SOP for Approved Fabric & Trim Card

Standard Operating Procedure (SOP): Approved Fabric & Trim Card

 Department: Merchandising
Process: Stores
Performed by: Merchandiser
Reporting to: Merchandising Manager

Purpose of the SOP:

 This SOP aims to establish a standardized process for preparing, maintaining, and using Approved Fabric and Trim Cards to ensure product quality and adherence to buyer approvals. It provides authentic and reliable information on fabrics and trims to be used in manufacturing, facilitating seamless communication between departments and stakeholders.

Scope of the Procedure:

 This procedure applies to the preparation, validation, and maintenance of approved fabric and trim cards. These cards serve as an official reference across all departments — cutting, sewing, finishing, and quality assurance — to ensure product consistency and compliance with buyer expectations.

Responsibilities:

•  Merchandiser: Prepare and verify fabric and trim cards; ensure compliance with buyer approvals. 
• Merchandising Manager: Responsible for supervising the entire process and granting approval for the finalized trim cards before production begins.
• Stores In-Charge: Store and manage fabric and trim samples; certify accuracy.
• QA Manager: Authorize and endorse the trim cards, verifying that all quality criteria are fulfilled.

Step-by-Step Procedure:

Initial Approval:
Merchandiser  grants approval for the trim card and routes it to the store via the PPC department.

Distribution of Trim Cards :

 The store must produce four identical trim cards: one for the store, and three for distribution—one to the buying office, one for production, and one for the master file. 

Bulk Material Handling:
Upon receiving bulk fabric and trims, the merchandiser collects three sets of fabric/trim cards, including fabric swatches and samples.

Validation in Store:
The Stores In-Charge verifies the trims and fabrics against the original buyer-approved card and certifies their accuracy.

Strict Control Over Changes:
No changes are allowed to any item listed on the approved trim card unless re-approved by the Buyer, Merchandiser, and QA Manager.

Sign-Off & Final Approval:
Both the Merchandiser and QA Manager must sign off on the card before it’s used in production.

Post-Production Handling:
Once production is completed, the approved trim card is securely filed for future reference or audits.

Pre-Production Check:

 Bulk production must not start until all trims and fabrics have been approved by the Buyer, Merchandiser, and QA Manager.

Key Benefits

• Ensures all fabrics and trims are buyer-approved
• Promotes quality assurance and consistency across departments
• Provides a clear reference for what materials should be used
• Helps prevent production errors or mismatches
• Supports audit readiness and traceability

Materials and Tools:
 Information/Data: QA, Production, Stores, and Departments

 Samples: Actual fabric and trim samples, swatches

 Related Documents: BOM (Bill of Materials), Order Sheets

 Formats: Approved trim and fabric card templates.

Final Thoughts: 

 Maintaining an accurate and approved Fabric & Trim Card SOP is essential in modern apparel production. It ensures all departments work with uniform standards, reduces mistakes, and reinforces buyer trust in your process. Make sure this SOP is followed strictly for every production order to meet high standards of quality and compliance.

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Related SOPs You Might Find Useful:

1. SOP for Trim Card Preparation and Approval.
2. SOP of Style Material status for Apparel Stores.
3. SOP of Approved Fabric Standard.
4. SOP of Style reconciliation.
5. SOP of Inventory item In & Out.
6. SOP of Stores Link with Accounts.
7. SOP for Leftover Records.
8. SOP for Bin Cards.
9. SOP for Ledger in the garments.
10. SOP for Goods Transferring Procedure.
11. SOP for Fabric Segregation Records.
12. SOP for Daily Issuing Preparation.
13. SOP for Purchase Order in the apparels.
14. SOP for Garments Stores.
15. Department Standard Process Flow Chart.

Tags: #ApparelManufacturing #SOP #FabricTrimCard #QualityControl #GarmentProduction

#MerchandisingProcess #BOM #TrimsAndFabrics

How to calculate productivity in garment?

In the garment industry, productivity is a vital metric that significantly influences both efficiency and profitability. Particularly in garment sewing, high productivity levels are essential for optimizing manufacturing operations and ensuring competitive advantage. Understanding how to calculate productivity can help manufacturers identify areas for improvement and implement strategies to enhance overall performance. Here's a comprehensive guide on how to calculate productivity in the garment industry:

How to calculate productivity in garment manufacturing?

1. Define Productivity Metrics:

Before calculating productivity, it's essential to define the metrics that will be used. In the garment industry, productivity is often measured in terms of output per unit of input. Common metrics include:

• Pieces per Operator per Hour (PPOH): This metric measures the number of garments produced by an operator in one hour.

• Pieces per Machine per Hour (PPMH): This metric measures the number of garments produced by a machine in one hour.

• Efficiency Percentage: This metric measures the ratio of actual output to the standard output, expressed as a percentage.

2. Collect Data:

To calculate productivity, you need accurate data on the production process. This includes:

• Total Output: The total number of garments produced in a specific period.
• Total Input: The total number of operators or machines used in the production process.
• Standard Time: The time required to produce one garment under standard conditions.

3. Calculate Pieces per Operator per Hour (PPOH):

To calculate PPOH, use the following formula:

PPOH = Total Output Total / (Operators x Total Hours Worked)
For example, if 1000 garments are produced by 100 operators working 8 hours each, the PPOH would be:

PPOH = 1000 / (100 x 8 ) = 1.25 pieces per operator per hour

4. Calculate Pieces per Machine per Hour (PPMH):

To calculate PPMH, use the following formula:

PPMH = Total Output Total / (Machines x Total Hours Worked)
For example, if 100 garments are produced by 5 machines working 8 hours each, the PPMH would be:

PPMH = 100 / (5×8) = 2.5 pieces per machine per hour.

5. Calculate Efficiency Percentage:

Utilize the following formula to calculate the efficiency percentage:

Efficiency Percentage = (Total Output × Standard Time) / Total Hours Worked x 100
For example, if the standard time to produce one garment is 0.5 hours, and 100 garments are produced in 80 hours, the efficiency percentage would be:

Efficiency Percentage = (100 × 0.5) / 80 x 100 = 62.5 %

6. Analyze and Improve:

Once you have calculated the productivity metrics, analyze the results to identify areas for improvement. Look for bottlenecks in the production process, inefficiencies, and opportunities to enhance performance. Implement strategies such as training programs, process optimization, and investment in advanced technology to improve productivity.

Conclusion:

Understanding how to calculate productivity in the garment industry is crucial for optimizing production processes and boosting overall efficiency. By defining productivity metrics, collecting accurate data, and analyzing the results, manufacturers can identify areas for improvement and implement strategies to boost productivity. Whether it's through automation, workforce training, or process optimization, improving productivity in garment sewing can lead to significant benefits for the industry.

You can visit my post to learn more. Visit here to know what is operation breakdown, layout of shirt, operation breakdown of skirt, layout of trouser, trim card. You can visit my post to learn more about the bulletin or breakdown of garments in the garment industry.

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Thank you for reading. Your support means a lot to me and I'm grateful for your encouragement to create more content related to Industrial Engineering. Feel free to share your thoughts on how I can improve this article or suggest topics for future posts.

Maximizing productivity within the garment industry is crucial for maintaining competitiveness and profitability. In a fast-paced environment where trends change rapidly, ensuring that your processes are optimized can lead to significant outcomes. In my industrial engineering tutorial series, I am sharing the article “24 Effective Ways to Improve Productivity in Garment Production”. It will be boost up the Efficiency and Productivity in Garment Production.

24 Effective Ways to Improve Productivity in Garment Production

24 effective strategies that can be implemented to streamline garment production processes and improve overall efficiency. Here are 24 innovative strategies to enhance efficiency in the garment sector.

1. Implement Lean Manufacturing Practices:

Adopting lean principles helps eliminate waste, increase value, and improve workflow efficiency across all production stages.

2. Invest in Technology:

Embracing digital technologies, such as automated cutting machines and computer-aided design (CAD) software, can streamline operations and reduce manual errors.

3. Optimize Supply Chain Management:

Utilize advanced supply chain management systems to ensure timely delivery of materials and reduce stock-outs, which can delay production.

4. Train Your Workforce:

Regular training programs will enhance the skills of your employees, leading to improved efficiency and quality in production.

5. Foster a Collaborative Work Environment:

Encouraging teamwork and open communication can streamline processes and enhance problem-solving capabilities among workers.

6. Utilize Data Analytics:

Leverage data analytics tools to monitor production metrics, identify bottlenecks, and make informed decisions to improve efficiency.

7. Adopt a Just-In-Time (JIT) Inventory System:

The JIT approach minimizes inventory costs and reduces waste by synchronizing material orders with production schedules.

8. Set Clear Goals and KPIs:

Establish clear performance objectives and key performance indicators (KPIs) to track productivity and motivate your team.

9. Upgrade Equipment:

Investing in modern machinery can improve production speed and quality, significantly boosting overall efficiency.

10. Streamline Communication Channels:

Implement clear communication structures to ensure that all team members are on the same page and reduce misunderstandings.

11. Conduct Regular Productivity Assessments:

Regularly evaluate production processes to identify areas for improvement and ensure that operations run smoothly.

12. Empower Employees:

Encourage workers to take ownership of their roles and make suggestions for improvements, fostering a culture of continuous improvement.

13. Reduce Cycle Time:

Analyze and reduce cycle times by finding ways to speed up repetitive tasks without sacrificing quality.

14. Enhance Quality Control:

Implementing stringent quality control measures will decrease rework and defects, improving overall productivity.

15. Use Eco-Friendly Practices:

Incorporating sustainable practices can lead to better resource management and efficiency while appealing to eco-conscious consumers.

16. Standardize Processes:

Develop standardized operating procedures for repetitive tasks to ensure consistency and improve training for new employees.

17. Manage Time Effectively:

Encourage time management skills among employees to ensure that tasks are completed efficiently and deadlines are met.

18. Incorporate Ergonomic Solutions:

Designing workspaces with ergonomics in mind can reduce worker fatigue and increase output.

19. Implement QCO (Quick Change Over Time):

Implement QCO (Quick Change Over Time) to Reduce Line Setting Time. Research indicates that production lines usually achieve their optimal productivity around the sixth or seventh day after an order is loaded. However, the time lost during the initial setup, often termed the learning curve, can adversely affect average labor productivity. A primary contributor to this downtime is the excessive time spent configuring the line for new styles. To counteract this, it's imperative to streamline the line setting process to uphold high productivity levels.

1. Conduct Detailed Garment Assessments:
   Engineers should perform a thorough examination of the garment. This detailed understanding facilitates more effective line setups.

2. Create Comprehensive Operation Bulletins:
   Before production begins, prepare precise operation bulletins that specify machine requirements and procedural steps. These serve as vital references for the production team, ensuring everyone is aligned.

3. Design an Efficient Machine Layout:
   Draft a strategic machine layout plan that enhances the arrangement of equipment. An optimized layout minimizes unnecessary movements, accelerating the line-setting timeline.

4. Foster Proactive Communication:
   Establish proactive dialogues with line supervisors and the maintenance team to keep them informed about necessary requirements. This collaboration ensures that essential resources are available when needed, smoothing the setup process.

5. Implement Continuous Improvement Practices:
   Continuously assess and refine the line-setting process based on team feedback and performance metrics to identify areas for further enhancement.

Pre-Production Checklist for Enhanced QCO Efficiency

In order to optimize production and sustain operational efficiency, certain fundamental pre-production tasks must be finalized prior to the Production Sewing Date (PSD). These tasks are outlined as follows:

1. One Week Prior to the Production Sewing Date (PSD):

Finalizing PP Samples: The pre-production (PP) sample should receive validation from the buyer or the internal quality assurance team, ensuring all essential files are documented and finalized.

Fabric Inspection: Confirm the arrival of all necessary fabrics, ensuring they are inspected and approved for production. Any quality concerns should be addressed immediately.

Accessorizing for Success: Guarantee that all required trims, labels, zippers, buttons, and other accessories are in stock to avert any delays during production.

2. Five Days Before the PSD:

Size Set Verification: Complete the size set cutting process to assess pattern accuracy, fit, and grading across all sizes, ensuring uniformity prior to initiating bulk cutting.

3. Four Days Prior to the PSD:

Preparation of Machine Equipment: Ensure all necessary machine folders, guides, and attachments are arranged and set up for the new style, alongside any special adjustments that may be required.

Quality Check on Size Sets: Confirm that the size set garments are fully sewn and scrutinized for quality and dimension accuracy.

Finalize Operational Details: Prepare the operational bulletin, outlining every step within the sewing process, along with a layout plan for the workspace—clearly indicating any critical steps that might need extra focus or training.

4. Three Days Before the PSD:

Conducting the Pre-Production Meeting: Hold a pre-production meeting with essential participants, encompassing teams from production, quality assurance, industrial engineering, and planning. This session should address potential challenges, confirm readiness for production, and finalize any adjustments that may be necessary.

Specialized Training for Critical Processes: Offer targeted training to operators for any operations requiring specific skills or technical knowledge. This focused approach aids in minimizing defects and bolstering efficiency as bulk production commences.

5. One Day Prior to the PSD:

Establishing Input Buffers: Prepare input buffers by ensuring that all necessary materials, cut panels, and associated resources are organized and ready for a seamless start to production. This strategy helps in reducing interruptions and promotes a consistent workflow.

By employing these strategies, garment manufacturers can significantly reduce line setting time, thereby increasing overall productivity.

20. Enhancing Line Balancing for Optimal Performance:

Line balancing plays a crucial role in minimizing operator downtime and maximizing output. The aim is to create a workflow that reduces idle time, allowing for a seamless production experience.

1. Strategic Operator Selection:
   During the setup phase, choose operators based on their individual skill sets in relation to the tasks required. This alignment between operator capabilities and job needs ensures high-quality output and improved efficiency.

2. Perform Regular Capacity Evaluations:
   After the line is established, conduct capacity evaluations periodically to assess performance and identify any bottlenecks in the production process.

3. Utilize Pitch Diagram Techniques:
   Apply pitch diagrams to identify bottlenecks within the production line. Analyzing these critical points allows for the development of targeted strategies aimed at reducing Work in Progress (WIP) levels.

4. Maximize Operator Utilization:
   As line balancing improves, expect to see enhanced operator utilization. This increased efficiency allows for higher production volume without the need for additional resources.

By integrating these line balancing techniques, garment manufacturers can efficiently enhance productivity and overall operational effectiveness. Implementing these methods will not only streamline processes but also lead to measurable improvements in output.

21. Prioritize Maintenance:

Regular maintenance of equipment will reduce downtime and ensure that machines are running at optimal performance levels.

22. Leverage Cross-Training:

Cross-train employees to handle multiple roles within the production line, which can enhance flexibility and coverage during peak times.

23. Encourage Innovation:

Create an environment where employees feel free to propose new ideas and innovate processes, which can lead to substantial efficiency gains.

24. Gather Feedback:

Soliciting regular feedback from employees can unveil hidden inefficiencies and areas for improvement, fostering an adaptive workplace.

By implementing these 24 strategies, garment manufacturers can significantly improve their productivity while also creating a more engaged and efficient workforce. Embrace change, invest in the right tools, and watch your operations thrive.

How to Improve Productivity in the Garment Industry?

By introducing new machines, tools, and equipment in the apparel industry, manufacturers can significantly increase productivity. Streamlining production processes and investing in advanced technology are also essential steps.

How to Improve the Textile Industry?

The textile industry can benefit from similar strategies. Implementing lean manufacturing principles, optimizing material usage, and enhancing workforce skills are key to improving productivity. Additionally, leveraging AI and machine learning can help optimize production processes and improve quality control.

How to Increase Efficiency in the Garment Industry?

Efficiency in the garment industry can be increased by streamlining production processes, investing in advanced technology, and enhancing workforce skills. Implementing lean manufacturing principles and optimizing material usage are also crucial steps.

How to Increase Productivity in Garments?

Increasing productivity in garments involves automating repetitive tasks, streamlining production processes, and investing in advanced technology. Enhancing workforce skills and implementing lean manufacturing principles are also essential.

How to Increase Productivity in the Apparel Industry?

The apparel industry can increase productivity by introducing new machines, tools equipment, optimizing material usage and machine learning.

Productivity Improvement in the Garments Industry.

Productivity improvement in the garments industry involves a combination of automation, technology, and workforce development. By implementing these strategies, manufacturers can significantly enhance productivity and stay competitive in the global market.

You can visit my post to learn more. Visit here to know what is operation breakdown, layout of shirt, operation breakdown of skirt, layout of trouser, trim card. You can visit my post to learn more about the bulletin or breakdown of garments in the garment industry.

You Might Find Useful Related to Industrial Engineering:

• How to calculate productivity in the garments?
• Productivity Improve in Garments Industry.
• What is Assort Called in Garment Industry?
• Technical audit in the garment industry.
• What is sewing needle in the garment industry?
• What is 5S in the garment industry?
• What is garment sample in garments Factory?
• Difference between TQM and QMS.
• How to solve bottleneck problem in the Garment Industry? 
• Productivity improvement factors in garment industries.
• Various Types of Industrial Sewing Machines.
• What is operation breakdown in the garment industry?
• Industrial Engineering (IE) in Garment Industry.

Thank you for reading. Your support means a lot to me and I'm grateful for your encouragement to create more content related to Industrial Engineering. Feel free to share your thoughts on how I can improve this article or suggest topics for future posts.