Needle control is a major factor in Apparel manufacturing industry . I have developed this flow chart by accumulating the main brands standard requirement. This Flow chart made on the base of American Eagle Outfitters advice . Thanks to Mr. Simons & Mr. Prakash of AEO .

1. If Ok
If Ok
If Ok
If Not Ok
If Found
If Not Found
If Found
If Ok
If
Not Found
If Ok
If Not Ok
If Ok
If found passed
Needle Control Flow Chart
Needle Storage
at main Store
Receive Needle Requisition from
Sub store.
Review Stock & Usage
Accountability
1. Requisition Slip
Form No: F|ST|47
2. Needle stock Register
Form No: F|ST|48
Issue Needle to Sub store
Sub store shall review the
daily Stock & Usage
Accountability
Receive Needle Requisition from Sewing Line
Needle stock Register
Form No:F|ST|48
Assess the requisition type
& consult with line
/production
If it’s Used Needle case
Needle issuer
will compare &
Issue new needle
Operator will start the production
immediately
Used needle disposal log
Form No:F|ST|49
Revise the Needle
Requisition slip
If Not Ok
If Not Ok
Revise the Needle
Requisition slip
Needle Issuer shall issue new Needle,
and Mechanic shall fix the needle in M/c.
Metal contaminated Garments
Form No:F|ST|52
No:F|ST|52
If Not Ok
If Found , Not Passed
Metal Contamination Notification
Form No:F|ST|51
If supervisor / operator lost broken
needle parts
If Its Broken Needle case
Operator shall stop the sewing
M/C & search for the broken
parts and inform the Line Chief
/Supervisor
Broken needle log
Form No:F|ST|50
Supervisor shall accumulate the broken
parts and carry them in a plastic container to
the Needle Issuer
QA Manager will decide to
take the all line garments to
metal detection m/c for
scanning
Needle issuer will
compare the broken
parts & keep record
QA & production team shall identify the
location of detected broken needle parts in
garments.
Needle Issuer shall issue new Needle
Mechanic / supervisor shall fix the issued
needle in the Sewing M/C
Send the goods to Metal contaminated
box
Metal Detection Calibration Report
Form No: F|QA|PAC|28
No:F|ST|52
Metal Detection Report (Hourly)
Form No: F|QA|PAC|21
No:F|ST|52
Calibrate the Metal Detector by the test
card
Check the
calibration status
Pass all the garments through metal
detector machine.
Check & Review the Hourly
Metal Detection Report
Send the garments to
the packing section