Document Number :

NR / PR / 04

NON-ROUTINE OPERATIONAL PROCEDURES

Issue :
00
Date :
01 April 2014

Process :

Production Process
Page :

Procedure for Sewing

Objective:

1.0

This

1 of 4

procedure

describes

all

non-routine

operations

associated with Sewing is documented to ensure that the Sewing is carried out under
controlled conditions, whenever a deviation or nonconformity happens in the standard work
operation.

2.0

Scope :

This procedure is applicable only for Production all Plants

3.0

Method of Training:

On the Job training by Production Manager

4.0

Handling damage panels inline:

1.

5.0

Sewing operation shall be carried out without

6.

any Cut Panel damages.

3.

7.

Tagged non-conformity panels shall be replaced

2.

or repaired and issued again to the line by

If any variation in panels found while starting or

creating the Cut Panel reentry note from

progressing of Sewing operation, the variation

Cutting.

shall

8.

be

informed

first

to

QA

Supervisor/Executive by Production supervisor.

9.

Issue of tagged non-conformity panels to

4.
5.

Damage

Sewing operation shall be mentioned or marked

panels

found

variation

shall

be

about the non-conformity clearly to Sewing

segregated and mark non-conformity tag by QA

operators, QA and Production supervisors.

supervisors , then inform about this variation to

10.

cutting Incharge by clear documentation (NCR

Report)

raised

by

QA

Supervisor

11. Sewing operation shall be followed up tightly for

from

the

Production Line.

non-conformed

panels

throughout

the

operations

12.

6.0

Handling inline Sewing defects:

9.0
10.0

7.0

11.0

1. While doing the Sewing operation, it shall be

3. If the operation carries more inline damages by

free from Sewing defects.

operator, machine, material and method shall

8.0

be monitored and followed by QA supervisor on

2. If any variation found while doing Sewing

periodic basis.

operation by operators continuously, shall be

12.0

informed to QA supervisors and traffic light

4. The Sewing defects shall be documented on

system(Inline Quality Assurance Report - 7.0

different categories on periodic basis, then

System) shall be monitored on periodic basis for

actions taken for top prioritized defects by QA

all Sewing operations.

Revision No :

Revision Date :

Prepared By :

Approved By

Document Number :

NON-ROUTINE OPERATIONAL PROCEDURES

NR / PR / 04
Issue :
00
Date :
01 April 2014

Process :

Production Process
Page :

Procedure for Sewing

2 of 4

Supervisor / Executive by raising corrective

and meeting conducted regarding inline defects

action (CA) report.

to

13.0

damages to relevant Supervisor / Executives.

make awareness on action taken on inline

15.0

5. The monitoring of inline damages shall be

documented and ends with corrective and

7. Graphical

representation

of

inline

Sewing

preventive action report duly signed and agreed

defects and actions taken on them shall be

by Production and QA incharges.

clearly prioritized and displayed to relevant

14.0

incharge on periodic basis.

6. Corrective and preventive action document shall

16.0

be updated in weekly basis by QA incharges

17.0
18.0

19.0

Handling Rejected Garments:

1.

2.

The garment produced in Production line shall

3.

The garment gets rejected by QC shall be

be in good condition with defined specification

tagged and segregated at the end line, then

in Daily Measurement Chart.

accounted it for recut process in Daily End Line

20.0

defect analysis report on hourly basis.

If any variation found in garment specification

against
Checkers

defined

specification

(QC)

shall

be

by

21.0

Quality

notified

4.

Then the accounted rejected garment / panels

and

shall be accounted for Recut Process

documented, then communicated to Production

and QA Supervisor.

22.0
23.0

Handling snap defects:

24.0
1.

3.

If snap defect found by QC, then the entire snap

Garment produced in Production Line after

defected

attaching snap button shall be 100 % defect

informed to QA incharge then corrective and

free while passing QC processes like visual

preventive action taken in very conscious

attachment, button pull test and button attach

manner to make error free snap attach.

shall

be

rejected

then

28.0

width etc.

25.0
2.

garment

4.

The entire garment confirmed as snap defect

If any variation found in the snap attaching

shall be directly accounted for Recut Process

operation,

with clear documentation on End line defect

the

entire

garment

shall

be

analysis report.

accounted it for recut and documented in the

snap defect file (Daily Button Mistake Analysis

29.0

Report).

5.

And those garments are segregated and put

26.0

them into Red color bin provided in Production

27.0

Line which is labelled as Recut Bin.

Revision No :

Revision Date :

Prepared By :

Approved By

Document Number :

NR / PR / 04

NON-ROUTINE OPERATIONAL PROCEDURES

Issue :
00
Date :
01 April 2014

Process :

Production Process
Page :

Procedure for Sewing

30.0

34.0

31.0

35.0

32.0

36.0

33.0

37.0

38.0

40.0

39.0

3 of 4

Handling more than 2 % Recut:

1.

The Production Line shall get up to 2 %

of Recut quantity for each Item wise order
quantity as per the norms of factory procedure.

6.

7.

Based
Production

2.

3.

on

the

Department,

Debit

Note

Merchandizers

from
will

proceed the process to get fabric for more than

If any deviation is found beyond more

2 % Recut of an Item.

than 2 % of allowed Recut quantity in the form

of more damages.

8.
9.

After arrival of an extra fabric to recut

section, more than 2 % recut quantity is fulfilled

4.

5.

Debit Note shall be raised in order to get

on time.

extra fabric for more than 2 % Recut quantity of

an Item by Production Manager Approval.
10.

Revision No :

Revision Date :

Prepared By :

Approved By

41.0

Records:

End line rework report shall be maintained by quality checker

1.

Job issue note completion report shall be maintained by packing leader

2.

Daily button mistake analysis report shall be maintained by quality checker

3.
42.0

Related Procedures:

a)

Standard Work Instruction for Sewing

- SW /PR / 04

a)

Daily End line defect analysis report

- FO / QA / 07

1.
43.0

Related Documents:

1.

b)

Inline Quality Assurance report 7.0 System

- FO / QA

/ 35
b

Corrective Action and Preventive Action form Sewing department - FO / QA / 30

Daily button mistake analysis report

- FO / QA / 47