Denim factory-SOP

Denim 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 spraying
effect 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.