GOUS UPDATE SOP MANUAL

Gous Fashion Industries Ltd.
Standard Operating Procedure.
1
SOP – gfil property
GFIL.ORG.01
Version # 3
Issue Date : Feb02, 2013
Revision Date : March20, 2014
Organization Chart

2
GFIL.WFD.01
Version # 3
GFIL Work Flow Diagram

3

4
GFIL.QMS.ORG.01
Version # 3
GFIL QA Organ gram Chart

5
GFIL.QMS.WFD.01
Version # 3
GFIL QA Work Flow Diagram
Fabric Inspection Department.
01.Fabric inspection
,10%
02.Fabric Shrinkage
Test, 10%
03.Fabric Weight Test,
10%
04.Fabric Shade & Grade
Separation,
100% w ash blanket
Inventory
Accessories Inspection Department.
01.Acc. Inspection ,
10%
02.Carton Inspection,
10%
03.Barcode Scanning Report.Test,
10%
Inventory
Cutting Department
01.Fabric Relax
02. Marker Checking ,
100%
03.Spreading
Inspection
04.Cutting Marking
Check,
05.Cut Panel &
Bundle Inspection.
100% For Big parts

6
Sewing Department
01.Process
Check- Front
& Back Part
Inspection.
02.Final End
Table
Inspection
03.
Measurement
04.Hourly Lot
Pass
Inspection-
A.Q.L-1.5.
05.Daily
Defect
Analysis
06.Daily
Wash Repo,
10%rts
07.Weekly
Quality Goals
08. Traffic
Light Chart
w ith Process
Mock-up
09.Stitch
Monitoring
P.P. Meeting / 1st output
Meeting / Pilot Run Meeting
Finishing Department
01.Process
Inspection.
02.Final End
Table Inspection
03.Hourly Lot
Pass Inspection-
A.Q.L-1.5
04.Daily Iron
Defect
Identification
05.Weekly
Quality Goals
06.Daily Carton
Audit – A.Q.L.-
2.5,Level-1
07.Pre-Final
Inspection-
A.Q.L-.2.5,Level-
1
08. Key Point
Measurement

7
GFIL.DDC.PRO.01
Version # 3
5. Documents, Samples& Data Control
1. Purpose & Scope:
To give a clear guideline to the concerned personnel to use and control the documents
used in each department. This procedure is a “controlled” document and authorized for
use. Before using a printed copy of this document, it should be ensured that it is the
most up to date version by checking the date and version numbers with the Document
Control Department. Unauthorized changes to the document and overwriting or using
fluid are strictly prohibited. This policy specifies how important documents (hardcopy,
online or other media) should be controlled, distributed, retained, protected and disposed.
The policy also ensures that:
a) Necessary and important documents are preserved for future reference
b) Documents that are not necessary are destroyed to avoid any confusion
c) Documents are easily accessible
d) Documents are of current version, executed, controlled and clearly defined how,
where and who will be responsible to control and dispose the documents
2. To successfully implement the operational procedures the Factory HR and FE
Departments must assure the following:
a) Implement the policy in correct way and ensure its functional activities.
b) Educate all concerned persons about the policy and organize the training for all
respective departments to execute the policy at all stagesfully and efficiently.
c) Regularly monitor to ensure the documents are segregated, retained and disposed
as per the policy.
d) Regularly monitor the Document destruction procedure (must be maintained as per
the local law) and Collect the destruction form with evidence from the respective
departments.
e) That the retained documents are easily accessible.
f) Any need to change or modifyany of the procedure and related documents must be
approved through a meeting with the presence of the Managing Director.
g) Conductat least one yearly meeting including Managing Director to review the
implementation and execution of the procedures.
3. Responsibilities:
Each department head and other relevant personnel are responsible for the control,
distribution (if applicable) and handling of their respective departments’ documents. The
Managing Director of in consultation with individual department heads will categorize the
types of documents/records that need to be maintained and will assign retention periods
upon periodic review of company policies and procedures. All forms used in the day to
day activities must be controlled as per the general document control policy, however the
authorized person to make changes will be the Chief Operating Officer after consulting
with the Department Heads.

8
All revisions to forms must be made after consultation with the heads of the relevant
departments.
All running production related documents must be kept in their specific area with the
identification and after completion of an order [final shipment] all documents should be
shifted to Documents Control Room.
GFILemploys responsible personsbearing the designation ofDocuments Controllerswho
are responsible to collect the obsolete documents, organize the entire Documents
Control Room, which is located on the 3rd floor besides the Managing Director’s room.
The designated room is identified by a signage as ‘Documents Control Room’.
Persons authorized toaccess and use the Document Control Room are listed andvisibly
posted at theentry gate of the room.
The Document Controller will retain the documents, maintain the records and dispose the
documents with evidence maintaining the relevant company policy and procedures.
Manager, Technical Compliance & Auditis responsible to make sure the policies and
procedures are implemented and controlled. If any non-compliance issues arise in any
area the Manager, Technical Compliance & Auditwill issue a Non Conformance slip and
report the same to the Factory COO and the Managing Director.
Controlled documents are found as mentioned in the master list of controlled document.
4. Document Control:
4.1 Document Coding:
4.1.1 The documents are numbered in the form of GFIL.AAA.BBB.##, where:
4.1.1.1 GFIL stands for Gous Fashion Industries Ltd.
4.1.1.2 AAA is the department code.
• DDC Document & Date Control
• MKT Marketing
• MER Merchandising
• HRM Human Resources
• TCA Technical Compliance & Audit
• SCP Social Compliance
• QMS Quality Management
• QAS Quality Assurance
• QCS Quality Control
• ICQ Incoming Quality Control
• PQT Pre-final Quality Team
• SPL Sample
• SEW Sewing
• CUT Cutting
• FIN Finishing
• TST Testing
• IVS Inventory & Stores
• MNT Maintenance

9
• IEP Industrial Engineering & Planning
• TCT Technical Team
• ICT Information Technology & Communication
• FAD Finance & Accounts
• CCA Cost Control & Internal Audit
• COM Commercial
• CLA Corporate & Legal Affairs
4.1.1.3 BBB is the document level, represented by 2 or 3 letters.
• ORG Organization charts
• WFD Work flow diagrams
• PRO Procedure
• WI Work Instruction
• QP Quality Plan
• FRM Format
• LST List
• FL File
• MNC Memos & Notices
• MMT Meeting Minutes
• NCM Non Conforming material record
• NCS Non Conformance Slip
• CLB Calibration documents
• CAP Corrective action plan
• SNG Digital printed signage
4.1.1.4 ## is the individual document number, starting from 01.
4.1.1.5 Revision of document:
Whenever a new document is first created it is identified as version
1. As changes are made to the same document when any update
or correction is implemented by Managing Director or by a buyer,
the document version changes incrementally. For example, after a
change is made to the first document, the version changes to 2
and will continue incrementally.
4.2 Document Authorization and Approval:
GFIL has approved certain personnel who are authorized signatories and also
responsible to initiate anddistribute related documents in their respective
departments and as appropriate. They are called Authorised Document
Controllers.
Any new or revision requirement of any document must be prepared in
consultation with the Manager TC&A.

10
All new or revised documents must be crossed checked thoroughly, signed,
dated, the version number must be included by the authorized personnel as stated
in the list of AuthorisedDocument Controllers below. For revised documents the
old versions must be recalled and made obsolete as per the Control of Obsolete
Documents procedure for ensuring the use of current and up to date versions
only.
All new or revised documents must be submitted to the Manager TC&A who will
review, sign and acquire final approval from the Managing Director prior to
distribution.
In case of emergency and in absence of the Managing Director the COO may
provide temporary approval but the final approval must be acquired by the
Managing Director as soon he / she is available.
Please see the list of AuthorisedDocument Controllers below.
Sl. No. Section Name
Authorised
Documents
Controller
Designation
01. Information & Technology(IT)
SM Shameem Iqbal Managing Director
02. Finance & Accountants (FAD)
03.
CostControl & Internal Audit
(CCA)
04. Commercial (COM)
05.
Corporate & Legal Affairs
(CLA)
06. Marketing (MKT)
Khurshid Alam COO
07. Merchandising (MER)
08. Cutting (CUT)
Mokter Ahmmed GM
09. Sewing (SEW)
10. Finishing (FIN)
11. Maintenance (MNT)
12. Inventory & Stores (IVS)
13. Human Resources (HRM)
Nurul Huq
Manager – HR &
Admin14. Social Compliance (SCP)
15.
Technical Compliance & Audit
(TCA)
Sujan Barua
Manager – Technical
Compliance & Audit
16.
Quality ManagementSystem
(QMS)
Sarwar Kamal
Sr. Manager – Quality
Assurance17. Quality Assurance (QAS)
18. Quality Control (QCS)
4.3 Control of Obsolete Document:
Whenever a document is revised or becomes obsolete as notified by the
Authorised Document Controllers or any relevant authority as maybe appropriate it
must be ntified to the Manager of TC&A.
The Manager TC&A will recall the document from relevantsections of the operation
and make it obsolete by putting an OBSOLETE stamp on it.

11
If there is a new version of a document, it is distributed following the Revision of
Documents procedure. At the same time the obsolete document is removed from
use.
The Manager TC&A is responsible to ensure the management of obsolete
documents as per the above procedure.
4.4 Revision [amendment] of Documents:
4.4.1 The Authorised Document Controller is responsible to identify the need for any
change required in any document and initiate process of revision.
4.4.2 The document number is given an extension with “ – “followed by the change
number.
4.4.3 Revised document is prepared by Authorised Document Controller and submitted
to Manager TC&A for approval.
4.4.4 All the revised / amended documents are distributed according to the Clause # 4.5.
4.5 Document Distribution:
Authorised personnel can only initiate distribution of new or revised documents
after acquiring approval from Manager TC&A and the Managing Director as stated
in 4.3.
Once the Managing Director has approved the new or revised document the
Manager TC&A will hand it over to the respective Authorised Document Controller
who shall then conduct the distribution process.
The Authorised Document Controller must acquire acknowledgment from any
personnel the document is provided to and maintain such record at his own and
provide a copy of such acknowledgement to the Manager TC&A for record in the
document control system.
4.6 Closing, Storing, Disposal & Retention Period of Document:
4.6.1 When the last shipment of a Style is completed all related documents (SIP/PVP &
SOP files) and samples are collected and the file is closed for that Style. And It will
be OBSOLETE, Once the document is closed, it cannot be retrieved without the
approval of the Managing Director.
4.6.2 All Production Documents and Samples are gathered together and stored in
document control room. There will be a check list posted in document control room
for the identification to find details of style, production start date, last shipment
date, document retentions period and disposal date of the document. The same
information will be mentioned on the file as well.
4.6.3 All documents are to be disposed after the retention period as per local disposal
law.
4.6.4 Hardcopy of documents shall be shredded after they have been retained until the
end of the Document Retention Schedule. Digital copies will be destroyed by
formatting the hard-drive/ storage media. Stored Media such as CDs, DVDs, etc
will be destroyed by proven means to destroy such media after they have been
retained until the end of the Document Retention Schedule.
we will designate any disaster area, documents – will be sold at Paper mill for
recycling purpose or will burn for maintaining the local environment law and take a
digital images for evidence and all disposing items name should be enclosed at
Documents destruction form with time period.
4.6.5 A designated area shall be provided in the Store to store documents that shall be
disposed or destroyed eventually.
4.6.6 Paper documents maybe sold to the local paper mills or its representatives for
recycle purpose maintaining local and environmental laws.

12
4.6.7 Digital image shall be taken and updated on the Document Destruction Form for all
disposal and destruction activities of documents.
4.6.8 Any document being disposed must be updated and listed in the Documents
Destruction Form.All such forms shall be filed and kept in theDocuments Control
Room.
4.6.9 The Manager TC&A is authorized to conduct the destruction of any document and
may seek the assistance of Inventory & Store personnel besides his / her own
team for the task.
4.6.10 Relevant Document: Documents Destruction Form – GFIL.DDC.FRM.01
4.7. Accessibility of Documents:
4.7.1 The current and updated version of all documents must be readily available at the
Document Control Room in custody of the Manager TC&A. The TC&A shall
provide such documents when requested by the Authorised Document Controller
for his / her respective department.
4.7.2. All documents shall be printed, implemented, distributed and retained according to
the Master List of Documents. The Manager TC&A must ensure that the Master
List of Documents is always updated and current and none of the old or revised
documents are found anywhere in the company once the new or revised version
has been circulated / distributed.
4.7.3 A copy of any unused, old and modified documents shall be kept in Documents
Control Room for record but clearly marked and stampedas OBSOLETE
Documents.

13
GFIL.DDC.MLD.01
Version # 3
Issue Date: 02 Feb 2013
Revision Date: 20 March 2014
6. Master List of Controlled Documents:
Sl.
No. Section
Documents Types
Documents
Types
Version Documents ID Issue Id Retention
Period
1
Merchandising
Pvp / Sip / Master
File Including All
Testing Results
Master file 1 GFIL.MER.FL. 01 16.02.2014
Five (05)
Years
2
Monthly Shipment
Tracking Sheet
Form 1
GFIL.MER.FRM. 02
16.02.2014
Tw o (02)
Years
3
Suppliers
Performance
Evaluation Form
Form
1
GFIL.MER.FRM. 03
16.02.2014
Tw o (02)
Years
4 ApprovalSample Sample 1 GFIL.MER.SPL 04 16.02.2014
Five (05)
Years
5
Vendor
Recertification
Notices
Certificate 1 GFIL.MER.CR. 05 16.02.2014
Five (05)
Years
6 Production Test Plan Form 2 GFIL.MER.FRM 06 10.03.2014
Five (05)
Years
7
Stores
Requisition Form 1 GFIL.IVS.FRM.01 01.03.2013
One (01)
Year
8
Blunt/Broken Needle
Log Book
Form 3 GFIL.IVS.FRM.02 12.2.2014 One (01)
Year
9
Needle Exchange
Log Book
Register 2 GFIL.IVS.FRM.03 12.2.2014
One (01)
Year
10
Needle Exchange
Request Form
Form 2 GFIL.IVS.FRM.04 12.2.2014
One (01)
Year
11
Needle Stock
Register
Register 1 GFIL.IVS.REG.05 01.03.2013
One (01)
Year
12
Needle StockRecord Form 2 GFIL.IVS.FRM.05A 12/2/2014
One (01)
Year
13
Fabric Register Book Register 1 GFIL.IVS.REG.06 01.03.2013
One (01)
Year
14
Accessories Register
Book
One (01)
Year
15
Bin Card Form 2 GFIL.IVS.FRM.08 20.03.2014
One (01)
Year
16
Inventory Card Form 1 GFIL.IVS.FRM.09 01.03.2013
Tw o (02)
Years
17
Purchase Requisition Form 1 GFIL.IVS.FRM.10 01.03.2013
One (01)
Year

14
18
Delivery Challan/
Gate Pass
One (01)
Year
19
Re-Issue Form For
Missing Broken
Needle
Form 3 GFIL.IVS.FRM.14A 12.2.2014
One (01)
Year
20
Inventory Report Form 2 GFIL.IVS.FRM.15 16.07.2013
Tw o (02)
Years
21
Non Confirming Item
Receive Register
One (01)
Year
22
Security register for
Out Bound Goods
Form 2 GFIL.IVS.REG.17 1.7.2013
Tw o (02)
Years
23
Shipment Register Register 1 GFIL.IVS.REG.18 01.03.2013
Tw o (02)
Years
24
Spare Parts Register
Book
One (01)
Year
25
Stationary Register
Book
One (01)
Year
26
Electrical Register
Book
Register 1 GFIL.IVS.REG .21 01.03.2013
One (01)
Year
27
Bolt Seal Register Register 1 GFIL.IVS.REG.22 01.03.2013
One (01)
Year
28
Wash Send & Rcv
Report
One (01)
Year
29
Thread Recvd &
Issue Register
One (01)
Year
30
Finishing
Accessories Rcvd &
Issue Reg
One (01)
Year
31
Needle Display Display 2 GFIL.IVS.DPL.01 03.07.2014
One (01)
Year
32
Fabrics and
Accessories
Inspection
Fabric Shrinkage
Test Report
Form 1 GFIL.QCS.FRM.02 3/2/2013
Five (05)
Years
33
Fabric Inspection
Report(4 Point
System)
Five (05)
Years
34
Fabric Weight Report Form 1 GFIL.QCS.FRM.03 3/2/2013
Five (05)
Years
35
Measurement Tape
Calibration Report
Form 1 GFIL.CLB.FRM.08 3/2/2013
Tw o (02)
Years
36
Non-Conforming
Fabric Records
Form 2 GFIL.NCM.FRM.07 3/2/2013
Tw o (02)
Years
37
Accessories
Inspection Report
Five (05)
Years
38
10% Inspection
Reject Trims
Register .
Tw o (02)
Years

15
39
Light Box Log
Register
Form 2 GFIL.QCS.FRM.06 01.03.2014
Tw o (02)
Years
40
Shade Analyze
Report
Five(05)
Years
41
Barcode Scanning
Report
Five(05)
Years
42
Cutting
Section
Spreading Report
Cutting Section
Form 1 GFIL.CUT.FRM.01 01.03.2013
One (01)
Year
43
Cutting Number
Sheet
One (01)
Year
44
Po Size Wise Cutting
Details
One (01)
Year
45
Po Size/ Po Wise
Input Details
One (01)
Year
46
Cutting Report Form 1 GFIL.CUT.FRM.05 01.03.2013
One (01)
Year
47
Fusing Machine Test
Report
Form 2 GFIL.TST.FRM.06 15.04.2014
Five (05)
Years
48
Non Conforming
Materials
Form 1 GFIL.NCM.FRM.07 05.03.2013
Tw o (02)
Years
49
Line w ise Daily input
register
Reg 1 GFIL.CUT.REG.02 20.03.2014
One (01)
Year
50
PO / SIZE w ise
cutting plan and
consumption
One (01)
Year
51
Cutting QC
Qc Attendance
Register
Register 1 GFIL.QCS.REG.10 05.03.2013
One (01)
Year
52
Spreading Quality
Control Report
Five (05)
Years
53
100% Cutting
Inspection Report
Five (05)
Years
54
Cutting Spare Parts
Issue Register
Register 1 GFIL.CUT.REG.11 05.03.2013
One (01)
Year
55
Sharp Tools Control
Records
Register 1 GFIL.SPT.REG. 01 05.03.2013
One (01)
Year
56
Fabric Relaxation
Report
Tw o (02)
Years
57
Marker Inspection
Report
Form 1 GFIL.QCS.FRM.13A 05.03.2013
One (01)
Year
58
Cutting Quality
Control Report 100%
Five (05)
Years
59
Cutting Register Register 1 GFIL.CUT.REG.16 05.03.2013
One (01)
Year
60
Cutting Machine And
Hand Gloves
One (01)
Year

16
Register
61
Reject Part
Replacement
Register
One (01)
Year
62
Sew ing
Input Output Register Form 1 GFIL.SEW.REG.01 01.07.2013
One (01)
Year
63
Flagging Records Form 1 GFIL.SEW.FRM.02 01.07.2013
One (01)
Year
64
Line Wise Production
Status
Form 1 GFIL.SEW.FRM.03 20.03.2014
One (01)
Year
65
Daily Reject Report Form 1 GFIL.SEW.FRM.05
01.07.2013 One (01)
Year
66
Hourly Production
Report.
Form 1 GFIL.SEW.FRM.06
01.07.2013 One (01)
Year
67
Sharp Tools Control
Records
Form 1 GFIL.SPT.REG. 01 01.03.2013
One (01)
Year
68
Sew ing Quality
Measurement Spec
Sheet
Five (05)
Years
69
Quality Measurement
Checking Report
Form 2 GFIL.QCS.FRM.15A 08.03.2014
Five (05)
Years
70
Pre-Production
Meeting Report
Form 3 GFIL.PPE.FRM.16 10.03.2014
Five (05)
Years
71
First Piece Bulk
Production Review
With Sample
Form 3 GFIL.PPE.FRM.17 08.03.2014
Five (05)
Years
72
Pilot Run Form 1 GFIL.PPE.FRM.17A 15.02.2014
Five (05)
Years
73
Inline Process
Quality Reports/End
line Quality Reports
Five (05)
Years
74
Traffic Light System
Report
Form 1 GFIL.QMS.FRM.19 18.02.2014
One (01)
Year
75
Lot Pass Form 3 GFIL.QCS.FRM.20 08.03.2014
Five (05)
Years
76
Sew ing Quality
Daily Inline
Goals/Quality
Meeting And Cap
One (01)
Year
77
Daily And Weekly
Quality Defects
Analysis And Goals
Dg board 2 GFIL.QMS.DG. 21A 16.2.2014
One (01)
Year
78
Weekly Defects
Trend Analysis
Form 1 GFIL.QMS.FRM. 22 15.03.2014
One (01)
Year
79
Weekly Quality
Goals Meeting
Attendance Sheet
Form 2 GFIL.QMS.FRM. 22A 16.02.2014
One (01)
Year

17
80
Machine Setting
Report
Form 2 GFIL.SEW.FRM.11 15.2.2014
One (01)
Year
81
Stitch Monitoring
Records On Daily
Basis
Form 2 GFIL.QMS.FRM. 23 15.2.2014
One (01)
Year
82
Production Stop
Report Due To
Quality
Nonconformity
One (01)
Year
83
Weekly Quality
Goals
Form 1 GFIL.QCS.FRM.22B 20.03.2014
One (01)
Year
84
Defects
Classification
List 2 GFIL.QCS.DCL.25 01.03.2013
Five(05)
Years
86
Sew ing Quality
Style Start up check
list activities
Check List 1 GFIL.QCS.CL.26 20.03.2014
One (01)
Year
87
Daily Machine Check
Report
One (01)
Year
88
Process Mock -up Mock-up 1 GFIL.QMS.MOCK.01 20.03.2014
One (01)
Year
89
Finishing
Daily Thread Cutting
Report
Form 1 GFIL.FIN.FRM.01 1/3/2013
One (01)
Year
90
Daily Alter Repairing
For Line Report
Reg 1 GFIL.FIN.REG.02 1/3/2013
One (01)
Year
91
Daily Alter Repairing
For Finishing Report
Reg 1 GFIL.FIN.REG. 03 1/3/2013
One (01)
Year
92
Daily Reject Report Reg 1 GFIL.FIN.REG..04 1/3/2013
One (01)
Year
93
Daily Bar tack Alter
Report
One (01)
Year
94
Daily Iron Section
Production & Alter
Report
One (01)
Year
95
Daily Button
Attaching Production
& Alter Checking
Report
One (01)
Year
96
Daily Poly Report Form 1 GFIL.FIN.FRM.08 1/3/2013
One (01)
Year
97
Daily Finishing
Production Report
One (01)
Year
98
Hourly Production
Report
Form 1 GFIL.FIN.FRM.09A 20.03.32014
One (01)
Year
99
Sharp Tools Control
Records
Form 1 GFIL.SPT.REG. 01 1/3/2013
One (01)
Year
100
Daily Spot Removing
Register
Form 1 GFIL.FIN.FRM.10 20.03.2014
One (01)
Year

18
101
Broken Button
Register
Reg 1 GFILFIN.REG.05 07.07.2014
One (01)
Year
102
Finishing QC
Factory Quality Audit
Report
Five (05)
Years
103
Button / Snap Button
Pull Test Reports
Form 2 GFIL.TST.FRM. 02 09.03.2014
Five (05)
Years
104
Prefinal And Fri
Reports
Form 2 GFIL.QMS.FRM.01A 20.03.2014
Five (05)
Years
105
Metal Detector
Scanning Report
Form 2 GFIL.PSD.FRM.O3 03.02.2013
Five (05)
Years
106
Needle detector
calibration log
Form 3 GFIL.PSD.FRM.03A 20.03.2014
Five (05)
Years
107
Daily Spec Defects
Tally
One (01)
Year
108
Process Checking
Defects Tally
One (01)
Year
109
Daily Wash Check
Report
One (01)
Year
110
Hourly Lot Audit Form 1 GFIL.QCS.FRM.32 10.03.2014
One (01)
Year
111
Inside Process
Checking records
and repair register
One (01)
Year
112
Weekly Defects
Trend Analysis
Form 1 GFIL.QMS.FRM.22C 15.03.2014
One (01)
Year
113
Finishing
Accessories
AccuracyCheck
Tw o (02)
Years
114
Maintenance
Machine Stock
Register
Register 1 GFIL.MNT.REG.01 01.03.2014
Tw o (02)
Years
115
Machine Servicing
Register
Register 2 GFIL.MNT.REG.02 20.03.2014
Tw o (02)
Years
116
Machine Servicing
Card
Card 1 GFIL.MNT.CRD.01 01.03.2014
Tw o (02)
Years
117
Daily Machine Check
list
Form 1 GFIL.MNT.FRM.04 01.03.2014
One (01)
Year
118
Monthly Machine
Servicing Schedule
Form 1 GFIL.MNT.REG. 03 01.03.2014
One (01)
Year
119
Folder and tools
register
Reg 1 GFIL.MNT.REG.04 20.03.2014
One (01)
Year
120
Machine Rent
approval
One (01)
Year
121
Machine Transfer
Form
One (01)
Year

19
122
Documents
Control
Documents
Destruction Form
Form 1 GFIL.DDC.FRM. 01 10.03.2014
Five (05)
Years
123
Documents
Receiving
Confirmation
Form 2 GFIL.DCP.FRM.01 10.06.2014
One (01)
Year
124
Documents Check
List
Form 1 GFIL..DDC.CL.01 20.03.2014
Subject to
the
documents
retention
period
125
Documents Control
Register
Reg 1 GFIL.DDC.REG.01 20.03.2014
One (01)
Year
126
Training
Operator Training
Records
Form 1 GFIL.TRN.FRM.03 09.03.2014
One (01)
Year
127
Quality Training
Records
Form 1 GFIL.TRN.FRM. 04 09.03.2014
One (01)
Year
128
Maintenance
Training Records
Form 1 GFIL.TRN .FRM.05 09.03.2014
One (01)
Year
129 CARA
Corrective And
Remedial Action
Format 2 GFIL.CAP.FRM. 01 10.03.2014
Tw o (02)
Years
130 CNCM
All Sections CNCM
Records
Form 1 GFIL.NCM.FRM.07 05.03.2013
Tw o (02)
Years
131
LEFT OVER
AT ALL
SECTION
Left Over Register Reg 1 GFIL.IVS.REG.25 01.03.2014
Tw o (02)
Years
132
SWATCH
CARD
Trims Card Card 1 GFIL/SWC.01 15.03.2014
Five (05)
Years
133
Fabrics Shade Card Card 1 GFIL.MER .SWC.02 01.03.2014
Five (05)
Years
134
Process Mock-
up
Process mock-up Card 1 GFIL.QMS.MOCK.01 20.03.2014
One (01)
Year
135
SAMPLE
Sample Distribution
Register
Reg 1 GFIL.SPL.REG.01 01.03.2014
Five (05)
Years
136
Pattern & Marking
Distribution Register
Reg 1 GFIL.SPL.REG.02 01.03.2014
Five (05)
Years
137
First Fit/Second fit
approvalreport
Form 1 GFIL.SPL.FRM.03 01.03.2014
Five (05)
Years
138
Meeting
Minutes
Meeting minutes Form 1 GFIL.MMT.FRM.01 20.03.2014
One (01)
Year
139
List
Approved Suppliers
list
Form 1 GFIL.MER.LST.01 16.02.2014
One (01)
Year
140
Subcontractor List Form 1 GFIL.MER.LST.02 16.02.2014
One (01)
Year
141
PVP checklist Form 1 GFIL.MER.LST.03 20.03.2014
One (01)
Year
142
PP File Check List Form 1 GFIL.MER.LST.04 20.03.2014
One (01)
Year

20
143
Plan
Monthly Master Plan Form 1 GFIL.MER.PLN.01 01.03.2014
Five (05)
Years
144
Style w ise Plan Form 1 GFIL.MER.PLN.01A 01.03.2014
Five (05)
Years
145 Layout
Machine layout Form 2 GFIL.MER.LYT.01 20.03.2014
Five (05)
Years
146
Washing
Wash send and
receive register
Reg 1 GFIL.IVS.REG.26 01.03.2013
One (01)
Year
147
Floor w ise wash
garments receive
register
Reg 1 GFIL.IVS.REG.26A 01.03.2013
One (01)
Year
148
Wash garments hand
over register
Reg 1 GFIL.IVS.REG.26B 01.03.2013
One (01)
Year
GFIL.QMS.PRO.01
Version # 3
7. Quality Management
Purpose:
GFIL uses a quality management system that can be used by the top management to guide the
organization towards improved performance. GFIL quality policy is to achieve sustained, profitable
growth by providing services that consistently satisfy the needs and expectations of its customers. This
level of quality is achieved through adoption of a system of procedures that reflect the competence of
our company to existing customers, potential customers, and independent auditing authorities.
Responsibilities:
To achieve and maintain the required level of assurance the Managing Director retains responsibility for
the Quality Management System with routine operations controlled by the Quality Manager.
Procedure:
01. Assure all incoming raw materials are meet the safety rules and regulations . GFIL has
established the in house inspection system for all incoming raw materials before to start
production.
02. Organizing a Pre-production meeting and review the production test plan , sample, testing
results at P.P. meeting and meeting notes are communicate with all concern person for
reference.
03. Implementing the cutting inline inspection to control the defects rate at sewing.
04. Establish the Quality layout at sewing section such as In process and end line checking
procedure based on products it may be vary.
05. Provide the checking instruction to all inline check point and implement the Traffic light
system to control the defects rate and improve the quality level.

21
06. In house testing procedure (Shrinkage test, GSM test, button pull test etc.) are executed to
ensure the meet quality safety rules and regulations.
07. To allocate the inline checking procedure at finishing stage for confirm the packed goods
are meet the customers quality level.
Backup Quality Procedure:
Overview:
The factory keeps extra quality inspector trained on various process of several work. In the
event of shortage in QC coverage in any department, these QC’s are assigned as
replacements in any respective departments.
Purpose:
The purpose of this procedure is to establish and process for ensuring 100% quality coverage
for every production unit in every shift.
Scope:
In case of any emergency / migration, GFIL maintains a backup QC team to smoothly support
the regular work. Back up QC are mostly used in Sewing Quality and Cutting Quality. These
departments must always be facilitated by backup QC at all times.
Responsibility:
Floor Sewing Quality Controller / In Charge will be responsible to maintain attendance register
for QCs. In any absentees floor sewing quality controller need to follow the backup QC
procedure. Similarly cutting, store and finishing QC In Charge need to maintain QC attendance
registers and follow the procedure in case of any absentees. Quality manager has the
responsibility to ensure the procedure is followed.
Number of Backup QCs:
GFIL maintains a total of five [5] well trained Backup QCs, who are assigned to work under the
Finishing .
Backup QC Procedure:
1. A Backup QC register with name and ID no of the personnel must be maintained daily
by floor QC In Charge, Cutting QC In Chare, Store QC In Charge, Finishing QC In
Charge for the permanent station QCs.
2. Another register is maintained to record status of presence for the Backup QCs.
3. If any permanent assigned QC is on leave or absent than a Backup QC will be allotted
for the coverage of that shift.
Record of Revisions:
Version
Number
Date Section(s) Page(s) Summary of Changes Signature

22
GFIL.TRN.PRO.01
Version # 3
Employee Training Procedure
Purpose:
GFIL recognizes that to realize the vision of the company by pursuing its mission to ‘strive to earn
customer delight & trust by exceeding the quality and timeliness of our business commitments’ it needs
high quality human resources engaged at the various functions of the company. Therefore GFIL is
committed to continuously develop its human resources through training and coaching at all levels of
the structure to meet its goals.
This procedure outlines the methods of the training programs to improve the efficiency and productivity
of the employees of the company by focusing on the following:
 Develop and maintain a friendly working environment
 Freedom for all to be able to share opinions with their respective superiors without any
hesitation or apprehension of any kind
 Firm intent to increase the working skills of all concerned
 Building a strong team spirit
 Respect for the individual
 Striving for excellence
 Awareness of company policies and procedures and respectfully adhering to them
 Reduction of cost by eliminating waste at all aspects of operation
Scope:
This training and development procedure is particularly for the workers of GFIL.
Responsibility:
All training initiatives are from the HRD. The head of HRD is responsible to ensure that all its resources
are aligned toward achieving the goals of the company. He will thus identify all training needs in
consultation with department heads and design and administer all training programs through his
department and team.
Procedure:
The skill levels of workers from the production, quality and mechanical departments are particularly
assessed on a regular basis.
During the hiring process the initial skill levels are at first determined. This is done by testing the
workers on their particular jobs and from this test the workers are assigned a suitable grade based on a
scale between A (highest skill level) to E (lowest skill level). The results are then stored in the Initial Skill
Assessment Database. Depending on the individuals initial skill level a training curriculum is made for
the worker to improve their knowledge, efficiency and productivity. The following procedures should be
followed to select the trainees of different departments.
Our all training directed by Factory HR team and Factory Technical Compliance and audit team as a
result Training is very effective and fruitful.
We strongly believe that the main path to achieve the goals is Effective and efficient training in case of
develop the :
Gous Fashion has a monthly training calendar where clearly defined the training time , date , trainers
name , subjects and trainees section and Training are conducting maintaining the Calendar.

23
Objectives :
 Develop a skilled manpower.
 Develop multi skilled operators.
 Motivate all to take a initiatives to fix the issues.
 Make a plan and strongly agree to implement the plan in efficiently.
 Develop a friendly working environment.
 Implement the Right First time concept at all stages.
Trainees selection criteria:
Gous Fashion Industries Ltd. Select the trainees in several criteria such as ;
a) New workers :During the hiring process the initial skill levels are at first determined. This is
done by testing the workers on their particular job and from this test the workers are
assigned a suitable grade based on a scale between A (highest skill level) to E (lowest skill
level). Factory welfare officers and social compliance officers are responsible to share the
company policy , code of conduct, fire and safety policy , sharp tools controlling policy ,
leave and wages facilities , sharp tools controlling policy to all new workers .
b) Existing employees :The skill levels of workers from the production, quality and mechanical
departments are particularly assessed on a schedule basis.
Production:
Unit wise production manager are assigned to provide the training to operators and helpers. The
production floor employees are trained per the following processes:
1. The training department has to maintain the Production Worker Initial Skill Assessment
Database which specifies the initial skill levels of the operators who are able to operate different
types of sewing machines. The data is gathered during the hiring process and is used as an
initial skill level assessment guide.
2. Operators will be assigned an initial skill level (A, B, C, D, or E) based upon their ability to
operate different types of machines and also on the ability to perform different types of sewing
processes.
3. Initial Operators skills are assessed upon the ability to operate the following sewing machines:
a. Single Needle
b. Double Needle
c. Over-lock
d. Feed-Of-Arm
e. Kansai
f. Eyelet
g. Bar-tack
h. Button Hole/Stitching
4. Operator skills are also assessed upon the ability to perform the following processes:
a. Waist band attachment
b. All kinds of pocket attachment
c. Fly attachment
d. Zipper attachment
e. Collar attachment
f. Front rise
g. Back rise
h. Bottom Hem
i. Other critical sewing processes
5. All operators are trained further based on the finding from Initial Skill Assessment Data.
6. The operators with lower grades should be trained on subjects that they are weak on to
upgrade their skill level.
7. Helpers will also be trained so that they are able to become sewing operators. The sewing floor
supervisors will recommend the helpers that they think are fit to become operators.

24
8. All operators who are identified as ‘weak’ and in need of training by the In-process Audit
Procedure will also are trained on the particular process that they have failed upon. Upon
successful completion of training they are returned to the production floor.
9. Records of all training imparted upon all production employees will need to be filed in their
personal file.
Quality Personnel:
The skill level of Quality Inspectors and QC staffs are assessed by the QA Manager. And QA Manager
are assigned to provide the QA related all training. The following process has to be followed for training
quality personal:
1. The Initial Skill Assessment is done on the newly hired quality worker by testing them on five
pieces of garments with 10 major defects per the buyer’s Defect Classification List
2. The QC worker is assigned a skill level (A+, A, B, C, D or E) based on the number of defects
that they were able to find
3. Based upon this data the quality worker defect detection weaknesses are identified and is
trained on those weaknesses following the buyer’s Defects Classification List
4. The training will be conducting every end of the month by the Quality Manager.
5. After conducting training, exam will be taken after 3 months.
6. During the training the defective garments and garment parts are displayed so that QC trainees
are able to identify the defects readily.
7. Upon successful completion of their training their skill levels are to be adjusted accordingly and
documentation retained in their personal files.
8. Re-training should be done on a regular basis and the workers should also be tested again
when the buyer’s Defect Classification List are updated.
Mechanics:
The maintenance helpers and also the new maintenance staffs are trained by the Maintenance
Manager and by the sewing machine company Technicians whenever required. The following training
process has to be implemented by the factory:
The initial skill level assessment of the mechanic has to be determined during the hiring process.
1. The initial skill level will be based on the following types of machines:
a. Single Needle
b. Double Needle
c. Over-lock
d. Kansai
e. Feed-of-Arm
f. Eyelet
g. Bar-tack
h. Button Hole/Stitching
2. The maintenance worker will be tested on the following relevant skills for each machine:
a. Preventive Maintenance
b. Stitch Forming System
c. Thread Handling System
d. Feed Handling System
e. Computerized Machine Knowledge
f. Folder Settings
g. Overhauling
3. Records will need to be maintained in the personal file for all training imparted upon the
maintenance worker.

25
4. Relevant Documents :
 Sewing Operators training records –GFIL.TRN.FRM.03
 Quality Training Records – GFIL.TRN.FRM.04
 Maintenance Training Records – GFILTRN.FRM.05
 New Workers orientation program – GFIL.TRN.REG.06

26
GFIL.MER.PRO.01
Version # 3
9. SOP For Merchandising Department
1.0 Purpose and Scope :
Booking the all raw materials as per order sheet and follow – up inventory , production and
Finishing stage and regular communicate with Factory Production team and Customers to meet
the ship date.
2.0 Responsibilities :
2.1 Respective Merchandiser is responsible to follow-up the individual buyer’s order.
2.2 Merchandiser Manager will implement and monitor the entire process.
2.3 All Materials price , nominated new suppliers , product price should be get approval
from Head of Operation before to fixed.
3.0 Procedure :
3.1 Communicate with customers and confirm the order.
3.2 Select the suppliers as per Suppliers approval procedure for Non nominated.
3.3 Forward to booking for fabrics and accessories and assure to delivery time.
3.4 Booking details communicate with inventory and stores department.
3.5 Communicate with customers to get shade approval.
3.6 Collect the inventory reports for all raw materials.
3.7 Issue the requisition for size set to sample section.
3.8 Trims card must be approved according to the Customer approval.
3.9 Organize the Production validation packet or master file with a below documents :
3.9.1 PO Sheet & PID / Technical details
3.9.2 Size spec
3.9.3 Machine List
3.9.4 Production planning
3.9.5 Fabrics approval swatch
3.9.6 Trims and accessories swatch
3.9.7 3RD Part testing reports
3.9.8 Floor ready
3.9.9 Inspection and FE reports
3.9.10 Placement meeting
3.10 Organize the Pre-production Meeting with the Internal Auditor.
3.11 P.P. meeting notes must be communicate with Store, cutting , sewing and Finishing
department.
3.12 Handover the below documents –
3.12.1 Provide the PO Sheet , spec sheet , fabrics and accessories approval swatch ,
garments test reports and wash approval to cutting section , quality department
& sewing department.
3.12.2 Fusing suppliers requirements and testing reports provide to quality and
mechanics department.
3.12.3 Packing list and invoice provide to inventory & store department.
3.12.4 Review the fabrics and accessories testing reports and 3rd party testing reports.
3.12.5 Monitoring the daily production status.
3.12.6 Review the packing list and offer for final inspection.
3.12.7 After get satisfactory result arranges to ship the goods.
3.13 Evaluate the suppliers based on several criteria (Pls see suppliers evaluation criteria
check list) in every quarterly.

27
4.0 Relevant Documents :
 Production validation packets / master file – GFIL.MER.FL.01
 Monthly shipment tracking sheet – GFIL.MER.FROM.02
 Suppliers Performance Evaluation Form – GFIL.MER.FRM.03

28
GFIL.MER.PRO.02
Version # 3
10. SOP for Supplier Management Selection and Evaluation
1.0 Purpose & Scope:
To select the qualityful and best suppliers and be a business partner.
To evaluate the suppliers of the raw materials, products and services which impact the final product
quality, safety and legality.
2.0 Responsibility:
The respective Merchandiser is responsible to evaluate the suppliers based on the defined criteria
and Sourcing or Merchandising Manager is responsible to validate the process in case of Raw
Material and Chief Operating Officer is responsible for other products & service as the case may
be.
3.0 Procedure:
3.1 Supplier Selection process is defined as below :
3.1.1 Materials Supplier:
3.1.1.1 In most of the cases, the buyer nominates the supplier. In such case, the
nominated supplier is used of procurement of materials. The selection is purely based
on buyer nomination.
3.1.1.2 In case of no nomination form the buyer that means Open or Vendor Sourcing ,
the supplier selection is done based on the following criteria :
3.1.1.2.1 Suppliers Background about their market strength.
3.1.1.2.2 Capacity to meet the quality , safety & legal requirement of the
material. Whether the supplier can deliver the products as per US safety and
regulatory requirements/ buyer requirements.
3.1.1.2.3 Capability to meet the delivery on time.
3.1.1.2.6 An established traceability system in place to be able to trace the
raw materials back to source.
3.1.1.2.7 Quality level
3.1.1.2.8 Responsiveness
3.1.1.2.9 Price

29
Supplier Approval Checklist
Supplier Name: Product: Contact Person:
Contact No.:
Address:
Question
Point
s Yes No
1. Is the supplier’s nominated by the buyer? If the supplier is nominated skip the
following Questions and forward for approval. 1
2. Is the Supplier’s business history is good or bad? 1
3. Does the Supplier’s meet the local labor law? 1
4. Is the supplier’s production capacity and capabilities are sufficient? 1
5. Dose the supplier’s have any kind of certification like ISO, UKAS, OEKO-TEX or
anything Similar? 1
If so state details here:
6. Whether the supplier can deliver the products as per US safety and regulatory
requirements/ buyer requirements? 1
7. Does the supplier’s meet the quality standard? 1
8. Does the supplier’s maintain the traceability? 1
9. Are the supplier’s quoted price is reasonable? 1
10. Does the supplier’s after sales service is satisfactory? 1
Total points- 10
In based on the check list Our Sourcing or Merchandising Manager are scored
the suppliers based on their availability and rating as below ;
Above 90% = Excellent
70 – below 90% = Good
60 – below 70% = Medium
Below 60% = Bad
Our main motto is to select the best suppliers and be a good business partner.
3.1.2 Manufacturing Process Outsourcing & Service Contract
3.1.2.1 During the manufacturing process, if the company do not have in house capability ,
the process / service is considered for outsourcing.

30
3.1.2.2 The supplier of the service or process is selected based on below criteria
3.1.2.2.1 Standing of the company in the market i.e supplier history and past
Performance
3.1.2.2.2 Availability & condition of the machinery
3.1.2.2.3 Ability to deliver to the required specification
3.1.2.2.4 Capacity to meet the quality , safety & Legal requirement
3.1.2.2.5 Maintenance of the social compliance requirement
3.1.2.2.6 Capability to meet on time delivery
3.1.2.2.7 Responsiveness
3.1.2.2.8 Price
3.2 Suppliers Evaluation :
3.2.1 The system of periodic (every quarterly) evaluation and re-evaluation of suppliers has
been in vogue.
Each supplier is evaluated for the compliance & performance against the set criteria
annually.
3.2.2 The criteria for evaluation and re-evaluation includes :
3.2.2.1 Quality performance
3.2.2.2 Delivery of correct quantity
3.2.2.4 On-time delivery
3.2.2.5 Price / cost competitiveness of product
3.2.2.6 Transparency in information sharing
3.2.2.7 Responsiveness
3.2.2.8 Traceability
3.2.3 Quantity of supply is the prime factor for evaluation followed by timely supplies and
efficient service
3.2.4 The evaluation system varies according to the nature of goods / process & service
purchased.
3.3 The records of list of approved supplier & the supplier evaluation is maintained.
3.3. Rating :
Factory has a own check list whether respective merchandisers are responsible to analyze the
individual suppliers based on the above criteria;
Total achieved points are 5 out of 5 = Green
Total Achieved Points are 4 out of 5 = Yellow (Need Improve)

31
Total achieved points are 3 out of 5 = Orange ( Below standard)
Total achieved points are 2 out of 5 = Red (Not acceptable) .
In every quarterly Merchandiser Manager will review the performance results and take a decision
discussing with Company top management.
3.4. Relevant Documents :
 Supplier’s Performance analysis – GFIL.MER.FRM. 03

32
GFIL.MER.PRO.03
Version # 3
11. Product Test Plan [PTP]
Purpose:
1. To develop and implement the Product Test Plan [PTP] as appropriate to the product and the
process involved to manufacture the product in order to validate product quality, safety and
compliance with rules, bans, standards & regulations.
2. To meet the Consumer Product Safety & Improvement Act (CPSIA) rules and regulations.
3. To avoid customer compliant regarding any safety issue in future.
Scope:
This procedure is applicable to all the products being manufactured at and/or for all the
production units of GFIL.
Responsibilities:
The respective Merchandiser and Manager – Technical Compliance and auditare responsible
to develop the PTP and COO is responsible to approve the PTP
Procedure:
1. PTP is a documented plan for validating product quality, safety and compliance with rules,
standards and regulations.
2. PTP guides all the concerns about:
2.1 The types of testing and inspections for the product
2.2 The process monitoring stages and requirements
2.3 The frequency to conduct 4.2.1 & 4.2.2
2.4 The criteria to conduct 4.2.1 & 4.2.2
2.5 Covered section and respective concern person with designation.
2.6 Clearly defined the tolerance level.
2.7 Measurement method, reaction and documents control id are including at PTP.
3. Respective Merchandisers and Manager Technical Compliance & Audit are assigned to
prepare the PTP appropriate to product & process with following considerations:
3.1 Category of the product
3.2 Product risk level
3.3 Product regulations
3.4 Manufacturing processes
3.5 Raw Material used
3.6 Factory capabilities

33
4. The PTP is developed in accordance with GFIL process flow chart with control checks to
ensure that all the factory testing, inspections and process monitoring activities are
captured on the PTP.
5. The PTP must act as manufacturing control plan.
6. Once respective Technical Manager develops the PTP, the same is being reviewed and
approved by COO.
7. On approval from COO, the PTP is discussed during the PP meeting and documents as
part of meeting notes.
8. The copy of PTP is circulated to all the relevant personals.
9. Respective departments head must be ensured the PTP is executed and Manager –
Technical Compliance and audit should be validate the every section to properly executed
the PTP at every stages.
Sample of Production Test Plan
Plot # A (6&7) , Block # B , BSCIC I/A. Sagorika Road, Pahartoli. Chittagong
PRODUCTION TEST PLAN
BUYER: BHS Limited ITEM
:
GB SHEETING CROP & GB
SHEETING SHORTS
STYLE# 220644 & 220653 DATE
:
08.03.2014
Raw Material Process
TYPE CRITERIA FREQUEN
CY
Sl.
No
PROCES
S AREA
SECTIO
N
NAME
Re
spo
nsi
ble
Per
son
Desi
gnat
ion
MFG.
EQPMNT.
PROCESS SPEC
WITH TOLERANCE
Msr
mt
Met
hod
SAMPLING
FREQUEN
CE
CON
TROL
MET
HOD
RE
AC
TIO
N
DOC. CNTRL
ID
01 Fabric
Receiving
Store's Mr.
Zia
Str.
Ex.
Doc. Review
(Inventory)
Check Against
Packing List Tolerance
- 0
Standard Broad ,
100% ctn w oven
sheeting fabrics ,
20x20/60x60
and Rib - 2x2
Visu
al
Every
Consignme
nt
Recei
ving
Inspe
ction
NC
M
GFIL/FRM/STR
-15
02 Fabric
Inspectio
n
Store's Mr.
Moi
n
In
char
ge -
Fabri
c
Insp
ectio
n
Fabric
Inspection
M/C
04 Points system,40
Points Per 100 Square
yds& up to overall
results acceptable
level 24%
Visu
al
Every
consignmen
t of
incoming
fabric,
select all
colors and
lot w ise
10% of
receiving
fabrics.
Inspe
ction
NC
M
GFIL/FRM/QA
S - 01

34
03 Fabric
Weight
Store's Mr.
Moi
n
In
char
ge -
Fabri
c
Insp
ectio
n
Fabric Weight
M/C
Each shipment of
incoming fabric, all
colors and lot.
Acceptable level± 5%
, Check against
standard w eight 150
GSM
Visu
al
Every
consignmen
t , select
10% of
receiving
fabrics.(afte
r w ash &
before
w ash)
Inspe
ction
NC
M
GFIL/FRM/QA
S - 03
04 Fabric
Shrinkag
e
Store's Mr.
Moi
n
In
char
ge -
Fabri
c
Insp
ectio
n
Washing M/C Cutting the fabrics 60
x 60 cm2 and marking
the L/W 50 x 50 cm2
in Fabric. Sent to
w ash as per 135-
Normal Garments
Wash and Then take
After wash
Measurement
Acceptable level+10%
& -5%
Visu
al
Every
consignmen
t , select
10% of
receiving
fabrics.
Inspe
ction
Rec
tify
Patt
ern
GFIL/FRM/QA
S - 02
05 Fabric
Shade &
Grade
Separatio
n
Store's Mr.
Moi
n
In
char
ge -
Fabri
c
Insp
ectio
n
Confirmed by
Light Sourch
Machine in
Primary UL
3500 and
secondary
D65 light .
Match w ith approval
Shade band.
Visu
al
Every
consignmen
t Of
Incoming
Fabric,
100% Wash
Blanket,
Check In
Light
Source
Inspe
ction
Sen
d
For
App
rov
al
To
Mer
cha
ndi
ser
GFIL/FRM/QA
S - 04
06 Accessori
es
Receiving
Store's Mr.
Nu
pur
Str.
Ex
Doc. Review
(Inventory)
Check Against
Packing List
Tolerance - 0
Visu
al
Every
Consignme
nt
Recei
ving
Inspe
ction
NC
M
GFIL/FRM/STR
- 15
07 Label Store's Mr.
Am
an
Str.
Ex
Match With
Approval
sw atch, check
lettering,
foreign yarn ,
w ord color.
Lot Selected By
AQL 10%
Tolerance - 3%
Visu
al
Every
Consignme
nt Of
Incoming
Accessories
Inspe
ction
NC
M
GFIL/FRM/QA
S - 05
08 Button Store's Mr.
Am
an
Str.
Ex
Match With
Approval
sw atch ,
checkbutton
ligner and
quality, Button
Ligner for
plastics and
metal - 30 L ,
26L , 20L
Lot Selected By
AQL 10%
Tolerance - 3%
Visu
al
Every
Consignme
nt Of
Incoming
Accessories
Inspe
ction
NC
M
GFIL/FRM/QA
S - 05
09 Thread Store's Mr.
Am
an
Str.
Ex
Match With
Approval
sw atch ,
checkthread
count , shade
and durability.
Count - 20s/3,
20s /2 , 40s/3
, 40s/2 &
Lot Selected By
AQL 10%
Tolerance - 3%
Visu
al
Every
Consignme
nt Of
Incoming
Accessories
Inspe
ction
NC
M
GFIL/FRM/QA
S - 05

35
20s/9
10 Draw
Cord
Store's Mr.
Am
an
Str.
Ex
Match With
Approval
sw atch ,
checklength ,
w idth and clr
bldng
Lot Selected By
AQL 10%
Tolerance - 3%
Visu
al
Every
Consignme
nt Of
Incoming
Accessories
Inspe
ction
NC
M
GFIL/FRM/QA
S - 05
11 Hang Tag
& GV Tag
Store's Mr.
Am
an
Str.
Ex
Match With
Approval
sw atch, check
lettering,
barcode
number.
Lot Selected By
AQL 10%
Tolerance - 3%
Visu
al
Every
Consignme
nt Of
Incoming
Accessories
Inspe
ction
NC
M
GFIL/FRM/QA
S - 05
12 Carton Store's Mr.
Am
an
Str.
Ex
Match With
Approval
carton , check
carton ply,
shipping
mark.3 ply
Lot Selected By
AQL 10%
Tolerance - 3%
Visu
al
Every
Consignme
nt Of
Incoming
Accessories
Inspe
ction
NC
M
GFIL/FRM/QA
S - 05
13 Poly Store's Mr.
Am
an
Str.
Ex
Match With
Approval
sw atch, check
w arning letter
& thickness.
Lot Selected By
AQL 10%
Tolerance - 3%
Visu
al
Every
Consignme
nt Of
Incoming
Accessories
Inspe
ction
NC
M
GFIL/FRM/QA
S - 05
14 Carton
Sticker
Store's Mr.
Am
an
Str.
Ex
Match With
Approval
sw atch, check
DPCI number
and Barcode
number.
Lot Selected By
AQL 10%
Tolerance - 3%
Visu
al
Every
Consignme
nt Of
Incoming
Accessories
Inspe
ction
NC
M
GFIL/FRM/QA
S - 05
15 Hanger
Sticker
Store's Mr.
Am
an
Str.
Ex
Match With
Approval
sw atch, check
size and
lettering
Lot Selected By
AQL 10%
Tolerance - 3%
Visu
al
Every
Consignme
nt Of
Incoming
Accessories
Inspe
ction
NC
M
GFIL/FRM/QA
S - 05
16 Washing
Test for
all
accessori
es
attaching
w ith
fabrics
sw atch
Store's Mr.
Am
an
Str.
Ex
Match With
Approval
accessories
and fabrics
sw atch
(Check
shrinkage test
color bleeding
test , ferrus
test , sharp
point test and
stain mark
test for all
incoming
accessories.
Attach all accessories
( 01pcs for allitems)
w ith fabricsduring
accessories/fabric
inspection.
Visu
al
Every
Consignme
nt Of
Incoming
fabric and
Accessories
Inspe
ction
Re-
w or
k or
co
mm
uni
cat
e
w ith
mer
cha
ndi
ser
GFIL/FRM/QA
S - 5A

36
Process Control
CY
SL.
NO.
PROCE
SS
AREA
SEC
TIO
N
NAM
E
MFG
EQUIPMENT
PROCESS SPEC
WITH TOLERANCE
MEA
SUR
EME
NT
MET
HOD
SAMPLING
FREQUEN
CE
CON
TROL
MET
HOD
RE
AC
TIO
N
DOC. CNTRL
ID
01 Spreadi
ng
Inspecti
on at
cutting
section.
Cutti
ng
Mr.
musle
m
Cuttin
g Spv
Follow Our
Ow n S.O.P
Check Marker Placing,
Ends, Splices, Narrow
Goods, Leaning &
Tension
Visu
al
Every
Spreading
Inspe
ction
NC
M
GFIL/CUT /QC
- 09
02 Cutting
Marker
Check
at
cutting
section.
Cutti
ng
Mr.
musle
m
Cuttin
g Spv
Follow Our
Ow n S.O.P
Grain Line Check,
Ratio Wise Parts
Check, Way /
Direction Check,
Jumping Check,
Notches Check &
shape of Parts
Visu
al
Every
Marking
Inspe
ction
NC
M
GFIL/CUT/QC-
14
03 Cut
Panel &
Cut
Bundle
at
cutting
section.
Cutti
ng
Mr.
musle
m
Cuttin
g Spv
Follow Our
Ow n S.O.P
Check Miscut,
Matching Plies,
Ragged Cutting,
Notches, Fabric &
Pattern Check 100%
for all criticalparts
Visu
al
Every
cutting &
Every Day
Inspe
ction
NC
M
GFIL/CUT/QC -
10
04 Sew ing
Machin
e
Setting
Sew i
ng
Mr.
Mokte
r
GM Prior to start
new style and
monitor
output per
operator to
ensure
product meets
operation
standard
Prior to start new style
or may vary to
improve production
standards.
All
Part
s Of
Ever
y
Gar
ment
s
As Per
Layout
Depe
nds
On
Layou
t
NC
M
GFIL/SEW/MS
R - 11
05 Process
Mock-
up & 05
Pcs
checkin
g at
sew ing
section.
Sew i
ng
Mr.
Asad
QM 05 Pcs
Checking
System
(Every M/C)
Monitor per operator
to ensure quality
improvement.
Visu
al
Min.Three
Times Per
day/
Operator
Inspe
ction
NC
M
GFIL/SEW/TRL
AG- 06
06 In-
Process
Inspecti
on at
sew ing
section.
Sew i
ng
Mr.
Asad
QM 100% check
all garments
process and
need to adjust
the inspection
table w ith 100
F.C light
value.
100% checkall
garments process.
Visu
al
All parts Clock
w ise
Inspe
ction
NC
M
GFIL/SEW/PR
OQR-05
07 Daily
measur
ement.
Sew i
ng
Mr.
Asad
QM as per aql
basis
Min. 3 pcs/color/size Visu
al
Min. 20 pcs
per Line Inspe
ction
NC
M
GFIL/SEW/SP
EC-01

37
08 End
Table
Inspecti
on at
sew ing
section.
Sew i
ng
Mr.
Asad
QM 100% check
all garments
process and
need to adjust
the inspection
table w ith 100
F.C light
value.
100% checkall
garments process.
Visu
al
All
garments
Clock
w ise
Inspe
ction
NC
M
GFIL/SEW/PR
OQR-05
09 Lot
Pass
Inspecti
on at
sew ing
section.
Sew i
ng
Mr.
Asad
QM Day light 100
F.C
(Inspection
table).
As per AQL – 1.5 Visu
al
Every Hour
& Every
Day
Inspe
ction
NC
M
GFIL/SEW/LOT
P-07
10 Daily
w ash .
Indu
strial
Was
h
Mr.
Bipul
Fin.
Mng
Industrial
w ashing m/c
135 Normal Garments
w ash
Visu
al
Every Day Inspe
ction
NC
M
Washing plant
w illprovide
report id.
11 After
w ash
garment
s check
.
Finis
hing
Mr.
Asad
QM visualcheck
of 10%
garments ,
checkcolor
fastness,
w ashing
defect, hand
feel.
10 % garments Visu
al
Every Day Inspe
ction
NC
M
GFIL/FIN/QAS-
06
12 Hourly
key
point
measur
ement.
Finis
hing
Mr.
Asad
QM Take the
measurement
of key parts
i.e. chest ,
sw eep, slv
length , front
length , back
length &
shoulder of
100 %
garments
100 % garments Visu
al
100 %
garments Inspe
ction
NC
M
GFIL/SPEC -
1A
13 Lot
Pass
Inspecti
on at
finishing
section.
Finis
hing
Mr.
Asad
QM Day light 100
F.C
(Inspection
table).
As per AQL – 2.5 Visu
al
Every Hour
& Every
Day
Inspe
ction
NC
M
GFIL/FIN/QAS-
07
Product Safety Process
CY
01 Barcod
e
Scanni
ng
Stor
e's
Mr.
Ama
n
Str.
Ex
Barco
de
Scanni
ng
M/C
Lot selected by 10% for hang tag
and 100% scanning for carton
sticker
Visu
al
Every
consignme
nt of
incoming
Price ticket
& Carton
Sticker, Lot
selected by
AQL 2.5
(Level2)
Intern
al
Test
NC
M
GFIL/FRM/QA
S-029

38
02 Fusing
Test
Inter
nal
Test
Mr.
Musl
em
QA
SPV
Fusing
&
Bondin
g Test
M/C
Maintain log documentation, Visu
al
Tw ice Per
Day
Intern
al
Test
NC
M
GFIL/CUT/QC-
06
03 Button
Pull
Test
Inter
nal
Test
Mr.
Asad
QM Button
Pull
Test
M/C
Maintain log documentation as
per requirement 20.2 lbs/10 sec
Visu
al
Tw o Times
Per Day
Intern
al
Test
NC
M
GFIL/FIN/QAS-
02
4 Needle
Log
Inter
nal
Test
Miss.
Rebe
cca
Str.
Ex
Follow
Our
Ow n
SOP
Maintain Log For All Broken
Needles/blunt needle, check
needle sharpness daily.
Visu
al
Time To
Time
Intern
al
Test
NC
M
GFIL/FRM/ST
R-03
5 Metal
Detecti
on
Inter
nal
Test
Mr.
Kao
w sar
Meta
l
Dete
ctor
optr
Metal
Detecti
on
M/C
All product checked utilizing
metal detection at 1.2 mm ferrus
card.
Tolerance Level - 0
All
Gar
ment
s
Ever
y
Hour
All
garments
Intern
al
Test
NC
M
GFIL/FIN/FRM-
03
3rd Party LAB Process
CY
01 Pre-
Produc
tion
Test
After Care Process
TYPE CRITERIA FREQUENCY
01 QUALI
TY
AUDIT
Fini
shin
g
MR.
Mas
um
DQA Daily
Ctn
Pack
Qnty
As per AQL
– 2.5.
(Level1)
Visual Every Day Inspe
ction
NC
M
GFILFIN/QAS-
01
02 P.O.
Wise
Pre-
Final
Fini
shin
g
MR.
Mas
um
DQA TTL
P.O.
Pack
Qnty
As per AQL
– 2.5.
(Level1)
Visual After 80%-100%
Carton completed
Inspe
ction
NC
M
GFILFIN/QAS-
01
Internal Auditor/DQA Manager – MR COO

39
GFIL.MER.PRO.04
Version # 01
Issue Date: 20March 2014
Revision Date: N/A
12. Changing Materials, Components, Design or Manufacturing
1.0 Purpose & Scope:
To facilitate the change materials, components, design or manufacturing process to meet the
product safety and manufacturing efficiency in the plant from time to time if required.
2.0 Responsibilities:
Sourcing Manager and Sample manager are responsible to implement the policy in
consultation and clear communication with the customers through the Marketing &
Merchandising department.
3.0 Procedure:
3.1. If at some point a need arise to change some of the approved material, components,
design or manufacturing processes it should to be discussed with Merchandising or
Sourcing Manager and he will analyze along with Sample Manager to evaluate if the
changes may affect the product in meeting any of the following requirements:
3.2.1. Safety
3.2.2. Regulatory
3.2.3. Quality requirements
3.3 Implement the process to get approval from departments
3.4 If the considered change is expected to affect the safety, regulatory or quality
requirement, the merchandiser will notify the same to the customer and acquire written
approval prior to implementing the changes.
3.5. Upon acquiring the approval copy from the customer, the Sample Manager will
authorize the changes to effect.
3.6 The approval copy should be recorded in hard copy in the order file.
4.0 Relevant Documents:
 Approval Records – GFIL.MER.FL.06

40
GFIL.MER.PRO.05
Version # 3
13. Product Recall Procedure
Purpose:
This procedure is for the removal of unsafe product from the distribution chain/buyer.
Scope:
Product Recall procedure extends up to the distribution chain but does not extend to product sold to the
consumer.
Responsibilities:
Chief Operating Officer is responsible to implement and follow the procedure.
Procedure:
1. When a recall is initiated, our actions in recalling the affected products need to be co-ordinate
with the buyers.
2. The buyers shall be notified as soon as a recall is likely.
3. GFIL will clarify the product safety issue and the exposure (who and where risk exists), and
will provide details on distribution and the method of recall.
4. A Committee shall be formed whose members will include personnel from across the
company. Typically the committee would have a mix of knowledge across the following areas:
a. Production
b. Quality
c. Purchasing
d. Merchandising / Marketing
e. Legal Services
5. The recall committee is responsible for the management of all recall activities and to adhere
to this procedure. Duties of the recall committee are to:
a. Assess the overall problem
b. Notify the relevant regulatory authority
c. Evaluate the hazard in the product and the extent of contamination
d. Determine a strategy to be followed
e. Make decisions about product still in manufacture or in storage
f. Decide who makes any press statements

41
Recall Decision Flow Chart
Custom er complaint
Identification of a
Internal Finding
potential product
Any other source
non-compliance
issue
Information to
Quality Unit
Preliminary
Response to
no customer and
Recall
documentation of
Assessment
Findings
yes
Convene Recall
Committee
1. Technical Assessment
2. Documents for Recall
yesno
Recall
Implementation
Decision
Relevant Documents:
 Products Recall documents – GFIL.MER.FL.07

42
SOP – g:fil property
GFIL.SPL.PRO.01
Version # 1
Issue Date : March20, 2014
Revision Date : N/A
14.Sample Section Control
Purpose and Scope:
1. Develop the sample as per customer’s requirements.
2. Develop the pattern and marking and adjust the bulk pattern.
Responsibilities:
Sample Manager is responsible to implement the procedure efficiently and monitor the process.
Procedure:
1. Sample Process:
a. Review the specs and designing chart and proceed for development sample
b. Review the customer comments and proceed for prototype sample
c. Develop the Pre-production or GSA sample
d. Make a Size set sample
e. Proceed for PM reference sample
f. Making an Ongoing Random sample
2. Pattern and Marking Process:
a. Master Pattern (attached with computer plotter) will be made
b. Size set will be made: if any adjustment are needed the pattern have to be rectified
c. Pilot run cutting will be by manual marker: if any adjustment needed the pattern have to be
rectified
d. Bulk production to be from Computer Marker
e. Patterns are approved by Sample Manager
f. Sample Manager is authority to rectify all types patterns
3. Quality Process :
a. Sample Quality is responsible to check the measurement for all types sample .If any discrepancy
found then make sure to re-adjust the pattern by Sample manager and re make the sample and take a
measurement again, and reports submit to quality manager.
b. Sample quality is also check the workmanship of all sample and update the reports accordingly.
Relevant Documents:
 Sample Records – GFIL.SPL.REG.01
 Pattern & Marking Distribution Records – GFIL.SPL.REG.02
 Fabrics and Accessories Receiving Register - GFIL.SPL.REG.03
 Inline process quality reports/End line quality reports – GFIL.QCS.FRM.18
 Quality measurement checking reports – GFIL.QCS.FRM.15A

43
GFIL.IVS.PRO.01
Version# 03
15. Inventory & Store Control:
Purpose:
To develop, implement and maintain procedures for efficient functioning of the inventory management with clarity of
roles & responsibilities and to ensure accurate record keeping of the same.
Scope:
This procedure is applicable to all items procured from various supply chain partners including but not limited to raw
materials, machinery, equipments, spare parts, stationary that are used at Gous Fashion Industries Ltd.
Responsibility:
The Inventory Manager is responsible to implement and maintain the procedures and relevant records in the
department.
Procedure:
1.0 Raw Material Inventory Management
1.1 Store department receives booking chart of fabric and trims from merchandising team through email /
hard copy along with approved fabric and trim cards.
1.2 Commercial / merchandising team forwards Packing List of shipped items to the store through email /
hard copy after receiving the shipment information from suppliers.
1.3 Commercial team provides the arrival schedule to store vide email.
1.4 Goods arrive at the factory. Upon unloading, goods received according to the delivery information
available in clearing / transport agency’s challan are matched with the Packing List already available
with the department. Thereafter an Inventory card is prepared.
1.5 The Inventory Controller checks 100% of the received quantity and tallies with the expected quantities
as per packing list to check accuracy / excess / shortage quantity.
1.6 If any shortage / excess of good are detected, Inventory Controller shall inform the same to the
Commercial and Merchandising team vide the Inventory Discrepancy Report. The Inventory Manager
will sign the Inventory Discrepancy Report prior to dispatching it to the Commercial & Merchandising
team.
1.7 Merchandising / commercial team determines the reason for the discrepancy.
1.8 If it is for error on the part of the GFIL team then a reorder is placed or other alternative arrangement
for the required quantity is arranged.
1.9 If the error is found to be on the part of the supplier then a replacement quantity is requested or other
replacement arrangement is made by the merchandising / commercial team.
1.10 The Inventory team is notified of the alternative plan and the new schedule and packing list of
reordered items if applicable.
QUALITY INSPECTION: See QCS Procedures 16 and 17.

44
1.11 QA inspection is conducted on all received goods to ensure goods are of expected quality. If the quality
is APPROVED then the Bin Card is Marked GREEN demarking that it is ready to be issued for
production / use.
1.12 If the quantity is found to be correct a Bin Card is issued for each item and the goods are stored in the
respective areas marked for relevant item in the warehouse and update the respective registers.
1.13 If the Inventory QA finds the goods to be non-conforming to the expected / approved quality then the
Bin Card is marked RED and the goods are with held from being issued. The Non- conformance Report
is completed by the QA and informed to all concerned with a copy of the non-conformity report and the
Non-conforming Material register is updated.
1.14 Non-conforming goods are removed to the specific area storing non-conforming material.
2.0 Material Movement Management:
2.1 Various production departments shall issue a material requisition vide the Requisition Form to the
nearest Sub-store.
2.2 Cutting Department will issue the Requisition Form directly to the Inventory department. All requisitions
shall approved by the Inventory Manager.
2.3 For other production departments the sub-store officers will monitor consumptions and maintain
inventory at the sub-store to promptly service the various production departments. The sub-store will
issue Requisition Forms to the Inventory Manager to maintain such inventory based on the ongoing
production.
2.4 Sub-Store will send Store Runners to the Inventory Manager who will review the requisition and
approve it for issue. Store runner will bring two copies of the requisition. Leave one copy with the
Inventory Manager & get the other signed & take back and file it in the respective sub-store and keep
for record along with the issued goods.
2.5 Upon each issue the Inventory Controller shall update the bin cards and respective registers
accordingly.
2.6 Store runners will carry all goods to the sub-stores and issue to production departments from time to
time based on requisitions received from the respective production departments.
2.7 Sub-store shall issue goods to production departments upon receiving a duly completed & signed
requisition form from the respective production department heads.
2.8 Respective production departments shall send Floor Runners with two sets of the requisition form to
the sub-stores. One copy will be signed by the sub-store officer and returned to the Floor Runner to
take back to its respective production department along with the issued goods. The other copy shall be
preserved at the sub-store for record.
3.0 Finished Goods Management:
3.1 All finished goods are QC checked at the Finishing department and handed over to the designated
finished goods officer in the inventory department. Finished goods are stored at the designated area in
the warehouse.
3.2 Finished goods are released vide Delivery Challan / Gate Pass upon confirmation of release vide
Goods Release Order signed by designated commercial department officer. The Inventory Manager is
the signing authority for the Delivery Challan / Gate Pass.

45
3.3 Three sets of the Delivery Challan / Gate Pass are prepared; One copy is completed at the inventory
department; one copy is provided to the transport agency; Two copies are forwarded to the commercial
department, one of which is left with the commercial department and another one brought back with a
received acknowledgment is acquired and filed at the inventory department.
4.0 Needle Control:
4.1 Sub-stores shall maintain adequate inventory of needles for the respective production floors it services.
To acquire needles the sub-store shall follow the procedures as stated in 2.4 to 2.6.
4.2 Sub-stores are responsible to maintain the needle control procedures.
4.3 Respective sewing floor managers will issue needle requisition to the sub-store and the floor runners
shall bring the broken needles to the sub-store along with the requisition.
4.4 Sub-store officer shall match all the broken parts of the needles one by one. It shall only issue the
number of needles that it was able to put together as one unit.
4.5 The sub-store shall maintain record of the broken parts compiling it to a whole needle for each needle
and preserve the record in the Needle Log Book.
4.6 For any broken needle where the broken parts do not compile it to a whole it shall complete a needle
exchange request form and acquired all signatures as required in the form and then issue the required
needles. Thereafter the sub-store officer shall update Log Book.
5.0 Support Inventory Services:
5.1 The Inventory department is responsible to maintain spare parts, stationary and all other support
service inventory of the company.
5.2 The procedure to maintain and control it shall be the same as with the raw material.
5.3 All spares will be stored in the main store area under the classified spare storage area. Maintenance
department will follow requisition procedure to avail machinery or any other spare parts.
5.4 Support Service Inventory officer shall maintain registers for the relevant items under the section.
5.5 All shipment status must be included on the Shipment Register customer and style wise. Store
executive will track the bolt seal using quantity and update the register in time.
5.6 At the end of a style or an order, all raw materials will be collect by respective store executive from the
floors and shifted to left over area and identified clearly with its records maintained on the Left Over
Register.
5.7 The left over items will be disposed in the following manner:
a) Reuse: The Chief Operating Officer (COO) is authorized to take a decision which items can be
reused and how it will be reused.
b) Donate and or Sell: Reviewing the items in person the COO may decide to donate the items to
the underprivileged or to any disaster stricken area as case may present itself or he may chose
to sell the garments by removing all types branded labels and tags.
c) Recycling: All types of machinery spare parts are recycled in an environmentally friendly manner
through 3rd party based on agreements.

46
5.0 Relevant Documents:
 Fabrics Register Book GFIL.IVS.REG.06
 Accessories Stock Register GFIL.IVS.REG.07
 Machinery Spare Parts Stock Register GFIL.IVS.REG.19
 Thread Received and Issue Register GFIL.IVS.REG.24
 Finishing Accessories Received & Issue Register GFIL.IVS.REG.23
 Stationary Register Book GFIL.IVS.REG.20
 Electrical Register Book GFIL.IVS.REG.21
 Needle Stock Register GFIL.IVS.REG. 5
 Shipment Register GFIL.IVS.REG.18
 Bolt Seal Register GFIL.IVS.REG.22
 Thread Stock Register GFIL.IVS.REG.24
 Finishing Accessories Issue & Receive Register GFIL.IVS.REG. 23
 Left Over Register GFIL.IVS.REG.25
 Non Conforming Reports GFIL.NCM.FRM.07
 Requisition GFIL.IVS.FRM.01
 Needle Exchange Log Book GFIL.IVS.FRM.03
 Purchase Requisition GFIL.IVS.FRM.10
 Delivery Challan GFIL.IVS.FRM.12
 Re-issue Form for Missing Broken Needle GFIL.IVS.FRM.14
 Inventory Report GFIL.IVS.FRM.15
 Wash Send & Received Reports GFIL.IVS.FRM.26
 Bin Card GFIL.IVS.CRD.08
 Inventory Card GFIL.IVS.CRD.09

47
GFIL.QCS.PRO.01
Version # 3
16.Procedure for Fabric Inspection
1.0 Purpose & Scope
To identify and determine the extent of fabric defects, the different width and other quality level of fabric lot
received so as to ensure the fabrics confirms to the required standard before spreading.
2.0 Responsibilities
2.1 The IQC In-charge is responsible for the monitoring and the implementation of the fabric inspection
system and to verify the authenticity of the fabric inspection report.
2.2 The Fabric Inspectors [QA] are assigned to carry out the fabric inspection and to maintain the
inspection reports.
3.0 Procedures
4 point system fabric inspection:
1. Sampling: For the inspection, a minimum of 10% of the fabric covering each color and each dye lot and
different width of fabric is covered based on the fabric lot size.
1.1 Shipment of 1,000 yards or less - 100% inspection
1.2 Shipment of 1,001 yards or more - 10% inspection (minimum 1000 yards)
2. The inspection is carried out major fabric defects
2.1 Major woven fabric defects are slubs, hole, missing yarn, conspicuous yarn variation,
end out, soiled yarn etc
2.2 Major knitted fabric defects are mixed yarn, yarn variation, runner, needle line, bare,
slub, holes, press off etc
2.3 Major dye or printing defects are out of register, dye spot, machine stop, color out,
color smear or shading.
3. Points are allocated to every fault as per the point’s table listed below:
Size of defects (in inches – length wise) Penalty points
Up to 3 inch 1 Point
3 inch to 6 inch 2 Points
6 inch to 9 inch 3 Points
Over 9 inch to 36 inch 4 Points

48
(A maximum of 4 points can be charged to one linear yard)
4. All holes regardless of size, shall be penalized 4 points. There must be two or more yarns broken at
the same place, for the defect to be considered a hole.
5. The fabric width should be checked a minimum of three times during the inspection of a roll (at the
beginning, middle and end).
6. No piece shall be accepted as first quality where the usable width (which is the width between the
insides of the selvages or between the stenter pinholes) is less than the minimum usable width as
accepted.
Calculation :
Total Penalty points / Actual Fabric length x 36 / cut able width x 100 = result.
Acceptance Limit :
Pass = Total defects percentage upto 24 % of total consignment .
Fail = Total defects percentage over 24%
Defects points over 40 for any individual roll (for 100 yards roll) will be unsatisfactory and
those rolls will be shifted at Non conforming materials area.
If total consignment results is over 24% then must be re-check the again 10% and while result also
unsatisfactory then should be re inspect the 100% rolls with the presence of Fabrics suppliers.
Shade Checking
1.1 To check side to side , end to end, side to middle and roll to roll shading check, 10” x 10”
fabric panels are cut from each roll (100%).
1.2 Checking of the Shade band: The reason for preparing a shade band is to ensure that the
same shade is cut in ratio. We cut a fabric swatch from all the rolls received (In case of
Washed garments stitch them together in the form of a blanket. we get it washed to the
standard required ) and then segregate the shades accordingly, Shade must be confirmed by
Light box as per clients requirements i.e.
Customer wise Standard Light Sources Requirements.
While same shade is check and confirmed by Primary and secondary light source then it will be
treated as a Metamersim check.
Sl. No. Customer Name Primary Source Secondary
Source
01. Target UL3500 D65
02. BHS D65 N/A
03. MANGO D65 N/A

49
which facilitates the cutting of the particular shades in ratio.
1.3 No piece shall be accepted as first quality that exhibits a noticeable degree of shading from
side-to-side or side-to-center.
1.4 No piece shall be accepted as first quality exhibiting a noticeable degree of shading end-to-
end, when checked by laying panels, cut from the beginning of the roll, across the opposite
end.
Fabric Bowing / Skewing
Bowing should be done for plaid/ stripe fabrics, skewing should be done for heavy denim and twill fabrics
from 5% of received fabrics.
1. Fabric bowing or bias should be within the following tolerances.
1.1 Yarn-dyed in check pattern: No piece shall be accepted as first quality exhibiting more
than 1.5 inches (3.8 cm) of bow or bias on 60 inch (152cm) goods.
1.2 Printed in check or stripe pattern: No piece shall be accepted as first quality exhibiting
more than 1.2 inches (3cm) of bow or bias on 60 inch (152cm) goods.
1.3 Single jersey knitted fabrics within 5%. Note that fabric should be within 5% skew after
washing
X = Bowing deepth, Y= Straight Line
SKEWING CALCULATION
Skewing % = X / Y * 100
X
Y
BOWING CALCULATION
Bowing % = X / Y * 100
X
XY

50
X = Skewing deepth, Y = Staright line
Running Defect
Any defect found to repeat and or run in a continuous manner will constitute a running defect.
1.1 Any piece having a running or repeating defect through more than three (3) continuous
yards shall be rejected regardless of the point count.
1.2 More than one occurrence, in excess of three (3) yards, in an audit can cause the lot to
be rejected.
Reporting and Acceptance
1. Record results on Fabric inspection reports, as per 4-point system
2. To get the percentage of total defects in each roll separately we have to use the formula mentioned
below:
% Point = Total penalty points X 100x 36
Total yardage checked (actual length ) x cuttable width
3. If the final percentage is more than 40 pt per 100 linear yards / 24 pt per 100 Sq. yards, the result is
recorded and IQC In-charge is informed and additional 10% fabric is inspected.
5. If the % is again more, then the lot is rejected and informed to the QA/QC Manager and Merchandiser.
Again re inspect the total quantity with the presence of Supplier’s representative.
6. If the total number of second quality yardage is 20% of the total inspection quantity, the lot fails
inspection. The following types of defects are included:
6.1 Bowed or bias in excess of stated tolerances.
6.2 Dye streaks or unevenness.
6.3 Loose, wavy or tight selvages.
6.4 Narrow width.
6.5 Shading side-to-side or side-to-center.
6.6 Shaded end-to-end
6.7 Any combination of the above.
7. Note that for defects such as bowing or bias, incorrect hand-feel, narrow width, and side-to-side/side-
to-center/end-to-end shading no penalty points shall be assigned. However, the entire roll shall be
graded as second quality and should be rejected.
8. The IQC In-charge re-inspects the non-conforming roll / sample and decides whether the roll should be
rejected or not and record the decision on Fabric Inspection Report. The decision to reject the roll is
based on the fact that whether the defects can be avoided in Cutting and cut panel inspection or not.

51
9. If the defects cannot be avoided in cutting or cut panel inspection and the wastage will be too high then
the Merchandiser is forwarded the Non-conforming Fabric Report who then gets the customer approval
and the details are recorded on Non-Conforming Fabric Report.
10. Rejection rolls are identified by putting “Rejected” sticker and are kept in rejected goods area.
Fabric Shrinkage Testing:
1. To ensure the color wise shrinkage of the fabric, the inspector has to cut a swatch measuring 50 cm x
50 cm ( or as specified by the buyer ) of every color and quality of 10% fabric in a lot by using
calibrated measuring tape and get is washed to the correct approved washing standard (for wash
program) and steam press the non wash program.
2. The fabric inspector records note the measurement after wash on shrinkage test report.
3. The shrinkage % is calculated using the following formula.
4. The results are recorded and is approved by Head of QA/QC
To obtain the lengthwise shrinkage, the following formula should be used:
Before wash length – After wash length X 100 = Shrinkage of Length
Before wash length
To obtain the width wise shrinkage, the following formula should be used:
Before wash width – After wash width X 100 = Shrinkage of width
Before wash width
Acceptance :
Results are accepted upto +10% for length &width wise and -5% for length & width wise.
Fabrics Weight Test :
1. To ensure the fabrics weight according to the customer requirements. the inspector has to cut a
swatch but GSM Cutter of every color and quality of 10% fabric in a lot and measuring a weight of
every cut piece and get is washed to the correct approved washing standard (for wash program) .
2. The fabric inspector records note the measurement after wash on Fabrics weight test report.
3. The weight % is calculated using the following formula.
4. The results are recorded and is approved by Head of QA/QC .
5. As per fabrics construction we count the yarn of 10% rolls using by Yarn counting metre and count the
actual yarn length and width wise and compare against actual requirements and results are recorded in
Weight Test report.
Calculation :
Average weight – required gsm / required gsm x100 = % results
Acceptance :
Results are accepted upto +-5% .

52
Relevant Documents :
 Fabrics Inspection Reports – GFIL.QCS.FRM.01
 Fabrics shrinkage reports – GFIL.QCS.FRM.02
 Fabrics weight Reports – GFIL.QCS.FRM.03
 Shade analyze Reports – GFIL.QCS.FRM.04
 Light Box Log Register – GFIL.QCS.FRM.06
 Non Conforming Records – GFIL.CNCM.FRM.07

53
GFIL.QCS.PRO.02
Version # 3
17. Accessories/TrimsInspection
1.0 Purpose & Scope
To identify and determine the extent of Trims defects before issuing in the line.
2.1 The IQC In charge is responsible for the monitoring and the implementation
of the trims inspection system and to verify the authenticity of the trims
inspection report.
2.2 The trims Inspectors (QA) are assigned to carry out the trims inspection and
to maintain the inspection reports.
3.0 Procedures
3.1 IQC QA is assigned to carry out the trims inspection as per priority basis.
3.2 Inspection is done by following the Swatch card which is approved by the merchandiser.
3.3 All the material where the color check is mandatory, color must be judged under
customer specified light source.
3.4 The accessories inspection is conducted on 10% sample check basis from the received
quantity.
3.5 This 10% should be taken randomly.
3.6 If rejected percent exit 3% then the accessories will be reported as quality fail.
3.7 This information must be communicate with Merchant team immediately.
The following points must be inspected while inspecting the trims:
I. Quantity against invoice and order
II. Color consistency with buyer’s requirements
III. Trim design must be compared with approved sample for artwork and other details
IV. Material consistency must be compared with approved samples/ buyer’s standards
V. Weight must be checked if required
VI. Other requirements as per buyer’s need
4.0 Acceptance:
4.1 If the lot is accepted, IQC passes the lot and release clearance is given to store
along with approval signature on swatch card.
4.2 If the defectives exceed the acceptable limit, the lot is hold and the details are
referred to Merchandiser / Sourcing for further action / decision. Those
defective materials will be kept in a NCM box with evidence.

54
Trims & Accessories Testing Standards
 All trims must be inspected under the buyer specified lighting in the light box
 Color must be verified against the approved sample for lightness, hue and achroma
 Design and size must be verified against the approved sample
 Metal items if required must be sent to third party testing laboratories and must be tested as per buyer
required standards
 Trims are normally being checked against standards on the following parameters.
 Shade matching
 Shrinkage (for lace, draw cord, twill tape, etc)
 Color bleeding
 Width and thickness
 Strength
 Lettering ,Number and size
 Fiber content
 Text content/font/language in labels and tags
 Durability for thread
 Ligner for button
 Puller strength test for zipper
 Fusing bonding strength test for interlining.
 Warning and thickness for poly
 Main mark word , Ply and strength for carton.
Relevant Documents :
 Accessories Inspection Reports – GFIL.QCS.FRM.05
 10% Inspection trims reject register – GFIL.QCS.FRM.28
 Barcode Scanning Reports – GFIL.QCS.FRM.29
 Non conforming records – GFIL.NCM.FRM.07

55
GFIL.QCS.PRO.03
Version # 3
18. Light box using procedure
1.1 Confirm the color and shade for raw materials as per customers requirements.
1.2 Buyer recommended certified Light Boxes must be used to review all materials (fabrics and trims).
Fabrics and Accessories Inspector are responsible to perform this jobs and In charge – Fabrics and Accessories
Inspection will review the records.
3.0 Procedure :
The Light Box used by Gous Fashion Inds Ltd. with D65, UL 3500, TL84 and UV light sources
 The light Box has to calibrated by certified technician and a valid calibration certificate has to be obtained and
must be kept with the machine
 The light box has to be placed in a dark room where it can be used to check the shades variance of machine
 The fabric and trims should be checked under several lighting conditions as specified by the Buyer and proper
records should be kept for color match evaluations
 For best visual review of the colors in both daylight and store light simulation, the following procedure is
recommended:
a) The sample material (trims or fabric) and the color standard must be placed side by side touching each
other
b) They also must be in the same direction, with regard to weave, knit and textile, etc.
 Must be ensure by primary and secondary light source and checked the metamerism for inspected items.
 The bulbs have to be replaced as per the manufacturer recommended changing periods so that there are no
errors while checking the shade variances of material. The replacement date is determined by the following
process:
a) Using time is recorded from the timing meter installed in the box
b) Total hour is calculated as per cumulative reading records from the meter
c) Bulbs are replaced with this information as per the following specified times:
i) Day Light- 4000 hours
ii) Illuminant “A” 2000 hours
iii) Cool White Fluorescent 4000 hours
iv) UL35 4000 hours
v) UV 4000 hours
 Shade light using activities records – GFIL.QCS.FRM.06

56
GFIL..PPE.PRO.01
Version# 03
19. Pre-production Meeting
1.0 Purpose & Scope
1.1 Review the approved Sample.
1.2 Highlight the potential product safety, quality & productivity issue.
1.3 Communicate all potential points with related supervisors, QAs & Other persons
1.4 Take measureable steps to avoid any future unavoidable circumstances.
2.1 The Internal Auditor and Merchandiser are responsible to monitor and to implement the pre-
production meeting procedure.
2.2 Planning & central QA is assigned to ensure that the meeting is conducted before start of
production, and maintain the records.
3.0 Procedures
3.1 On receipt of the style file from planning, the unit in-charge gets the approved sample from
P&D.
3.2 Unit in-charge, reviews the sample along with the production executives, technical executive &
floor QA Executive.
3.3 After the review, Size set samples stitched two pcs in each size / color, checked for workmanship,
styling, and measurement, and submitted to P&D for approval.
3.4 Upon size set approval, the results are communicated to technical team & planning.
3.5 Planning checks the material in-house status and calls for pre-production meeting.
3.6 Pre-production meeting is chaired by Factory Chief Operating Officer and attended by
representative from related floor, QA, Maintenance, Merchants, IQC, IE, planning,
P&D, Stores and central QA
3.7 In P.P. Meeting Internal auditor will assure to receive the all documents as per P.P.
meeting documents Check list.
Sl. No. Documents Types Yes No
Remarks
01 P.P. MEETING FORMAT (FILLED)
02
SIZE SET MEASUREMENT REPORTS
WITH SAMPLE
03 MACHINE LIST
04 LINE LAYOUT

57
05
PRODUCTION PLANNING WITH
CUTTING, SEWING AND FINISHING
06
FABRICS BOOKING AND RECEIVING
STATUS WITH PI
07
ACCESSORIES BOOKING AND
RECEIVING STATUS WITH PI
08
FABRICS INSPECTION REPORTS
WITH SHRINKAGE , WEIGHT AND
SHADE ANALYSING
09
ACCESSORIES INSPECTION
REPORTS WITH BARCODE
SCANNING
10
INTERNAL ALL PRODUCT SAFETY
TESTING REPORTS i.e. BUTTON
PULL TEST , FUSING TEST & HEAT
SEAL TEST ETC
11 PRODUCTION TEST PLAN
12 PO SHEET / ORDER DETAILS
13 PID OR TECHNICAL DETAILS
14 CRITICAL MOCK-UP
15 3RD
PARTY TESTING REPORTS
16 VRN (If applicable)
17
FIRST OUTPUT MEETING RECORDS
WITH MEASUREMENT
18
PILOT RUN MEETING RECORDS
WITH MEASUREMENT
19 TRIMS CARD
3.7 During the PP meeting following activities performed:
3.7.1 Buyer approved sample is reviewed.
3.7.2 Size set sample report is reviewed and the deficiencies discussed.
3.7.3 Make sure of the correct trims placement.
3.7.4 Highlighting potential product safety, quality & productivity issues

58
3.7.5 Discussing print & embroidery placement and appearance as applicable
3.7.6 Discussing finishing & packing details
3.7.7 Discussing production plan & delivery issues 3.8 at the
end of the meeting, all the attendee’s signs off the minutes.
3.9 Pre-production meeting notes , approval sample (approved by DQA
or Buyer QC) & PTP must be communicate with Stores, Merchandiser ,
cutting , sewing and finishing and COO/GM will give the decision to
proceed for Trial Cutting .
First Output Compare Meeting
1.1. Review the ist output garments and compare with approval sample.
1.2. Improve the quality and productivity to analyzing the ist output garments .
1.3. To adjust the pattern.
2.1 Factory Internal auditor and quality manager are responsible to organize the meeting and Production
GM will be chair by the meeting.
3.0 Procedure :
Review the size set sample and adjusted the pattern by Sample section according to the size set measurement
reports and Successfully completed the P.P. Meeting , P.P. Meeting chair will be permit for trial cutting (240 –
300 pcs) for all color and all size and During the meeting following activities performed:
3.1 First output garment must be reviewed with Buyer approved sample
3.2 Size set sample report is reviewed and the deficiencies discussed.
3.3 Make sure of the correct trims placement.
3.4 Highlighting potential product safety, quality & productivity issues
3.5 Discussing print & embroidery placement and appearance as applicable
3.6 Discussing production plan & delivery issues .
3.7 All workmanship and measurement discrepancy must be
recorded at compare meeting reports.
3.8 at the end of the meeting, all the attendee’s signs off the minutes
and meeting notes communicate with all respective department.
Pilot cut / Pilot run Meeting
Purpose and Scope :
1.1 Adjust the pattern review the measurement reports.
1.2 Review the finish garments and compare with approval sample.
1.3 Improve the quality and productivity to analyzing the ist output garments .
1.0Responsibilities :
1.1 Factory Internal auditor and quality manager are responsible to organize the meeting and Production
GM will be chair by the meeting.
2.0Procedure :

59
Review the finish garments of all color and all size and adjusted the pattern by Sample section according to the
size set measurement reports and Factory Chief Operating Officer / GM will be advised to proceed bulk
productions. During the meeting following activities performed:
2.1 Finish garments are reviewed .
2.2 Review the wash standard and hand feel.
2.3 Review the measurement.
2.4 Make sure of the correct trims placement.
2.5 Highlighting potential product safety, quality & productivity issues
2.6 Discussing print & embroidery placement and appearance as applicable
2.7 Discussing production plan & delivery issues .
2.8 All workmanship and measurement discrepancy must be
recorded at compare meeting reports.
2.9 at the end of the meeting, all the attendee’s signs off the
minutes and meeting notes communicate with all respective
department.
 Pre-production meeting Reports – GFIL.PPE.FRM.16
 First output compare records – GFIL.PPE.FRM.17
 Pilot run meeting records – GFIL.PPE.FRM.17A
 Measurement Reports – GFIL.QCS.FRM.15

GOUS UPDATE SOP MANUAL

Recommended

Recommended

More Related Content

What's hot

What's hot (18)

Viewers also liked

Viewers also liked (20)

Similar to GOUS UPDATE SOP MANUAL

Similar to GOUS UPDATE SOP MANUAL (20)

GOUS UPDATE SOP MANUAL