Practical Process of RMG Industry

What is Pre-Production Activities and Bulk Washing ?

Pre-Production Activities


1. Obtain vendor allocation from PDNS.

2. Review product feasibility based on vendor capability and capacity.

3. Receive all samples and review for risk analysis.

4. Negotiate and finalize finish cost with the vendor and share the same to SSM.

5. Establish lead time and capacity based on finishes with vendor and communicate the same to SSM.

6. Prepare risk analysis points and discuss with PD and QA for alignment and closure.

7. SSM places final orders with the vendor.

8. FE to work out TNA with vendor for finishing based on finishes, capacity available and ex-factory required.

9. SSM receives sealer sample from PD.

10. FE to review all sealer samples with SSM to ensure risk analysis closures.

11. SSM hand over the samples to vendor.

12. Bulk vendor calls for initial yardage to make the size set.

13. Size set washed as per sealer sample.

14. FE reviews and sends the sample for approval.

15. Vendor gets the bulk fabric.

16. Vendor makes the blanket.

Blanket Activity


1. Sewing vendor has to ensure that the shade blanket is washed in the same laundry where the bulk is planned.

2. Laundry needs to document the wash recipe for future reference.

3. Laundry In Charge will do the grouping of the rolls on the basis of shades and mark in the blanket ( A, B, C etc ) (rejected shades will be communicated to sewing not proceed with cutting).

4. Any variation from the master blanket needs to be verified from the mill / fabric team at this stage only. (reworkable shades to be taken trial separately in bulk and bring closer to std).

5. Any decision taken on shade or effect in spite of difference showing in bulk fabric & master roll fabric has to be authenticated in the garment from by the  Finish engineers


Pilot Run



1. Vendor has to ensure to provide at least 2-3 loads at the start of the bulk washing.

2. The number of the loads will be decided on the basis of order quantity and the machine capacity.

3. The pilot run pcs has to be from all shades --- all garments to be marked & details to be provided to the laundry.

4. The laundry will take the first load which will comprise of all shades as marked. Laundry will ensure that they load the maximum number of pieces from the shade close to the master blanket & lesser number of pieces from shades away from the master shade.

5. Laundry will start washing these 2-3 loads & segregate shades as per the original & will ensure any shade completely out of acceptable range will be reworked to bring the shade within the acceptable limit.

6. From these 2-3 loads Laundry will offer a range for F( Finish ) T( Tolerance ) L( Limit ) within a reasonable acceptable range.

7. The submit has to cover all possible detailing in the garment in that particular finish such as shade , dry Process , spray intensity etc.

8. LS&Co will seal the sample, numbered the pieces and send back to vendor, clearly mentioning on each garment for which purpose the garment is singed off.

9. From these 2-3 loads Laundry will also send pieces for bulk GPT testing.


Bulk Washing


1. The laundry will start bulk washing only on the receipt of a pass GPT. No bulk washing should start without a pass GPT.

2. The laundry will start bulk washing on the basis of the FTL (if any shades resulting out of Ftl range can't be rework able to be rejected self by vendor).

3. This FTL will be the only tool for bulk inspection for wash in laundry as well for FI for the QA.

4. Laundry will ensure to maintain all parameters in bulk so that the shades are all within the FTL.

5. Laundry will make sure to do random testing internally to ensure all parameters are met (if any failure, it has to be brought to LSIL notice).

6. Laundry to audit the final garments and only garments which meet the FTL will be sent to the packing section.


P.P.N


P.P.N Solution is a highly effective solution for neutralizing Potassium Permanagante treated denim garments. It is used as a neutaliser to produce snow white effect on denims. The whiteness achieved by P.P.N is much more than any other neutaliser like SBS, Hydrogen Peoxide etc.


ADVANTAGES OF USING P.P.N


· Instantaneous discharge, with improved whiteness.

· Compatible with most of the fabric softners & Silicon softners*.

· Odouorless. Hence no further wash is required.

· Water, Energy & Time Savings

· Eco-friendly.

· It can also act as a resit agent (For Potassium Permanganate).


PHYSICAL PROPERTIES OF P.P.N


· Colourless & Odourless Liquid.

· Ph = 3 to 4.5.


APPLICATION OF P.P.N IN DRUM WASHER


· Temperature = Room Temperature

· Dosage = 1.5% of the dry weight of garments

· Time = 10 Min to 20 Min


After satisfactory neutalisation of PP, water can be drained out. There is no need for further wash. In the next bath itself softner, silicon can be added.


PACKING


P.P.N is available in 35 Kg carboys to suit customer needs.


* Prior compatibility should be tested

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

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