SOP: Standard Operating Procedure of Shade Control for Non-Denim Washes | Non-Wash Denim Shade Control SOP

SOP – Shade Control for Non-Denim Washes

Shade Control for Denim Non-washes

Objective:

Aims to set the processes from fabric to final packing to ensure to achieve consistent shades as per buyer requirements in Non-Denim Washes.

Scope:

This procedure covers one of the activities of Fabric, Cutting, Sewing, Washing, Finishing & Packing.

Authority:

This procedure is being controlled by the Fabric, Cutting, Sewing, Washing, Finishing & Quality Managers/heads.

Responsibility:

Execution and maintenance of this procedure lies on the Fabric Quality, Cutting Team, Sewing Team, Washing Team & Finishing Team.

Procedure

Fabric Processes

Step 1 Blanket Making – Responsible -Fabric Quality

·         Supplier to provide 100% Roll wise shade details.

·         Supplier to provide Approved Bulk Dye Lot with Color Continuity Card

·         Non-Stretch Fabrics – Head Cutting 18” from each roll & additional 25” from 10% for Shrinkage testing.

·         For Stretch Fabrics – Head Cutting 30” from each Rolls

·         Segregate the head cutting as per supplier’s shades

·         Follow supplier’s shade information -One Blanket one shade. No random attaching. Every panels to have roll details along with supplier shade info.

·         3 sets of Blankets to be made.

Step 2 Blanket Reviewing Responsible – Quality Head/Fabric Quality/Washing Tech & RQS/GPQ

·         Buyer Wash standard or Approved C/S a must prior to blanket washing.

·         Wash 2 sets of Blankets first following Wash standard/Approved Sample.

Blanket review –

·         Washing team to review the Blankets along with Quality and GPQ/RQS Team

·         Blankets reviewed for shade consistency – Supplier’s quoted Shade must be consistent after wash (before wash “A” Shade Blankets must be consistent after wash). Rise the concern if shades not consistent after wash.

·         After wash shades reviewed against approved standard and shades matching within the range of approved standard been identified as APPROVED SHADES ROLLS and entered pro-cut. Recipe fixed for Approved shades.

Step 3 – OFF Shade Rolls –

Trials -Responsible -Wash Team

Intimate Suppliers – Responsible – SCM

Involving Buyers if Trails fails – Marketing Team

·         Rolls those are too much off from the standard considered as OFF SHADES ROLLS and a mail send to concern fabric Mills for Off Shade Rolls by keeping SCM/Marketing Team in CC.

·         Meantime, washing team to do trials and try to achieve the standard. If trails OK, fix the recipe as per trail.

·         If Trails NOT OK, review the trials with Fabric supplier for further improvements/Trials.

·         If Trails with supplier team fail meet the buyer with our trials for guidance.

·         OFF SHADE Rolls -Only Buyer can approve to proceed further.

·         Based on wash blanket review and trials, Recipe wise shades fixed.

·         Special Recipe shades should be identified with kimbal/string so that these garments washed with special recipe.

·         Shade bands approval in Leg Form where applicable

·         Leg Panels made from the shade family grouping – 5 sets from each shade group

·         These leg forms washed using the complete wash process as per buyer approval.

·         Shade bands submitted in leg form and get buyer approval prior to bulk cutting or bulk washing

Initial/Pilot/1^st Bulk

·         300 pcs or as required by washing team for bulk washing to be cut.

·         Shade band approval in garment form (Cutting number 99) – one or 2 layers from each shade should be included in initial bulk cutting. (Minimum 8 to 10 pcs per shade grouping) This should be marked properly and identified properly from cutting to washing to get shade bands approval in garment form from buyer.

·         Washing team who involved in blanket wash to be involved in 1st bulk garment wash.

·         1^st Bulk Washed garments to be reviewed with all concern and recipe to be finalized for bulk.

Shade Control at Cutting:

·         Cut Plan-Cut Plan to be Shade, Shrinkage & Width wise.

·         Cutting must be shade wise, mix shade not allowed in one cutting. If shades are more, must use separate sheet and bundling done separately to avoid any shade mix up.

·         Shade wise cutting to be issued sewing floor.

·         Cutting Number should have Shade code.. Example 1=A, 2=B, 3=C, 4=D, 5=D.

·         Cut Bundles to have shade name.

Shade Control at Sewing

·         Shade wise line feeding.

·         Hangers identified with shade numbers.

·         Shade numbers to be attached on garment as one of the first process while feeding the line..

·         QC Passed Output garments segregated shade wise

·         Special Recipe shades should be identified with kimbal/string so that these garments washed with special recipe.

·         Shade wise garments identified in a bag or trolley and passed to Washing.

Shade Control at Washing

·         Washing receiving team accept the sewn garments only shade wise

·         Garments to be washed based on Shade using the recipe fixed during blanket or leg form washing.

·         Washing Quality to check 100% for washing shade

·         Every wash lots been audited by independent Auditor Team for Shade & Measurements

·         Only shade OK garments passed to Finishing.

·         Off shade garments must be reworked.

·         Need to get more shade range approval from buyer if required.

·         Daily washing quality report shared on rework.

Shade control at Finishing/Packing

·         Dedicated shade segregation team-to ensures passed garments packed as per buyer requirements – One Country one shade or one shade one carton, etc

·         Independent hourly carton audit to ensure that only approved shades/same shades packed as per buyer requirement.

·         GPQ/RQS/NQC teams to check the packed cartons for shade control as per buyer requirements regularly to avoid any possible inline/pre-final & final inspection failure.

Hope this post will help you to know about Standard Operating Procedure of Denim Non-Wash fabric.