Practical Process of RMG Industry

Define Fabric Store Department Process

Define Fabric Store Department Process

Fabric Store Department Process


The responsible person is Store Keeper The lift can carry a weight of up to 100kg.The supplier brings the fabric/accessories to the gate and the receipt is checked at the gate, this order is then counted and when everything is confirmed to be right then the order is received and a challan is issued. The received material is then stocked with a Yellow card indicating that it has to be checked, along with the color card, there is also a bin card, which indicates the details of the material.

Fabric Store


Most of the fabric is imported and the main suppliers are from Asia. List of some of the fabric suppliers:

Sinotex United Co. Ltd. (China)
Prominent Apparel Ltd. (Hong Kong)
Unique Tex (Bangladesh)
KA International (India)
Alok Industries Ltd. (India)
Lucky Tex Co.Ltd. (Thailand)
Pen Fabric (Malaysia)
Hyundai Co. Ltd. (Korea)

The colors in the color card held the following meaning. Along with this color card, there is a Bin card, which indicates the detail of the fabric and including the buyer’s name and the supplier’s name, and had the following format.

There is a sticker on all the fabric rolls, which is provided by the supplier, and it indicates the fabric details. The sticker provided by Prominent Apparel had the following layout
The fabric is stocked on the wooden block, and the rolls are kept with 8 rolls of 60” width mounted one over other forming a stock square of fabric width X fabric width. The mounting extends to 10 rolls.

Accessory Store


The receiving of accessories is same as fabric but the section that stocks accessories is different. Two shelves are joined together to form one stocking zone. They were numbered sequentially. The shelves were further given Bin No. in alphabetical order, and a Bin card is attached to the shelves which holds all the stocking information about the accessories stored.

The supervisors and the department manager sits in between the accessory store and the thread and thread store.

The order is received and tested and the counting of the units is done. Pasting the samples of all the accessories makes the Swatch card. This Swatch card is sent to the merchandiser for the approval.

Thread Store


The main supply of threads is from the Coats. The following products of Coats are stocked

The thread section has racks named after the floors in the sewing section, i.e. the shelves are labeled. Apart from that it also follows a sequence number

Interlining Store


The interlining store is situated near the accessories and thread store, with a gap of swatch preparation section in between.

The stocking is done with the help of bin card, which follows the same format as the fabric store.

The interlinings are mainly of 3 types, namely

· Paper fuse interlining

· Cotton fuse interlining

· Cotton non-fuse interlining.

Packing Material Store


The packing materials mainly boxes are stored in the area adjacent to the store department on the ground floor.

The boxes, which are flattened, are stocked one over the other. These boxes have the details printed on them beforehand.

Fabric Inspection


Number of inspection tables: 02

Number of operators on each inspection table

(For Loading/Checking/Unloading):02

Light levels for Fabric Inspection machine
Inspection Equipment

The fabric examining machine with variable speed control, overhead light (daylight bulbs) and yardage counter. The machine must be clean with no oil and sharp edges to damage the fabric.

How much fabric to inspect

The garment making factory should inspect 10% of rolls from each delivery at random this should include all colors and dyelots within a delivery.

If the results show a high fault rate, then an additional 15% rolls should be inspected.

If these fail, the delivery is either rejected or 100% inspected.

Procedure
At the beginning of each roll, a 6” full cutting should be taken as a color reference and checked for side-to-side and side-to-center shading.

This is labeled with fabric reference number or name, batch number, piece number, color number, color name and date.

Width of the fabric between the stenter pins must be measured and compared with the given minimum usable width.

Each roll checked must be stopped at least 3 times during inspection (beginning, middle, end). At these points, side-to-side and side-to-center shading should be assessed.

Side-to-end shading must be checked by comparing the full width cutting to a point in the roll. Also the cutable width (between the stenter pins) should be measured.

The cutable width should be recorded on the inspection report, as should any color shading detected.

Check the fabric length stated on piece ticket against the actual length of roll for variance. Record both the values.

Apart from these defects, the fabric is also tested for shrinkage, color fastness, and the shade variation (through light box), within a roll and between two rolls.

Sampling


The sampling department works to make the sample as per requirements laid down by the merchandisers as per the buyer’s request. The work done is specifically for buyer orders and sampling of the company’s own brand, is done by the respective designer.

The sampling department receives the specifications sheet from the merchandiser, which carries the buyer’s requirements. The work then starts with the development of the pattern according to the specified styling and the specifications. The operators are employed for the making of the garments. The garments, in most cases, are shirts as the particular unit deals mainly with shirts.

The Development sample is then sent to the buyer through the merchandiser, who makes necessary changes in the provided sample. Then again a sample is produced and after finalization of the sample, or approval by the buyer, a production sample is produced. This pattern is accepted for the production purpose.

There are in all 5 pattern masters and 6 assistant pattern masters assist them. The pattern masters make patterns for according to the buyer’s specifications and also approve the patterns after grading from the CAD system.

The sampling department makes as many as 70 pieces per day, which accounts to an average of 3-4 pieces per operator per day. The operator efficiency is 65% and they are recruited on the basis of sewing test, in which they have to make a shirt, which is tested by the respective authority and the operator is selected or rejected.

The sampling department gets 18 yards of fabric from the merchandising department for the development of the shirt samples. The issue of the fabric is maintained in a register and also the swatches of the issued fabric are pasted on a register page. This format of keeping the record of issued fabric holds the style name, the buyer’s name and the length of the fabric received.

The sampling department gets the request from the merchandiser to make certain number of samples of a particular type, for this the following format

A tag is put on the sample indicating that it as made by the sampling department and is only for the purpose of merchandiser sample, this tag is of either of the 2 types, for development sample or for the promotional sample. In most of the cases, the sample is of the development type. The development tag has the following format

The plotter has two small bulbs; the yellow bulbs indicate a machine problem and the red bulb lights up when the machine stops. For controlling the machine, there are 2 buttons, the green button is used for starting the machine and the red one is used for stopping the machine. Apart from these, there is a reset knob that is used to reset the position of the plotter head.

Once the marker is made the details are written on it and then it is stocked before being sent to the pattern master for approval.

Engr. Kh. Mashiur Rahman Email: garmentspedia@gmail.com

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