2. We are following the special guidelines in
below process to improve the Garments
dye process;
01.Fabrics Mill Process
02.Factory In house Raw materials
inspection process
03.Cutting process
04.Production Process
05.Washing Process
06.Finishing Process
3. 01.Fabrics Mill Process :
a. Factory arrange the Grieg and prepare for the PFD
(Prepare For Dye) to tested the PH.
b. Factory will send the each dye lot fabric sample before the
shipment to factory for repeat lot variation get approval the
shade .
c. As per the each dye lot factory will prepare shade band
from each lot 5 to 7 shade variation this will represent for
bulk production.
d. Factory will sending each lot shade variation (5 to 7) to
buyer for get the shade approval.
e. If bulk shade variation within the approved shade factory
will resubmit to buyer any additional shade required.
d. After finalize shade with buyer factory are responsible to
4. 02. In house raw materials inspection process :
a. After we receive the fabrics we do the inventory with a packing list and booking.
b. We do separate all the fabrics rolls based on mill mention dye lots at Packing list .
c. We do the raw materials inspection as per the Company SOP. (Fabrics inspection ,
Shrinkage , Weight test and Shade separation).
d. After separate the fabrics roll according to the mill lot wise we calculate our PO
order quantity and color wise quantity which for the required fabrics yards for the
each color.
e. After calculating the required color wise yards we distribute the mill lot wise
quantity accordingly (We ensure the maximum one lot to distribute to the one color
for easy controlling the shade).
f. We do the blanket two set each fabrics lot and we write down the each blanket roll
number , serial number and roll length for easy identify before and after wash.
g. So based on the garments dye wash recipe we do the blanket washing in each color
and after wash separate the shades by A,B ,C etc within one color and one lot blanket,
according to blanket we do separate all fabrics roll within a lot.
h. After Finalizing the color wise yards and finalize the lot wise shades we do shades
separation reports mentioned by Color , serial number roll number and yards
according to the separation reports we issue the fabrics to cutting.
5. 03. Cutting process :
a. Receive the fabrics required yds as per the cutting plan PO , color
and size ratio wise .
b. Start the cutting according to the shade separation reports .
c. Do the layering chart according to the shade separation reports
and raminantes mention yds each roll number and shade number
balance yds for the future reference.
d. Do the numbering to identify Cutting number , size and parts
serial number and bundle card for each bundle mention buyer name
, style number , parts name , size , shade , serial number .
e. Maintain the cutting register PO , color and ratio wise and issue
register with PO , Color, ratio and shade wise.
f. We do cutting each PO , Color wise so each colors are not mixing
each other in cutting sections , sewing and washing as much as
possible in finishing. We issue the input accordingly.
6. 04. Sewing process :
a. Receive the PO , Color and size ratio quantity and maintain
the input output register accordingly .
b. Apply the shade separation label A , B, C etc for the each
garments for easy identify for shade separation according to
the cutting details.
c. We follow different numbering method not to mix in each
color in a line due to the raw garments is white ,we follow
different shade label E,F, G etc for identify the color.
d. At the End line QC monitoring process , we not allow any
garments with uncut thread , loose thread within a garments
inside and outside.
d. In End line we do separate the shade wise bundle system
(each bundle will be 25 pcs) and we sent to washing
according to the shade system.
7. 05. Washing process :
a. Receive the bulk shades approval and PO color , size wise plan quantity .
b. Check the quantity , quality , shade label and separate accordingly
c. Allocate the person to select lot washing quantity according to the size
ratio and kept each lot separately with register.
d. The washing technician will do the washing in a particular lot as per the
garments dye washing recipe.
e. After wash the particular lot will check QC as per the approved washing
shades.
f. After wash each lot QC will maintain the washing records .
g. Any variation of particular lot any quantity they will separate according
to light to darker , that particular quantity (light or dark) do separate
washing to bring back to the approved standard.
h. The final particular lot will maintain as per the approved standard due
to this lot quantity as per the size ratio. So , there will not affect within a lot
different shade at finishing as well as the ratio pack.
i. After confirmation of the each lot with the approved standard , will send
to the finishing.
8. 06. Finishing process :
a. Receive the PO order quantity , color and size ratio wise with shipment schedule.
b. Received the bulk approved shade for clarify the production.
c. We allocated the team once received the washing they had to ensure the color and
size wise quantity and they ensure 100% garments check with approved shade.
d. After confirm the shades all the garments going thru the finishing layout process up
to the CTPAT .
e. At a CTPAT section we had allocated team to check the shades 100% garments and
they have to ensure the packing ratio.
f. After confirm the shade and ratio we have allocated the special team to ensure the
ratio quantity are within a approved shade and one carton one shade.
g. After confirmation their process carton packer allow the carton.
h. At Finishing section , any shade variation we found we get separate and re
corrected the washing according to the approved standard. And any non rectify shade
reject garments will take them CNCM box with color , size to fulfill the future Pos,
those CNCM quantity we dispose as per the company policy.
i. Internal Auditor are responsible to follow above the process and he will ensure Pre
final are according to the Target criteria before he will submit to PSQA
