time table for factory tour

Time need Area Explaination

(min)
10 Labroom - Introduction which kind test Labroom can do:
+ Wet process
+ Phycical test
+ Darkroom for color test
- Show certificate which Buyer approve

15 Warehouse - Introduction flow of material

- Location and process:
+ Storage
+ Inspection (visual, color, shrinkage, weight…)
+ Spongin machine
+ Relax fabric SOP
- Visual display fabric status and location map
 7 Cutting - Explain number cutting table and equipment
- Process and SOP:
+ Spreading method
+ spreading high
+ Cutting QC for cutting accuracy
+ Panel inspection
+ Numbering process
- Introduction supermarket place

15 Sewing line - Start from input area of the line, show preparation process
- Explain flexible of the line for knit product with shorter line and
multi skill operator
- Traffic light system, mockup, 02 inline QC
- use some operation to explain detail process sewing like:
+ Overlock matching with notch
+ heming with coverstitch with high speed and consistence seam
sewing
- End line QC process

7 Iron - Explain iron SOP:

+ Iron standard
+ template in table
+ Neck template
- QC inspection after iron
- Measurement QC

6 Packing - Show hang tag area

- Metal detector process
- Register CTPAT enter
- Folding process:
+ Folding standard
+ Template for fast and accurate folding
- Packing

60

factory #2 tour need less time from Finishing back warehouse

 Script

'- This is place for container in and loading fabric and trim. After unload from container will move to quarantine area for cross
check with packing list
- Base on QTY each batch receive fabric WH supervisor will collect at least 10% QTY/LOT for visual inspection. And WH staff wil
move fabric to shelf.
- For easy for worker understand we visualize SOP local language for work follow.
- Speed for inspection, standard and 4 points system we train for staff understand and comply
- In mini Labroom we will inspect:
+ color with shade band 100% of fabric receive in card for check color same LOT in difference roll. This will check with approve
swatch and in light box with approve light source.
+ Weigh test will do 10% with tolerance is 5%
+ Shrinkage test will check 10% and with 02 times steam iron. This will present for process iron in sewing line and iron in finish
garment. All specimen after iron will keep relax in shelf 24h before process next testing.
+ if style have washing process will cut specimen send for washing company test and bring back do iron for check shrinkage.
- Which fabric high shrinkage or not consistence shrinkage we will use spongin machine for pre-shrink fabric for stable before
cutting. Also this machine can support reduce skewing or bowing issue due issue with shrinkage not stable.
- All knit fabric before cutting should relax at least 24h, normally with content rayon, spandex we will relax 48h and have record
in relax form. With date and time relax fabric, which shelf have green sticker mean this meet relax time and accept for release
for cutting
- For fabric we will put style by style and update information in report of each shelf. Which one we saw with inspection date
and green sticker mean this was inspected and pass. With reject we will put red sticker and move to reject area with lock.
- in cutting we have 12 cutting table and depend fabrication we will use spreading machine or manual.
- As the moment we cutting by manual cutting machine. But we already have auto cutting machine for woven fabric. This on
study process we will invest in near future
- Before start spread we have spreading sheet from cutting supervisor provide for worker follow. In spreading sheet we will
record detail number layer spreading and attached roll label at the back for easy control shade and shortage in roll if have.
- standed for spreading is maximum 4"
- Before cutting, QC will check spreading tenstion.
- During cutting QC will use hard pattern for check cutting accuracy for top, middle and bottom. If any problem QC will feedbac
immediatelly for cutter
- After cutting will have numberring process and panel inspection. if have any defect panel will sort out for replacement for
recut (in case)
- The place for supplier bundle to sewing line we call super market. This place visual for see for well cutting supplier bundle for
sewing line. And easy see which line need feed in bundle.
- Main item produce here is knit. Complicated style we need start with marking process or some have addition contorl in panel
- Compare with before now we make shorter line for flexible in changeover and reduce the production lead time. To run this
layout we must develop multi skill for sewer
- In process we have TFL system to control defect in process. This tool easy visualize the quality level for sewer. Make sure
standard for sewer and QC check we have full piece mockup. This is the evident show quality each operation can acheive.
- Each operation have guide and worker need follow strickly notch for control in sewing
- We haev GSD analyze to find the better method for sewing sew with less time and consistence quality
- Garment finish will check 100% before move to iron

- When start new style, supervisor will train for ironner standard to iron and post standard infront each table. Make sure same
style the SOP will do the same
- Knit item so need to control sharp in garment so in iron table need have template for control
- Neck is critical point so need have templete follow the sharp
- After garment finish iron will check by QC for iron performance
- Random for measurement and key measurement before move to packing

- Garment will tagging with hang tag size by size

- Garment will pass metal detector machine before folding. Machine wil calibrate 03 times/day follow 9 points standard
- in folding before process supervisor will make standard and guide for worker follow
- template will use to make folding accurate and more efficiency.
time table for factory tour
Time need Area Explaination
(min)
17 Warehouse - Introduction flow of material
- Show place control pre-shrinkage fabric with spoongin and fusing
machine
+ explain difference method in control woven fabric
+ Show relax attachment make fabric relax
- Location and process:
+ Storage
+ Inspection (visual, color, shrinkage, weight…)
+ Relax fabric SOP
- Visual display fabric status and location map
- Upstair for :
+ Brand protection label
+ color control fabric
+ Shrinkage test

13 Cutting - Explain different method for spreading fabric

- Spreading standard
- Cutting process:
+ Show auto cutting machine and explain
+ Panel inspection
- Fusing:
+ Calibrate
+ Explain difference fusing piece and block fusing

15 Sewing line - Start from input area of the line, show preparation process
- Explain different with layout for woven product and multi skill
operator
- Traffic light system, mockup, inline QC
- In line QC inspection before assembly linning
- use some operation to explain detail process sewing like:
+ Armhole setting machine
+ using template
- End line QC process

3 Button - Process control hand needle

- wrap for button
- Pulling test (if question)
5 Iron - Explain iron SOP:
+ Iron standard
+ Process iron
- QC inspection after iron
- Measurement QC

3 Packing - Show hang tag area

- Metal detector process
- Register CTPAT enter
- Folding process
- Packing

56
 Script

- This is place for container in and loading fabric and trim. After unload from container will move to quarantine
area check compare with packing list.
- left side is area for heavy trim like thread, shoulder pad, elastic… other like label we will keep separate room.
- this woven factory so for shrinkage control we have addition method with using fusing machine. Show in right
side. Depend fabrication we will do testing first when receive fabric, compare with 02 speciment for which
method shrinkage is stable and not change phycial of fabric we will chose this method. So we have spongin and
fusing machine with relax attachment make fabric really relax, reduce potiential issue with fold mark
- Fabric relax here follow the same standard with other (PI #1, PI #2)
- Storage the same with information fabric arrive, date inspected and status with green sticker
- Location map to identify style and fabric in the shelf
- Upstair with room for label for brand protection purpose with lock and person in charge
- Trim follow AQL 1.0 level 2 and have separate lock for reject trim
- other side is color test with shade band 100%, blanket 2413 and E2E for check color within roll
- Shrikage test with fusing and non fusing

- This factory produce woven so need only 6 spreading table.

- standard the same with maximum 4"
- spreading the same standard with attached label at the back spreading sheet
- Auto cutting machine with 02, Bummer and Lectra. Lectra is better quality and accurate, this model we will
keep invest after study from here
- With CAD can increase eff from 30%-40% and save more fabric because they can make buffer is 0.
- we have the same with panel inspection to filter defect panel
- Fusing we have big width suitable for fusing block
- Maintain standard quality, daily 02 time/day calibrate is the must practice here with thermo stripe and fusing
stadard from supplier
- for small part we also have small one for fusing

- Preparation table for marking panel

- Because woven style so line here longer than knit line
- In line QC and TFL process the same with PI #1, PI #2
- Sub-assembly process will have template for accurate quality and easy for output
- Armhole setting with special machine with skill worker
- before close linning with shelf body will have QC inspection before this operation
- 100% garment will inspect by endline QC before move to next section

- Centralize for button section so this can stable with button process like same SPI, tension…
- Wrap button have with epic or escolize thread
- random pulling test daily
- Because woven so iron will do by process with difference arm in iron table
- Iron standard make by supervisor and process follow in iron flow
- QC will inspect after iron and measurent QC will random check

- Follow same as standard in PI #1, #2