1. 1
ARVIND LIFESTYLE APPAREL MANUFACTURING PLC
QUALITY SYSTEM IN PLACE
• FABRIC - 4 .0 SYSTEM
• TRIMS - 0.5 AQL
• IN PROCESS - Process Control with 7/0 SYSTEM
• END LINE 100 % CHECKING FOR VISUAL . 5% for total
Measurement
• SEWING FACTORY OUT GOING - 1.5 AQL
• Incoming inspection in each department
• 100 % visual and 100% critical measurement point at end line
• NQA AND FIELD AUDIT - 2.5 AQL.
3. QA FLOW CHART-CUTTING
PATTERN
PILOT TEST
SIZE SET
INSPECTION
PPA SAMPLE
INSPECTION
RE
CONSTRUC-
TION OF
PATTERN
BUYER
DUPLICATION
OF MARKER
MARKERI
NG
(QAP 12-
L)
PPM
ORIT/P/3
REDRAW
OR
ALTERATIO
N
INSPECTION
4 POINT
SYSTEM(QA
P12A)
LAYERING(A
UTO & MANUAL
SPREADING)
INSPECTION
CUTTING
MANUAL &
AUTO
AUDIT
(QAO12H)
NUMBERING
ONLY EMB PRINT
PARTS
SHRINKAGE
TESTING
(QAP 12D)
SUPPLIER 100%
INSPECTION
RELAXATION
(STRETCH
FABRIC)
RE-CUT OR
ADJUSTMENT
(QAP12GT)
EMB/
FUSING/
PRINTING
INSPECTION
(QAP12AB)
RETURN TO SUPPLIER
CUT CLAIM
POLICY(QAP#02/ORIT-
P2
SEWING PLANT
FABRIC
REJECT
REJECT
OK
OK
OK
OK
OK
REJECT
REMAKE
OK
OK
OK
REJECT
REJECT
REJECT
(NON STRETCH
FABRIC)
OK
OK
OK
OK
(SCRAP)
REJECT
REJECT
OK
REJECT
OK
OK
INSPECTION OPERATION
TRANSPOTATIO
N
STORAGE
SYMBOLS
4. Arvind Lifestyle Manufacturing Plc - Ethiopia 4
Pre Production
• Fabric inspection
• Shrinkage testing
• Shade evaluation
• Roll allocation / cut sheet preparation - impotant
• Layering and accuracy
• Cut panel inspection / cutting
• Numbering
• Damage replacement - important
• Fusing and it testing
• Trial run evaluation
• Colour card and accessories approval
• Process / lycra audit
• CAP and other department problem solving
05/01/2022
5. QA FLOW CHART-SEWING
MEASURMENT
INSPECTION(QA0 05)
PPM
(ORITP05)
QAP#07
7/0 AUDIT SYSTEM AT
NEEDLE POINT
100% RESCREENING OR
RETURN TO SUPPLIER
100% VISUAL
INSPECTION(QAP 16)
OK
REJECT
REJECT
OK
INSPECTION OPERATION
TRANSPOTATIO
N
REWORK
CUT PANEL FROM
CUTTING
INPUT SEWING
LINE
CENTRALIZED
OPERATION SMALL
PARTS
SEWING LINE
ASSEMBLE
OPERATION
SEWING LINE FRONT
& BACK OPERATION
REWORK
AQL AUDIT BY
NQA(QAP 17)
WASHING
DEPARTMENT
10% INSPECTION(QAP
14)QAP18
ACCESSORIES
LABELS/ZIPPERS/RIVET/
THREAD
OK
OK
OK
OK
REJECT
OK
FUSING IF
NECESSOARY
CUT PANEL 10%
INSPECTION
OK
DO ANOTHER 10%
INSPECTION
REJECT
OK
REJECT
CENTRAL
CUTTING DPT.
SW1
STORAGE
OK
SYMBOLS
6. Arvind Lifestyle Manufacturing Plc - Ethiopia 6
SEWING PROCESS
• RA meeting / PP meeting
• Pp comment / pp meeting and its follow up
• Trial run evaluation
• 1 st pcs evaluation / line comparison
• 7/0 system
• Process / lycra audit
• Checker / operator training
• Correlation test
• 5 pcs audit by executive
• Needle / sharp tool control process
• AQL / DHU
• DEFECT REVIEW AND CAP
• CUT / SHIP ,
• Worker / Cadre / Gardian process . Evaluation
• Measurement process
• Lable process
05-01-23
8. Arvind Lifestyle Manufacturing Plc - Ethiopia 8
Washing Process .
• Shade band preparation
• Cc cards and its approval
• Recipe control
• Washing comment / shade band comment
• 1 st 50 / 1 st bulk evaluation
• Before wash AQL
• RA MEETING / pre wash requirement
• Style review meeting
• Process audit
• Cut – ship , reconciliation
• Defect and CAP
• Dryer follow up
05-01-2022
9. QA FLOW CHART-FINISHING
RESCREEN
& REPAIR
TAG ATTACHING
OUT SIDE CHECKING
OK
REJECT
REJECT
INSPECTION
OPERATION
TRANSPOTATIO
N
STORAGE
REWORK
RECEIVED FROM
WASHING AQL
BUTTON / RIVET
TRIMMING
OK
OK
REJECT
INSIDE
CHECKING
REWORK
IRON
MEASUREMENT
CHECKING
INSPECTION
SORTING & PACKING
PRE-FINAL AUDIT
QMP /FINAL
AUDIT(BUYER AUDIT)
SHIPPING
OK
OK
OK
OK
OK
REJECT
REJECT
OK
OK
9
SYMBOLS
10. Arvind Lifestyle Manufacturing Plc - Ethiopia 10
Finishing process
• AQL report evaluation
• Trim cards / packing approval
• 1 st pcs / 1 st carton evaluation process - allocate one person
• Button and rivet process
• Checker correlation/ training
• Damage repairing / CAP
• Lable procedure
• Pre final
• Trims checking
• Scanning / re scanning process
• 2nd
segregation process
• Left over removing process
• Re check process
05-01-2022
11. Arvind Lifestyle Manufacturing Plc - Ethiopia 11
Finishing process
• Do after wash AQL , 20 % ACCEPT . Recheck lot need to correct by relevant party .
• Size wise in put
• Shipment plan line wise. Planning has to provide it
• AQL report need to observe by line qa / production supervisor
• Gather data with respect to line wise plan . Need to done by line QA
• Style file need to read before line in put .
• Pack sample / trim card check with respect to style file .
• 7/0 system need to implement for finishing. LINE QA has to conduct it .
• Hourly finishing QA report need to observe by QAM . Get QA coordinator for finishing
and observe hourly report
• Every new style , 1 st garment for rivet / button / leather patch need to get signature
from line QA . Put a book for each and every po .
05-01-22
12. IN LINE INSPECTION FLOW CHART 7/0 SYSTEM
Next
Operation
Inspection 7 pcs from
Completed Bundle Finish/ semi
finished
Hand Over Bundle
to Production
Supervisor
100% Inspection &
Rectification by Operator
7/0 Qa Re-inspect with
Supervisor
Hand Over Bundle to
PM / Technician
Reject
OK (Green Tag )
Reject (Found 2 Damage )
Red Tag
If Found Minor Defect
OK
Yellow Tag
Found minor
Next
Bundle
2nd
Consecutive
Bundle
OK
Training Line
Reject
OK OK
Reject
Call Technical
Manager / Trainer
QAM / FM
Train &
Educate the
Operator
Stitch New
Bundle
OK
OK
Send to
Training line
Reject
Yellow Tag
INSPECTION
OPERATION
SYMBOLS
13. BROKEN ISSUE NEEDLE POLICY FLOW CHART
Find All Broken Needle Parts
01
Sewing
Needle Breakage
Get Hand Metal Detector
from Needle Clerk and Find Broken Part
02
Issue New Needle
QAP# 16
Put all Defected
Garments into
Red Box
Send Through Metal
Detector Machine
03
Destroy the Garments or with
Respect to GM/QAM/PM
Advice Provide Alternative
Solution
04
Attach in Needle
type wise file .
Use Needle
Blunt needle
NO
OK
OK
OK
NO
NO
INSPECTION
OPERATION
SYMBOLS
14. STORE AT SHADE BAND LIBRARY
FINISHING SECTION
WASHING WET
EACH DAY 7.30AM SELECT THE
WASHED FINISHED GARMENTS
FROM BULK & SET A SHADE BAND.
APPROVED SHADE BAND WITH BUYER
SEAL
BULK PRODUCTION SHADE
DUPLICATION
CHECK SELECTED BAND WITH
APPROVED BAND.
GET APPROVAL FROM RELEVANT
PARTICULAR BUYER / NQA
STICK A STICKER WITH NQA
SIGNATURE, MAINTAIN PHOTO
LOG SHEET.
EVERY 24 HOURS SHADE BANDS
NEED TO REPLACE & MAKE A LOG
BOOK WITH PHOTO.
EACH DAY 7.30AM SELECT THE
WASHED FINISHED GARMENTS
FROM BULK & SET A SHADE BAND.
CHECK SELECTED BAND WITH
APPROVED BAND.
GET APPROVAL FROM RELEVANT
PARTICULAR BUYER / NQA
STICK A STICKER WITH NQA
SIGNATURE MAINTAIN PHOTO
LOG SHEET.
EVERY 24 HOURS SHADE BANDS
NEED TO REPLACE & MAKE A LOG
BOOK WITH PHOTO.
GET APPROVAL
FROM BUYER
/WASHING ENGINEER
Fail Fail
REWASH
REJECT & ATTACHED
RED TAG AND 2ND
SEAL
Fail
Fail
Ok
Ok
Ok
Ok
SHADE BAND DUPLICATION PROCESS
