G-16 Best Practice Handbook

World Cat Global Quality Assurance
Title: To: Best Practice Factory Handbook (PUMA/WC, Garment Suppliers)
Introduction: This document shows some of the best practices in various divisions within PUMA factories. Best practices are procedures, systems or equipments executed above the normal requirement. This handbook is a guideline for all factories and WC quality personnel and should encourage everybody to implement similar or other best practices. The best practices outlined in the following pages are aligned with the current quality audit requirements of PUMA. This document is not complete and will be extended on a regular basis. The following factories have contributed to this book: Kin Fung Garment Fashion Ltd. (Xiamen China) Domex Co. Ltd. (HCMC Vietnam) Shan Lian Clothing Co. Ltd. (Shanghai China) Shenzhou Co. Ltd. (Phnom Penh Cambodia) Shenzhou Knitting Co. Ltd. (Ningbo China) Hytex Apparel Co. Ltd. (Suzhou China) PCCS (Phnom Penh Cambodia) PCCS (Batu Pahat Johore Malaysia) Square Fashion Ltd. (Dhaka Bangladesh) ICC4 Gokaldas (Bangalore India) Yumei Garment Co. Ltd. (Shantou China) Jiaxing Quang Viet Garment Co. Ltd. (HCMC Vietnam) Ginma Industries PTE. Ltd.(Kluang Johore Malaysia) Universal Garment Co. Ltd. (Zhong Shan China) PT Bintan Bersatu Apparel (Batam Indonesia) Good Dale Ltd. (Dong Guang China) Union Regent Garment Ltd. (China) Valid from: This document is valid from July 2008 onwards, open for continues improvement Author: Edgar Picazo Date: 01.07.2008 Approved by: Sandra Vollmert Date: 09.07.2008 Document No.: G-16 Version: 1 1
Content:
Fabric and Accessory Procedure 1. 2. 3. 4. 4.2 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. System for fabric storage Material location board Fabric identification system Fabric is clearly separated by status (waiting for inspection) Fabric is clearly separated by status (passed for inspection) Fabric inspection area and machines Fabric inspection Fabric defect example reference W.C. fabric inspection manual Fabric inspection area requirements Nominated factory Q.C. for fabric inspection Fabric inspection report Documentation of light box usage Laboratory testing area Warehouse accessories directory board Accessories storage Thread warehouse/storage PUMA security labels storage Fabric relaxation Fabric relaxation record Steam fabric relaxation machine Performance depending fabric inspection
Cutting 1. 2. 3. 4. 5. 6. Panel inspection procedure Separation of defective and passed cut panels Replacement procedure for defective cut panels Bundle instruction guide Bundle ticket Storage and transportation of cut panels
Heat transfers/Sublimation Print 1. 2. Pneumatic heat transfer machine Heat transfer instructions
Author: Edgar Picazo Date: 01.07.2008
Approved by: Sandra Vollmert Date: 09.07.2008
Document No.: G-16 Version: 1 2
Printing/screen prints 1. 2. 3. 4. Print library Moving infra red flash cure and glass top surface printing table Frame storage Print area
Production 1. 1.2 2. 3. 4. 5. 6. 7. 8. 9. Rewinding machine (Taining) Rewinding machine (Hacoba) Sewing machine maintenance record Production file Special machine equipment to join elastic Identification of critical operation Machine engineered parts Tool room, storage of attachments Working table to insert draw cord Line feeding work station
Embroidery 1. Approved sample
Garment washing in knit factories 1. Approved sample storage
Inspection/Packaging 1. 2. 3.1 3.2 3.3 4. 5. 6. 7. 8. 9. Final inspection area Approved packing sample Packing tools (drawer storage for hangtag guns) Packing tools (storage for hangtag guns in board) Packing tools (storage for tape dispenser in board) Pre sorting of packed garment Carton storage Carton pallet transportation Packing instruction and details Shipment sample Sealing & size set sample Approved by: Sandra Vollmert Date: 09.07.2008 Document No.: G-16 Version: 1 3
Metal detecting policy 1. 2. 3. Broken needle exchange procedure Needle exchange area Metal detecting policy
Training 1. 2. 3. 4. Training center Fabric inspection training Metal detection training Trainee assessment
FABRIC AND ACCESORY STORAGE:

1. Shelf system for fabric
Shelves size matches to fabric width Fabric is stored by style, customer, color and dye lots Clean, organized and spacious storage area Nominated staff assignment displayed at each shelf
Approved by: Sandra Vollmert Date: 09.07.2008 Document No.: G-16 Version: 1 5
2. Material location board (manually updated)
Good organized and visual Material location matches to shelves content Board information and material location matches to inventory system
3. Fabric Identification system
Color codes describe the status of the fabric clearly Displayed and accessible in the warehouse
4.1 Fabric is clearly separated by status
Fabric is stored per color, dye lots, batch, arrival and customer Fabric is identified with color coding (yellow sticker means waiting for inspection) Fabric is stored in shelve recorded and identified per index card
4.2 Fabric is clearly separated by status
Fabrics stored per color, dye lots and customer Fabrics identified with color coding (green sticker means passed inspection) Fabrics stored at shelves recorded and identified with index card
5. Fabric inspection area and machines
Automatic fabric roll transport system Clean, organized and spacious inspection area
6. Fabric inspection
Approved sample of fabric color way is displayed for inspector reference at the machine
7. Fabric defect example reference
Various fabric defects are displayed at the fabric inspection area on a transparent board Guideline to identify fabric defects
8. Display of WC fabric inspection manual
WC fabric inspection manual displayed nicely at inspection areas Manual displayed in original and local language
9. Fabric inspection area requirements
Displayed/posted requirements Written in local and English language

10. Nominated factory Q.C for fabric inspection
Trained and nominated staff displayed in the working area
11. Fabric inspection report
Fabric inspection report is filled up correctly and maintained as per WC procedure at every visit
12. Documentation of light box usage
Recorded usage per style, customer, type of bulb used, signed by nominated staff
13. Laboratory testing area
Clean and organized laboratory for basic fabric tests and garment wash tests Complete equipment
14. Warehouse Accessories directory board
Clear and easy identification of accessories and their location in the warehouse
15. Accessories storage
Clean, organized and properly stored accessories Every shelf with index card for inventory and identification Fiberglas shelves ensure easy item identification
16. Thread warehouse/storage
Clean and organized storage Threads stored by types and brands Label at every shelf for identification Stored thread in numbered shelves matches inventory system
17. PUMA security labels storage
Security labels are locked in a cabinet with nominated access Inventory control is documented nicely Labels stored separately by country and color
18. Fabric relaxation
Shelf height limits the Number of fabric layers to assure good relaxation result Relaxed fabric is covered during relaxation to protect it from dust and dirt Separate and spacious area for fabric relaxation Custom made racks fit the fabric in width/length Racks have bull casters for easier transport and increased flexibility Clean and organized area
19. Fabric Relaxation record
Each record contains style, fabric article No. , yardages, color and relaxing time
20. Steam fabric relaxation machine
Perfect relaxation with steam for knit and elastic fabric

21. Performance depending fabric inspection
Fabric suppliers are evaluated based on the inspection results of the incoming fabrics. Fabric suppliers are classified, the percentage of fabric that will be inspected depends on the rejection ratio
CUTTING: 1. Panel inspection procedure
Clear procedure explains every step how to inspect panels in various kinds of fabric defects Procedure helps and guide workers to understand how to conduct panel inspection
2. Separation of defective and passed cut panels
Separate boxes to store passed and defective panels after inspection Every box is labeled for its own purpose
3. Replacement procedure for defective cut panels
Leftover yardage is stored properly in plastic tubes in a separate area for cut panel replacement Replacement yardage in every roll is recorded, marked and documented for easy identification
4. Bundle instruction guide
Clear instruction for the staff which parts of the garment and how many must be bundled in one bundle Nice visual system with approval stamp
5. Bundle ticket
Bundle plan
Mini marker
Bundle tickets
Panel breakdown
Complete and detailed information for bundle ticket preparation Mini marker is used to identify cut parts of the panels
6. Storage and Transportation of cut panels
Separate storage location for embroidery panels, print panels, ready for production panels Clear and easy identification of cut panel status
HEAT TRANSFER/SUBLIMATION PRINT: 1. Pneumatic heat transfer machine
Heat transfer conditions including wash test sample and document displayed at the machine Heat transfer SOPs placed at every machine Heat Transfer sample is displayed in the area
2. Heat Transfer instructions
Heat Transfer instructions and guidelines by heat transfer supplier displayed in the heat transfer section
PRINTING/SCREEN PRINT: 1. PUMA print library
Print samples organized and placed in glass cabinet to avoid dirt and dust Print sample displayed inside printing office for easy access and reference
2. Moving infra red flash cure and glass top surface printing table
Clean and safe working place Glass surface allows easy cleaning and removal of leftover print paste Panels can be easily removed (no overstretching)
3. Frame storage
Clean racks to store frames, frames are made of metal Racks located to the end of printing tables and easy accessible for the staff
4. Print area
Clean and safe environment Spacious and organized working area
PRODUCTION: 1.1. Rewinding machine (Taining)
Separated and clean area for rewinding threads Nominated rewinding machine from Taining Plastic bins to place and sort used cones
1.2. Rewinding machine (Hacoba)
Nominated rewinding machine from Hacoba Multiple thread winder with big capacity
2. Sewing machine maintenance record
Regular and properly filled machine maintenance record Individual maintenance record attached at every sewing machine
3. Production file
Complete production file displayed in production protected under glass All information is translated into local language
4. Special machine equipment to join elastic band
Pneumatic machine, full automatic High accuracy, very efficient
5.
Identification of critical operation
Sign board to identify critical operations within the lines Easy reference and guidance for line QCs and supervisors
6. Machine engineered parts
Increased accuracy and efficiency for difficult seams
7. Tool room, storage of attachments
Safe and organized storage in glass cabinet for machine attachment Easy access and visible
8. Working table to insert draw cord
Custom made working table with roll bars and drop box for loose threads, loose threads will not fall on the floor Table with bull caster for easy movement
9. Line feeding work station
Separate workstation for Line feeding Clean, tidy workplace with enough place for storage (three levels)
EMBROIDERY: 1. Approved sample
Approved embroidery swatches per colorway displayed at every machine
Approved embroidery swatches displayed at every inspection table as a reference for the quality inspection
GARMENT WASHING IN KNIT FACTORIES: 1. Approval sample storage
Approval samples are stored properly, covered with polybag for reference, reports are attached
INSPECTION/PACKAGING: 1. Final inspection area
Separate area for final inspection Clean, spacious and organized Standard final inspection table with adequate light, space and Information Color coded storage box for segregation
2. Approved packing sample
Displayed in the packing area for staff reference by style Maintained and controlled
3.1 Packing tool storage
Hang Tag guns are stored separately, inventory is documented and controlled
3.2 Packing tool storage
Separately stored hang tag guns and hanged in the tag gun control board/cabinet Staff name marked on the control board to identify users
3.3 Packing tools for tape (dispenser on board)
Packing tape dispenser stored separately with controlled inventory
4. Pre sorting of packed garments
Ready made garment in poly bags are sorted by colors, size and customer
5. Carton storage
Spacious, clean, organized carton storage on pallets Cartons stored by style, size and customer/P.O. Documented shelves and controlled per location
6. Carton pallet transportation
Automatic pallet carrier used to transport cartons for loading Convenient and safe for workers
7. Packing instruction and details
Displayed in the packing area, nice, organized, visual Translated into local language
8. Shipment sample
Shipment sample is displayed in final inspection room and used as a reference by WCQC during final inspection to assure the color/shade continuity from the first to the last shipment window Sample is displayed from the first shipment sample by style, color and sizes
9. Sealing and size set samples
Approved sample is arrange and displayed for on going styles for production Easy access and visible to everyone who needs sample for verification
METAL DETECTING POLICY: 1. Broken needle exchange procedure
Displayed in the needle exchange secured area Translated into local language
2. Needle exchange area
Needle exchange is done in a secured area with nominated access Factorys needle exchange procedure is displayed in the area
3. Metal detection policy
WC metal detecting policy is displayed in the metal detection area WC metal detecting policy is translated into local language
TRAINING: 1. Training center
Separate training center for training only Clean and organized training center facility with all necessary machines and equipment
2. Fabric inspection training
Training is conducted regularly Attendance record for every training session available
3. Metal detection training
Training is conducted regularly Attendance record for every training session available
5. Trainee assessment
Documented training activity and performance evaluation Graphic result

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World Cat Global Quality Assurance

Title: To: Best Practice Factory Handbook (PUMA/WC, Garment Suppliers)

Author: Edgar Picazo Date: 01.07.2008

Approved by: Sandra Vollmert Date: 09.07.2008

Document No.: G-16 Version: 1 2

Embroidery 1. Approved sample

Garment washing in knit factories 1. Approved sample storage

Author: Edgar Picazo Date: 01.07.2008

Author: Edgar Picazo Date: 01.07.2008

Approved by: Sandra Vollmert Date: 09.07.2008

Document No.: G-16 Version: 1 4

FABRIC AND ACCESORY STORAGE:

Author: Edgar Picazo Date: 01.07.2008

2. Material location board (manually updated)

Author: Edgar Picazo Date: 01.07.2008

Approved by: Sandra Vollmert Date: 09.07.2008

Document No.: G-16 Version: 1 6

3. Fabric Identification system

Author: Edgar Picazo Date: 01.07.2008

4.1 Fabric is clearly separated by status

Author: Edgar Picazo Date: 01.07.2008

4.2 Fabric is clearly separated by status

Author: Edgar Picazo Date: 01.07.2008

5. Fabric inspection area and machines

Author: Edgar Picazo Date: 01.07.2008

Author: Edgar Picazo Date: 01.07.2008

Approved by: Sandra Vollmert Date: 09.07.2008

Document No.: G-16 Version: 1 11

7. Fabric defect example reference

Author: Edgar Picazo Date: 01.07.2008

Approved by: Sandra Vollmert Date: 09.07.2008

Document No.: G-16 Version: 1 12

8. Display of WC fabric inspection manual

Author: Edgar Picazo Date: 01.07.2008

Approved by: Sandra Vollmert Date: 09.07.2008

Document No.: G-16 Version: 1 13

9. Fabric inspection area requirements

Displayed/posted requirements Written in local and English language

Author: Edgar Picazo Date: 01.07.2008

10. Nominated factory Q.C for fabric inspection

Trained and nominated staff displayed in the working area

Author: Edgar Picazo Date: 01.07.2008

Approved by: Sandra Vollmert Date: 09.07.2008

Document No.: G-16 Version: 1 15

11. Fabric inspection report

Author: Edgar Picazo Date: 01.07.2008

Approved by: Sandra Vollmert Date: 09.07.2008

Document No.: G-16 Version: 1 16

12. Documentation of light box usage

Author: Edgar Picazo Date: 01.07.2008

13. Laboratory testing area

Author: Edgar Picazo Date: 01.07.2008

Approved by: Sandra Vollmert Date: 09.07.2008

Document No.: G-16 Version: 1 18

14. Warehouse Accessories directory board

Author: Edgar Picazo Date: 01.07.2008

15. Accessories storage

Author: Edgar Picazo Date: 01.07.2008

Approved by: Sandra Vollmert Date: 09.07.2008

Document No.: G-16 Version: 1 20

16. Thread warehouse/storage

Author: Edgar Picazo Date: 01.07.2008

17. PUMA security labels storage

Author: Edgar Picazo Date: 01.07.2008