LINE FEEDING PROCESS

SR. RESPONS-
ACTIVITY
NO. IBLE
PERSON
Production supervisor’s, quality controller’s responsibility is stitching a line

sample for the new style prior to start of production and sample must be revived by QA executive, Production executive and technician.

Check randomly selected panels of bundles

1 Quality supervisor
against the approved hard pattern.
If rejected at the random check it should be
2 corrected by cutting department. If approved allow for the line feeding. Quality supervisor

Refer style layout, PP report and identify

3 WS executive
operations and operators’ requirement.
Identify the skill requirement for each operation
Supervisor, WS
4 and assign operators in the given production line for each operation according to the lay out. executive
If there is any critical operation, train allocated Supervisor,
5
operators before the line feeding. Technician
Ensure that received cut and trims are correct as
6 Quality supervisor
for the trim approval.
Style induction meeting to be held for line/
particular style for better understand of
expecting quality and production levels. Following members to be involved on this.
 Production supervisor
7  Technician
 Mechanic
  Quality supervisors
 Checkers and auditors
 All operators, ironing people, packers, helpers and line leader.
First bulk should be stitched (200 pieces)
followed by machine lay out, approved Tech pack, PP meeting report, approved
8
sealer sample and measurements sheets.
Start line feeding followed by machine lay out
9 Technician
where given by WS department.
Stitch three pieces and instruct operator and
supervisor about how to stitch, correct method
10 Technician
and required quality based on the tech pack/ approved sample.
Stitch five garments under the supervision of
11 technician following the correct method as per instruction of technician. Operator.

Production supervisor’s, QC supervisors

responsible is to involve for line feeding and closely monitoring operators during the line Quality supervisor, production

12 feeding. As well study method implemented by Technician. supervisor

Check operator stitched 5 garments. Ensure the

13 Quality supervisor
accuracy of stitching method.
Update the style feeding report and if operator
failed to stitch particular operation as per given standard than stop machine and inform
14 Quality supervisor
to supervisor and technician.
15 Technician’s responsibility to retrain operators. Technician.
Cross checks thread and trim consumption
Production /work- study Executive
16 against the approved consumption. And if any mismatch take necessary action.

17 Prepare operation specification sheet and mock Quality supervisor

 up for each and every operation.
Decide and select suitable type of marking chalk
18 Technician
for marking operation.
Select operation wise needle, pressure foot
19 Mechanic.
accordingly fabric type.
Critical operations and points to be informed to
Technician,
20 operators which were identified during the PP meeting.
supervisor.

Provide checking instruction (lay out, label

21 details, and other critical Points) to checkers and provide approved Quality supervisor

checking standard.
Provide approved reference sample for
22 Q.A. Manager
particular production line.
Provide approved pressing samples for ironing
23 Q.A. Manager
people.
Provide approved packing samples and packing
24 FCA
details for packers.
Sewing line always starts new style with yellow
25 Quality supervisor
color TLS tags.
Critical operations have to be highlighted by
26 Quality supervisor.
displaying “critical operation” tag.
 INLINE QUALITY INSPECTION PROCESS
1 Open a new in line report at the beginning of the day. Line QC

2 Enter following details in to the report. Line QC

 Date
 Line no
 QC name / EMP No
 Supervisor name
 EMP No of operators and operations name.

3 Highlight critical operations and new operators in the report QC

4 Check samples from each operation with in first 1 1/2 hours .and record findings on the report. QC

5 Fill machine chart entering by following details for specific operation. QC

 Date
 Operator EMP No
 Style
 Operation name
 Time
 SPI
 Needle size
 Gauge/ Margin
 Thread tension
 Measurements

6 These samples should check according to the given instruction and production approved sample. QC

7 If defects are found from an operator than it should mark on the report. QC

8 Mark the defect type in the “defect” column by writing the relevant letter assign for the particular defect. QC

9 If defects are found operator should signed the report. Operator

10 If zero defects found TLS color will remain green, one defect found TLS color change to yellow and two or more QC
defects found TLS color change to red.

11 Work station on yellow would expect thigh monitoring by QC supervisor. QC supervisor

12 Work station on red will cause to stop machine. Technical and production team Technician/ Production
 investigate it all together to identify reason for supervisor
the mistakes. Determine and validate Root cause and corrective action
plan by technician and production supervisor.
13 Follow up Visit for “RED” has to be checked after 15 minutes once it QC
corrected.
Follow up visit for “yellow” has to be checked within 30 minutes.
14 If the defect is because of machine than machine should be repaired. If the Mechanic/ Technician
defect from operator’s handling than operator should be re trained. If
defect from any other technical issue than technically it has to corrected.
15 QC supervisor’s visit on operation has to be followed following time line QC supervisor
1st Visit - 7.00 to 8.30 (All operations)
2nd Visit -9.45 to 10.15 (Critical operations) 3rd Visit - 10.45 to
12.15(All operations)
4th Visit - 1.30 to 2.00 (Critical operations)
5th Visit - 2.45 to 4.15 (All operations)
6th Visit – 5.00 to 5.30 (Mandatory Visit Red and yellow)
16 All paper work should be done by pencil. No pens are allowed to use while QC
inspection garments.
17 Production supervisor, QA executive should be signing the report. Production supervisor/QC
18 Within every 3 hours 6 garments should be QC
check for measurements and workmen ship. Record findings on
measurements report.
19 At end of the day top 3 defects, top3 defects operations have to be In house QA
identified and mark on the relevant place.
20 At end of the day prepare daily meeting report “TOP 3 DEFECTS” and QC
handover it to production supervisor.
 MID LINE /END LINE QUALITY INSPECTION PROCESS
1 At the beginning of new style below guide lines should provide to checkers. QC
Approved checking standard with comments and QC supervisor’s
signature.
Checking lay out with local language. If required label details.
If required critical measurements. Measurement sheet.
Checking table report, pencil, defect stickers, QC pass stickers.
Defect clarification diagram.
2 At the beginning of day fills following data on the check table report. Checker
Table Line Style
Po No and colors Date
Checker ID No.
Operations name and related operators ID No.
3 Garments should be checked according to the given sequence of the Checker
diagram displays on the check table.

4 Identified defects should mark on the reports as follows. Checker

Insert the related defect code in the relevant cell of the operator for the
particular hour.
Circle the defect code.
Mark the defects using by tally bars.

5 Past defect sticker for defect where found on the component part Checker
/garments. And keep on the table (place where marked “DEFECTS”) for the
repairing
6 If garment/ component part is free of defects than past a QC pass sticker Checker
behind the care label.
7 Repaired garments should be re inspected after re worked. Checker
 DECREASING ALTERATIONS IN THE SEWING ROOM

• Detect the sewing lines having maximum alteration

• Identify the major causes of defects
• Suggest possible measures to reduce defects
• Train operators to the new way of working