G-16 Best Practice Handbook

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Author: Edgar Picazo Approved by: Sandra Vollmert Document No.: G-16

Date: 01.07.2008 Date: 09.07.2008 Version: 11

Title: Best Practice Factory Handbook

To: (PUMA/WC, Garment Suppliers)

Introduction:This document shows some of the best practices in various divisions within PUMAfactories. Best practices are procedures, systems or equipments executed above thenormal requirement.

This handbook is a guideline for all factories and WC quality personnel and shouldencourage everybody to implement similar or other best practices.

The best practices outlined in the following pages are aligned with the current qualityaudit requirements of PUMA.

This document is not complete and will be extended on a regular basis.

The following factories have contributed to this book:Kin Fung Garment Fashion Ltd. (Xiamen China)Domex Co. Ltd. (HCMC Vietnam)

Shan Lian Clothing Co. Ltd. (Shanghai China)Shenzhou Co. Ltd. (Phnom Penh Cambodia)Shenzhou Knitting Co. Ltd. (Ningbo China)Hytex Apparel Co. Ltd. (Suzhou China)PCCS (Phnom Penh Cambodia)PCCS (Batu Pahat Johore Malaysia)Square Fashion Ltd. (Dhaka Bangladesh)ICC4 Gokaldas (Bangalore India)

Yumei Garment Co. Ltd. (Shantou China)Jiaxing Quang Viet Garment Co. Ltd. (HCMC Vietnam)Ginma Industries PTE. Ltd.(Kluang Johore Malaysia)

Universal Garment Co. Ltd. (Zhong Shan China)PT Bintan Bersatu Apparel (Batam Indonesia)Good Dale Ltd. (Dong Guang China)Union Regent Garment Ltd. (China)

Valid from: This document is valid from July 2008 onwards, open for continues improvement

World Cat – Global ualit Assurance





Content:

1. System for fabric storage2. Material location board

3. Fabric identification system4. Fabric is clearly separated by status (waiting for inspection)4.2 Fabric is clearly separated by status (passed for inspection)5. Fabric inspection area and machines6. Fabric inspection7. Fabric defect example reference8. W.C. fabric inspection manual9. Fabric inspection area requirements10. Nominated factory Q.C. for fabric inspection11. Fabric inspection report12. Documentation of light box usage13. Laboratory testing area14. Warehouse accessories directory board15. Accessories storage16. Thread warehouse/storage17. PUMA security labels storage18. Fabric relaxation19. Fabric relaxation record20. Steam fabric relaxation machine21. Performance depending fabric inspection

1. Panel inspection procedure2. Separation of defective and passed cut panels3. Replacement procedure for defective cut panels4. Bundle instruction guide5. Bundle ticket6. Storage and transportation of cut panels

1. Pneumatic heat transfer machine2. Heat transfer instructions

Heat transfers/Sublimation Print

Fabric and Accessory Procedure

Cutting





1. Print library2. Moving infra red flash cure and glass top surface printing table3. Frame storage

4.

Print area

1. Rewinding machine (Taining)1.2 Rewinding machine (Hacoba)2. Sewing machine maintenance record3. Production file4. Special machine equipment to join elastic5. Identification of critical operation

6. Machine engineered parts7. Tool room, storage of attachments8. Working table to insert draw cord9. Line feeding work station

1. Approved sample

1. Approved sample storage

1. Final inspection area2. Approved packing sample3.1 Packing tools (drawer storage for hangtag guns)

3.2 Packing tools (storage for hangtag guns in board)3.3 Packing tools (storage for tape dispenser in board)4. Pre sorting of packed garment5. Carton storage6. Carton pallet transportation7. Packing instruction and details8. Shipment sample9. Sealing & size set sample

Embroidery

Garment washing in knit factories

Inspection/Packaging

Production

Printing/screen prints





1. Broken needle exchange procedure2. Needle exchange area3. Metal detecting policy

1. Training center2. Fabric inspection training3. Metal detection training4. Trainee assessment

Metal detecting policy

Training





FABRIC AND ACCESORY STORAGE:

1. Shelf system for fabric

• Shelves size matches to fabric width

• Fabric is stored by style, customer, color and dye lots

• Clean, organized and spacious storage area

• Nominated staff assignment displayed at each shelf





2. Material location board (manually updated)

• Good organized and visual

• Material location matches to shelves content• Board information and material location matches to inventory system





3. Fabric Identification system

• Color codes describe the status of the fabric clearly

• Displayed and accessible in the warehouse





4.1 Fabric is clearly separated by status

• Fabric is stored per color, dye lots, batch, arrival and customer

• Fabric is identified with color coding (yellow sticker means waiting forinspection)

• Fabric is stored in shelve recorded and identified per index card





4.2 Fabric is clearly separated by status

• Fabrics stored per color, dye lots and customer

• Fabrics identified with color coding (green sticker means passedinspection)

• Fabrics stored at shelves recorded and identified with index card





5. Fabric inspection area and machines

• Automatic fabric roll transport system

• Clean, organized and spacious inspection area





6. Fabric inspection

• Approved sample of fabric color way is displayed for inspector reference atthe machine





7. Fabric defect example reference

• Various fabric defects are displayed at the fabric inspection area on atransparent board

• Guideline to identify fabric defects





8. Display of WC fabric inspection manual

• WC fabric inspection manual displayed nicely at inspection areas• Manual displayed in original and local language





9. Fabric inspection area requirements

• Displayed/posted requirements

• Written in local and English language





10. Nominated factory Q.C for fabric inspection

• Trained and nominated staff displayed in the working area





11. Fabric inspection report

• Fabric inspection report is filled up correctly and maintained as per WC procedure at every visit





12. Documentation of light box usage

• Recorded usage per style, customer, type of bulb used, signed bynominated staff





13. Laboratory testing area

• Clean and organized laboratory for basic fabric tests and garment washtests

• Complete equipment





14. Warehouse Accessories directory board

• Clear and easy identification of accessories and their location in thewarehouse





15. Accessories storage

• Clean, organized and properly stored accessories

• Every shelf with index card for inventory and identification

• Fiberglas shelves ensure easy item identification





16. Thread warehouse/storage

• Clean and organized storage

• Threads stored by types and brands

• Label at every shelf for identification

• Stored thread in numbered shelves matches inventory system





17. PUMA security labels storage

• Security labels are locked in a cabinet with nominated access

• Inventory control is documented nicely• Labels stored separately by country and color





18. Fabric relaxation

• Shelf height limits the Number of fabric layers to assure good relaxationresult

• Relaxed fabric is covered during relaxation to protect it from dust and dirt• Separate and spacious area for fabric relaxation• Custom made racks fit the fabric in width/length• Racks have bull casters for easier transport and increased flexibility• Clean and organized area





19. Fabric Relaxation record

• Each record contains style, fabric article No. , yardages, color and relaxingtime





20. Steam fabric relaxation machine

• Perfect relaxation with steam for knit and elastic fabric





21. Performance depending fabric inspection

• Fabric suppliers are evaluated based on the inspection results of theincoming fabrics. Fabric suppliers are classified, the percentage of fabricthat will be inspected depends on the rejection ratio





CUTTING:

1. Panel inspection procedure

• Clear procedure explains every step how to inspect panels in various kindsof fabric defects

• Procedure helps and guide workers to understand how to conduct panelinspection





2. Separation of defective and passed cut panels

• Separate boxes to store passed and defective panels after inspection • Every box is labeled for its own purpose





3. Replacement procedure for defective cut panels

• Leftover yardage is stored properly in plastic tubes in a separate area forcut panel replacement

• Replacement yardage in every roll is recorded, marked and documentedfor easy identification





4. Bundle instruction guide

• Clear instruction for the staff which parts of the garment and how manymust be bundled in one bundle

• Nice visual system with approval stamp





5. Bundle ticket

• Complete and detailed information for bundle ticket preparation

• Mini marker is used to identify cut parts of the panels

Mini marker

Panelbreakdown

BundleticketsBundle plan





6. Storage and Transportation of cut panels

• Separate storage location for embroidery panels, print panels, ready for production panels

• Clear and easy identification of cut panel status





HEAT TRANSFER/SUBLIMATION PRINT:

1. Pneumatic heat transfer machine

• Heat transfer conditions including wash test sample and documentdisplayed at the machine

• Heat transfer SOP’s placed at every machine

• Heat Transfer sample is displayed in the area





2. Heat Transfer instructions

• Heat Transfer instructions and guidelines by heat transfer supplierdisplayed in the heat transfer section





PRINTING/SCREEN PRINT:

1. PUMA print library

• Print samples organized and placed in glass cabinet to avoid dirt and dust• Print sample displayed inside printing office for easy access and reference





2. Moving infra red flash cure and glass top surface printing table

• Clean and safe working place

• Glass surface allows easy cleaning and removal of leftover print paste

• Panels can be easily removed (no overstretching)





3. Frame storage

• Clean racks to store frames, frames are made of metal

• Racks located to the end of printing tables and easy accessible for the staff





4. Print area

• Clean and safe environment

• Spacious and organized working area





PRODUCTION:

1.1. Rewinding machine (Taining)

• Separated and clean area for rewinding threads

• Nominated rewinding machine from Taining

• Plastic bins to place and sort used cones





1.2. Rewinding machine (Hacoba)

• Nominated rewinding machine from Hacoba

• Multiple thread winder with big capacity





2. Sewing machine maintenance record

• Regular and properly filled machine maintenance record• Individual maintenance record attached at every sewing machine





3. Production file

• Complete production file displayed in production protected under glass• All information is translated into local language





4. Special machine equipment to join elastic band

• Pneumatic machine, full automatic

• High accuracy, very efficient





5. Identification of critical operation

• Sign board to identify critical operations within the lines

• Easy reference and guidance for line QC’s and supervisors





6. Machine engineered parts

• Increased accuracy and efficiency for difficult seams





7. Tool room, storage of attachments

• Safe and organized storage in glass cabinet for machine attachment• Easy access and visible





8. Working table to insert draw cord

• Custom made working table with roll bars and drop box for loose threads,loose threads will not fall on the floor

• Table with bull caster for easy movement





9. Line feeding work station

• Separate workstation for Line feeding

• Clean, tidy workplace with enough place for storage (three levels)





EMBROIDERY:

1. Approved sample

• Approved embroidery swatches per colorway displayed at every machine

• Approved embroidery swatches displayed at every inspection table as areference for the quality inspection





GARMENT WASHING IN KNIT FACTORIES:

1. Approval sample storage

• Approval samples are stored properly, covered with polybag for reference,reports are attached





INSPECTION/PACKAGING:

1. Final inspection area

• Separate area for final inspection

• Clean, spacious and organized

• Standard final inspection table with adequate light, space andInformation

• Color coded storage box for segregation





2. Approved packing sample

• Displayed in the packing area for staff reference by style

• Maintained and controlled





3.1 Packing tool storage

• Hang Tag guns are stored separately, inventory is documented andcontrolled





3.2 Packing tool storage

• Separately stored hang tag guns and hanged in the tag gun control

board/cabinet• Staff name marked on the control board to identify users





3.3 Packing tools for tape (dispenser on board)

• Packing tape dispenser stored separately with controlled inventory





4. Pre sorting of packed garments

• Ready made garment in poly bags are sorted by colors, size and

customer





5. Carton storage

• Spacious, clean, organized carton storage on pallets

• Cartons stored by style, size and customer/P.O.• Documented shelves and controlled per location





6. Carton pallet transportation

• Automatic pallet carrier used to transport cartons for loading

• Convenient and safe for workers





7. Packing instruction and details

• Displayed in the packing area, nice, organized, visual• Translated into local language





8. Shipment sample

• Shipment sample is displayed in final inspection room and used as areference by WCQC during final inspection to assure the color/shadecontinuity from the first to the last shipment window

• Sample is displayed from the first shipment sample by style, color andsizes





9. Sealing and size set samples

• Approved sample is arrange and displayed for on going styles for production

• Easy access and visible to everyone who needs sample for verification





METAL DETECTING POLICY:

1. Broken needle exchange procedure

• Displayed in the needle exchange secured area

• Translated into local language





2. Needle exchange area

• Needle exchange is done in a secured area with nominated access

• Factory’s needle exchange procedure is displayed in the area





3. Metal detection policy

• WC metal detecting policy is displayed in the metal detection area

• WC metal detecting policy is translated into local language





TRAINING:

1. Training center

• Separate training center for training only

• Clean and organized training center facility with all necessary machines

and equipment





2. Fabric inspection training

• Training is conducted regularly

• Attendance record for every training session available





3. Metal detection training

• Training is conducted regularly

• Attendance record for every training session available



Documents

G-16 Best Practice Handbook