Pre-Production Quality Control System | SOP for Pre-Production Quality Control System | Garments-Info

Pre-Production Quality Control System – SOP

pre-production quality system

Pre-production sampling –Size Set:

Objective

Pre-production sampling (Size Set) aims to identify potential quality problems during bulk production as well as availability of skill, machinery, work aides and production capacity.

Scope:

This procedure covers sampling activities done by production upon receipt of Approved Sealed Sample comments from the customer plus other necessities for production like actual fabrics, trims and other order details.

Authority:

Quality Head is controlling this procedure.

Responsibility:

It is the responsibility of the Pre-production Control team to implement this procedure. It shall be composed by the following.

·         Sample Room Head, Production Head, sewing in-charge, Technician, QA Manager, Cutting Room in-charge, Technical in-charge, IE, Planning & Finishing in-charge

Procedure:

·         Sample room must ensure that Pattern adjustments/Grading is made based on within 3 days upon receipt of buyer’s final approval comments.

·         Planning department shall plan schedule of size set based upon the master production Schedule.

·         Technical team shall make the size set in align with the sewing team where it is planned for bulk production. The use of possible work aides like sewing Folders needs to be tried during of making size set.

·         Planning Department must ensure that the following information is available to production line during the process of making size set.

ü  Approved sample with complete specification sheet with Final approval comments.

ü  Actual fabric and trims.

·         Respective line QA shall be tasked to make initial evaluation using the Size Set Report.

·         The Pre-production team shall evaluate the size set in terms of workmanship, fit/presentation and formulate possible sets of solutions accordance with the following agenda during the PP meeting.

·         Fabric Characteristic at cutting, Possible spreading and Cutting method, Anticipated sewing difficulty and methods, Potential quality problems in all aspect of production, Availability of work aides, machines and skills, Number of pieces to be made shall depend from customer to customer.

PILOT PRODUCTION

The first trial lay of production considered the pilot lot. It is actually the first cutting load to sewing line and the time to apply anticipated method foreseen during PPS/Size Set stage.

Objective:

·         To be able to apply Quality Standard for each and every sewing operations as well as work methods at the beginning of the process.

·         To be able to identify potential problems not seen during the course of PPS.

Scope:

This procedure covers the startup process of any new style being produced in the sewing line.

Authority:

This procedure is under the control of Production Head of Unit where the concerned order will be produced.

Responsibility:

The production In-charges/APM from Cutting to Finishing are responsible is ensuring that PPS action plan is being applied during the pilot Production Run.

Procedure:

Production in-charges & supervisors from Cutting to Finishing must see to it that SEAL sample and or PPS samples with respective comments, order details and other relevant information are available in production in setting Standard Quality Reference for each and every operation.

Unit Production Planning & Control

·         Based on production schedule furnished by Planning Department, ensure that the following information is available to production in-charges before Pilot and bulk production starts.

·         Approved Trim Card for Material information.

·         Order Details

·         Sealed Approved PPS sample

·         Other relevant information available.

Cutting

·         Cutting Manager shall check style requirement based on the information on hand as follows.

·         Fabric information on Quality from Fabric Inspection

·         Shrinkage allowance details

·         Fabric Guidelines

·         Matching requirements if any

·         Consumption

·         Cutting department is responsible to keep the First trial (Pilot) cutting panels ready two days prior to sewing Line loading.

·         Consequently check 100% of Pilot Cut panels on the following

ü  Cut pieces quality against pattern

ü  Fabric defects if any

·         Cutting department can only precede cutting with subsequent markers of the same style on the following conditions.

·         If feedback on Cutting Quality is Good after Pilot Meeting Review.

·         And 100% inspection proves no fabric defect on Finished Garment.

·         However, if quality rejections reach to about 5% or more on fabric defects only, cutting head shall notify the Merchandising department for immediate disposition.

·         Based on production schedule furnished by Planning Department, ensure that the following information is available to production managers/in-charges before Pilot and bulk production starts.

ü  Approved Trim Card for Material information.

ü  Order Details

ü  Sealed Approved PPS sample

ü  Other relevant information available.

Sewing:

 IE and Maintenance department ensure that the following are prepared prior to pilot run,

ü  Operations break down and lay out

ü  Machines and folders requirements

ü  Skill requirement

·         Based on the Operations Breakdown/Layout, operator and helpers shall be trained by the supervisor and Line in-charge on the proper work methods in the attainment of Quality Standard.

·         Quality standards been developed for each and every operations based on Approved Seal sample and duly signed by concern Operator, Sewing line supervisor, Sewing in-charge, Line QA & QA Supervisor. By doing so, all the operators are aware and agreed on Quality Requirements of each and operation and enable to achieve Right First Time Quality from each operation.

·         Line QA inspector shall evaluate the pilot samples on the basis of workmanship, use of right materials and its specified position and measurement specs.

Finishing:

·         Finishing in-charges shall prepare the following immediately after receipt of advice from Merchant department about Pilot Run.

ü  Packing Trim Card

ü  Packing Details of that particular style.

ü  Packing Methods

·         Finishing Quality team shall set the quality standard at every single process in finishing with references to seal sample from customer.

Pilot/1st output Review Meeting

Chaired by Quality Manager and attended by Sample Room Head, Production Manager, Sewing in-charge, Sewing Line Chief, QA In-Charge, Line QC/QA Auditor, Cutting Room in-charge, finishing in-charge to review Pilot samples and take necessary action to ensure that Right First Time Quality from Cutting to Finishing.

·         Accuracy of Production Patterns in achieving consistent specs

·         Fabric related concern and necessary action

·         Cutting concerns & necessary action plan

·         Workmanship concern & action plan

·         Achievement of Fitting as same as Sealed Approved sample.

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