Wednesday, May 29, 2013

Document Control in Garments Industry, ISO requirment

1.0 Objective
To ensure that all documents forming the Quality Management System (QMS) are controlled and distributed so that only latest documents issued are in use by those employees requiring them.

2.0 Scope
This procedure covers all document control activities regarding the quality management system.

3.0 Responsibility
The Management Representative (MR) is responsible for directing activities relating to this procedure. Where other functions have responsibility, they are so indicated.

4.0 Procedure
4.1 Document Hierarchy

Level 1:           Quality Manual
Level 2:           Procedures, Matrix, Work Instructions, Quality Plan & External origin
Level 3:           Quality Records & Formats

4.2 Document Identification
4.2.1 The documents are identified by their titles, codes or by the ISO 9001:2000 standard clause reference

4.3 Document Coding
4.3.1 The corner of pages contains:
        Document Code      example:                PRD/2/012
        Issue Number                                       Issue 1
        Page Number                                       Page 1 of 4

4.3.2 The document code is of the form AAA/B/CCC, where:

          • AAA             is the department (see list below). Can be 2 to 4 letters.
          • B                   is the document level, 2, or 3.
          • CCC             is the individual document number, starting from 01.
The exception is the quality manual, which is coded simply as QM/1.

4.3 Procedures Structure
The format of the documents is not standardized with respect to design and layout, however, level 1, level 2 (except the External origins) and Level 3 documents contain at least the following information:

     -Related Documents (If any)
      -Written and Reviewed by
      -Approved by
      -Issue Date & No.

4.4 Document Initiation/Review/Approval

4.4.1 Documents are written by or with the help of the appropriate personnel involved with the activity.
4.4.2 Reviewed by the author of the documents or the person indicated.
4.4.3 Approvals:
Departmental Procedures – Managing Director/ Factory Manager/ Management Representative
MR Procedures – Managing Director/Factory Manager
Quality Manual – Managing Director

4.5 Issuing Documents
4.5.1 The original document, signed, unstamped and dated, is retained in the Central Quality File. This file comprises separate folders for each department, containing all the quality system documents for that department.
4.5.2 Copies of all Level 1 & 2 documents are made and issued to a department are stamped “Controlled Copy” and are recorded on a Document Master List (MR/3/01) for each department.
4.5.3 A Circulation Record, MR/3/002, accompanies each original document.
4.5.4 Copies of documents are distributed to the appropriate personnel who sign the Circulation Record.
4.5.5 Uncontrolled photocopies are only allowed for use by external parties, e.g. customers, auditors, etc. These are stamped on the front page as “Uncontrolled Copy”. Distribution records are not maintained for these copies.
4.5.6 The preparation and updating the work instructions (if required) is the responsibility of the departmental heads. If the work instructions are to be displayed on the board, the departmental head will ensure that the latest version of the work instruction is displayed. The original, approved text of the work instruction will be retained in the Central Quality File, along with a Circulation Form.
4.5.7 Job Descriptions, Quality Plans, Quality Policy and Objectives are circulated in the same way.
4.5.8 Some level 3 documents are maintained on electronic media (soft copies). These documents are controlled through custom made software security system. These documents are identified by their name/title. These documents are backed up on weekly basis.

4.6 Amending Documents
4.6.1 Changes required are raised on a Change Request Form, and submitted to the Management Representative.
4.6.2 Management Representative in consultation with the personnel who initially wrote and approved the document gives approval of proposed change.
4.6.3 If the changes are approved a new issue is published. The issue number advances, that is, Issue 1 becomes Issue 2, etc.
4.6.4 The change(s)/new addition(s) are identified by underline / highlighting the amended section.

4.7 Withdrawal of Obsolete Documents
4.7.1 The amended document is issued and distributed according to procedure (see section 4.6).
4.7.2 The Document Master List (MR/3/01) is updated.
4.7.3 All obsolete copies are withdrawn and signed for according to the Circulation Record.
4.7.4 The original copy of the obsolete document, along with its Circulation Record and Change Proposal, is kept for reference purposes, in an Obsolete Document File, MR/3/04. The front page is red stamped as “Obsolete”.
4.7.5 Old documents are stamped in red as “Obsolete”. They are retained, if required for reference, or destroyed on the authority of the concerned department head. All remaining copies are destroyed

4.8 Issuing & Amending Level 3 Formats
4.8.1 Preparation of formats is the responsibility of department heads.
4.8.2 A blank (for sample) copy is attached to the relevant procedure or work instruction in Central Quality File for reference. If the same format is used for more than one document, then it need not be attached with every procedure.
4.8.3 They are printed on white paper and include a code number and issue number.
4.8.4 Copies are allowed for working activities.
4.8.5 Changes are made according to sections 4.6.1 and 4.6.2 and the issue number advanced and the previous copy is replaced in central Quality File.
4.8.6 Amended issues are sent to the Management Representative for inclusion in controlled copies of the relevant document. The Change Proposal and a copy of the obsolete document is kept in the Obsolete Document File.
4.8.7 Department heads are responsible for withdrawal and destruction of old issues and distribution of new issues to the concerned work areas

4.9 Control of External Origin Documents
External Documents are controlled in the same way like internal documents except the copy of the external document may not be retained in the central quality file.

4.10 Document Maintained
A Master List of Documents (MR/3/01) is maintained in central quality file to identify the latest issue of the document in circulation the revision status is incorporated in the individual documents.

4.11 Computer Back-up
All the documents of the Quality Management System are stored in the computer and for safety purpose a back up in the form of floppy disks and are kept by the Management Representative.

5.0 Related Documents
Document Master List           MR/3/01
Circulation Record                MR/3/02
Change Proposal                   MR/3/03
Wish You Good Luck..................................
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Tuesday, May 28, 2013

Procedure for Garments Measuring And Monitoring Devices based on ISO

1.0 Objective
This procedure ensures that appropriate Inspection, Measuring and Test Equipment are identified, calibrated, preserved, controlled and maintained.

2.0 Scope
Applies to all Inspection, Measuring and Test equipment (IM&T) used in Muazuddin Textile Limited

3.0 Responsibility
Manager Quality control shall ensure appropriate control, calibration and maintenance of inspection, Measuring and Test equipment.

4.0 Procedure
4.1 Identification:

4.1.1 All the measuring and monitoring devices which are used in Swan Garments Limited Will be identified with unique identification number.

4.1.2 Location of measuring equipments is done by the following codes:
 - QC Quality Control department
 - PR Production department

4.1.3 The identification number will be indicated on all measuring equipment by affixing of sticker, permanent ink pen or any other suitable indicator.

4.1.4 All those equipment that do not require calibration will be identified with a sticker showing ‘CNR’ (Calibration Not Required).

4.2 Master List of All Inspection Measuring & Test (IMT) Equipment

4.2.1 A master list of Measuring and Monitoring Devices shall be maintained by the QC Manager.

4.2.2 The Master List shall include Equipment Name, Equipment ID, Location, Model (If available), Range / Capacity, Calibration Frequency & Calibration done by.

4.3 Calibration Type
4.3.1 External Calibration
4.3.1.1 Out-side calibration services agencies will be approved by the top management. Before approval, top management will ensure that calibration agency has appropriate accredited standards, which are traceable to any national/international standards.

4.3.1.2 Person responsible for calibration will send the equipment to calibration agency in proper packages or he will inform the concerned agency to send their engineers to our premises for calibration/maintenance what so ever is required.

4.3.1.3 Upon receiving the equipment from calibration agency, he will make sure that “Calibration Status Sticker” is pasted on equipment. This sticker shows the date of calibration and next due date.

4.3.1.4 He will also ensure that the calibration agency has sent a calibration certificate along with each equipment.

4.3.1.5 He will maintain records of these certificates.

4.3.2 In House Calibration
4.3.2.1 The person responsible will perform the in-house calibration in a controlled environment, if required.

4.3.2.2 All the in-house calibration will be performed according to appropriate calibration procedures.

4.3.2.3 After performing calibration, he will affix the calibration status sticker, indicating the date of calibration, next due date and the signature of the person who performs the calibration as shown below:


Calibration Sticker

Equipment ID _______________ Sig. ____________________


Calibration Date_____________ Next Due Date_____________



4.3.2.4 He will also maintain the record in calibration data card.

4.4 Calibration Interval
4.4.1 The person responsible for calibration with co-ordination of concerned department head will decide the interval of different equipment on the basis of their sensitivity / usage or on advice of manufacturer (if any).

4.4.2 He will increase or decrease the calibration interval of equipment on the basis of calibration results.

4.5 Action Taken when Calibration Results are not satisfactory.
4.5.1 If calibration results are found out of tolerance (Accuracy required), the user/person who has performed the calibration will immediately inform the concerned department about the results.

4.5.2 Concern department head will take actions to validate the previous inspection made from this equipment, if possible.

4.5.3 He will also consider the effects of these not satisfactory results on the quality of the final product.

5.0 Related Documents
Master List of Measuring and Monitoring Devices
External Calibration Certificates
Calibration Data Card (In-house Calibration)
Wish You Good Luck..................................
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Control of Non-conforming product in garments manufacturing

1. PURPOSE
-  To provided a system for evaluating defective products
-  Evaluating the cause of defects and eliminate the nonconformity.
-  Creating a permanent solution that prevents recurrence of problems.

2. SCOPE
All non-conforming fabrics, accessories, packing materials are purchased and garments are made by Muazuddin Textile Limited.

3. RESPONSIBILITIES & AUTHORITIES
Merchandising Manager, Factory Manager, Production Manager, Quality Control Manager, Cutting In-charge, Finishing In-charge, Store In-charge, Quality Inspectors & Maintenance In-charge are responsible for following this procedure.

4. PROCEDURE
4.1 In-coming product
4.1.1 If products (fabrics, accessories, washing, packaging materials & spare parts) do not meet the specification are stored separately from the conforming products and identified as “Non-conforming Product”
4.1.2 Store In charge prepares Non-conforming Report and submits it to the Production Manager/Quality Control Manager.

4.1.3 Production Manager /QC Manager review the non-conformity product and give disposition decision after discussing with the respective merchandiser & Factory Manager.
4.1.4 Store-In charge disposes the material as per decision taken by the Factory Manager or by the respective Merchandiser.

4.2 In Process Non-conforming material /products (Cutting)
4.2.1 If any discrepancy identified during marker inspection then marker is segregated and recorded in Spreading Quality Report. Identified Non-conforming marker is rectified as per the specification and cutting quality inspector re-checks the marker.
4.2.2 Identified non-conforming items are segregated during Cutting Quality Inspection and Panel check. The acceptable components are stored for making another size. The components which are not acceptable will be treated as rejected or destroyed or stored as stock lot. Cutting QC Inspector / Quality Control Manager is responsible to give disposition decision on identified non-conforming items.
4.3 In-process Non-conforming material/product (Sewing)
4.3.1 Non-conforming garments identified by Quality Inspector during the complete garments checking (100% garments).
4.3.2 The defective items sent back to line for re-work. Garments which are not re-workable shall be rejected and segregated. Disposition record of such is maintained in the same form in the comments column
4.3.3 Operators will correct the non-conformity. Record of disposition shall be maintained in respective checking record form. The corrected garments will be re-inspected in normal routine process.

4.4 Finished Garments

4.4.1 Non-conforming finished garments are identified during inspection in finishing area and recorded in the inspection report.

4.4.2 Non-conforming finished garments may be disposed as per decision of the Quality Control Manager /Production Manager. The decision may be as follows:

• Repaired, inspected and shipped to original buyer
• Repaired and sold to another buyer as stock lot in concession
• Destroy which are not repairable

4.5 Non-conformity identified after shipment
If any non-conformity is identified after shipment of the garments by Muazuddin Textile Limited. The Factory Manager or Merchandiser will immediately notify the buyer via e-mail, Fax or Telephone.

4.6 Records
Non-Conforming Report
Wish You Good Luck..................................
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