SOP for Garments Fabric and Trims Store

20.5.16

Garments Fabric and Trims

Ensuring the required quality and quantity of the Garments Fabric and Trims store /Accessories is made available to the Production department just in time...

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To optimize more cut quantity which will boost the production of the Orders and be converted to extra shipments with the same efforts and more revenue to the company.

SOP of Fabric Warehouse

The quality of a final garment depends on the quality of a Garments Fabric when it is received as a roll. Even the most outstanding manufacturing methods cannot compensate for defective materials. Normally, we inspect 10% of the rolls we receive and evaluate them based on a four-point system.

Procedure

Key Points
Fabric Receipt from Nominated Supplier
Physical Counting of rolls
Compare the quantity with purchase order or invoice.
Any shortage/damaged packaging is informed to commercial dept, purchase dept and merchandiser.
Responsibilities & Jobs
All types of store ledger/Data base audit
Physical stock & inventory audit
Store evaluation by a common questionnaire
Problem & pitfall identification
Recommendation for improve quality of work.
(All the work would be done by in a common format/ formation)
Randomly number of 3/4 factory may selected for audit every month.
To ensure each roll has got the Supplier Stamp at the Head end.
To cut 20” of the full Width Fabric from the Head End for testing in LAB.
To Write the following Details on Both parts 1) 20” Head End 2) Balance Fabric Roll
Give the Cut Head Ends to the Fabric Manager with memo mentioning the Invoice # & Qty.
Each Roll at the time of head end cutting has been given a unique software printed tag having specified information printed on it.
Monoprix accessories delivery registers.
Bill register.
Shipment voucher + get pass.
Local voucher.
Cubus accessories delivery registers.
Jules accessories delivery registers.
Stradivarius accessories delivery registers.
Finex thread received voucher file.
Domain thread syntax industries
Button received voucher file.
Button requisition file.
Bill file.
This code is referred as during further processes of Garments Fabric inspection, shade segregation, warehouse keeping, issuing, and cutting.
Fabric Inspection : Fabric Inspection is done by American 4 Point System
4 Point System of Fabric Inspection : No of roll selection - 10% of the shipment.
Once the Garments Fabric inspection, shade segragation and lab testings are passed then the fabric is kept in ware house as per Auto wise, color wise and shade wise.
Shade wise inventory is maintained in register as well as in Computer system.

SOP for Trims Store

1st thing is physically counting of the no. of packages received e.g. No. Carton / Bales / Sacks received.
Then compare the quantity mentioned on the packs multiplied with number of packs, with the the quantity mentioned on packing list or invoice. Any loss, damage or open boxes is informed to commercial dept, purchase dept and merchandiser.
Store Keeper prepares and signs a Goods received note or GRN in which Name of the item, actual quantity received is clearly mentioned and also he mentions the identification mark of the shortage i.e. Carton No., Bale no. etc. and gives a copy to commercial dept.

Maintenance Store

Electric DB board registers.
Electric switch board registers.
Electric light panel register.
Wash room light register.
Cargo lifts register.
I.P.S and Emergency light register.
Ceiling fan check registers.
Exhaust fan check register.
Machine oil checks register.
Machine servicing register.
Air condition servicing register.
Electrical equipment registers.
Tools distribution and uses register.
Spare parts used register.

SOP Of Trims Inspection

Trim Card : before starting inspection, QC in the store collects Merchandiser Approved Trim Card* and compare the Trims with Trim Card
Trim Card is a collection of all the trims used in a particular style pasted together in a card board for approval and referance.
First QC checks and compares the trims with trim chart she checks the style no. Auto no. etc.
QC Randomly takes 10% of the trims and transfers to the trims inspection bin where QC is doing the inspection for quality of the trims.She compares the quality with merchandiser’s trim chart.
And prepares a quality inspection report duly signed by Store Manager and QA Manager.
If it is approved from the merchandiser then 6 pcs of each item is sent to merchandiser to prepare Trim chart for Production reference. And all the trims goes to inventory.
If the inspection is rejected re-inspection is done for 100% trims.If pass goes to inventory if not the whole lot is rejected and report is sent to merchandiser.

Quality Checks for Sewing Trims

Zipper – color, length, puller, working condition etc
Label – print quality, color, size etc
Button – broken, without hole, color, size, thickness etc
Thread – color, no. of ply, tkt no. etc
RROW STICKER
ART LINE MARKER
BALL PEN (RED)
BALL PEN (BLACK)
CLIP BOARD
CALCULATOR
CARBON PAPER
COAT BRUSH
EMARY PAPER
ERASER
FOAM
GLUE GUM
LEATHER BOARD
LECO PLAST
MAGAZIN FILE
MAGIC CHALK
MARKER PEN
MANOLA BOARD
MARKING BOARD
MASKIN TAPE
MASTER GUM
MASUREMENT TAP.
MILLAT POWDER
NOTE BOOK
NUMBER STICKER
OFFICE FILE
PUNCH MACHINE
PERSONNEL FILE
PLASTIC BUSKET
TOOTH BRUSH
CELLO PEN
PENCIL 4H
PENCIL 2H
PENCIL 2B
PENCIL 3B
PENCIL 4B
WHITE PENCIL
PENCIL HB
SLEEPER (MENS)
SLEEPER (LADIES)
Elastic – width, stretchability
Twill Tape – width, weave structure, color
Labels – size,color,print quality
Hang Tags – size,color,print, string
Stickers – gum strength, color, size print quality etc
Sizer – Print quality, size.
Polybag – measurement, print quality

Quality Check for Accessories

Belt – length, width, color buckle quality etc. On receipt of goods they prepares inspection shortage report in case of no discrepancy in quantities is observed the inspection shortage report shall show the variance as nil. And forward the inspection shortage report to commercial and also to the concern merchandiser.

Qualification of Store Staff

Store GM - Degree in Masters, Minimum Experience of 10yrs in store and logistics

Store Manager - Degree in Masters , Minimum Experience of 05yrs in store and logistics

Store Executive - Degree in Bachelors, Minimum Experience of 03yrs in Store

Store QC-Minimum SSC, Fresh Recruited and Passed Undergone Auto Training

Store Keeper -Minimum SSC, Fresh Recruited and Passed 01 month on job training under

Time and Action Calender

Activity Time Line

Goods Receipt Note and Inventory 02 Days

Trims 10% Inspection 02 Days

Warehouse – Trims Storing item wise 01 Day

Ware house – Fabric Storing Color/ Shade wise 02 Day consumption wise as per requisition 05 Hrs

Trims Issue as per cut bundle sheet 02 Hrs

Evaluation Methodology

Simple System of evaluation by means of getting audit by departments other than store
Every Week system Audit for housekeeping, working system of stores, QCs and ware house keeping.
Accessories received register.
Accessories received file.
Accessories requisition file sewing and finishing.
Zara accessories delivery registers.
Gum tape received voucher file.
Gum tape requisition file.
Lock pin received voucher file.
Lock pin requisition file.
Voucher book
Tag pin requisition file.
Sewing thread P.I file.
Daily Lab audit for ware house racks, to verify identification tags of shades and colors of fabric and if trims are kept as per bin card.
Crosschecking of performance of fabric inspection QCs and trims inspection QCs by production floor QCs

Assessing Performance after Evaluation and Reward

Team for Assessmennt
CEO
ACEO
GM Production
GM Quality
GM HR and ADMIN

Method:Every Saturday at 11.00am, along with top management the reports of audits are reveiwed. Necessary guidelines, steps and actions are taken to improve performance of each individual.

Reward: Persons performing excellent are been rewarded every week by offering to have lunch with CEO of company. Moral Boosting and Self Esteem. Special Renumeration and Promotions

Defining New Targets

Management decides new target based on
Assessment and progress
Need of new systems on the basis of market competion
Update in infrastructre
Update of Customer Policy
Central Store
Accessories received issue & stock ( For all buyer)
Trim card send register.
Accessories delivery registers for floor.
Accessories received file.
Accessories requisition file.
Accessories delivery registers.
Hanger + seizer register.
Jc accessories issue register.
Action on New Target
Management support by providing edequated resources and infrastructure
Education and Training
Follow up by doing in time audits
Counseling for Garments Fabric and Trims Store

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