workers on their particular jobs and from this test the workers are assigned a suitable grade based on a scale between A (highest skill level) to E (lowest skill level). The results are then stored in the Initial Skill Assessment Database. Depending on the individuals initial skill level a training curriculum is made for the worker to improve their knowledge, efficiency and productivity. The following procedures should be followed to select the trainees of different departments. Our all training directed by Factory HR team and Factory Technical Compliance and audit team as a result Training is very effective and fruitful. We strongly believe that the main path to achieve the goals is Effective and efficient training in case of develop the : Gous Fashion has a monthly training calendar where clearly defined the training time , date , trainers name , subjects and trainees section and Training are conducting maintaining the Calendar.
- 23. Gous Fashion Industries Ltd. Standard Operating Procedure. 23 SOP – gfil property Objectives : Develop a skilled manpower. Develop multi skilled operators. Motivate all to take a initiatives to fix the issues. Make a plan and strongly agree to implement the plan in efficiently. Develop a friendly working environment. Implement the Right First time concept at all stages. Trainees selection criteria: Gous Fashion Industries Ltd. Select the trainees in several criteria such as ; a) New workers :During the hiring process the initial skill levels are at first determined. This is done by testing the workers on their particular job and from this test the workers are assigned a suitable grade based on a scale between A (highest skill level) to E (lowest skill level). Factory welfare officers and social compliance officers are responsible to share the company policy , code of conduct, fire and safety policy , sharp tools controlling policy , leave and wages facilities , sharp tools controlling policy to all new workers . b) Existing employees :The skill levels of workers from the production, quality and mechanical departments are particularly assessed on a schedule basis. Production: Unit wise production manager are assigned to provide the training to operators and helpers. The production floor employees are trained per the following processes: 1. The training department has to maintain the Production Worker Initial Skill Assessment Database which specifies the initial skill levels of the operators who are able to operate different types of sewing machines. The data is gathered during the hiring process and is used as an initial skill level assessment guide. 2. Operators will be assigned an initial skill level (A, B, C, D, or E) based upon their ability to operate different types of machines and also on the ability to perform different types of sewing processes. 3. Initial Operators skills are assessed upon the ability to operate the following sewing machines: a. Single Needle b. Double Needle c. Over-lock d. Feed-Of-Arm e. Kansai f. Eyelet g. Bar-tack h. Button Hole/Stitching 4. Operator skills are also assessed upon the ability to perform the following processes: a. Waist band attachment b. All kinds of pocket attachment c. Fly attachment d. Zipper attachment e. Collar attachment f. Front rise g. Back rise h. Bottom Hem i. Other critical sewing processes 5. All operators are trained further based on the finding from Initial Skill Assessment Data. 6. The operators with lower grades should be trained on subjects that they are weak on to upgrade their skill level. 7. Helpers will also be trained so that they are able to become sewing operators. The sewing floor supervisors will recommend the helpers that they think are fit to become operators.
- 24. Gous Fashion Industries Ltd. Standard Operating Procedure. 24 SOP – gfil property 8. All operators who are identified as ‘weak’ and in need of training by the In-process Audit Procedure will also are trained on the particular process that they have failed upon. Upon successful completion of training they are returned to the production floor. 9. Records of all training imparted upon all production employees will need to be filed in their personal file. Quality Personnel: The skill level of Quality Inspectors and QC staffs are assessed by the QA Manager. And QA Manager are assigned to provide the QA related all training. The following process has to be followed for training quality personal: 1. The Initial Skill Assessment is done on the newly hired quality worker by testing them on five pieces of garments with 10 major defects per the buyer’s Defect Classification List 2. The QC worker is assigned a skill level (A+, A, B, C, D or E) based on the number of defects that they were able to find 3. Based upon this data the quality worker defect detection weaknesses are identified and is trained on those weaknesses following the buyer’s Defects Classification List 4. The training will be conducting every end of the month by the Quality Manager. 5. After conducting training, exam will be taken after 3 months. 6. During the training the defective garments and garment parts are displayed so that QC trainees are able to identify the defects readily. 7. Upon successful completion of their training their skill levels are to be adjusted accordingly and documentation retained in their personal files. 8. Re-training should be done on a regular basis and the workers should also be tested again when the buyer’s Defect Classification List are updated. Mechanics: The maintenance helpers and also the new maintenance staffs are trained by the Maintenance Manager and by the sewing machine company Technicians whenever required. The following training process has to be implemented by the factory: The initial skill level assessment of the mechanic has to be determined during the hiring process. 1. The initial skill level will be based on the following types of machines: a. Single Needle b. Double Needle c. Over-lock d. Kansai e. Feed-of-Arm f. Eyelet g. Bar-tack h. Button Hole/Stitching 2. The maintenance worker will be tested on the following relevant skills for each machine: a. Preventive Maintenance b. Stitch Forming System c. Thread Handling System d. Feed Handling System e. Computerized Machine Knowledge f. Folder Settings g. Overhauling 3. Records will need to be maintained in the personal file for all training imparted upon the maintenance worker.
- 25. Gous Fashion Industries Ltd. Standard Operating Procedure. 25 SOP – gfil property 4. Relevant Documents : Sewing Operators training records –GFIL.TRN.FRM.03 Quality Training Records – GFIL.TRN.FRM.04 Maintenance Training Records – GFILTRN.FRM.05 New Workers orientation program – GFIL.TRN.REG.06
- 26. Gous Fashion Industries Ltd. Standard Operating Procedure. 26 SOP – gfil property GFIL.MER.PRO.01 Version # 3 Issue Date : Feb02, 2013 Revision Date : March20, 2014 9. SOP For Merchandising Department 1.0 Purpose and Scope : Booking the all raw materials as per order sheet and follow – up inventory , production and Finishing stage and regular communicate with Factory Production team and Customers to meet the ship date. 2.0 Responsibilities : 2.1 Respective Merchandiser is responsible to follow-up the individual buyer’s order. 2.2 Merchandiser Manager will implement and monitor the entire process. 2.3 All Materials price , nominated new suppliers , product price should be get approval from Head of Operation before to fixed. 3.0 Procedure : 3.1 Communicate with customers and confirm the order. 3.2 Select the suppliers as per Suppliers approval procedure for Non nominated. 3.3 Forward to booking for fabrics and accessories and assure to delivery time. 3.4 Booking details communicate with inventory and stores department. 3.5 Communicate with customers to get shade approval. 3.6 Collect the inventory reports for all raw materials. 3.7 Issue the requisition for size set to sample section. 3.8 Trims card must be approved according to the Customer approval. 3.9 Organize the Production validation packet or master file with a below documents : 3.9.1 PO Sheet & PID / Technical details 3.9.2 Size spec 3.9.3 Machine List 3.9.4 Production planning 3.9.5 Fabrics approval swatch 3.9.6 Trims and accessories swatch 3.9.7 3RD Part testing reports 3.9.8 Floor ready 3.9.9 Inspection and FE reports 3.9.10 Placement meeting 3.10 Organize the Pre-production Meeting with the Internal Auditor. 3.11 P.P. meeting notes must be communicate with Store, cutting , sewing and Finishing department. 3.12 Handover the below documents – 3.12.1 Provide the PO Sheet , spec sheet , fabrics and accessories approval swatch , garments test reports and wash approval to cutting section , quality department & sewing department. 3.12.2 Fusing suppliers requirements and testing reports provide to quality and mechanics department. 3.12.3 Packing list and invoice provide to inventory & store department. 3.12.4 Review the fabrics and accessories testing reports and 3rd party testing reports. 3.12.5 Monitoring the daily production status. 3.12.6 Review the packing list and offer for final inspection. 3.12.7 After get satisfactory result arranges to ship the goods. 3.13 Evaluate the suppliers based on several criteria (Pls see suppliers evaluation criteria check list) in every quarterly.
- 27. Gous Fashion Industries Ltd. Standard Operating Procedure. 27 SOP – gfil property 4.0 Relevant Documents : Production validation packets / master file – GFIL.MER.FL.01 Monthly shipment tracking sheet – GFIL.MER.FROM.02 Suppliers Performance Evaluation Form – GFIL.MER.FRM.03
- 28. Gous Fashion Industries Ltd. Standard Operating Procedure. 28 SOP – gfil property GFIL.MER.PRO.02 Version # 3 Issue Date : Feb02, 2013 Revision Date : March20, 2014 10. SOP for Supplier Management Selection and Evaluation 1.0 Purpose & Scope: To select the qualityful and best suppliers and be a business partner. To evaluate the suppliers of the raw materials, products and services which impact the final product quality, safety and legality. 2.0 Responsibility: The respective Merchandiser is responsible to evaluate the suppliers based on the defined criteria and Sourcing or Merchandising Manager is responsible to validate the process in case of Raw Material and Chief Operating Officer is responsible for other products & service as the case may be. 3.0 Procedure: 3.1 Supplier Selection process is defined as below : 3.1.1 Materials Supplier: 3.1.1.1 In most of the cases, the buyer nominates the supplier. In such case, the nominated supplier is used of procurement of materials. The selection is purely based on buyer nomination. 3.1.1.2 In case of no nomination form the buyer that means Open or Vendor Sourcing , the supplier selection is done based on the following criteria : 3.1.1.2.1 Suppliers Background about their market strength. 3.1.1.2.2 Capacity to meet the quality , safety & legal requirement of the material. Whether the supplier can deliver the products as per US safety and regulatory requirements/ buyer requirements. 3.1.1.2.3 Capability to meet the delivery on time. 3.1.1.2.6 An established traceability system in place to be able to trace the raw materials back to source. 3.1.1.2.7 Quality level 3.1.1.2.8 Responsiveness 3.1.1.2.9 Price
- 29. Gous Fashion Industries Ltd. Standard Operating Procedure. 29 SOP – gfil property Supplier Approval Checklist Supplier Name: Product: Contact Person: Contact No.: Address: Question Point s Yes No 1. Is the supplier’s nominated by the buyer? If the supplier is nominated skip the following Questions and forward for approval. 1 2. Is the Supplier’s business history is good or bad? 1 3. Does the Supplier’s meet the local labor law? 1 4. Is the supplier’s production capacity and capabilities are sufficient? 1 5. Dose the supplier’s have any kind of certification like ISO, UKAS, OEKO-TEX or anything Similar? 1 If so state details here: 6. Whether the supplier can deliver the products as per US safety and regulatory requirements/ buyer requirements? 1 7. Does the supplier’s meet the quality standard? 1 8. Does the supplier’s maintain the traceability? 1 9. Are the supplier’s quoted price is reasonable? 1 10. Does the supplier’s after sales service is satisfactory? 1 Total points- 10 In based on the check list Our Sourcing or Merchandising Manager are scored the suppliers based on their availability and rating as below ; Above 90% = Excellent 70 – below 90% = Good 60 – below 70% = Medium Below 60% = Bad Our main motto is to select the best suppliers and be a good business partner. 3.1.2 Manufacturing Process Outsourcing & Service Contract 3.1.2.1 During the manufacturing process, if the company do not have in house capability , the process / service is considered for outsourcing.
- 30. Gous Fashion Industries Ltd. Standard Operating Procedure. 30 SOP – gfil property 3.1.2.2 The supplier of the service or process is selected based on below criteria 3.1.2.2.1 Standing of the company in the market i.e supplier history and past Performance 3.1.2.2.2 Availability & condition of the machinery 3.1.2.2.3 Ability to deliver to the required specification 3.1.2.2.4 Capacity to meet the quality , safety & Legal requirement 3.1.2.2.5 Maintenance of the social compliance requirement 3.1.2.2.6 Capability to meet on time delivery 3.1.2.2.7 Responsiveness 3.1.2.2.8 Price 3.2 Suppliers Evaluation : 3.2.1 The system of periodic (every quarterly) evaluation and re-evaluation of suppliers has been in vogue. Each supplier is evaluated for the compliance & performance against the set criteria annually. 3.2.2 The criteria for evaluation and re-evaluation includes : 3.2.2.1 Quality performance 3.2.2.2 Delivery of correct quantity 3.2.2.4 On-time delivery 3.2.2.5 Price / cost competitiveness of product 3.2.2.6 Transparency in information sharing 3.2.2.7 Responsiveness 3.2.2.8 Traceability 3.2.3 Quantity of supply is the prime factor for evaluation followed by timely supplies and efficient service 3.2.4 The evaluation system varies according to the nature of goods / process & service purchased. 3.3 The records of list of approved supplier & the supplier evaluation is maintained. 3.3. Rating : Factory has a own check list whether respective merchandisers are responsible to analyze the individual suppliers based on the above criteria; Total achieved points are 5 out of 5 = Green Total Achieved Points are 4 out of 5 = Yellow (Need Improve)
- 31. Gous Fashion Industries Ltd. Standard Operating Procedure. 31 SOP – gfil property Total achieved points are 3 out of 5 = Orange ( Below standard) Total achieved points are 2 out of 5 = Red (Not acceptable) . In every quarterly Merchandiser Manager will review the performance results and take a decision discussing with Company top management. 3.4. Relevant Documents : Supplier’s Performance analysis – GFIL.MER.FRM. 03
- 32. Gous Fashion Industries Ltd. Standard Operating Procedure. 32 SOP – gfil property GFIL.MER.PRO.03 Version # 3 Issue Date : Feb02, 2013 Revision Date : March20, 2014 11. Product Test Plan [PTP] Purpose: 1. To develop and implement the Product Test Plan [PTP] as appropriate to the product and the process involved to manufacture the product in order to validate product quality, safety and compliance with rules, bans, standards & regulations. 2. To meet the Consumer Product Safety & Improvement Act (CPSIA) rules and regulations. 3. To avoid customer compliant regarding any safety issue in future. Scope: This procedure is applicable to all the products being manufactured at and/or for all the production units of GFIL. Responsibilities: The respective Merchandiser and Manager – Technical Compliance and auditare responsible to develop the PTP and COO is responsible to approve the PTP Procedure: 1. PTP is a documented plan for validating product quality, safety and compliance with rules, standards and regulations. 2. PTP guides all the concerns about: 2.1 The types of testing and inspections for the product 2.2 The process monitoring stages and requirements 2.3 The frequency to conduct 4.2.1 & 4.2.2 2.4 The criteria to conduct 4.2.1 & 4.2.2 2.5 Covered section and respective concern person with designation. 2.6 Clearly defined the tolerance level. 2.7 Measurement method, reaction and documents control id are including at PTP. 3. Respective Merchandisers and Manager Technical Compliance & Audit are assigned to prepare the PTP appropriate to product & process with following considerations: 3.1 Category of the product 3.2 Product risk level 3.3 Product regulations 3.4 Manufacturing processes 3.5 Raw Material used 3.6 Factory capabilities
- 33. Gous Fashion Industries Ltd. Standard Operating Procedure. 33 SOP – gfil property 4. The PTP is developed in accordance with GFIL process flow chart with control checks to ensure that all the factory testing, inspections and process monitoring activities are captured on the PTP. 5. The PTP must act as manufacturing control plan. 6. Once respective Technical Manager develops the PTP, the same is being reviewed and approved by COO. 7. On approval from COO, the PTP is discussed during the PP meeting and documents as part of meeting notes. 8. The copy of PTP is circulated to all the relevant personals. 9. Respective departments head must be ensured the PTP is executed and Manager – Technical Compliance and audit should be validate the every section to properly executed the PTP at every stages. Sample of Production Test Plan Gous Fashion Industries Ltd. Plot # A (6&7) , Block # B , BSCIC I/A. Sagorika Road, Pahartoli. Chittagong PRODUCTION TEST PLAN BUYER: BHS Limited ITEM : GB SHEETING CROP & GB SHEETING SHORTS STYLE# 220644 & 220653 DATE : 08.03.2014 Raw Material Process TYPE CRITERIA FREQUEN CY Sl. No PROCES S AREA SECTIO N NAME Re spo nsi ble Per son Desi gnat ion MFG. EQPMNT. PROCESS SPEC WITH TOLERANCE Msr mt Met hod SAMPLING FREQUEN CE CON TROL MET HOD RE AC TIO N DOC. CNTRL ID 01 Fabric Receiving Store's Mr. Zia Str. Ex. Doc. Review (Inventory) Check Against Packing List Tolerance - 0 Standard Broad , 100% ctn w oven sheeting fabrics , 20x20/60x60 and Rib - 2x2 Visu al Every Consignme nt Recei ving Inspe ction NC M GFIL/FRM/STR -15 02 Fabric Inspectio n Store's Mr. Moi n In char ge - Fabri c Insp ectio n Fabric Inspection M/C 04 Points system,40 Points Per 100 Square yds& up to overall results acceptable level 24% Visu al Every consignmen t of incoming fabric, select all colors and lot w ise 10% of receiving fabrics. Inspe ction NC M GFIL/FRM/QA S - 01
- 34. Gous Fashion Industries Ltd. Standard Operating Procedure. 34 SOP – gfil property 03 Fabric Weight Store's Mr. Moi n In char ge - Fabri c Insp ectio n Fabric Weight M/C Each shipment of incoming fabric, all colors and lot. Acceptable level± 5% , Check against standard w eight 150 GSM Visu al Every consignmen t , select 10% of receiving fabrics.(afte r w ash & before w ash) Inspe ction NC M GFIL/FRM/QA S - 03 04 Fabric Shrinkag e Store's Mr. Moi n In char ge - Fabri c Insp ectio n Washing M/C Cutting the fabrics 60 x 60 cm2 and marking the L/W 50 x 50 cm2 in Fabric. Sent to w ash as per 135- Normal Garments Wash and Then take After wash Measurement Acceptable level+10% & -5% Visu al Every consignmen t , select 10% of receiving fabrics. Inspe ction Rec tify Patt ern GFIL/FRM/QA S - 02 05 Fabric Shade & Grade Separatio n Store's Mr. Moi n In char ge - Fabri c Insp ectio n Confirmed by Light Sourch Machine in Primary UL 3500 and secondary D65 light . Match w ith approval Shade band. Visu al Every consignmen t Of Incoming Fabric, 100% Wash Blanket, Check In Light Source Inspe ction Sen d For App rov al To Mer cha ndi ser GFIL/FRM/QA S - 04 06 Accessori es Receiving Store's Mr. Nu pur Str. Ex Doc. Review (Inventory) Check Against Packing List Tolerance - 0 Visu al Every Consignme nt Recei ving Inspe ction NC M GFIL/FRM/STR - 15 07 Label Store's Mr. Am an Str. Ex Match With Approval sw atch, check lettering, foreign yarn , w ord color. Lot Selected By AQL 10% Tolerance - 3% Visu al Every Consignme nt Of Incoming Accessories Inspe ction NC M GFIL/FRM/QA S - 05 08 Button Store's Mr. Am an Str. Ex Match With Approval sw atch , checkbutton ligner and quality, Button Ligner for plastics and metal - 30 L , 26L , 20L Lot Selected By AQL 10% Tolerance - 3% Visu al Every Consignme nt Of Incoming Accessories Inspe ction NC M GFIL/FRM/QA S - 05 09 Thread Store's Mr. Am an Str. Ex Match With Approval sw atch , checkthread count , shade and durability. Count - 20s/3, 20s /2 , 40s/3 , 40s/2 & Lot Selected By AQL 10% Tolerance - 3% Visu al Every Consignme nt Of Incoming Accessories Inspe ction NC M GFIL/FRM/QA S - 05
- 35. Gous Fashion Industries Ltd. Standard Operating Procedure. 35 SOP – gfil property 20s/9 10 Draw Cord Store's Mr. Am an Str. Ex Match With Approval sw atch , checklength , w idth and clr bldng Lot Selected By AQL 10% Tolerance - 3% Visu al Every Consignme nt Of Incoming Accessories Inspe ction NC M GFIL/FRM/QA S - 05 11 Hang Tag & GV Tag Store's Mr. Am an Str. Ex Match With Approval sw atch, check lettering, barcode number. Lot Selected By AQL 10% Tolerance - 3% Visu al Every Consignme nt Of Incoming Accessories Inspe ction NC M GFIL/FRM/QA S - 05 12 Carton Store's Mr. Am an Str. Ex Match With Approval carton , check carton ply, shipping mark.3 ply Lot Selected By AQL 10% Tolerance - 3% Visu al Every Consignme nt Of Incoming Accessories Inspe ction NC M GFIL/FRM/QA S - 05 13 Poly Store's Mr. Am an Str. Ex Match With Approval sw atch, check w arning letter & thickness. Lot Selected By AQL 10% Tolerance - 3% Visu al Every Consignme nt Of Incoming Accessories Inspe ction NC M GFIL/FRM/QA S - 05 14 Carton Sticker Store's Mr. Am an Str. Ex Match With Approval sw atch, check DPCI number and Barcode number. Lot Selected By AQL 10% Tolerance - 3% Visu al Every Consignme nt Of Incoming Accessories Inspe ction NC M GFIL/FRM/QA S - 05 15 Hanger Sticker Store's Mr. Am an Str. Ex Match With Approval sw atch, check size and lettering Lot Selected By AQL 10% Tolerance - 3% Visu al Every Consignme nt Of Incoming Accessories Inspe ction NC M GFIL/FRM/QA S - 05 16 Washing Test for all accessori es attaching w ith fabrics sw atch Store's Mr. Am an Str. Ex Match With Approval accessories and fabrics sw atch (Check shrinkage test color bleeding test , ferrus test , sharp point test and stain mark test for all incoming accessories. Attach all accessories ( 01pcs for allitems) w ith fabricsduring accessories/fabric inspection. Visu al Every Consignme nt Of Incoming fabric and Accessories Inspe ction Re- w or k or co mm uni cat e w ith mer cha ndi ser GFIL/FRM/QA S - 5A
- 36. Gous Fashion Industries Ltd. Standard Operating Procedure. 36 SOP – gfil property Process Control TYPE CRITERIA FREQUEN CY SL. NO. PROCE SS AREA SEC TIO N NAM E MFG EQUIPMENT PROCESS SPEC WITH TOLERANCE MEA SUR EME NT MET HOD SAMPLING FREQUEN CE CON TROL MET HOD RE AC TIO N DOC. CNTRL ID 01 Spreadi ng Inspecti on at cutting section. Cutti ng Mr. musle m Cuttin g Spv Follow Our Ow n S.O.P Check Marker Placing, Ends, Splices, Narrow Goods, Leaning & Tension Visu al Every Spreading Inspe ction NC M GFIL/CUT /QC - 09 02 Cutting Marker Check at cutting section. Cutti ng Mr. musle m Cuttin g Spv Follow Our Ow n S.O.P Grain Line Check, Ratio Wise Parts Check, Way / Direction Check, Jumping Check, Notches Check & shape of Parts Visu al Every Marking Inspe ction NC M GFIL/CUT/QC- 14 03 Cut Panel & Cut Bundle at cutting section. Cutti ng Mr. musle m Cuttin g Spv Follow Our Ow n S.O.P Check Miscut, Matching Plies, Ragged Cutting, Notches, Fabric & Pattern Check 100% for all criticalparts Visu al Every cutting & Every Day Inspe ction NC M GFIL/CUT/QC - 10 04 Sew ing Machin e Setting Sew i ng Mr. Mokte r GM Prior to start new style and monitor output per operator to ensure product meets operation standard Prior to start new style or may vary to improve production standards. All Part s Of Ever y Gar ment s As Per Layout Depe nds On Layou t NC M GFIL/SEW/MS R - 11 05 Process Mock- up & 05 Pcs checkin g at sew ing section. Sew i ng Mr. Asad QM 05 Pcs Checking System (Every M/C) Monitor per operator to ensure quality improvement. Visu al Min.Three Times Per day/ Operator Inspe ction NC M GFIL/SEW/TRL AG- 06 06 In- Process Inspecti on at sew ing section. Sew i ng Mr. Asad QM 100% check all garments process and need to adjust the inspection table w ith 100 F.C light value. 100% checkall garments process. Visu al All parts Clock w ise Inspe ction NC M GFIL/SEW/PR OQR-05 07 Daily measur ement. Sew i ng Mr. Asad QM as per aql basis Min. 3 pcs/color/size Visu al Min. 20 pcs per Line Inspe ction NC M GFIL/SEW/SP EC-01
- 37. Gous Fashion Industries Ltd. Standard Operating Procedure. 37 SOP – gfil property 08 End Table Inspecti on at sew ing section. Sew i ng Mr. Asad QM 100% check all garments process and need to adjust the inspection table w ith 100 F.C light value. 100% checkall garments process. Visu al All garments Clock w ise Inspe ction NC M GFIL/SEW/PR OQR-05 09 Lot Pass Inspecti on at sew ing section. Sew i ng Mr. Asad QM Day light 100 F.C (Inspection table). As per AQL – 1.5 Visu al Every Hour & Every Day Inspe ction NC M GFIL/SEW/LOT P-07 10 Daily w ash . Indu strial Was h Mr. Bipul Fin. Mng Industrial w ashing m/c 135 Normal Garments w ash Visu al Every Day Inspe ction NC M Washing plant w illprovide report id. 11 After w ash garment s check . Finis hing Mr. Asad QM visualcheck of 10% garments , checkcolor fastness, w ashing defect, hand feel. 10 % garments Visu al Every Day Inspe ction NC M GFIL/FIN/QAS- 06 12 Hourly key point measur ement. Finis hing Mr. Asad QM Take the measurement of key parts i.e. chest , sw eep, slv length , front length , back length & shoulder of 100 % garments 100 % garments Visu al 100 % garments Inspe ction NC M GFIL/SPEC - 1A 13 Lot Pass Inspecti on at finishing section. Finis hing Mr. Asad QM Day light 100 F.C (Inspection table). As per AQL – 2.5 Visu al Every Hour & Every Day Inspe ction NC M GFIL/FIN/QAS- 07 Product Safety Process TYPE CRITERIA FREQUEN CY 01 Barcod e Scanni ng Stor e's Mr. Ama n Str. Ex Barco de Scanni ng M/C Lot selected by 10% for hang tag and 100% scanning for carton sticker Visu al Every consignme nt of incoming Price ticket & Carton Sticker, Lot selected by AQL 2.5 (Level2) Intern al Test NC M GFIL/FRM/QA S-029
- 38. Gous Fashion Industries Ltd. Standard Operating Procedure. 38 SOP – gfil property 02 Fusing Test Inter nal Test Mr. Musl em QA SPV Fusing & Bondin g Test M/C Maintain log documentation, Visu al Tw ice Per Day Intern al Test NC M GFIL/CUT/QC- 06 03 Button Pull Test Inter nal Test Mr. Asad QM Button Pull Test M/C Maintain log documentation as per requirement 20.2 lbs/10 sec Visu al Tw o Times Per Day Intern al Test NC M GFIL/FIN/QAS- 02 4 Needle Log Inter nal Test Miss. Rebe cca Str. Ex Follow Our Ow n SOP Maintain Log For All Broken Needles/blunt needle, check needle sharpness daily. Visu al Time To Time Intern al Test NC M GFIL/FRM/ST R-03 5 Metal Detecti on Inter nal Test Mr. Kao w sar Meta l Dete ctor optr Metal Detecti on M/C All product checked utilizing metal detection at 1.2 mm ferrus card. Tolerance Level - 0 All Gar ment s Ever y Hour All garments Intern al Test NC M GFIL/FIN/FRM- 03 3rd Party LAB Process TYPE CRITERIA FREQUEN CY 01 Pre- Produc tion Test After Care Process TYPE CRITERIA FREQUENCY 01 QUALI TY AUDIT Fini shin g MR. Mas um DQA Daily Ctn Pack Qnty As per AQL – 2.5. (Level1) Visual Every Day Inspe ction NC M GFILFIN/QAS- 01 02 P.O. Wise Pre- Final Fini shin g MR. Mas um DQA TTL P.O. Pack Qnty As per AQL – 2.5. (Level1) Visual After 80%-100% Carton completed Inspe ction NC M GFILFIN/QAS- 01 Internal Auditor/DQA Manager – MR COO
- 39. Gous Fashion Industries Ltd. Standard Operating Procedure. 39 SOP – gfil property GFIL.MER.PRO.04 Version # 01 Issue Date: 20March 2014 Revision Date: N/A 12. Changing Materials, Components, Design or Manufacturing 1.0 Purpose & Scope: To facilitate the change materials, components, design or manufacturing process to meet the product safety and manufacturing efficiency in the plant from time to time if required. 2.0 Responsibilities: Sourcing Manager and Sample manager are responsible to implement the policy in consultation and clear communication with the customers through the Marketing & Merchandising department. 3.0 Procedure: 3.1. If at some point a need arise to change some of the approved material, components, design or manufacturing processes it should to be discussed with Merchandising or Sourcing Manager and he will analyze along with Sample Manager to evaluate if the changes may affect the product in meeting any of the following requirements: 3.2.1. Safety 3.2.2. Regulatory 3.2.3. Quality requirements 3.3 Implement the process to get approval from departments 3.4 If the considered change is expected to affect the safety, regulatory or quality requirement, the merchandiser will notify the same to the customer and acquire written approval prior to implementing the changes. 3.5. Upon acquiring the approval copy from the customer, the Sample Manager will authorize the changes to effect. 3.6 The approval copy should be recorded in hard copy in the order file. 4.0 Relevant Documents: Approval Records – GFIL.MER.FL.06
- 40. Gous Fashion Industries Ltd. Standard Operating Procedure. 40 SOP – gfil property GFIL.MER.PRO.05 Version # 3 Issue Date: 02 Feb 2013 Revision Date: 20 March 2014 13. Product Recall Procedure Purpose: This procedure is for the removal of unsafe product from the distribution chain/buyer. Scope: Product Recall procedure extends up to the distribution chain but does not extend to product sold to the consumer. Responsibilities: Chief Operating Officer is responsible to implement and follow the procedure. Procedure: 1. When a recall is initiated, our actions in recalling the affected products need to be co-ordinate with the buyers. 2. The buyers shall be notified as soon as a recall is likely. 3. GFIL will clarify the product safety issue and the exposure (who and where risk exists), and will provide details on distribution and the method of recall. 4. A Committee shall be formed whose members will include personnel from across the company. Typically the committee would have a mix of knowledge across the following areas: a. Production b. Quality c. Purchasing d. Merchandising / Marketing e. Legal Services 5. The recall committee is responsible for the management of all recall activities and to adhere to this procedure. Duties of the recall committee are to: a. Assess the overall problem b. Notify the relevant regulatory authority c. Evaluate the hazard in the product and the extent of contamination d. Determine a strategy to be followed e. Make decisions about product still in manufacture or in storage f. Decide who makes any press statements
- 41. Gous Fashion Industries Ltd. Standard Operating Procedure. 41 SOP – gfil property Recall Decision Flow Chart Custom er complaint Identification of a Internal Finding potential product Any other source non-compliance issue Information to Quality Unit Preliminary Response to no customer and Recall documentation of Assessment Findings yes Convene Recall Committee 1. Technical Assessment 2. Documents for Recall yesno Recall Implementation Decision Relevant Documents: Products Recall documents – GFIL.MER.FL.07
- 42. Gous Fashion Industries Ltd. Standard Operating Procedure. 42 SOP – g:fil property GFIL.SPL.PRO.01 Version # 1 Issue Date : March20, 2014 Revision Date : N/A 14.Sample Section Control Purpose and Scope: 1. Develop the sample as per customer’s requirements. 2. Develop the pattern and marking and adjust the bulk pattern. Responsibilities: Sample Manager is responsible to implement the procedure efficiently and monitor the process. Procedure: 1. Sample Process: a. Review the specs and designing chart and proceed for development sample b. Review the customer comments and proceed for prototype sample c. Develop the Pre-production or GSA sample d. Make a Size set sample e. Proceed for PM reference sample f. Making an Ongoing Random sample 2. Pattern and Marking Process: a. Master Pattern (attached with computer plotter) will be made b. Size set will be made: if any adjustment are needed the pattern have to be rectified c. Pilot run cutting will be by manual marker: if any adjustment needed the pattern have to be rectified d. Bulk production to be from Computer Marker e. Patterns are approved by Sample Manager f. Sample Manager is authority to rectify all types patterns 3. Quality Process : a. Sample Quality is responsible to check the measurement for all types sample .If any discrepancy found then make sure to re-adjust the pattern by Sample manager and re make the sample and take a measurement again, and reports submit to quality manager. b. Sample quality is also check the workmanship of all sample and update the reports accordingly. Relevant Documents: Sample Records – GFIL.SPL.REG.01 Pattern & Marking Distribution Records – GFIL.SPL.REG.02 Fabrics and Accessories Receiving Register - GFIL.SPL.REG.03 Inline process quality reports/End line quality reports – GFIL.QCS.FRM.18 Quality measurement checking reports – GFIL.QCS.FRM.15A
- 43. Gous Fashion Industries Ltd. Standard Operating Procedure. 43 SOP – g:fil property GFIL.IVS.PRO.01 Version# 03 Issue Date: 03 Feb 2013 Revision Date: 20 March 2014 15. Inventory & Store Control: Purpose: To develop, implement and maintain procedures for efficient functioning of the inventory management with clarity of roles & responsibilities and to ensure accurate record keeping of the same. Scope: This procedure is applicable to all items procured from various supply chain partners including but not limited to raw materials, machinery, equipments, spare parts, stationary that are used at Gous Fashion Industries Ltd. Responsibility: The Inventory Manager is responsible to implement and maintain the procedures and relevant records in the department. Procedure: 1.0 Raw Material Inventory Management 1.1 Store department receives booking chart of fabric and trims from merchandising team through email / hard copy along with approved fabric and trim cards. 1.2 Commercial / merchandising team forwards Packing List of shipped items to the store through email / hard copy after receiving the shipment information from suppliers. 1.3 Commercial team provides the arrival schedule to store vide email. 1.4 Goods arrive at the factory. Upon unloading, goods received according to the delivery information available in clearing / transport agency’s challan are matched with the Packing List already available with the department. Thereafter an Inventory card is prepared. 1.5 The Inventory Controller checks 100% of the received quantity and tallies with the expected quantities as per packing list to check accuracy / excess / shortage quantity. 1.6 If any shortage / excess of good are detected, Inventory Controller shall inform the same to the Commercial and Merchandising team vide the Inventory Discrepancy Report. The Inventory Manager will sign the Inventory Discrepancy Report prior to dispatching it to the Commercial & Merchandising team. 1.7 Merchandising / commercial team determines the reason for the discrepancy. 1.8 If it is for error on the part of the GFIL team then a reorder is placed or other alternative arrangement for the required quantity is arranged. 1.9 If the error is found to be on the part of the supplier then a replacement quantity is requested or other replacement arrangement is made by the merchandising / commercial team. 1.10 The Inventory team is notified of the alternative plan and the new schedule and packing list of reordered items if applicable. QUALITY INSPECTION: See QCS Procedures 16 and 17.
- 44. Gous Fashion Industries Ltd. Standard Operating Procedure. 44 SOP – g:fil property 1.11 QA inspection is conducted on all received goods to ensure goods are of expected quality. If the quality is APPROVED then the Bin Card is Marked GREEN demarking that it is ready to be issued for production / use. 1.12 If the quantity is found to be correct a Bin Card is issued for each item and the goods are stored in the respective areas marked for relevant item in the warehouse and update the respective registers. 1.13 If the Inventory QA finds the goods to be non-conforming to the expected / approved quality then the Bin Card is marked RED and the goods are with held from being issued. The Non- conformance Report is completed by the QA and informed to all concerned with a copy of the non-conformity report and the Non-conforming Material register is updated. 1.14 Non-conforming goods are removed to the specific area storing non-conforming material. 2.0 Material Movement Management: 2.1 Various production departments shall issue a material requisition vide the Requisition Form to the nearest Sub-store. 2.2 Cutting Department will issue the Requisition Form directly to the Inventory department. All requisitions shall approved by the Inventory Manager. 2.3 For other production departments the sub-store officers will monitor consumptions and maintain inventory at the sub-store to promptly service the various production departments. The sub-store will issue Requisition Forms to the Inventory Manager to maintain such inventory based on the ongoing production. 2.4 Sub-Store will send Store Runners to the Inventory Manager who will review the requisition and approve it for issue. Store runner will bring two copies of the requisition. Leave one copy with the Inventory Manager & get the other signed & take back and file it in the respective sub-store and keep for record along with the issued goods. 2.5 Upon each issue the Inventory Controller shall update the bin cards and respective registers accordingly. 2.6 Store runners will carry all goods to the sub-stores and issue to production departments from time to time based on requisitions received from the respective production departments. 2.7 Sub-store shall issue goods to production departments upon receiving a duly completed & signed requisition form from the respective production department heads. 2.8 Respective production departments shall send Floor Runners with two sets of the requisition form to the sub-stores. One copy will be signed by the sub-store officer and returned to the Floor Runner to take back to its respective production department along with the issued goods. The other copy shall be preserved at the sub-store for record. 3.0 Finished Goods Management: 3.1 All finished goods are QC checked at the Finishing department and handed over to the designated finished goods officer in the inventory department. Finished goods are stored at the designated area in the warehouse. 3.2 Finished goods are released vide Delivery Challan / Gate Pass upon confirmation of release vide Goods Release Order signed by designated commercial department officer. The Inventory Manager is the signing authority for the Delivery Challan / Gate Pass.
- 45. Gous Fashion Industries Ltd. Standard Operating Procedure. 45 SOP – g:fil property 3.3 Three sets of the Delivery Challan / Gate Pass are prepared; One copy is completed at the inventory department; one copy is provided to the transport agency; Two copies are forwarded to the commercial department, one of which is left with the commercial department and another one brought back with a received acknowledgment is acquired and filed at the inventory department. 4.0 Needle Control: 4.1 Sub-stores shall maintain adequate inventory of needles for the respective production floors it services. To acquire needles the sub-store shall follow the procedures as stated in 2.4 to 2.6. 4.2 Sub-stores are responsible to maintain the needle control procedures. 4.3 Respective sewing floor managers will issue needle requisition to the sub-store and the floor runners shall bring the broken needles to the sub-store along with the requisition. 4.4 Sub-store officer shall match all the broken parts of the needles one by one. It shall only issue the number of needles that it was able to put together as one unit. 4.5 The sub-store shall maintain record of the broken parts compiling it to a whole needle for each needle and preserve the record in the Needle Log Book. 4.6 For any broken needle where the broken parts do not compile it to a whole it shall complete a needle exchange request form and acquired all signatures as required in the form and then issue the required needles. Thereafter the sub-store officer shall update Log Book. 5.0 Support Inventory Services: 5.1 The Inventory department is responsible to maintain spare parts, stationary and all other support service inventory of the company. 5.2 The procedure to maintain and control it shall be the same as with the raw material. 5.3 All spares will be stored in the main store area under the classified spare storage area. Maintenance department will follow requisition procedure to avail machinery or any other spare parts. 5.4 Support Service Inventory officer shall maintain registers for the relevant items under the section. 5.5 All shipment status must be included on the Shipment Register customer and style wise. Store executive will track the bolt seal using quantity and update the register in time. 5.6 At the end of a style or an order, all raw materials will be collect by respective store executive from the floors and shifted to left over area and identified clearly with its records maintained on the Left Over Register. 5.7 The left over items will be disposed in the following manner: a) Reuse: The Chief Operating Officer (COO) is authorized to take a decision which items can be reused and how it will be reused. b) Donate and or Sell: Reviewing the items in person the COO may decide to donate the items to the underprivileged or to any disaster stricken area as case may present itself or he may chose to sell the garments by removing all types branded labels and tags. c) Recycling: All types of machinery spare parts are recycled in an environmentally friendly manner through 3rd party based on agreements.
- 46. Gous Fashion Industries Ltd. Standard Operating Procedure. 46 SOP – g:fil property 5.0 Relevant Documents: Fabrics Register Book GFIL.IVS.REG.06 Accessories Stock Register GFIL.IVS.REG.07 Machinery Spare Parts Stock Register GFIL.IVS.REG.19 Thread Received and Issue Register GFIL.IVS.REG.24 Finishing Accessories Received & Issue Register GFIL.IVS.REG.23 Stationary Register Book GFIL.IVS.REG.20 Electrical Register Book GFIL.IVS.REG.21 Needle Stock Register GFIL.IVS.REG. 5 Shipment Register GFIL.IVS.REG.18 Bolt Seal Register GFIL.IVS.REG.22 Thread Stock Register GFIL.IVS.REG.24 Finishing Accessories Issue & Receive Register GFIL.IVS.REG. 23 Left Over Register GFIL.IVS.REG.25 Non Conforming Reports GFIL.NCM.FRM.07 Requisition GFIL.IVS.FRM.01 Needle Exchange Log Book GFIL.IVS.FRM.03 Purchase Requisition GFIL.IVS.FRM.10 Delivery Challan GFIL.IVS.FRM.12 Re-issue Form for Missing Broken Needle GFIL.IVS.FRM.14 Inventory Report GFIL.IVS.FRM.15 Wash Send & Received Reports GFIL.IVS.FRM.26 Bin Card GFIL.IVS.CRD.08 Inventory Card GFIL.IVS.CRD.09
- 47. Gous Fashion Industries Ltd. Standard Operating Procedure. 47 SOP – g:fil property GFIL.QCS.PRO.01 Version # 3 Issue Date : Feb02, 2013 Revision Date : March20, 2014 16.Procedure for Fabric Inspection 1.0 Purpose & Scope To identify and determine the extent of fabric defects, the different width and other quality level of fabric lot received so as to ensure the fabrics confirms to the required standard before spreading. 2.0 Responsibilities 2.1 The IQC In-charge is responsible for the monitoring and the implementation of the fabric inspection system and to verify the authenticity of the fabric inspection report. 2.2 The Fabric Inspectors [QA] are assigned to carry out the fabric inspection and to maintain the inspection reports. 3.0 Procedures 4 point system fabric inspection: 1. Sampling: For the inspection, a minimum of 10% of the fabric covering each color and each dye lot and different width of fabric is covered based on the fabric lot size. 1.1 Shipment of 1,000 yards or less - 100% inspection 1.2 Shipment of 1,001 yards or more - 10% inspection (minimum 1000 yards) 2. The inspection is carried out major fabric defects 2.1 Major woven fabric defects are slubs, hole, missing yarn, conspicuous yarn variation, end out, soiled yarn etc 2.2 Major knitted fabric defects are mixed yarn, yarn variation, runner, needle line, bare, slub, holes, press off etc 2.3 Major dye or printing defects are out of register, dye spot, machine stop, color out, color smear or shading. 3. Points are allocated to every fault as per the point’s table listed below: Size of defects (in inches – length wise) Penalty points Up to 3 inch 1 Point 3 inch to 6 inch 2 Points 6 inch to 9 inch 3 Points Over 9 inch to 36 inch 4 Points
- 48. Gous Fashion Industries Ltd. Standard Operating Procedure. 48 SOP – g:fil property (A maximum of 4 points can be charged to one linear yard) 4. All holes regardless of size, shall be penalized 4 points. There must be two or more yarns broken at the same place, for the defect to be considered a hole. 5. The fabric width should be checked a minimum of three times during the inspection of a roll (at the beginning, middle and end). 6. No piece shall be accepted as first quality where the usable width (which is the width between the insides of the selvages or between the stenter pinholes) is less than the minimum usable width as accepted. Calculation : Total Penalty points / Actual Fabric length x 36 / cut able width x 100 = result. Acceptance Limit : Pass = Total defects percentage upto 24 % of total consignment . Fail = Total defects percentage over 24% Defects points over 40 for any individual roll (for 100 yards roll) will be unsatisfactory and those rolls will be shifted at Non conforming materials area. If total consignment results is over 24% then must be re-check the again 10% and while result also unsatisfactory then should be re inspect the 100% rolls with the presence of Fabrics suppliers. Shade Checking 1.1 To check side to side , end to end, side to middle and roll to roll shading check, 10” x 10” fabric panels are cut from each roll (100%). 1.2 Checking of the Shade band: The reason for preparing a shade band is to ensure that the same shade is cut in ratio. We cut a fabric swatch from all the rolls received (In case of Washed garments stitch them together in the form of a blanket. we get it washed to the standard required ) and then segregate the shades accordingly, Shade must be confirmed by Light box as per clients requirements i.e. Customer wise Standard Light Sources Requirements. While same shade is check and confirmed by Primary and secondary light source then it will be treated as a Metamersim check. Sl. No. Customer Name Primary Source Secondary Source 01. Target UL3500 D65 02. BHS D65 N/A 03. MANGO D65 N/A
- 49. Gous Fashion Industries Ltd. Standard Operating Procedure. 49 SOP – g:fil property which facilitates the cutting of the particular shades in ratio. 1.3 No piece shall be accepted as first quality that exhibits a noticeable degree of shading from side-to-side or side-to-center. 1.4 No piece shall be accepted as first quality exhibiting a noticeable degree of shading end-to- end, when checked by laying panels, cut from the beginning of the roll, across the opposite end. Fabric Bowing / Skewing Bowing should be done for plaid/ stripe fabrics, skewing should be done for heavy denim and twill fabrics from 5% of received fabrics. 1. Fabric bowing or bias should be within the following tolerances. 1.1 Yarn-dyed in check pattern: No piece shall be accepted as first quality exhibiting more than 1.5 inches (3.8 cm) of bow or bias on 60 inch (152cm) goods. 1.2 Printed in check or stripe pattern: No piece shall be accepted as first quality exhibiting more than 1.2 inches (3cm) of bow or bias on 60 inch (152cm) goods. 1.3 Single jersey knitted fabrics within 5%. Note that fabric should be within 5% skew after washing X = Bowing deepth, Y= Straight Line SKEWING CALCULATION Skewing % = X / Y * 100 X Y BOWING CALCULATION Bowing % = X / Y * 100 X XY
- 50. Gous Fashion Industries Ltd. Standard Operating Procedure. 50 SOP – g:fil property X = Skewing deepth, Y = Staright line Running Defect Any defect found to repeat and or run in a continuous manner will constitute a running defect. 1.1 Any piece having a running or repeating defect through more than three (3) continuous yards shall be rejected regardless of the point count. 1.2 More than one occurrence, in excess of three (3) yards, in an audit can cause the lot to be rejected. Reporting and Acceptance 1. Record results on Fabric inspection reports, as per 4-point system 2. To get the percentage of total defects in each roll separately we have to use the formula mentioned below: % Point = Total penalty points X 100x 36 Total yardage checked (actual length ) x cuttable width 3. If the final percentage is more than 40 pt per 100 linear yards / 24 pt per 100 Sq. yards, the result is recorded and IQC In-charge is informed and additional 10% fabric is inspected. 5. If the % is again more, then the lot is rejected and informed to the QA/QC Manager and Merchandiser. Again re inspect the total quantity with the presence of Supplier’s representative. 6. If the total number of second quality yardage is 20% of the total inspection quantity, the lot fails inspection. The following types of defects are included: 6.1 Bowed or bias in excess of stated tolerances. 6.2 Dye streaks or unevenness. 6.3 Loose, wavy or tight selvages. 6.4 Narrow width. 6.5 Shading side-to-side or side-to-center. 6.6 Shaded end-to-end 6.7 Any combination of the above. 7. Note that for defects such as bowing or bias, incorrect hand-feel, narrow width, and side-to-side/side- to-center/end-to-end shading no penalty points shall be assigned. However, the entire roll shall be graded as second quality and should be rejected. 8. The IQC In-charge re-inspects the non-conforming roll / sample and decides whether the roll should be rejected or not and record the decision on Fabric Inspection Report. The decision to reject the roll is based on the fact that whether the defects can be avoided in Cutting and cut panel inspection or not.
- 51. Gous Fashion Industries Ltd. Standard Operating Procedure. 51 SOP – g:fil property 9. If the defects cannot be avoided in cutting or cut panel inspection and the wastage will be too high then the Merchandiser is forwarded the Non-conforming Fabric Report who then gets the customer approval and the details are recorded on Non-Conforming Fabric Report. 10. Rejection rolls are identified by putting “Rejected” sticker and are kept in rejected goods area. Fabric Shrinkage Testing: 1. To ensure the color wise shrinkage of the fabric, the inspector has to cut a swatch measuring 50 cm x 50 cm ( or as specified by the buyer ) of every color and quality of 10% fabric in a lot by using calibrated measuring tape and get is washed to the correct approved washing standard (for wash program) and steam press the non wash program. 2. The fabric inspector records note the measurement after wash on shrinkage test report. 3. The shrinkage % is calculated using the following formula. 4. The results are recorded and is approved by Head of QA/QC To obtain the lengthwise shrinkage, the following formula should be used: Before wash length – After wash length X 100 = Shrinkage of Length Before wash length To obtain the width wise shrinkage, the following formula should be used: Before wash width – After wash width X 100 = Shrinkage of width Before wash width Acceptance : Results are accepted upto +10% for length &width wise and -5% for length & width wise. Fabrics Weight Test : 1. To ensure the fabrics weight according to the customer requirements. the inspector has to cut a swatch but GSM Cutter of every color and quality of 10% fabric in a lot and measuring a weight of every cut piece and get is washed to the correct approved washing standard (for wash program) . 2. The fabric inspector records note the measurement after wash on Fabrics weight test report. 3. The weight % is calculated using the following formula. 4. The results are recorded and is approved by Head of QA/QC . 5. As per fabrics construction we count the yarn of 10% rolls using by Yarn counting metre and count the actual yarn length and width wise and compare against actual requirements and results are recorded in Weight Test report. Calculation : Average weight – required gsm / required gsm x100 = % results Acceptance : Results are accepted upto +-5% .
- 52. Gous Fashion Industries Ltd. Standard Operating Procedure. 52 SOP – g:fil property Relevant Documents : Fabrics Inspection Reports – GFIL.QCS.FRM.01 Fabrics shrinkage reports – GFIL.QCS.FRM.02 Fabrics weight Reports – GFIL.QCS.FRM.03 Shade analyze Reports – GFIL.QCS.FRM.04 Light Box Log Register – GFIL.QCS.FRM.06 Non Conforming Records – GFIL.CNCM.FRM.07
- 53. Gous Fashion Industries Ltd. Standard Operating Procedure. 53 SOP – g:fil property GFIL.QCS.PRO.02 Version # 3 Issue Date : Feb02, 2013 Revision Date : March20, 2014 17. Accessories/TrimsInspection 1.0 Purpose & Scope To identify and determine the extent of Trims defects before issuing in the line. 2.0 Responsibilities 2.1 The IQC In charge is responsible for the monitoring and the implementation of the trims inspection system and to verify the authenticity of the trims inspection report. 2.2 The trims Inspectors (QA) are assigned to carry out the trims inspection and to maintain the inspection reports. 3.0 Procedures 3.1 IQC QA is assigned to carry out the trims inspection as per priority basis. 3.2 Inspection is done by following the Swatch card which is approved by the merchandiser. 3.3 All the material where the color check is mandatory, color must be judged under customer specified light source. 3.4 The accessories inspection is conducted on 10% sample check basis from the received quantity. 3.5 This 10% should be taken randomly. 3.6 If rejected percent exit 3% then the accessories will be reported as quality fail. 3.7 This information must be communicate with Merchant team immediately. The following points must be inspected while inspecting the trims: I. Quantity against invoice and order II. Color consistency with buyer’s requirements III. Trim design must be compared with approved sample for artwork and other details IV. Material consistency must be compared with approved samples/ buyer’s standards V. Weight must be checked if required VI. Other requirements as per buyer’s need 4.0 Acceptance: 4.1 If the lot is accepted, IQC passes the lot and release clearance is given to store along with approval signature on swatch card. 4.2 If the defectives exceed the acceptable limit, the lot is hold and the details are referred to Merchandiser / Sourcing for further action / decision. Those defective materials will be kept in a NCM box with evidence.
- 54. Gous Fashion Industries Ltd. Standard Operating Procedure. 54 SOP – g:fil property Trims & Accessories Testing Standards All trims must be inspected under the buyer specified lighting in the light box Color must be verified against the approved sample for lightness, hue and achroma Design and size must be verified against the approved sample Metal items if required must be sent to third party testing laboratories and must be tested as per buyer required standards Trims are normally being checked against standards on the following parameters. Shade matching Shrinkage (for lace, draw cord, twill tape, etc) Color bleeding Width and thickness Strength Lettering ,Number and size Fiber content Text content/font/language in labels and tags Durability for thread Ligner for button Puller strength test for zipper Fusing bonding strength test for interlining. Warning and thickness for poly Main mark word , Ply and strength for carton. Relevant Documents : Accessories Inspection Reports – GFIL.QCS.FRM.05 10% Inspection trims reject register – GFIL.QCS.FRM.28 Barcode Scanning Reports – GFIL.QCS.FRM.29 Non conforming records – GFIL.NCM.FRM.07
- 55. Gous Fashion Industries Ltd. Standard Operating Procedure. 55 SOP – g:fil property GFIL.QCS.PRO.03 Version # 3 Issue Date : Feb02, 2013 Revision Date : March20, 2014 18. Light box using procedure 1.0 Purpose and Scope : 1.1 Confirm the color and shade for raw materials as per customers requirements. 1.2 Buyer recommended certified Light Boxes must be used to review all materials (fabrics and trims). 2.0 Responsibilities : Fabrics and Accessories Inspector are responsible to perform this jobs and In charge – Fabrics and Accessories Inspection will review the records. 3.0 Procedure : The Light Box used by Gous Fashion Inds Ltd. with D65, UL 3500, TL84 and UV light sources The light Box has to calibrated by certified technician and a valid calibration certificate has to be obtained and must be kept with the machine The light box has to be placed in a dark room where it can be used to check the shades variance of machine The fabric and trims should be checked under several lighting conditions as specified by the Buyer and proper records should be kept for color match evaluations For best visual review of the colors in both daylight and store light simulation, the following procedure is recommended: a) The sample material (trims or fabric) and the color standard must be placed side by side touching each other b) They also must be in the same direction, with regard to weave, knit and textile, etc. Must be ensure by primary and secondary light source and checked the metamerism for inspected items. The bulbs have to be replaced as per the manufacturer recommended changing periods so that there are no errors while checking the shade variances of material. The replacement date is determined by the following process: a) Using time is recorded from the timing meter installed in the box b) Total hour is calculated as per cumulative reading records from the meter c) Bulbs are replaced with this information as per the following specified times: i) Day Light- 4000 hours ii) Illuminant “A” 2000 hours iii) Cool White Fluorescent 4000 hours iv) UL35 4000 hours v) UV 4000 hours 4.0 Relevant Documents : Shade light using activities records – GFIL.QCS.FRM.06
- 56. Gous Fashion Industries Ltd. Standard Operating Procedure. 56 SOP – g:fil property GFIL..PPE.PRO.01 Version# 03 Issue Date: 03 Feb 2013 Revision Date: 20 March 2014 19. Pre-production Meeting 1.0 Purpose & Scope 1.1 Review the approved Sample. 1.2 Highlight the potential product safety, quality & productivity issue. 1.3 Communicate all potential points with related supervisors, QAs & Other persons 1.4 Take measureable steps to avoid any future unavoidable circumstances. 2.0 Responsibilities 2.1 The Internal Auditor and Merchandiser are responsible to monitor and to implement the pre- production meeting procedure. 2.2 Planning & central QA is assigned to ensure that the meeting is conducted before start of production, and maintain the records. 3.0 Procedures 3.1 On receipt of the style file from planning, the unit in-charge gets the approved sample from P&D. 3.2 Unit in-charge, reviews the sample along with the production executives, technical executive & floor QA Executive. 3.3 After the review, Size set samples stitched two pcs in each size / color, checked for workmanship, styling, and measurement, and submitted to P&D for approval. 3.4 Upon size set approval, the results are communicated to technical team & planning. 3.5 Planning checks the material in-house status and calls for pre-production meeting. 3.6 Pre-production meeting is chaired by Factory Chief Operating Officer and attended by representative from related floor, QA, Maintenance, Merchants, IQC, IE, planning, P&D, Stores and central QA 3.7 In P.P. Meeting Internal auditor will assure to receive the all documents as per P.P. meeting documents Check list. Sl. No. Documents Types Yes No Remarks 01 P.P. MEETING FORMAT (FILLED) 02 SIZE SET MEASUREMENT REPORTS WITH SAMPLE 03 MACHINE LIST 04 LINE LAYOUT
- 57. Gous Fashion Industries Ltd. Standard Operating Procedure. 57 SOP – g:fil property 05 PRODUCTION PLANNING WITH CUTTING, SEWING AND FINISHING 06 FABRICS BOOKING AND RECEIVING STATUS WITH PI 07 ACCESSORIES BOOKING AND RECEIVING STATUS WITH PI 08 FABRICS INSPECTION REPORTS WITH SHRINKAGE , WEIGHT AND SHADE ANALYSING 09 ACCESSORIES INSPECTION REPORTS WITH BARCODE SCANNING 10 INTERNAL ALL PRODUCT SAFETY TESTING REPORTS i.e. BUTTON PULL TEST , FUSING TEST & HEAT SEAL TEST ETC 11 PRODUCTION TEST PLAN 12 PO SHEET / ORDER DETAILS 13 PID OR TECHNICAL DETAILS 14 CRITICAL MOCK-UP 15 3RD PARTY TESTING REPORTS 16 VRN (If applicable) 17 FIRST OUTPUT MEETING RECORDS WITH MEASUREMENT 18 PILOT RUN MEETING RECORDS WITH MEASUREMENT 19 TRIMS CARD 3.7 During the PP meeting following activities performed: 3.7.1 Buyer approved sample is reviewed. 3.7.2 Size set sample report is reviewed and the deficiencies discussed. 3.7.3 Make sure of the correct trims placement. 3.7.4 Highlighting potential product safety, quality & productivity issues
- 58. Gous Fashion Industries Ltd. Standard Operating Procedure. 58 SOP – g:fil property 3.7.5 Discussing print & embroidery placement and appearance as applicable 3.7.6 Discussing finishing & packing details 3.7.7 Discussing production plan & delivery issues 3.8 at the end of the meeting, all the attendee’s signs off the minutes. 3.9 Pre-production meeting notes , approval sample (approved by DQA or Buyer QC) & PTP must be communicate with Stores, Merchandiser , cutting , sewing and finishing and COO/GM will give the decision to proceed for Trial Cutting . First Output Compare Meeting 1.0 Purpose and Scope : 1.1. Review the ist output garments and compare with approval sample. 1.2. Improve the quality and productivity to analyzing the ist output garments . 1.3. To adjust the pattern. 2.0 Responsibilities : 2.1 Factory Internal auditor and quality manager are responsible to organize the meeting and Production GM will be chair by the meeting. 3.0 Procedure : Review the size set sample and adjusted the pattern by Sample section according to the size set measurement reports and Successfully completed the P.P. Meeting , P.P. Meeting chair will be permit for trial cutting (240 – 300 pcs) for all color and all size and During the meeting following activities performed: 3.1 First output garment must be reviewed with Buyer approved sample 3.2 Size set sample report is reviewed and the deficiencies discussed. 3.3 Make sure of the correct trims placement. 3.4 Highlighting potential product safety, quality & productivity issues 3.5 Discussing print & embroidery placement and appearance as applicable 3.6 Discussing production plan & delivery issues . 3.7 All workmanship and measurement discrepancy must be recorded at compare meeting reports. 3.8 at the end of the meeting, all the attendee’s signs off the minutes and meeting notes communicate with all respective department. Pilot cut / Pilot run Meeting Purpose and Scope : 1.1 Adjust the pattern review the measurement reports. 1.2 Review the finish garments and compare with approval sample. 1.3 Improve the quality and productivity to analyzing the ist output garments . 1.0Responsibilities : 1.1 Factory Internal auditor and quality manager are responsible to organize the meeting and Production GM will be chair by the meeting. 2.0Procedure :
- 59. Gous Fashion Industries Ltd. Standard Operating Procedure. 59 SOP – g:fil property Review the finish garments of all color and all size and adjusted the pattern by Sample section according to the size set measurement reports and Factory Chief Operating Officer / GM will be advised to proceed bulk productions. During the meeting following activities performed: 2.1 Finish garments are reviewed . 2.2 Review the wash standard and hand feel. 2.3 Review the measurement. 2.4 Make sure of the correct trims placement. 2.5 Highlighting potential product safety, quality & productivity issues 2.6 Discussing print & embroidery placement and appearance as applicable 2.7 Discussing production plan & delivery issues . 2.8 All workmanship and measurement discrepancy must be recorded at compare meeting reports. 2.9 at the end of the meeting, all the attendee’s signs off the minutes and meeting notes communicate with all respective department. 4.0 Relevant Documents : Pre-production meeting Reports – GFIL.PPE.FRM.16 First output compare records – GFIL.PPE.FRM.17 Pilot run meeting records – GFIL.PPE.FRM.17A Measurement Reports – GFIL.QCS.FRM.15
- 60. Gous Fashion Industries Ltd. Standard Operating Procedure. 60 SOP – g:fil property GFIL.CUT.PRO.01 Version# 03 Issue Date: 03 Feb 2013 Revision Date: 20 March 2014 20. Cutting Section controlling Procedure 1.0 Purpose and Scope: 1.1 . Make a cutting plan and cutting the fabrics as per plan. 2.0 Responsibilities : 2.1 Cutting Manager is responsible to monitoring the entire process. 3.0 Procedure : 3.1 Cutting Manager must be present at Pre-production meeting with cutting pan . After Successfully completed the P.P. meeting he will get all kinds of documents , sample and p.p. meeting notes . 3.2 He will proceed for trail cutting 240 – 300 pcs for all color and all size. 3.3 Provide the requisition for fabrics to stores. 3.4 Proceed to draw the markings based on the approval pattern and QC Team assure the markings. 3.5 Spread the rolls maintaining the color consistency. 3.6 Parts number obviously put in the inside. 3.7 Maintain the bundle integrity 30 pcs a one bundle. 3.8 Cutting information recorded at cutting recording sheet . 3.9 Cutting recording sheet must be provided to store and sewing section. 3.10 End of pilot run production , Factory Internal auditor and respective merchandiser will organize the ist output/Pilot run meeting and based on the measurement reports pattern are rectified by Sample manager. 3.11 Proceed for bulk cutting PO wise and daily cutting information must be recorded at daily cutting register. Fabric Relaxation Procedure 1.0 Purpose and Scope : To do the Fabric relaxation before spreading, in order to have proper measurement control in the final product. 2.0 Responsibility : 2.1 The Cutting Executive of the respective production unit is responsible to ensure & implement the procedure. 2.2 The QA Executive of the respective production unit is responsible to monitor the process. 3.0 Procedure : 3.1 All the fabric, depending on the packing method and the structure, need to be relaxed before spreading as per the below criteria: Type Relaxation Time ( Minimum ) All Knit fabric in roll form 24 hrs to 72 Hours
- 61. Gous Fashion Industries Ltd. Standard Operating Procedure. 61 SOP – g:fil property All Knit fabric in folded form 24 hours to 48 hours All Elastomeric fabric 24 hrs Woven Fabric (Spandex , Joerjet , Denim) Need relaxation min 12 hours to 24 hours 3.2 The fabric must be relaxed as per the criteria in 3.1 by opening the fabric roll and converting it in the folded form . 3.3 The fabric should be stored in the fabric relaxation racks and allowed to be relaxed for the specified time. 3.4 Each fabric roll is tagged with the relaxation card as below : FABRIC RELAXATION INFORMATION Date Customer Style No. P/O No. Batch No. Roll No. Start Date & Time End Date & Time GFIL Garment’s Division ( Cutting Section ) 3.5 The details of the all the rolls relaxed is entered in the fabric relaxation status . 3.6 The fabric can be taken for spreading purpose only after completion of the specified relaxation period. Garments Parts Numbering procedure 1.0 Purpose and Scope : Produce a good quality garment avoiding shading within the garment, pack garments having one shade in one carton and have the traceability in case of any issue. Numbering machine it should at least facilitate 08 digits. Sticker Stickers' gum quality has to be chosen according to the fabric. This has to be checked before starting every new style. Not doing this will be led to unnecessary issues. Numbering System
- 62. Gous Fashion Industries Ltd. Standard Operating Procedure. 62 SOP – g:fil property Cut No Size Serial No E.G. 05 XXL 999 2 digit 3 digit 3 digits All the panels have to be numbered as per above system. After completing the garment, the product Checker check the sticker to confirm that garment is stitched following the numbering stickers. Relevant Documents : Spreading Reports – GFIL.CUT.FRM.01 Cutting Numbering Sheet – GFIL.CUT.FRM.02 PO wise cutting details – GFIL.CUT.FRM.03 PO SIZE Wise input details – GFIL.CUT.FRM.04 Cutting reports – GFIL.CUT.FRM.05 Non Conforming materials reports – GFIL.NCM.FRM.07
- 63. Gous Fashion Industries Ltd. Standard Operating Procedure. 63 SOP – g:fil property GFIL.QCS.PRO.04 Version# 03 Issue Date: 03 Feb 2013 Revision Date: 20 March 2014 21. Cutting Marker Checking . 1.0 Purpose and Scope : 1.1 To avoid missing any parts at marking. 1.2 Avoid to overlapping at marking. 2.0 Responsibilities : 2.1 QA Supervisor are responsible to check the each markings before to start productions. 3.0 Procedure : 01.Marker man should follow the Grain Line of the Pattern .He has to mark the checking point in each Pattern Top & Bottom by using Measurement Tape or Steel scale & check the Grain Line alignment. 02.Should be count all parts as per ratio and confirmed ratio is correct (as per Buyer requirement.) 03.Should be One Garment or all garments all parts in a one way . 04.Check with the correct method so that no parts over lapping or cross the edge line. Spreading Quality Control 1.0 Purpose & Scope To ensure the accuracy of Spreading Process to prevent / minimize the issues in final product. 2.0 Responsibilities 2.1 QA Executive is responsible for the implementation of the Spreading Quality Control System. 2.2 The Cutting QA is responsible to carry out the spreading quality control activities. 3.0 Procedure 3.1 Before starting the spreading, check & ensure that the fabric inspection report is passed and shade grouping is done on the batch. 3.2 The QA must check for the defects mentioned bellow & record the observations on spreading quality control report 3.2.1 Table Marks : Check for table marks as the table is marked. Allow no minus tolerance for the splices. 3.2.2 Shade Group : Ensure the rolls taken for spreading belongs to same shade groups as per the shade band report. 3.2.3 Marker : Ensure that no markers are creased, damaged or have overlap parts. 3.2.4 Ends : Check both end of fabric layers to ascertain whether is straight or not.
- 64. Gous Fashion Industries Ltd. Standard Operating Procedure. 64 SOP – g:fil property 3.2.5 Tension : Check the Tension during spreading. This is very important on knit fabric. 3.2.6 Shading: Check for shading. It is essential to have a system to control shading 3.2.7 Splice: After completion of spread, check splice laps to see that both plies extend passed the splice mark by no less than half inch & no more than one inch. 3.2.8 Narrow Goods: After completion of the spread, check the “Far Edge” of the spread to see that all plies extend beyond the marker line. 3.2.9 Count Check: Verify the count after the completion of spreading, and before cutting, a count all plies must be taken at both ends. There is no tolerance. 3.2.10 Leaning: Check carefully and to ensure that one edge of the fabric is aligned with the tabletop. 3.2.11 Fabric Faults: All major fabric defects are identified using arrow sticker. 3.2.12 Marker Placement: Check that the marker is placed on the spread with the edge parallel to the salvage of the piece goods. To verify that all cut pieces will be complete. 3.3 For marker, count check, fabric faults, ends, marker placement, narrow good, shading and table mark faults the spreading QA inspector can stop the spreading process and ask cutting dept. to take corrective actions. CUTTING QUALITY CONTROL 1.0 Purpose & Scope: To ensure the accuracy of Cutting Process to prevent / minimize the issues in final product. 2.0 Responsibilities: 2.1 QA Executive is responsible for the implementation of the Cutting Quality Control System. 2.2 The Cutting QA is responsible to carry out the cutting quality control activities. 3.0 Procedure: The Cutting QA should check for following issues in cutting process: Match the layer (Top , Middle , Bottom) with hard pattern for the all big parts (Front and Back) cutting lots and re cutting the same layer when layer cutting is smaller than smallest size and reshape the layer while layer is bigger than size. After bundling complete , before to issue input Cutting QA are responsible to check the every layers for all big parts (Front and Back). During the inspection check the below points. 3.1 Miscut : Check for miscut or failure of the cutter to “split the line.”. Tolerance is ± 1/16“. Report all defects of Miscut 3.2 Matching Plies : Check top ply, middle & bottom ply. Compare all to see exact match. Tolerance is ± 1/8“. Report all defects. 3.3 Ragged Cutting : Check for ragged cutting. This is judgment defect and is more important on critical parts. If the part has to be re-cut, it is a defect.
- 65. Gous Fashion Industries Ltd. Standard Operating Procedure. 65 SOP – g:fil property 3.4 Notches ( Cut Mark ) : Check the notch location by placing the pattern over the top & bottom ply. Tolerance is ± 1/8“.If the notch is more than 1/8“ off, report as defect. 3.5 Pattern Check : Compare the pattern to paper marker to ensure that the correct marker used. With the hard pattern Qc need to check , Top , Middle & Bottom Panel 3.6 Numbering Check Check the all parts layer serial number during bundling check. Relevant Documents : Marking Check – GFIL.QCS.FRM.13 Spreading quality control – GFIL.QCS.FRM.11 100% Cutting inspection reports – GFIL.QCS.FRM.12 Cutting quality control report 100% - GFIL.QCS.FRM.14 Sharp tools control register – GFIL.SPT.REG.01
- 66. Gous Fashion Industries Ltd. Standard Operating Procedure. 66 SOP – g:fil property GFIL.TST.PRO.01 Version# 03 Issue Date: 03 Feb 2013 Revision Date: 20 March 2014 22. Fusing Machine Operating Procedure 01. Purpose and Scope : Assure the attached fusing are meet the minimum strength according to the customer requirements. 02. Responsibility : Fusing Machine operator is responsible to accomplish the assigned jobs. 03. Procedure : Gous classified the procedure in below way ; 1.1 Safety Procedure The operator must use fabric gloves while operating machine. Care must be taken so that hands do not get between the rollers. 1.2 Quality Procedure The fusing recommendation for all fabrics will be posted near the machine. Fusing machine operator will have to test the machine as per the form (1) and the start bulk production if all is ok. The form (1) has a practical test to check the bonding strength plus a thermal strip has to be used to check the belt temperature. The machine will be tested in the morning & after the lunch break. For wash program , need to test the fusing bonding strength daily 3.3 Maintenance The daily routine check list will have to be checked and filled before the machine is handed over for production. The machine check list form has the following check a) Belt cleaning. b) Oiling of rollers. c) Machine cleaning. d) Pressure check. e) Temperature check. f) Belt alignment. 3.4 Machine Operating/Production Procedure The machine has to be switched on 30 minutes before start of production so that it reaches the require temperature on the time. The operator need to see that the fusing is placed, on the fabric properly before passing it into the machine, The fusing has to be smaller than the fabric to avoid belt staining.
- 67. Gous Fashion Industries Ltd. Standard Operating Procedure. 67 SOP – g:fil property In case the machine temperature/pressure drops down the machine have to be stopped and maintain department has to be informed of breakdown. 3.5 Preventive Maintenance Procedure for Pressing All pressing machine must be serviced monthly to keep the machine running un-interrupted. Steam lines and pressure should be proper. The next servicing/maintenance date should be noted on the maintenance card. Pressing table should also be checked and the cloths on the table should be changed if they are dirty. Vacuum pressure should be controlled and adjusted. Preventive Maintenance card should be hanged beside the machine. 4.0 Relevant Documents : Fusing Machine Test Report – GFIL.TST.FRM.06
- 68. Gous Fashion Industries Ltd. Standard Operating Procedure. 68 SOP – g:fil property GFIL.SEW.PRO.01 Version # 3 Issue Date : Feb02, 2013 Revision Date : March20, 2014 23.Sewing Department controlling procedure 1. Purpose and Scope : 1.1. Confirm to continue the input flow smoothly and assure not to back log in production and achieved the production with quality. 2. Responsibilities : 2.1 Production supervisor and Production In charge are responsible to accomplish their job responsibilities. 2.2 Production Manager will monitor the process. 3. Procedure : 3.1 Before the start of input into the sewing lines all pre-production procedures must be completed. 3.2 All technical requirements like mockups, approved sample, swatches, etc must be displayed for easy understanding. 3.3 Before input starts all Machine Mechanics must check all sewing machines before the start of work for problems and record their finding in the inline machine adjustment log. 3.4 All machine issues found must be fixed before starting work. 3.5 The operators have to check the needle point everyday by following the needle points check procedure. 3.6 All mechanics, operators, supervisors and line chiefs must check to see if the machine thread handling systems are clean and correct. 3.7 Before starting the production every operator has to clean their machine. 3.8 All mechanics must adjust the machine to control and minimize oil marks. 3.9 All employees must maintain cleanliness to control stains and dirty spots on garments 3.10 No garments or parts can be kept on the floor and must be kept in the assigned place. Sewing Safety Instructions: All operators must use PPE (Personal Protective Equipment) that have been provided to them All operators must not remove any PPE from any machine
- 69. Gous Fashion Industries Ltd. Standard Operating Procedure. 69 SOP – g:fil property All operators must wear dust masks to avoid breathing in fabric dusts Input & Assembly: Bundling system needs to be followed 100% cutting wise to avoid size mistake and shading. Input flow must maintain bundles of 30 pieces While sewing all operators must keep the stitch quality as per the buyer’s requirement and verify the SPI (stitch per inch). If there are issues it must be escalated to the supervisor for immediate action. All production employees must maintain and follow the correct bundle serial and numbering systems to avoid size mistake All operators must follow parts attaching mark and pay particular attention to all difficult processes like pocket, flap attachment, belt joint etc. as per buyer requirement. If any parts are rejected during sewing process, the particular part must be replaced by selecting another piece from the same fabric roll to avoid any kind of shading. The rejected parts are returned to the cutting section and quarantined in reject box. GFIL.SEW.PRO.02. Version#01 Issue Date : March20, 2014 Revision Date : N/A 24. Alternation Procedure in Sewing Line : Quality must be kept the defective garments in a Defective boxes with a records and handover to sewing supervisors those bundle with defective garments and within same hours sewing supervisors will return the bundle be repaired. QC will re-check the bundle and forward to next steps. Relevant Documents : Input Output Register – GFIL.SEW.REG.01 Flagging Records – GFIL.SEW.FRM.02 Daily Reject Report – GFIL.SEW.FRM.05 Hourly Production Report – GFIL.SEW.FRM.06 Operator Training Records – GFIL.TRN.FRM.04
- 70. Gous Fashion Industries Ltd. Standard Operating Procedure. 70 SOP – g:fil property GFIL.QCS.PRO.05 Version # 3 Issue Date : Feb02, 2013 Revision Date : March20, 2014 25. Sewing Quality Monitoring System 1.0 Purpose & Scope : Ensure to control and reduce the defects rate at line and assure to improve the quality standard. 2.0 Responsibilities : QA Manager is responsible to implement the quality management system at line and monitor to improve the process. 3.0 Procedure : QIs are responsible to make sure the product processing is in control and making good quality garments. QIs check the garments in 4 stages: 1. FRONT 2. BACK 3. WAISTBAND 4. OUT PUT In every stage they make sure the following procedure are in place: Details of inspected quantity – Inspect, Pass, Defective, Repaired, Re-inspected, Passed, Reject Enter the defective points in defect tally report every hour. Handover the defective garments to the sewing supervisor and take sign before an end of every hour. Re-inspect the rectified garments if found ok mention ( ok ) with soap chalk and pass & sign. If found any Garment reject which can’t be Used should be handover to the Line Qc as a Non –conforming Garment and should be kept in Red box with details. Line Qc need to Attend all the process check point every hour to analyzes the report. Line Qc need to make sure the accounting is done properly for Pass , Defect , Reject And Total Pieces checked. Bartack: All garments coming into the bartack section must have passed all quality procedures at the out put Quality inspection point. Bartack points on the garment must be made following buyer specifications and instructions given during the PP meeting. Care must be taken so that the stitching quality and the density of the stitch is as per buyer specification. Daily Measurement Audit : QC supervisors is responsible to do the daily measurement before wash min 03 pcs per size/color and must be follow AQL 2.5 level – S4. Same garments must be sent o washing factory hanged the thread at main label .
- 71. Gous Fashion Industries Ltd. Standard Operating Procedure. 71 SOP – g:fil property Same garments measure the all points after wash. Communicate the daily measurement reports to Quality manager , production manager and general manager. Out Put Garments Audit:- Out Garments Audit will be done on AQL 1.5. The goods will be pulled by the inspector randomly from the out production which are ready to send for wash. If the Audit fails for any major issue the lot need to be re-checked 100%. Inline dupro inspection report must have before wash spec attached on every sizes. Auditor need to do minimum of 4 pieces spec audit of every size & color. Hourly Lot Audit : Assure to forward the qualitible garments in next steps. Count the lot in correctly in every hour. Select the lot as per AQL 1.5 , Level -1 randomly. Measure the Stitch per inch in different process within a same garments. Get the measurement. Check the workmanship according to the sample. Show the lot audit results to supervisors in every hour. If lot fail then recheck the entire lot by End table inspection. Records the every hour results in lot pass reports. Relevant Documents : Measurement Spec – GFIL.QCS.FRM.15 Inline Process quality Reports / End line quality reports – GFIL.QCS.FRM.18 Lot Pass – GFIL.QCS.FRM.20 Machine setting reports – GFIL.SEW.FRM.11 Stitch Monitoring records on daily basis – GFIL.QMS.FRM.23 Production stop reports – GFIL..QCS.FRM.24
- 72. Gous Fashion Industries Ltd. Standard Operating Procedure. 72 SOP – g:fil property GFIL.QMS.CRT.02 Version # 01 Issue Date: 20 March 2014 Revision Date: N/A 26. GFIL AQL [Acceptable Quality Level]Charts:
- 73. Gous Fashion Industries Ltd. Standard Operating Procedure. 73 SOP – g:fil property GFIL.QMS.PRO.03 Version # 3 Issue Date : Feb02, 2013 Revision Date : March20, 2014 27. Traffic Light Quality System 1.0 Purpose & Scope : 1.1 To instruct Quality Supervisors and Roaming Quality controllers about the Traffic light Quality system they are assigned to do in detail. This system is used to Stop Producing Defected Garments at Place. This is a random inspection system. Traffic light system is used for controlling factory floor quality and is better that other quality tools of its visual communication. 2.0 Responsibilities : 2.1 Quality Supervisors / Roaming QC are responsible to conduct the Traffic Light Check. 3.0 Procedure : Q.A. Manager, and Floor Quality controller shall instruct all Roaming QC’s about the job they are going to perform and responsibilities on each person. The given format is used for every single operator & machine. The single sheet will keep record for the whole month of an operator & operation. The quality controller, on the first day of the month must fill details such as operator name, operation name, line number & Month. Each columns contains 4 circles, represents four inspections a day. After inspection they must fill the respective circles according to the rating criteria. The roaming qc will randomly select 5 pieces and inspect for quality 4 times a day from every machine. If no defects are found then circle will have green color mark. If one defect found then the bundle fails and the circle will have yellow color mark. If two defects found then the circle will have red color mark. The failed bundle must be checked fully for issues found and should be rectified accordingly. The supervisor will attend the operation and will teach the operator for making improvement. If the same machine has again the issues on 2nd round inspection then the line supervisors, line chiefs, PM & Floor controller in charge will decide if the operator needs to be changed or need to be send for training. At the end of the day roaming quality controller has to sign report and get the relevant signatures from others. If too many defects in line they are not accepted. Quality manager have a right to stop the line. 4.0 Benefits: Will be help full to all roaming QC’s to clearly understand the Instruction to follow and perform their assigned Jobs. This document will show the acceptance of their jobs and responsibilities. At the same time it measures operators performance level in quality and since operators don’t like to be presented themselves as lower quality makers, they automatically concentrate on quality aspect during stitching garments and will improve them self’s.
- 74. Gous Fashion Industries Ltd. Standard Operating Procedure. 74 SOP – g:fil property Daily Goal SOP:- In Line 1.5 AQL standard is been followed. Factory has a procedure to keep the defect under 3.125% rate. Line Qc will collect the daily output table defect tally report from all lines at the end of the day. Line Qc will identify the top most defective Operations were it can be 2,3 or 4. After identifying top defects occurred on that day, Quality meeting will be held next day with the Quality and production Team. Discussion will be done on how the occurred defects will be controlled by giving an effective corrective action plan. After identifying the top defects of the day , Quality team will find out the reason , after getting the reas on of the defects a CAP will be generated. Same time in meeting discussion will be done on how the same will be sustained. So that in future the same defects does not arises again. In the daily goal report will be mention today defects % , & previous day defects % . Production team & Line Qc will be responsible person to make sure given CAP is been followed. Next Day QA manager will Verify the defect rate and will make sure that there is continues improvement seen on the given CAP and is effective. CAP can be changed if its seen that there is no continues improvement. Task is to reduce the defect rate at least 10-15% from daily goals report. Weekly Goal :- Floor controller will collect total week’s Output tally report from all the lines at the end of the week. Weekly goal report has to make based on daily output tally report. Weekly Goal meeting will be done with Production and Quality team attendance. Weeks Top 3 defects will be mentioned in weekly goal report. All the defects will be calculated based on a week’s defect summary. Weekly goal will be posted in Front of Output Tabel in Line in Big Board which will be visible to all workers. The Issues in the weekly goal will be recorded accordingly with previous week status, so that improvement can be understood easily. At the time of Weekly Defect Analysis Qc meeting should have Notes/Documentation reference production issues corrective action taken. Relevant Documents : Daily Inline Goals/Quality Meeting and CAP – GFIL.QMS.FRM.21 Defects Trend analysis – GFIL.QMS.FRM..09A Weekly Quality goals meeting recording sheet – GFIL.QMS.FRM.22A Traffic light Chart – GFIL.QMS.FRM.19
- 75. Gous Fashion Industries Ltd. Standard Operating Procedure. 75 SOP – g:fil property GFIL.SEW.PRO.03 Version # 01 Issue Date: Feb02, 2013 Revision Date: 20 March 2014 28. Broken and Blunt Needle Log Control Procedure: Purpose & Scope : Control the sewing needle in a factory and implement the procedure . Responsibilities : Needle Issuer is responsible to implement the policy and store manager is responsible to monitor the process. Procedure : Every factory that uses any type of needle operation, regardless of product, is required to comply with the Broken Needle Control Log procedure. The Broken Needle Control Log should include: o Date/Time of Incident o Production Line o Operation o Operator o Machine Type/Machine ID o Mount Broken Needle o Panel/Garment Destroyed – Yes or No o Mechanic‘s signature and Date Every factory must maintain a controlled needle inventory system and a broken needle control log. This log should include all broken parts or damaged needles along with any corrective action taken. Each sewing machine should have an ID (identification number). Needle replacement should be done only by designated factory personnel (e.g. inline supervisor, mechanic, needle log supervisor, etc.) to provide a log recording all parts of a broken needle have been accounted for. Note: Sewing operator should not have free access to spare needles. Production work areas are to be kept clear of unnecessary sharps (e.g. scissors, razor blades, staples, pins and loose metal parts). Machines and/or operators which continue to have broken needle issues should be reviewed and appropriate corrective action taken. Machines and their surrounding areas should be checked daily for needle and/or metal contamination. For products where a needle/metal detector is mandatory In the event of a needle breaking during any sewing operation, the panel or product piece being sewn should be retrieved from the production line and checked for broken parts. Broken parts should be sealed on the broken needle log control sheet indicating all details listed above.
- 76. Gous Fashion Industries Ltd. Standard Operating Procedure. 76 SOP – g:fil property If all broken parts are not accounted for, contaminated panels or product pieces should be passed through the needle detector. If the needle detector still detects metal parts and if after further investigation, the pieces cannot be found, the panel or product pieces should be destroyed and recorded on the log. For products where a needle/metal detector is not mandatory In the event of a needle breaking during any sewing operation, the panel or product piece being sewn should be retrieved from the production line and checked for broken parts. Broken parts should be sealed on the broken needle log control sheet indicating all details listed above. If all broken parts are not accounted for, contaminated panels or product pieces should be destroyed and recorded on the log. Compliance auditors must check if GFIL ’s Needle and Metal Contamination Policy is being followed by checking: Needle Inventory System Broken Needle control log for accuracy and integrity of the records. Sewing machines have ID number and are verified against the Needle Inventory System and Broken Needle control log. Check machine oil sump for any broken parts and surroundings for loose metal parts. Check that sewing operator does not have access to needles and unnecessary sharps by verifying machine surrounding and drawers. Relevant Documents : Broken Needle Log Book - GFIL.IVS.FRM.03 Needle Exchange Log Book - GFIL.IVS.FRM.04 Blunt & Broken Needle Log Book – GFIL.IVS.FRM.02 Needle Stock Register - GFIL.IVS.REG.05 Re-issue form for missing broken needle – GFIL.IVS.FRM.14 & 14A
- 77. Gous Fashion Industries Ltd. Standard Operating Procedure. 77 SOP – g:fil property GFIL.SPT.PRO.01 Version # 01 Issue Date: 20 March 2014 Revision Date: N/A 29. Sharp Tools / Blades Control Purpose: To control the usage of sharp tools and objects in the factory to ensure a safe working environment for all. Scope: GFIL considers scissors, trimmers, cutters, blades and all kinds of knifes as sharp tools. All sharp tools like scissors, trimmers, cutters, knifes, and other sharp objects must be accounted for by the supervisors and the person using the object. Responsibility: Section Supervisors are responsible to implement and sustain the policy and Technical Compliance and Audit team will validate the process at all stages. Procedure: 1. All trimmers, cutters and scissors must be attached the user name and card number and accounted for and must be attached to the sewing machine or table. 2. At the end of each working day all sharp objects have to be accounted for by the employees using the items and must secure them in their lockers, or return to the supervisor for safe keeping if they do not have a locker 3. If any item is lost, it must be reported immediately to their supervisor and all efforts have to be made to recover the item. If it cannot be found, then all garments in that area must be screen through the needle/metal detectors 4. If any sharp tool is broken during work, then all effort must be made to recover all broken parts. If all the broken parts are not found, then all garments in that area must be screen through the metal detectors 5. All broken parts of the broken sharp object must be returned to the store for disposal before a new item can be issued 6. Used and worn-off sharp objects will only be replaced by the store as an even exchange (1 used item for 1 new item of the same kind). Under no circumstances will the store issue a sharp object if the old item is not returned or if the item is not the same. 7. Records must be maintained for of all sharp objects being issued to the production and other departments. Relevant Documents: Sharp tools control records – GFIL.SPT.REG.01
- 78. Gous Fashion Industries Ltd. Standard Operating Procedure. 78 SOP – g:fil property GFIL.MNT.PRO.01 Version # 01 Issue Date : Feb02, 2013 Revision Date : March20, 2014 30.General Machine Maintenance Procedures (For All Types of Machines) 2.0 Purpose and Scope : Assure to adjust the feed mechanism and check the machine fitness according to the products. 3.0 Responsibilities : Section wise Mechanics are responsible to adjust the machine on regular basis and perform the preventive maintenance on schedule basis. Maintenance Manager will assure to review the records. 4.0 Procedure : Every type of machine must have two (2) types of records : a. Preventive Maintenance Record b. Daily Check List Maintenance Manager prepare a advance monthly preventive maintenance schedule. Sewing machines must have a third record – the Inline Machine Adjustment log Preventive Maintenance Records Card should be hang on every machine Every day all maintenance must check the machines in their charge with a Daily Maintenance Check List. They Must maintain the machines per the manufacturer’s guidelines following all health and safety procedures They must ensure equipment is operating with the correct setting and make the necessary adjustment if required They must ensure all safety systems on the machines are functional to ensure proper protection to the operators while they work with the machines If any problem is found in the machine the responsible person must put the machine in breakdown status and record this in the Preventive Maintenance Record and should try to fix the problem as soon as possible If the problem occurs while operating the machine, the operator must turn off the machine if possible and hang a red flag and report this immediately to their supervisor who will call the in-house maintenance person If the in-house maintenance person cannot fix the machine, then the machine supplier/manufacturer or their authorized dealer is contacted to have the machine repaired If a spare machine is available it is put into service in its place Once the repair is completed the machine is tested for safety and operational readiness and put bask into service or kept in storage if a spare was already issued in the place All records (Preventive Maintenance and Daily Checklists) must be updated with the necessary information and in case of sewing machines the Inline Adjustment log must be updated with the correct information
- 79. Gous Fashion Industries Ltd. Standard Operating Procedure. 79 SOP – g:fil property 3.6 Relevant Documents : Machine Stock Register – GFIL.MNT.REG.01 Machine Servicing Register – GFIL.MNT.REG.02 Machine Servicing Card – GFIL.MNT.CARD.01 Monthly Machine Servicing Schedule – GFIL.MNT.FRM.03
- 80. Gous Fashion Industries Ltd. Standard Operating Procedure. 80 SOP – g:fil property GFIL.TST.PRO.02 Version # 03 Issue Date: 02 February 2014 Revision Date: 20 March 2014 31. Button Pull test Purpose : To ensure the strength of the attachment of the buttons to the garment are adequate and meet customer requirements. Scope: Button attachment operation and related personnel. Responsibility: Pull Test operator is assigned to perform the jobs daily and Technical Compliance and Audit department must check compliance. Procedure: 1.0. Maintenance have to be adjusted according to the fabrication and button types. 2.0 Before to start production pull test operators must be do the button pull test twice a daily . 3.0 Pull test operators must follow the below requirements customer wise: Target 17 lbs / 10 sec for infant and toddler 15 lbs / 10 sec for boys and above BHS 20.2 lbs / 10 sec for all sizes Mango 20.2 lbs / 10 sec for all sizes 4.0 After successfully pass the pull testing Pull test operators will give the permission to continue production. 5.0 While pull test fail then informed to mechanics and re adjusted the machine. 6.0 Records must be kept in a Button pull test reports with sample. Relevant Documents : Button / snap button pull test reports – GFIL.TST.FRM.02
- 81. Gous Fashion Industries Ltd. Standard Operating Procedure. 81 SOP – g:fil property GFIL.FIN.PRO.01 Version # 03 Issue Date: 04 February 2014 Revision Date: 20 March 2014 32. Finishing Department Purpose: To develop, implement and maintain the procedures for the functions under the Finishing Department to validate accuracy of the product quality, track every product with record in the department for packing accuracy and in time shipments. Scope: This procedure is applicable to all concerned handling the products manufactured at Gous Fashion Industries Ltd, pertinently in the Finishing department. Responsibilities: The Finishing Manager is responsible to implement and maintain the procedures and relevant records in the department. Procedure: 1.0 Input of Garments: All goods coming in must be checked for quantity All goods must be segregated as per PO, Style, Color & Size All goods must be stored in a clean area before processing All incoming goods must be separated from goods that are being worked upon. 2.0 Shade Checking: All Shades must be sorted and segregated as per approved shade band 3.0 Loop Cutting: Loops must be trimmed as per clients requirement and as per approved sample Care must be taken not to damage the garment while cutting the loop tolerance 4.0 Size-wise Sorting: All goods must be sorted size-wise 5.0 Pocket Cleaning [for washed garments & if required only]: Pockets are checked inside out and cleaned of all dust particles manually and through thread sucker machine.
- 82. Gous Fashion Industries Ltd. Standard Operating Procedure. 82 SOP – g:fil property 6.0 Thread & Lint Trimming: Thread must be trimmed as per instructions and must be cut as much as possible without damaging the garment Excess thread must be trimmed from the outside of the garment The garment must be turned inside out and thread must be trimmed 7.0 Inside Ironing Iron pockets and waistbands INSIDE QUALITY CHECK POINT: See QMS Procedure 32 for reference. 8.0 Button Attaching: Button placement must be as per approved sample and buyer’s requirement Button must be snug against the garment and must not be loose Button Pull Test should be performed every hour and records logged 9.0 Ironing/Pressing: All pressing must be done as per buyer requirement Steam coming out of the iron must be dry All pressing machine must be serviced monthly to keep the machines running un-interrupted. Steam lines and pressure should be proper. The next servicing/maintenance date should be noted on the maintenance card. Pressing table should also be checked and the cloths on the table should be changed if they are dirty. Vacuum pressure should be controlled and adjusted. Preventive maintenance card should be hung beside the machine FINAL QUALITY CHECK POINT: See QMS Procedure 32 for reference. GETUP CHECK POINT: See QMS Procedure 32 for reference. MEASUREMENT CHECK POINT: See QMS Procedure 32 for reference. 10. Thread Sucking: All garments are passed through thread sucker machine to clean it out of all loose cut thread or other parts. 11.0 Hang Tag Attachment: Hang Tags, Price Tickets etc must be attached following buyer’s guidelines Placement must be as per buyer’s specifications
- 83. Gous Fashion Industries Ltd. Standard Operating Procedure. 83 SOP – g:fil property Hang Tags & Labels must be checked to make sure they are for the right color, size, shipment lot, style & PO 9.0 Metal Detection: If product is required to be metal detected during production all units must pass thru the needle detector following the company’s Needle & Metal Detection Procedure. OCR / SKU CHECK POINT: See QMS Procedure 32 for reference. 10.0 CTPAT Area: Hanger attachment: o Attach hangers to the garments o Match colour and sizes on hanger Folding o Folding method must be reviewed and compared with the clients approved method as per the approved folding sample and explained to the folding team o All folding must be done as per the buyer’s requirement o Folding instructions must be posted where the worker are working Poly bag o Poly bagging method must be done as per buyer specifications o Blisters must be made as per buyer’s packing requirement o Blisters must be sealed to prevent dust from entering and soiling the garments Assortment Box packing o Goods must be packed following buyer’s specifications o Stuffing of finished goods into the cartons must be done as per buyer’s instructions 11.0 Packed Garments: Packed cartons are handed over to the warehouse for storage in Finished Goods area under Inventory department ready for final inspection by the buyer QC. 12.0 Alternation Procedure in Finishing : QA team must keep the defective garments in the Defective boxes. Record should be maintained for all defective garments put in the defective box Finishing Supervisors will repair the garments and return to QA team within two hours. QC will re-check those garments and forward to next step. 12.0 Non Conforming goods in the finishing section: Garments identified to undergo repair at any stage of the finishing line will be forwarded to the Repair section from time to time and the section in charges will do the transaction. The Repair section shall maintain record of all repair in a register. The Finishing Manager will review the register and sign the register at the end of each day. All damaged or non-conforming garments at any stage of the finishing line shall be removed from the
- 84. Gous Fashion Industries Ltd. Standard Operating Procedure. 84 SOP – g:fil property finishing line and sent to the Non-Conform check desk. After assuring the non- conformance the garments will be stored in a clearly marked designated box that will remain locked. The Finishing Manager is the custodian for all non conforming garments in the Finishing department. The non conforming garments are collected by the Store department designated officer on a weekly basis and finally stored in the Inventory Department designated for storing non conformed goods. 13.0 Miscellaneous: The Finishing Supervisor will posses ear plugs & masks for all employees who need them for safe working conditions. A register that records the issuing of ear plugs & masks will be maintained by the Finishing Supervisor. The Finishing Manager shall maintain several other pertinent documents as mentioned under Document Control No. column with him in his chamber. 14.0 Storage before shipping: All finished cartons will be stored in the centralized carton areas following all C-TPAT and security requirements Cartons must be kept on pallets Cartons must be and separated PO wise, style-wise, color-wise and other ways as per buyer requirement 15.0 Relevant Documents : Daily thread cutting reports – GFIL.FIN.FRM.01 Daily alter repairing for line reports – GFIL.FIN.FRM.02 Daily alter repairing for finishing reports – GFIL.FIN.FRM.03 Daily Reject reports – GFIL.FIN.FRM.04 Daily bar tack alter reports – GFIL.FIN.FRM.05 Daily Iron section production and alter reports – GFIL.FIN.FRM.06 Daily button attaching production& alter checking report – GFIL.FIN.FRM.07 Daily Poly Reports – GFIL.FIN.FRM.08 Daily Finishing Production reports – GFIL.FIN.FRM.09 Non conforming Reports – GFIL.CNCM.FRM.07
- 85. Gous Fashion Industries Ltd. Standard Operating Procedure. 85 SOP – g:fil property GFIL.QCS.PRO.06 Version # 03 Issue Date: 04 February 2014 Revision Date: 20 March 2014 33. Finishing Section Quality Control Purpose: To meet the quality standards set by the clients. Scope: To check adherence to quality standard to ensure that the receipt of garments into the finishing section, shades, size assortments, Responsibilities: Quality Manager is responsible to allocate quality control resources to monitor the process in this stage of the operation. Procedure: 1.0 Inside Quality Check: Arrow stickers must be used to identify defects Checkers will check for defects as per Gous ’s Defect Classification List Defected garments which can be reworked needs to segregated and placed inside the red alter basket to be sent to the alter section Repaired items must have the arrow sticker pointing to the defect so that it can be verified that the defect was corrected Items that cannot be repaired must be quarantined by handing over to supervisor who will place it in the reject box and record in the log The following point among others needs to be checked during the inside quality check: Bottoms: Side Seam & Inseam Front Part, Front Rise, Front Pocket, & Fly Back Part, Back Rise, Back Pocket, Back Yoke if available Waist band, Loops Hem Tops: Side Seam Sleeve Joint and Seam, Cuff Joint Front Part of Body, Inside Placket, Collar Joint Back Part, Back Yoke, Back sleeve joint Bottom Hem 3.0 Outside Quality Check:
- 86. Gous Fashion Industries Ltd. Standard Operating Procedure. 86 SOP – g:fil property Arrow stickers must be used to identify defects Checkers will check for defects as per Gous ’s Defect Classification List Defected garments which can be reworked needs to segregated and placed inside the red alter basket to be sent to the alter section Repaired items must have the arrow sticker pointing to the defect so that it can be verified that the defect was corrected Items that cannot be repaired must be quarantined by handing over to supervisor who will place it in the reject box and record in the log The following point need to be checked during the outside quality check: Bottoms: o Waist Band and Loops o All Bar-tacks o Side Seam & Inseam o Front Pocket, Front Rise & Fly o Back Rise, Back Pocket o All Buttons, Snaps etc o Bottom Hem Tops: o Placket, Font Pocket o Collar o Cuff o Buttons o Bottom Hem o Sleeves, sleeve joint o Back Yoke 3.0 Final Quality Check: 100% of goods must be checked for defects as per the Defects Classification List (see quality management manual for details) All defects must be marked with a arrow sticker and defected garments that can be reworked must be segregated in the alter basket Non-conforming goods that cannot be reworked must be handed over to the supervisor who will quarantine the item in the reject box The final checkers will have to maintain a defect tally list for analyzing the defects and to make sure the specific defects found on the finished product are controlled and proper action is taken. The defects have to be totaled on a daily basis and proper steps have to be taken by the factory managers to make sure that all issues are controlled in the process. NOTE – Factories have to make a defect trend history style wise to keep in records and records have to be analyzed to identify defect trends with the factory manager so that factory can make improvements in systems and procedures to get better in future orders. 4.0 Measurement Check: Each piece of garment will be measured for all given specifications. 100% garments must be measured for Critical Measurements.
- 87. Gous Fashion Industries Ltd. Standard Operating Procedure. 87 SOP – g:fil property Critical Points for Top: o Neck Drop o Neck width / circumference o Sleeve length o Garment length (HPS / Center back) o Chest o Sweep o Across shoulders o Sleeve opening o Armhole o Across Front o Across Back Critical Points for Bottom: o Waist relaxed o Inseam o Out seam o Front rise o Back rise o High hip o Low hip o Thigh o Leg opening o Sweep All Top Back and Bottom Back need to be measured on both sides to ensure the asymmetrical shape of goods. The findings need to be recorded on the measurement chart to identify the difference clearly. Garments that are out of tolerance measurements must be segregated. All measurement points will be counted against AQL 4.0 4.0 Table Specs Checking Procedure: Factory has to make templates of all sizes in the particular style being checked and fix them on the table for checkers to check the critical specs on 100% garments. Defected garments for spec have to be recorded on an hourly basis. 6.0 Hourly Lot Audit: Assure to forward only the quality approved garments in next steps. Count the lot correctly every hour. Select the lot as per AQL 2.5, Level 1 randomly. Measure the stitch per inch in different process within same garments. Get the measurement. Check the workmanship according to the sample. Show the lot audit results to supervisors in every hour. If lot fail then recheck the entire lot by End table inspection. Records the every hour results in lot pass reports.
- 88. Gous Fashion Industries Ltd. Standard Operating Procedure. 88 SOP – g:fil property 7.0 OCR / SKU Check: Points to Check during Packing: Check for damaged cartons Check carton labels and markings Check carton measurements Check carton weight Before closing the carton confirm colors, sizes, and quantity of assortment in cartons are correct Confirm country of origin matches product labels Confirm packing method is according to clients packing method 8.0 Shade Segregation & Shade wise Assortment Making: All shade checker must be tested for Munsel Hue Eye Test There must be proper lighting in the shade segregation area Shade segregation must be done by comparing to the buyer approved shade band Shades must be assorted as per the approved shade numbers like A, B, C, D etc and these shade numbers must be marked on the checking table 9.0 Relevant Documents Factory Quality Audit Reports – GFIL.QCS.FRM.25 Daily spec defects tally – GFIL.QMS.FRM.27 Process checking defects tally – GFIL.QMS.FRM.28 Daily Wash Check reports – GFIL.QCS.FRM.31 Hourly lot audit – GFIL.QCS.FRM.32
- 89. Gous Fashion Industries Ltd. Standard Operating Procedure. 89 SOP – g:fil property GFIL.QMS.PRO.04 Version # 01 Issue Date : March 20,2014 Revision Date : N/A Procedure for Daily Packed Audit 1.0 Purpose and Scope : 1.1 Facility can make sure packed goods meet the Quality standard according to the Customer’s requirements. 2.0 Responsibilities : 2.1 Internal Auditor / Respective DQA or IQC is responsible for auditing the packed goods daily. 3.0 Procedure: 3.1. Conducting the Daily packed audit , must be reviewed the Approval sample and Master file. 3.3.Box Audit 3.3.1 The no. of cartons should be selected in such way to cover all the size / colors / assortment as available from the lot. 3.3.2 Apply the square root of the total cartons in the lot to determine the number of selected as per the following table. First conduct the box audit of all selected carton, Check main mark sequencly. 3.3.3Check the barcode sticker . 3.3.4 Carton measurement must be check as per layout. 3.4 Assortment Check 3.4.1 Open the carton and check : 3.4.1.1 Color 3.4.1.2 Size 3.4.1.3 Ratio 3.4.1.4 UPC number 3.5 Trims & Accessories Check 3.5.1 Match with approval sample . 3.5.2 Confirm using all trims & accessories design ,color and shade is approved. 3.6 Construction Check
- 90. Gous Fashion Industries Ltd. Standard Operating Procedure. 90 SOP – g:fil property 3.6.1 Ensure the sewing techniques , trims & accessories placement is correct and match with approval. 3.7 Workmanship Check 3.7.1 Identify the correct lot size for the audit. The lot size is the no. of units packed at the time pulling of the quantity. 3.7.2 Lot audits are conducted as per AQL 2.5 , level I. 3.7.3 Segregate the defective goods according to the Critical , major and minor. 3.7.4 A defect is any nonconformance of the unit of product with the specified requirements. 3.7.5 A defective is a unit of product which contains one or more defects. 3.7.6 Failure to meet requirements with respect to quality characteristics are usually described in terms of defects or defectives. 3.8 Measurement Audit 3.8.1 Select the garments for measurement audit as per AQL 2.5 , S4. 3.8.2 Records are maintained in measurement reports. 3.9 Defects in individual criteria beyond the limit , overall results will be fail and is rechecked. In case carton not completed in a day then inspector can perform the audit from blister to get approval from COO. 3.10 Reports must be communicated with GM and COO. 4.0 Relevant Documents: Daily Packed / Prefinal Audit Reports – GFIL.FRM.QMS.26 Quality Measurement Checking Report – GFIL.FRM.QCS.15A
- 91. Gous Fashion Industries Ltd. Standard Operating Procedure. 91 SOP – g:fil property GFIL.QMS.PRO.05 Version # 01 Issue Date : March 20,2014 Revision Date : N/A Procedure for Pre-Final Audit 1.0 Purpose and Scope : 1.1 Facility can make sure packed goods meet the Quality standard according to the Customer’s requirements. 2.0 Responsibilities : 2.1 Internal Auditor / Respective DQA or IQC is responsible for auditing the packed goods completing the minimum 80% to 100%. 3.0 Procedure: 3.1. Conducting the Daily packed audit , must be reviewed the Approval sample and Master file. 3.2 Box Audit 3.2.1 The no. of cartons should be selected in such way to cover all the size / colors / assortment as available from the lot according to the Packing list . 3.2.2 Apply the square root of the total cartons in the lot to determine the number of selected as per the following table. First conduct the box audit of all selected carton, Check main mark sequencly. 3.3.2 Check the barcode sticker . 3.3.3 Carton measurement must be check as per layout. 3.3 Assortment Check 3.3.1 Open the carton and check : 3.3.1.1 Color 3.3.1.2 Size 3.3.1.3 Ratio 3.3.1.4 UPC number 3.4 Trims & Accessories Check 3.4.1 Match with approval sample . 3.4.2 Confirm using all trims & accessories design ,color and shade is approved. 3.5 Construction Check 3.5.1 Ensure the sewing techniques , trims & accessories placement is correct and match with approval.
- 92. Gous Fashion Industries Ltd. Standard Operating Procedure. 92 SOP – g:fil property 3.6 Workmanship Check 3.6.1 Identify the correct lot size for the audit. The lot size is the no. of units packed at the time pulling of the quantity. 3.6.2 Lot audits are conducted as per AQL 2.5 , level I. 3.6.3 Segregate the defective goods according to the Critical , major and minor. 3.6.4 A defect is any nonconformance of the unit of product with the specified requirements. 3.6.5 A defective is a unit of product which contains one or more defects. 3.6.6 Failure to meet requirements with respect to quality characteristics are usually described in terms of defects or defectives. 3.7 Measurement Audit 3.7.1 Select the garments for measurement audit as per AQL 2.5 , S4. 3.7.2 Records are maintained in measurement reports. 3.8 Defects in individual criteria beyond the limit , overall results will be fail and is rechecked. Must be arise the corrective action plan for recheck and COO will validate. 3.9 Get satisfactory result Factory will offer for Final inspection. 4.0 Relevant Documents : Daily Packed / Prefinal Audit Reports – GFIL.QMS.FRM. 26 Quality Measurement Checking Report – GFIL.FRM.QCS.15A
- 93. Gous Fashion Industries Ltd. Standard Operating Procedure. 93 SOP – g:fil property GFIL.FIN.PRO.01 Version # 03 Issue Date: 04 February 2014 Revision Date: 18 March 2014 36. Needle & Metal Detection Policy Purpose: To make sure that all garments manufactured at GFIL are free of any broken needle or other metal parts which could cause injury to a person handling the product at any stage of the operation. Scope: All garments that need to be checked for metal is passed through metal detecting machine in the finishing department and else where as maybe applicable. Responsibility: Finishing Manager will ensure that all garments that are required to undergo metal detection is checked for metal and the Manager QA must ensure that the work is conducted adequately and at all times. Broken Needle Control Log and Metal Detection Procedure: Gous has implemented a set of guidelines and rules to be followed to ensure the policy is achieved. This is backed up with documentation and regular checks at the factory level. The following is the detailed outline of the procedure: 1.Needle and Metal Contamination Policy GFIL’s Needle and Metal Contamination Policy ensures that all its products are free of any broken needle or unwanted sharp metal parts. The Needle and Metal Contamination Policy is divided into two phases: 1.1 Prevention 1.2 Detection 1.1 Prevention: Broken Needle Control Log Procedure is applicable to produce Target products where needle operations are involved. Broken Needle Log Control Procedure: Every factory that uses any type of needle operation, regardless of product, is required to comply with the Broken Needle Control Log procedure. The Broken Needle Control Log should include: o Date/Time of Incident o Production Line o Operation o Operator o Machine Type/Machine ID o Mount Broken Needle o Panel/Garment Destroyed – Yes or No o Mechanic‘s signature and Date Every factory must maintain a controlled needle inventory system and a broken needle control log.
- 94. Gous Fashion Industries Ltd. Standard Operating Procedure. 94 SOP – g:fil property This log should include all broken parts or damaged needles along with any corrective action taken. Each sewing machine should have an ID (identification number). Needle replacement should be done only by designated factory personnel (e.g. inline supervisor, mechanic, needle log supervisor, etc.) to provide a log recording all parts of a broken needle have been accounted for. Note: Sewing operator should not have free access to spare needles. Production work areas are to be kept clear of unnecessary sharps (e.g. scissors, razor blades, staples, pins and loose metal parts). Machines and/or operators which continue to have broken needle issues should be reviewed and appropriate corrective action taken. Machines and their surrounding areas should be checked daily for needle and/or metal contamination. For products where a needle/metal detector is mandatory In the event of a needle breaking during any sewing operation, the panel or product piece being sewn should be retrieved from the production line and checked for broken parts. Broken parts should be sealed on the broken needle log control sheet indicating all details listed above. If all broken parts are not accounted for, contaminated panels or product pieces should be passed through the needle detector. If the needle detector still detects metal parts and if after further investigation, the pieces cannot be found, the panel or product pieces should be destroyed and recorded on the log. For products where a needle/metal detector is not mandatory In the event of a needle breaking during any sewing operation, the panel or product piece being sewn should be retrieved from the production line and checked for broken parts. Broken parts should be sealed on the broken needle log control sheet indicating all details listed above. If all broken parts are not accounted for, contaminated panels or product pieces should be destroyed and recorded on the log. Compliance auditors must check if GFIL ’s Needle and Metal Contamination Policy is being followed by checking: Needle Inventory System Broken Needle control log for accuracy and integrity of the records. Sewing machines have ID number and are verified against the Needle Inventory System and Broken Needle control log. Check machine oil sump for any broken parts and surroundings for loose metal parts. Check that sewing operator does not have access to needles and unnecessary sharps by verifying machine surrounding and drawers. 1.2 Detection: Needle/Metal Detector to be placed in appropriate places especially at the finishing department to check for needle or small metal parts for all garments produced at GFIL prior to packing. Detection
- 95. Gous Fashion Industries Ltd. Standard Operating Procedure. 95 SOP – g:fil property GFIL must have needle detection machines and must ensure all productions if required by the buyer passes through the needle detector. The Needle Detector should be placed in a controlled area to ensure there is a clear demarcation of the product that has passed through the needle detector, and those which does no not. The controlled needle detection area should be established so that no finished product can move to the packing/finishing area with out being passed thru the needle detector in advance. Note: Do not permit any metallic tools or fixtures in this area or on the person operating the machine. Keep all unnecessary metal away from this area. The Needle Detector must work at a minimum sensitivity level of 1.2mm diameter. A 9 point calibration procedure must take place a every hour basis. Units should be placed on the automated conveyor belt allowing it to pass through the detector head without manipulation. Detector should be calibrated by the authorized person only Never force the product through the detector head Product must pass through detector without operator assistance Records of production detected must be kept available for review (style-quantity/date/hour- operator-supervisor-contamination) Product passed through the detection equipment should be held in a separate holding area, minimum one hour passed garments must be kept in a holding area while next hour calibration is pass then previous hours garments forward to next steps. Contaminated goods (rejected) should be kept in quarantine box in the needle detection area, making sure potentially contaminated products do not get mixed with the accepted items. When any form of metal has been detected: Check for metal part using the hand held detector, if available, to identify location of metal part within product. If found: o Remove Metal and re-detect product to make sure all contamination has been removed. o Log and advise supervisor for decision to keep for records or return to department/owner. o Identify Root Cause and take corrective action. o Document the process implemented. If NOT found: o Call supervisor o Quarantine product o Identify root cause and take corrective action o Document and implement the process 2.0 Nine (9) Point Calibration Process The 9 Point calibration ensures that the equipment is functioning correctly and operating at the correct sensitivity (1.2mm).
- 96. Gous Fashion Industries Ltd. Standard Operating Procedure. 96 SOP – g:fil property The 9 Point calibration must be done a minimum of 2 times per shift by the authorized electrician. The 9 Point Calibration check on the detector is done by dividing the metal detector conveyor belt in 3 zones (ABC). The Calibration Card, supplied by machine vendor, is passed through each of these zones at three different height levels. The Detector sensitivity must be set at a level which is less than 1.2mm sphere to detect the Calibration Card. The Calibration Card is placed on the conveyor belt and passed through each zone – A, B and C. Readings are recorded on a 9 Point Calibration Report. The 9 Point Calibration Report should be marked as follows: o Y- If the needle detection activates (alarm sounds, light activates and machine stops) when the 1.2mm Ferrous Calibration Card is passed through the search head. o N - If the needle detector has no reaction (no alarm sound/light) when the 1.2mm Ferrous Calibration Card is passed through the search head. If there is no reaction during the 9 point Calibration procedure the operator must stop the machine and call the supervisor. All production must be placed on hold since last acceptable 9 Point Calibration Report record. If repairs are needed, a qualified technician responsible for the Needle/Mechanical detection equipment must be called and after repair a new 9 point Calibration test must be done for verification. Note: When conducting the calibration test, the calibration card and card holder must be only used, no paper or products are allowed to be put through the metal detector. The card is to be placed in the center slot of the holder (1 1/2 inches height) and passed through each zone – A, B and C. Readings are recorded on a 9 Point Calibration Report. The card is then placed at the top slot of the holder (3 inches height) and passed through each zone – A, B and C. Readings are recorded on a 9 Point Calibration Report. 3.0 Relevant Documents : Metal Detector Scanning Reports – GFIL.PSD.FRM.03 Metal Detector calibration logs – GFIL.PSD.FRM.03A
- 97. Gous Fashion Industries Ltd. Standard Operating Procedure. 97 SOP – g:fil property GFIL.CLB.PRO.01 Version # 03 Issue Date : Feb,02, 2013 Revision Date : March20, 2014 37. Measurement Tape Calibration 1.0 Purpose & Scope This procedure outlines Gous Fashion Industries Ltd.’s wide requirements for calibration of Measuring Tape. 2.0 Responsibilities Respective QA Manager / QA In-charge is responsible for implementation of this procedure and he will calibrate of measuring tape and maintaining calibration records. 3.0 Procedure 3.1 Calibration 3.1.1 All measuring tape is calibrated before issuing to any person for use. 3.1.2 Calibration is done against a BSTI calibrated master steel measurement scale. 3.1.3 When the discrepancy is over +/-1/8” over total of 36”, the tape is regarded as out of calibration and must be replaced / taken out of use and destroyed. 3.1.4 The tape should be recalibrated after two months of use. 3.1.5 Once issued for use , when the tape condition is poor, (wavy edges, twisting or torn) it must be replaced with a new one, even if the measurement discrepancy is within tolerance. 3.2 Issue for use: 3.2.1 Each tape after calibration is given a serial number and same is entered in log & written on the tape as well. 3.2.2 Calibrated tape is issued to a person for use, by entering all the details like Name, Emp. Code & Date of issue. 3.2.3 The name of person using the tape along with the id number, tape number, date of calibration & next calibration due is also written on the tape before issuing. 4.0 Relevant Documents : Measurement Tape Calibration Reports – GFIL.CLB.FRM.08
- 98. Gous Fashion Industries Ltd. Standard Operating Procedure. 98 SOP – g:fil property GFIL.CLB.PRO.02 Version # 03 Issue Date : Feb,02, 2013 Revision Date : March20, 2014 38. Procedure for Calibration 1.0 Purpose & Scope : To provide general guideline procedure for calibration of measuring & monitoring equipment, devices / tools critical to product safety, legality and quality in order to minimize the risk of manufacturing defective, unsafe or illegal product. 2.0 Responsibility : The Maintenance Manager of the factory is responsible to implement & monitor the process unless otherwise specified in the individual equipment / tools calibration SOP. 3.0 Procedure : 3.1 All the critical measuring & monitoring equipment are identified and the master list / calibration matrix along with the calibration schedule is established. 3.2 The calibration frequency is derived at based on but not limited to : 3.2.1Risk to product quality 3.2.2Legal requirements 3.2.3Supplier efficiency 3.2.4Operating environment & conditions 3.2.5OEM recommended intervals 3.2.6Historical data 3.2.7Failure analysis 3.2.8Reliability centered maintenance program 3.2.9Industry Experience 3.3 Measuring & monitoring equipment are calibrated against the Master equipment duly calibrated by BSTI against the national standard. 3.4 All measuring devices will have tamperproof calibration label firmly affixed with the following minimum details : 3.4.1Serial number / id number of the equipment 3.4.2Frequency of calibration 3.4.3Date of calibration 3.4.4Due date for next calibration
- 99. Gous Fashion Industries Ltd. Standard Operating Procedure. 99 SOP – g:fil property 3.4.5Deviation from the Master 3.5 The equipment which are found out of specification / out of calibration, are taken out of service, repaired, adjusted & readjusted as required before put into use again or rejected. 3.6 If any inaccurate measuring & monitoring equipment found in use, documented corrective action would be initiated. 3.7 This procedure is applicable to all the identified measuring & monitoring equipment in addition to the specific calibration procedures for each individual equipment as applicable. Master List of Calibrated Equipments: Sr. No Name of Equipment Calibration Frequency Calibration By 1 Master Measurement Scale Once in Year BSTI 2 Pull Test Dead Weight Once in Year SAS 3 GSM Balance Dead Weight Once a Year BSTI 4 Metal Detector Machine Once a month SAS 5 Shade Light Box Once a month SAS 6 Measurement Tape Every Two Months Internal - Maintenance 7 Pull Test Machine Twice a Day Internal- QC 8 Fusing Machine Once a Month SAS 9 Metal Detector Machine Every Hour Internal – Finishing 10 GSM Balance Twice a Day Internal – QC 11 Fabric Inspection Machine Once a Month SAS 12 Digital Scale Once a Year BSTI 4.0 Relevant Documents : 3rd Part Calibration Records – GFIL.CLB.FL.01
- 100. Gous Fashion Industries Ltd. Standard Operating Procedure. 100 SOP – g:fil property GFIL.TCA.PRO.01 Version # 01 Issue Date: 20March 2014 Revision Date: N/A 39. Traceability System 1.0 Purpose & Scope: To establish a sustainable method to track and trace the material used at GFIL from source to finished goods to ensure its quality and safety along the supply chain process. The Traceability System will help GFIL in the following way: Identify and trace any issues back to its origin Maintain compliance with regulatory requirements Achieve a greater degree of precision Increase efficiency Comply with buyer specification Support and ensure product safety Ability to inform buyers quickly of any issues found with regard to product safety 2.0 Responsibilities: All department heads are responsible to implement the traceability system at all stages and Technical Compliance & Audit team are authorized to validate the process to ensure the implemented traceability system is maintained efficiently. 3.0 Procedures: Traceability will be maintained by the following system: a. Traceability data must be documented through the daily data collecting system of the company. b. All traceable items must have a unique identification information assigned to it. a. This unique ID can be the batch, lot, roll or dye-lot number (must be in the issue invoice, requisition etc). b. In case of fabric cutting parts, a serial or part number must be included and records are to be maintained adequately. c. All Traceability Data must also include the following info: i. Item description ii. Quantity iii. Who was involved in handling the item? iv. Location (section, department, etc) v. Date or dates
- 101. Gous Fashion Industries Ltd. Standard Operating Procedure. 101 SOP – g:fil property Fabric Received: Log report of receivedfabrics in register . Monitoring process: Check if correct fabric is receivedfor cutting as per P.O., Style & Approved Swatch Compare fabrics rollnumber withshade segregationreport form . Compare Marker withcuttingpermission for clients P.O., Style #. Check CuttingMachine & Knife for defects log report inregister Check layer for defects while spreading fabric, log report inform . Record fabric roll number, dye lot informationin cutting report . Compare cut parts with approvedpatterns, logreport inform . Number all cut parts, logreport inregister Sort bundle andattachbundle cardwith number serial, cutting number Issue Record: Issue cut parts innumberingsequence (towhom, section, line & process) records in register . Fused Parts Record: Check machine calibrationsetting withapprovedtemperature & pressure setting Fused parts bondtest report, form . d. An item or items will be traced by using the traceability data and by linking one item to another until the root cause or origin is found. Traceability Flow Diagram: Received Goods: Client P.O.wiseinventoryin reports . 10% Inspection. Log Inspection report inform . o Factory Name o Customer o Style o Supplier o Invoice or Batch Number o Trims Inspection details o Storage Location Issue records: Log all issued report inregister . o Fabrics issue as perClients P.O., Style,fabricsupplier invoice / lot/ batch number &as per approvedswatchanddyelotwithinthecolor. o Trims & Accessories issue as per Clients P.O., Style, trims 7 accessories supplier invoice / lot/ batch number and as per approved swatch. o Log report to whom is issuedto & which section, sewing lineor process. 1 Store Raw Materials 2 Cutting & Fusing
- 102. Gous Fashion Industries Ltd. Standard Operating Procedure. 102 SOP – g:fil property Received for Finishing: Log reports ofallreceivedGarments information in register . Log reports ofallreceivedtrims & accessories as perinvoicenumber or batch number in register#SGFIN Compare trims & accessories withapprovedswatches oftheP.O. & Style Compare &sort shades with approved shades Compare Cartondetails with approved Sample Issue RecordsofTrims& Accessories: Issue Items as perprocess and toperson responsible Issue as per P.O. & Style, Sizeor any other requirementby client Finished Goods: Compare attachedtrims & Accessories withApproved Swatches and per P.O.& Style,Size and ifany other clients requirements Finished garments is to becompare and shades sortedwith approved shadebands Received Itemsfor Sewing: Log report ofall receivedCut &Fusedparts information inregister . o Cut number,Bundlenumber, parts serial number. Log report ofall receivedtrims & accessories and invoicenumber or batch numberin register. Compare trims & accessories withapprovedswatches as perP.O. & Styleand size Issue Recordsper Sewing Line: Log report ofall issueCut& Fused parts towhom/section/line/process/size wise as per P.O. & Style in register . o Cut number,Bundlenumber, parts serial number. Log report ofall issueTrims or Accessories towhom/section/line/process/size wiseand as per P.O. & Stylein register. o Invoice number or Batch number, QC Reports: In Put (Back & Front part) , Assembly, End Line& Bar Tack quality control process report Defect reports Person responsiblefor correctiveaction Non conforming or reject,segregation &dispatchreports Dispatch Sort (dye lot wise,size ratio),Bundle & Dispatch,logreport in form . 4 Finishing: Accessories & Trims Sorting size& shade check Measurementcheck SKU/UPC Check Carton mark check & audit 3 Sewing: In Put, Assembly End Table Dispatch
- 103. Gous Fashion Industries Ltd. Standard Operating Procedure. 103 SOP – g:fil property 3.1 Traceability System in Store: 3.1.1 Incoming Raw Materials: Details of all incoming goods are recorded in register. Details that are recorded include the supplier’s name, order quantity, item description, item number, batch number etc. A copy of the supplier’s delivery invoice is kept on file for reference Inspection is done on 10% of raw materials and 100% percent if the 10% inspection fails Records are maintained about the findings of the inspection to maintain the traceability process. All materials kept in a specific rack with a bin card. 3.1.2 Outgoing (Issue of) Raw Materials: Unique identification number will be the batch/lot number for trims and roll & dye-lot numbers for fabric Fabrics must be issued to the cutting department as per Clients P.O., Style, approved swatch and must be of the same dye lot within the color. The roll numbers, dye-lot numbers and other information must be recorded in the issue invoice. Trims & Accessories must be issued to sewing and finishing departments as per Clients P.O., Style, lot or batch number , floor requisition slip and as per approved swatch. Logs must be kept and details must include: To whom the items were issued, details must include receiver’s name, department, line number etc. Batch/lot/dye-lot number Item number, parts number etc 3.2 Traceability System in Cutting & Fusing: 3.2.1 Incoming Goods: Log report of received fabrics in register. Record fabric roll number, dye lot information in cutting report, unique identification will be the roll number 3.2.2 Outgoing (Issuing of) Goods: Unique identification will be the sequential part numbers and the cutting number 100% cut parts must be numbered sequentially Cut parts will be issued in bundles of 30 pcs with a bundle card and shade labels Cut parts must be issued with numbering sequence and information must contain the receiver’s name, section, line & process for which goods are being issued and records kept in register. If any printing or embroidery (value addition) is applicable, then the garments or items should be sent to such facilities color and size wise.
- 104. Gous Fashion Industries Ltd. Standard Operating Procedure. 104 SOP – g:fil property 3.3 Traceability System in Sewing: 3.3.1 Incoming Goods: Unique identification number will be the parts number and the bundle number Log report of all received Cut & Fused parts information in register. Information must include cutting number, bundle number, parts serial numbers. Log report of all received trims & accessories and invoice number or batch number in register. 3.3.2 Outgoing Goods: Unique identification number will be the shade labels & line number labels on the sewn goods 3.4 Traceability when sending for wash: 3.4.1 All garments must be segregated by color and size with separate bundle card and sent forwashaccordingly. 3.42. Same must be checked and ensured at the time receiving the goods back from washing. 3.5 Traceability System in Finishing: 3.5.1 Incoming Goods: Unique identification number will be the shade labels and the line number labels 3.5.2 Outgoing Goods: Unique identification number will be the QC number sticker, factory ID on the main label, DPCI label, etc. 4.0 Relevant Documents: Fabrics Stock Register – GFIL.IVS.REG.06 Accessories Stock Register - GFIL.IVS.REG.07 Bin Card - GFIL.IVS.FRM.08 Cutting Recording Sheet - GFIL.CUT.FRM.03 Sewing Input outputRegister - GFIL.SEW.FRM.01 Daily Finishing Records - GFIL.FIN.FRM.09 ShipmentRecords (POWise) - GFIL.MER.FRM.02
- 105. Gous Fashion Industries Ltd. Standard Operating Procedure. 105 SOP – g:fil property GFIL.CAP..PRO.01 Version # 3 Issue Date : Feb02, 2013 Revision Date : March20, 2014 40.SOP For Corrective Action Plan 1.0 Purpose and Scope : To take corrective action for root causes analysis , resolution of the non conformity arising at any stages or customer complaint for safety , regulatory and quality requirements and to avoid such kind of issues in future . 2.0 Responsibilities : Factory COO & Manger – Technical Compliance and Audit are responsible to monitor & analysis corrective action plan. Department Chief are responsible to prepare concrete remedial action. 3.0 Procedure : 3.1. CAP arises for any non conformity related issues arises on product , process system or customer complain . Such as : 01. Factory Audit , conducted by Buyer. 02.Factory Evaluation, Conducted by Company self Evaluator Team. 03.Pre-production meeting , Dupro / In-line Inspection 04.Pre-Final Inspection 05.Final Inspection. 06. In house testing fail for all incoming raw materials. 07. 3rd part testing failure. 08. Identified Non conforming materials. 09.Customer complain for quality , safety and regulatory. 3.2 Respective department head and Technical Compliance team will review the failure reason and plan for initiatives not to re-arise the previous raised problems. 3.3 To prepare a plan below mentioned subjects should be considered in this regards; 01.State the problem or weakness or issues. 02.Analysis the root causes 03.Break the solution into discrete, measurable actions that address the root cause
- 106. Gous Fashion Industries Ltd. Standard Operating Procedure. 106 SOP – g:fil property 04.Identify accountable person for each action 05.Set achievable deadlines 06.Monitor progress. 07.Collect Evidence & take picture or video after successfully completed. Corrective Action Plan – Sample Gous Fashion Industries Ltd. Plot # A (6&7) , Block # B , Sagorika Road. Pahartoli . Corrective and Remedial Action. Nature of Issue : Date : GFIL.FRM.CARA.01 Version : 02 Issue Date : 10th March 2014 Sl. N o. Issue s Causes of Defects / Root Causes Resolution / Corrective Action Taken Respon sible Name & Depart ment Comple tion Date (MM/D D/YY) Correction Photograph s Validatio n 4.0 Relevant Documents : Corrective and Remedial Action - GFIL.CAP.FRM.01
- 107. Gous Fashion Industries Ltd. Standard Operating Procedure. 107 SOP – g:fil property GFIL.NCM.PRO.01 Version # 01. Issue Date : Feb03, 2013 Revision Date : March20,2014 41. SOP FOR NON‐CONFORMING PRODUCT 01. Purpose & Scope : Factory has established the Non conforming materials controlling procedure to make sure all types of non conforming materials are not mix up with productions . To identify, segregate and dispose of non‐conforming materials which includes but not limited to raw materials, component and finished product. This procedure is applicable to all production units of GFIL Garments division. 02. Responsibility: Department heads are responsible to implement and monitoring the process at their own section and VFE captain will validate the system . Each Section allocated a Box (Red marked) with identified by Non Conforming Materials s ign and Department Head are authorized to keep the key for their NCM boxes. Factory Chief Operating Officer (COO) is only authorized to handle the central NCM boxes key as well as decision authority for disposition. Reviewing the section wise non conforming materials he will defined the disposition criteria. 03. Procedure : 3.1 NCM Locations : a. While any fabrics rolls are rejected by the internal assign QC as per inspection methods. b. If any trims or accessories are identified at Inspection stages. c. If any cutting parts are identified at cutting section. d. Sewing parts or complete garments can be identified at sewing section. e. Complete garments can be identified at finishing section. f. When any metal contaminated garments are identified at metal detector area. g. If any machineries spare parts are treated as a NCM at stores and production floors. 3.2 Segregation : When any non conforming materials are identified at any section by Operators , helpers , QCs then those garments are keep in front of department head’s table with attach tag “Temporary Reject” and department head and quality manager are responsible to review those garments daily two times (Before launch and before factory ending time) and which is possible to repair those garments will shifted to line for repair and which are not possible to repair those garments will keep in the CNCM box and update the CNCM Records (Documents Control Id # GFIL/CNCM – 07) accordingly. 3.3 CNCM Classification : Department head are analyzed the daily defective goods and analyze the root causes and take a concrete corrective action with the presence of relevant personnel. 3.4. Customers Notification System : While any non compliance issues are arises within a factory then factory will follow the following steps :
- 108. Gous Fashion Industries Ltd. Standard Operating Procedure. 108 SOP – g:fil property 3.4.1 Factory has identified the Non compliance issues and segregated by the categories. 3.4.2 Area head take a initiatives to fix the issues. 3.4.3. If fail to fix , then inform to Merchandising manager , he will communicate with suppliers. 3.4.4. Suppliers are take a necessary steps to solve the issues. 3.4.5. While Factory do not satisfy upon the suppliers decisions, then factory will communicate with customers. 3.4.6 Customers will validate the process and take a initiatives to solve the problems. 3.4.7 Get a decision from customers end factory will implement the system according to the customers decisions. 3.4.8 Concludes the matters and fix the issues and take a effective concrete corrective action to avoid this types of issues in future. 3.5 Disposition : 3.5.1 Send to suppliers : While any fabrics and accessories are treated as a non conforming materials then those defective materials will be return to suppliers for replace within two months. 3.5.2. Re use : Review the defective goods in every month within seven working days, COO will take the decisions which parts and how reuse the defective parts. 3.5.3 Donate or Sold : All non conforming goods (complete garments) except metal contaminated garments donate at disaster area or sold the local customers to remove the brand label. 3.5.4 Burn : All metal contaminated garments are burnt as per local labor law and update the documents destruction form with evidence. 4. Relevant Documents : Control of non conforming materials report – GFIL.NCM.FRM.07
- 109. Gous Fashion Industries Ltd. Standard Operating Procedure. 109 SOP – g:fil property GFIL.WFD.QMS.01 Version # 02 Issue Date : Feb02,2013 Revision Date : March20, 2014 42. Procedure for Undue Influence 01. Purpose and Scope Gous is committed to complying with the Undue Influence requirements of the Consumer Product Safety Improvement Act and the Final Rule on Testing and Certification of all adult & Children’s Products, issued by the Consumer Product Safety Commission and assure not to force or request to any factory personnel for change the result. 02. Responsibilities Undue influence is any action taken by Managing Director that could be undermine the integrity of laboratory test data used in the certification of children’s products or violate the Undue influence policy at factory premise. 03. Procedure 3.1 Gous is committed not to pressurize or request to change the fabrics or garments testing result to 3rd party lab. 3.2 In house testing , Factory Top management or Merchandiser could not request to change the testing result to Materials inspector. 3.3 Sewing department have no authority to force or request the Quality department to pass the defective goods. 3.4 No request will be accepted to offer final inspection when pre-final is fail. 3.5 Gous not request to Buyers to change the results or over loop the issues. 3.6 Factory do not pressure any workers to work more . 3.7 Factory will issue the NC (Non Compormance slip) tickets who will violate the process and NC tickets will forward his / her personnel file. 04. Relevant Documents Non Conformance Slip – GFIL.FL.NCS. 01
- 110. Gous Fashion Industries Ltd. Standard Operating Procedure. 110 SOP – g:fil property GFIL.TCA.PRO.01 Version # 01 Issue Date : MARCH20,2014 Revision Date : N/A. 43. Factory Technical Evaluation : 1.0 Purpose & Scope : GFIL has established the dedicated Technical Compliance and Audit team for evaluating the factory in daily basis for improve the process and keep sustainability. 2.0 Responsibilities : Manager – Technical Compliance and Audit Team , is responsible to organize the internal factory audit and review the audit reports and direct reports to the Factory Chief Operating Officer and Managing Director. 3.0 Procedure : GFIL has a own daily audit check list and team will perform the daily audit according to the check list and there will be two modes of Audit ; 1 Announce audit in quarterly. 2 Unannounced audit in weekly. Gous Fashion Industries Ltd. Plot A(6&7) , Block # B , BSCIC I/A. Sagorika Road. Pahartoli. CTG TechnicalAudit Check List AUDIT DATE : / / Rating Status GREEN Over 80% EXCELLENT AUDITOR NAME & SIGN:- YELLOW 70% - BELOW 80 % GOOD Audit Types : Initial VFE Follow-up ORANGE 60 % - BELOW 70% MEDIUM RED BELOW 60% BAD RESULT DPT. S/L NO AUDIT FORM YES NO CORRECTIVE ACTION RESPONSIBLE PERSON COMPLETION DATE
- 111. Gous Fashion Industries Ltd. Standard Operating Procedure. 111 SOP – g:fil property DOCUMENTS CONTROL 1 Has any written procedure to keep , retain and dispose the documents? 2 Has any authorized person to implement and execute the documents control policy? 3 Doe the Documents retaintion and disposition system meet the g:fil requirements? MERCHENDISING 4 Has any documents check list for update PVP File or master file ? 5 Are all documents contains in PVP file or master file contains all documents according to the check list? 6 Has any written procedure for approve the suppliers? 7 Has any written procedure to evaluation the suppliers based on their capabilities , quality etc.? 8 Does the factory evaluate the suppliers performance in periodically and keep records? 9 Is there any procedure for changing materials , component and design? 10 Has any system to maintain the sipment records? FABRIC/ACCESSORIESSTORES 11 Does the factory have any documented system for ensuring the incoming all raw materials meet the USA safety rules and regulations? 12 Is there an inventory system for all incoming raw materials and documented? 13 Has any procedure to log maintained for issue and received the materials? 14 Has any written procedure for log maintained of excess materials 0r Left over ? 15 Is there a system to maintain the Fabric Reject roll records? 16 Is the traceability system properly executed at source of raw materials and stores? 17 Has any practise to maintain Shipment records? 18 Is there a any records for bolt seal? 19 Are posted Approved Swatch & Display Board at working area? FABRIC INSPEC TION 20 Is the Fabric Inspection method is accurate and documented?
- 112. Gous Fashion Industries Ltd. Standard Operating Procedure. 112 SOP – g:fil property 21 Is there a procedure to weight test for Fabrics? 22 Has any procedure to test the fabrics shrinkage? 23 Are fabrics issue the shade & color wise and documented? 24 Has a procedure to keep the wash blanket and shrinkage swatch? 25 Does the Fabric (running) defective swatch posted at working area? 26 Does SOP posted at working area? 27 Are the materials keep in a secure place? 28 Is the specific area for keeping the hazards materials and documented? 29 Are the brand label keep in a secured area? 30 Has any approved Fabrics swatch avilable in working area? Accessories InspectionReport 31 Does the factory Perform the Accessories inspection according to the policy? 32 Is the barcode scanner is functional and inspect the hangtag and carton sticker's barcode accordingly? Machinarystore 33 Has any written procedure for log maintained of Machinary parts issue and receive? 34 Is the Needle issue and stock register is match with physical? 35 Has any system to replace the new one aginst old parts with requisition? CuttingSection 36 Is the relaxation procedure is effective and documented? 37 Does the factory use paper bottom of spreading? 38 Is the Layer chart maintained including all necessary information?
- 113. Gous Fashion Industries Ltd. Standard Operating Procedure. 113 SOP – g:fil property 39 Does the QA check the every marking before to start cutting? 40 Is the cutting inline inspection system to meet the requirements? 41 Are the cutting section receive approval sample , shrinkage and shade analyse reports? 42 Are the Daily cutting and issue recorded? 43 Does the keep records for Daily reject parts replacement ? Productions/Quality 44 Does the Quality department coverage all shifts? 45 Does the factory hold a P.P. Meeting before to start productions? 46 Are the sample & testing results reviewed at P.P. Meeting? 47 Do documented pre-production meeting records exists ? 48 Are both production and QC team represented the P.P. Meeting? 49 Does the factory hold the meeting for Ist output with sample? 50 Do documented Ist output meeting records exists ? 51 Does the factory organize the Pilot run meeting and documented? 52 Does the factory has any defect classification list? 53 Are Pre-production , ist output and pilot run meeting documents communicate with all cocerned department? 54 Are the working instruction provide to every operation? 55 Are the inline inspection instruction posted at every checking point? 56 Are the inline checking records effective ? 57 Doe the factory perform the Hourly Lot audit as per AQL (Tighter than Target)? 58 Is the daily Machine check effective?
- 114. Gous Fashion Industries Ltd. Standard Operating Procedure. 114 SOP – g:fil property 59 Are the QC team authorized to stop the Production for non conformity? 60 Has the Factory analysis the actual Weekly quality goals and posted at floor? 61 Do the on going QC meeting is demonstrate measureable, continuous improvement ? 62 Are the quality team is separate from production departments and empowered? 63 Does the factory perform the DUPRO as per AQL method (tighter than Target)? 64 Does the Factory conduct FRI as per AQL method (tighter than Target) before to offer final inspection. 65 Are the DUPRO and FRI inspection records documented? 66 Is the traffic light system is effective in a floor? 67 Are the production team present at Defect trend Analysis meeting and documented? 68 Do the Measurement is recorded (After & Before wash)? 69 Are the Broken & replace needle log register is maintained and secured and policy is properly executed? 70 Are the Daily input and output records maintaining? 71 Are the finished goods keep in a secure place? 72 Do the all concern using the calibrated Measurement Tape? MaintenanceRecord 73 Do the log maintain for all types machines? 74 Aare the machine servicing conducting in periodically? 75 Are the maintaining the records for Machine service & parts issue register. 76 Do the machine servicing is preventive ? 77 Are machines , equipment , fixtures, tools suitable for products? 78 Does the factory has written procedure for alternation and documented?
- 115. Gous Fashion Industries Ltd. Standard Operating Procedure. 115 SOP – g:fil property Finishing 79 Are the inline inspection recorded at finishing? 80 Does the factory conducting the Hourly lot audit? 81 Are the all garments pass thru Needle detector machine? 82 Are the machine check by 09 point calibration in every hour? 83 Is there any separate area for rescreen the metal contaminated garments? 84 Does the factory perform key point measurement of 100% garments? 85 Doe the after wash gmt (10%) is recorded? 86 Does the factory conduct the Daily & (P.O. wise) Pre-final inspection and documented? 87 Does the factory maintain the daily Carton register? 88 Does the factory maintain the daily dirty and damage register? 89 Does the factory maintain the Iron Table Defect Identification Records? TestReport 90 Are the all attach functional metal items test the pull strength? 91 Does the factory check the Fusing bonding strength and documented ? Same as heat seal (if applicable) CARA 92 Does the factory arise the Corrective action plan for any non conformity ? 93 Has any authorized person to validate the CAP end the stipulated time frame and documented? Traceability 94 Are the any written procedure for traceability system? 95 Are the all products can be easily identified at every stages? 96 Is the traceability system ensure it work? CNCM 97 Are the all empolyess aware about NCM policy? 98 Are the any written procedure for identify , segregate and dispose the NCM goods and recorded?
- 116. Gous Fashion Industries Ltd. Standard Operating Procedure. 116 SOP – g:fil property 99 Do the records maintaining for NCM goods Segregation? Production TestPlan 100 Are the implemented Production Test plan meet the Target requirements? 101 Is the PTP involved the all process and executed efficiently? Training 102 Does the Factory following the procedure for training need analysis? 103 Are the actual training is provided for all employees? 104 Are the training documents recorded? Social,C-TPAT&Site Conditions 105 Are the facility with electronic attendance machine and functional? 106 Are the facility well ventilated , clean , organize and proper lighting? 107 Are the security covering the respective departent? 108 Does the factory perform 07 point checking system for all incoming vehicles and recorded? GFIL.TCA.FRM.01 Version :01 Issue Date : March31,2014 Authorized By SM Shameem Iqbal Managing Director
- 117. Gous Fashion Industries Ltd. Standard Operating Procedure. 117 SOP – g:fil property GFIL.WSH.PRO.01 Version # 1 Issue Date: 29 May 2014 Revision Date: 44. Washing Process Control: Purpose and Scope: This procedure is expected to result in the adherence to approved quality standards of all garments that undergo washing treatment and also ensure accuracy of accountability of the garments moving between departments and third party laundry services. Responsibilities: Washing Supervisor is responsible to follow the entire process and co-ordinate between the merchandising team and the washing plant to maintain a smooth operation. He will report to the Head of Manufacturing Operation. Procedure: 1. Relevant merchandiser will provide the development sample as a leg panel form or garments form with standard wash recipe to Washing Plant through the washing supervisor. 2. Collect the sample from washing plant and provide to the account manager at the sales & merchandising team to acquire approval from customers. 3. Receive the finalized wash recipe and wash standard from relevant merchandiser and provide to washing plant. 4. Provide wash approval sample to washing factory and keep record of submission. 5. Receive sewn garments, buyer, style, color and size wise, from sewing floor and update record accordingly. 6. Handover garments to the concerned person at the washing plant & similarly update the records. 7. Acquire and maintain receipt acknowledgment from the concerned person at the washing plant on the delivery challanissued by GFIL. 8. QA team will visit to the washing plant from time to time and check the washed garments randomlyto ensure they meet the approved quality standards. 9. Receive the garments from washing plant; count for quantity accuracy and handover to finishing section. 10. If any garments goes missing from the washing plant it must be notified to relevant merchandiser and maintain record accordingly. 11. If any damaged garments are found at or received from the washing plant it must be collected and kept separately and handed over to the store to be preserved in the Non-conforming materials box. The record of the damaged garments must be maintained accordingly. Relevant Documents Wash send and receive report – GFIL.IVS.FRM.26 Floor wise wash garments receive register – GFIL.IVS.REG.26 A Non Conforming Records – GFIL.NCM.FRM.07 Wash garments Hand Over register – GFIL.IVS.REG.26 B