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SOP for denim factory
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Denim factory-SOPDenim factory-Standard Operating Procedure (An Analysis)
SOP FOR SEWING DEPARTMENT
SOP FOR SEWING OPERATOR –
Follow the instructions given by the sewing supervisor.■
Check the ticket no.( ticket no. 25 for needle thread,ticket no.50 for bobbin/looper/spreader■
thread) of the thread before filling the bobbin thread and needle thread.Check the SPI of the machine before starting the new order & get it checked from sewing■
If there are any problems with stitching machine and stitch quality like jump and skip stitches then■
bring it to the notice of the sewing supervisor and in turn maintenance department.Use the machine folders in systematic way.■
Ask for help from sewing supervisor in case of stitch related confusions.■
Take the bundles from the concerned operator /supervisor and keep it on the side table.■
Open the bundle and check the pieces.■
Take pieces one by one and do the sewing operations & keep the pieces one by one on side table or■
sewing table top if the space permits.Tie the bundle again after completion of sewing operation of all the pieces.■
Handover the bundle to the next sewing operator for the next operation.■
Collect the bundle barcode stickers and stick it on the paper to calculate the no.of pieces sewn by■
the operator for his/her wages.Hand over these papers to sewing supervisor.■
SOP FOR SEWING SUPERVISOR –
Check the order no. style no. customer lot no.order qty. before commencement of sewing.■
Get cutting program from cutting department.■
Take bill of materials hard copy and approved sample from quality person.■
Issue necessary trims from the stores.■
Inform maintenance department to attach necessary folders to the machines according to the■
sample.Also change the settings ( Groove setting ) of the machine by using maintenance fitters.Get these folders approved from the quality department.■
Start the production.■
Build the necessary WIP in the line which will not affect the production in case of style change.■
Leave some machine space to between the two styles to avoid confusion to operators and mixing of■
the style.Co-ordinate with the quality person regarding the measurements and and stitching quality.■
Do the alterations whenever needed.■
Report to Asst. Manager sewing .■
SOP FOR WASHING OPERATORS –
Check the details (lot no., style no, customer etc.) of the lot entered into the machine.■
Fill the machine with the required amount of the water.■
Check the water level and when it is arrived to a particular level close the water inlet.■
Enter the pieces of the lot into the machine.■
Close the front lid of the machine.■
Check with supervisor for any other special instruction for the lot.■
Enter the programme into the machine.■
Check the programme.■
Run the programme.■
Check accurate amount of the chemicals to be poured.■
Add chemicals from the side vent of the machine.■
Drain and fill up new water after rinsing and washing.■
At the end of the programme ensure that drum revolution will stop completely.■
Open the front door of the material.■
Take out the material from the machine.■
If necessary give one revolution to the drum to ensure that all the material should come out■
smoothly.Do not insert hand in rotating drum.■
Take out the material from in a trolley.■
Send the trolley for the drying.■
SOP FOR SUPERVISORS –
Check the details of the lot came for the washing.■
Ensure the material is of same lot to come in one group.■
Send to goods to their respective processes as per washing requirements.■
Check the parameters of washing programme.■
Give necessary instructions to washing operators regarding program no.(Type of wash)■
Ensure all the parameters are maintained while washing.■
Increase /decrease the chemical concentration to set the recipe as per the shade group.■
Check the quality of the material after washing.■
Ensure all the pieces washed are given for drying.■
Ensure lot wise loading of the material in drying Machine.■
Maintain proper record of the lots and pieces in the lots & give exact no. of received pieces to■
riveting.
SOP for SCRAPPING OPERATORS –
Check the details( lot no,style no,customer etc.) of the lot taken for scrapping.■
Pick one piece of denim & put it in scrapping bed.■
Increase the air pressure of both the legs.■
Ensure the pressure is so adjusted that there is no crease on the surface of the denim.■
Scrap it with scrapping paper.■
Change the scrapping paper periodically after its wearing off.■
Ensure the quality visually by considering the no. of scrappings/garment and its intensity.■
Switch off air pressure valve and disengage the garment from rubberized scrapping pad.■
Avoid loss of air pressure by operating the air valve efficiently.■
Remove the garment and keep it in the trolley.■
SOP FOR PP WASHING OPERATORS –
Check the details( lot no.,style no,customer etc.) of the lot taken for PP wash.■
Put the mask on your face.■
Prepare the PP solution of desired concentration by dissolving the PP granules into water.■
Stirr the solution properly.■
Take the piece & close its zipper.■
Hang the piece to verticle rubberized pad.■
Switch on the air pressure valve.■
Check the piece is properly adhered to the pad with creaseless condition.■
Ensure the orifice of the spraying gun is dust free.■
Pour the PP solution into the spraying gun reservoir.■
Check the spraying speed by adjusting the distance between the piece and the orifice of the■
spraying gun, or by adjusting the spraying pressure knob.Ensure the spraying is done on required areas and with same consistency of spraying maintaining■
the same distance between the garment and the spraying gun orifice to achieve even sprayingeffect throughout the garment.Switch off the air pressure knob and remove piece from the rubber pad.■
Hang the piece to the hanger.■
Take out all the pieces in the trolley and deliver it to the next process.■
SOP FOR DRYING OPERATOR –
Check the details (lot no.,style no,customer etc.) of the lot entered into the machine.■
Enter the pieces of the lot into the machine.■
Close the front lid of the machine.■
Check with supervisor for any other special instruction for the lot.■
Enter the programme into the machine.■
Check the programme.■
Run the programme.■
At the end of the programme ensure that drum revolution will stop completely.■
Open the front door of the material.■
Take out the material from the machine.■
If necessary give one revolution to the drum to ensure that all the material should come out■
smoothly.Do not insert hand in rotating drum.■
Take out the material from in a trolley.■
Send the trolley for the finishing.■
SOP for FINISHING DEPARTMENT
SOP FOR RIVETTING OPERATOR
Take out some piece from the trolley and keep it to nearby stand.■
Check the die is in proper position or not, if not then remove and fix it again.■
Take the buttons and shanks from the supervisor.■
Put them into their respective places.■
Start the air pressure valve.■
Put the shank in the bottom jaw & button into the upper jaw of the die.■
Take one piece from the side stand.■
Position this piece over bottom jaw in such a way that the right edge of the button should come■
into the line of stitch near the zipper ( SNLS stitch which joins the double fly with the front panel.Press the tredle & ensure the buttons is correctly attached to waistband.■
Unpress it & see that the upper jaw / die is moving upwards.■
Keep the piece on finished side stand.■
Repeat the operation for the required no. of pieces to be finished.■
SOP FOR PRESSING/IRONING OPERATOR
Check the live steam is coming from the iron or not and if water content is more then drain it by■
pressing a button placed on iron.Check the steam valve visually and there should not be any steam leakage ideally.■
If leakage is seen inform to maintenance department.■
Take one piece from side stand and put it flat on the ironing table.■
Ensure that the piece is in creaseless condition.■
Iron front part of the piece.■
Put the hand inside the piece from waistband opening & straighten the curved pocketing fabric&■
press that portion.Fold the piece in between & press both the sides.■
Fold the piece from bottom first & then from top side i.e.waistband side.■
Keep the piece on overhead storage assembly above ironing table.■
SOP FOR INSPECTION OPERATOR
Pick the pieces from the overhead storage assembly of ironing table & keep it on side table.■
Take out some pieces from the lot & keep it on one side of inspection table.■
Check the lighting conditions( Tube Light ) before start.■
Tube light must be dust free before inspection.■
If you find the dust, switch off,wait some time to cool it down and wipe it with cotton cloth.■
Take one piece at a time on inspection table,inspect it as front first and then back panel■
afterwards.Do the inspection by opening the button & unzipping the zipper.■
Inspect the piece for below defects –■
Fabric Defects – 1) Hole/Cut/Damage■
2) Missing End/ Pick
3) Shade difference between garment parts.
2) Stitching defects – 1) Jump Stitch
2) Broken Stitch
3) Skip stitch
4) Puckering/Gathering
3) Trims defects – 1) Position of button/rivette/labels
2) Checking positions of all trims on appropriate places of the garment.
4) Other garment Defects – Checking of bottom hemming & seat stitching.
Stick the quality sticker inside the pocket bag which indicate the piece is checked & by a specific■
person.
SOP FOR SEGREGATION OF PIECES –
Segregate the piece according to the style,fit & size.■
Check size label,stitching style,stitching type/style,button & rivet type,brand label etc.to segregate■
the pieces.Check for the shade difference within the style and if exist show it to the supervisor & QC■
Manager.Segregate these pieces for separate packing as per the the instruction of the QC Manager.■
SOP FOR MEASUREMENT OF PIECES –
Take every measurement of first ten pieces when each new style is coming for inspection using■
specification sheet provided by the buyer.If the measurements are according to specification sheet and within the tolerance limits specified■
by buyer then show it to supervisor and QC Manager.If the measurements are not falling within the tolerance limit bring it to the notice of the■
supervisor & QC manager, which in turn informs it to the sewing department.Meaure every piece of the lot for its waistband & in seam■
SOP FOR TRIMMING OPERATORS –
Take one piece for trimming & lay it flat on the table .■
Check the piece for the loose threads & cut the protruding thread using the cutter.■
Turn the piece upside down and cut the protruding thread from the backside also.■
Fold the piece and send it to packing.■
SOP FOR PACKING –
Take the paper hang tag, plastic tag & plastic strand packets from the finishing supervisor.■
Open the packets properly & attach one of the assembly(hang tag, plastic tag & attaching string)■
to the prescribed loop of the piece.Show this sample to QC supervisor and get it approved from it.■
If QC approves it then start the process of attaching these tags to the loop.■
If QC rejects it,get the tags changed by handing it over to finishing supervisor.■
Start attaching the paper hang tag,plastic tag to garment loop using the plastic strand.■
Check the inside size label to ensure that correct tags are to be attached.■
Hand it over these attached pieces to polybag packing operator to pack it into polybag .■
Put the denim inside the polybag in such a way that the waistband is opposite to polybag opening.■
Remove the plastic from the sealant tape & stick this tape to the other edge of the polybag.■
Keep it into different cartons according to their sizes.■
Pieces of the same size but different shades are to be packed in different cartons.■
Check the carton ply as per the specification of the customer and get it approved from finishing■
and quality supervisor.Change the cartons in case of specifications are not met.■
Convert the carton ply into box & seal the bottom by adhesive tape.■
Take out the pieces from these temporary cartons and arrange it in the cartons to be dispatched.■
Seal the cartons with adhesive tape.■
Write down size, no.of pieces in a box,carton no.out of total cartons,gross weight,net weight■
,colour of denim etc. to be dispatched.The type of details are depend upon the customer.■
Seal the top of the carton by adhesive tape.■
Load in into container/truck /transporting vehicle.■
SOP FOR FINISHING SUPERVISOR –
Check the lot no.,order no,.customer name ,order quantity, style before the receiving for the■
finishing.Give necessary instruction to finishing operators.■
Check the quality of finished goods regularly and give necessary instructions to the staff.■
Issue buttons, rivettes and other accessories used in packing from stores and issue to finishing■
operators.Guide finishing operators regarding changes in the shade within the same style.■
Give separate packing instructions regarding the change of the shade.■
Assist the finishing operators to achieve the production target by material planning, eliminating■
and bottlenecks.Report to finishing manager/concerned top authority.■