Académique Documents
Professionnel Documents
Culture Documents
SUBMITTED BY
GURPREET KAUR SLAICH (MFM/17/987)
HIBA NASIR (MFM/17/696)
HARSHA VARDHINI. D (MFM/17/319)
INDU SINGH (MFM/17/1034)
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VASTRAM EXPORTS
Poyampalayam Pirivu,, P.N.Road, Tirupur-641602,
Tamil Nadu, India.
Phone: 0421-2201218, 0421-2201215.
VASTRAM EXPORTS was founded in 1994, Head quartered in Tirupur and have factories in
Erode and Karur. From a modest growth at the time of inception to the current business volume
of US$50 million per annum, the company has come a long way. We currently cater Men’s
Knitted garments and Kid’s wear. Our company is a name synonymous with success and
accomplishment. It is one among pioneer manufacturing and exporting garment in Tirupur. The
various department of the company are coordinated in such a way that optimum efficiency is
obtained.
Product development is the real strength of the company. An excellent product development
system, managed by a creative team of professionals capable of producing and providing design
inputs by constantly monitoring worldwide requirements.
At Vastram we produce quality garments that can guarantee complete customer satisfaction.
We can create the right and high quality product that the customers requires and deliver it at
the right time.
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TABLE OF CONTENT
Serial No. Topic Page no.
INTRODUCTION
1.0 Scope 5
1.1 Policy 5
1.2 Application 5
2.0 AMENDMENTS & REVISION OF QUALITY 5
MANUAL
2. 1 Revision control 5
2. 2 Reviews 5
3. 0 ORGANIZATION 5
3. 1 Quality manager 5
3. 2 Responsibilities 6
4 .0 OUALITY PROGRAME 6
4 .1 Planning 6
4.2 Indoctrination and training 6
5. 0 PROCUREMENT DOCUMENT CONTROL 6
5 .1 System procurement 6
5. 2 Review & Approval 7
5 .3 Changes to document 7
6. 0 SAMPLING 7
6.1 First approval samples 7
6.2 Pre-Production samples 8
6.3 Shipping samples 9
7.0 FABRIC AND ACCESSORIES 10
7.1 Fabric and accessories : General Quality Requirements 10
7.2 Fabric specific quality requirements 10
7.3 Accessory quality requirements 11
7.4 Submission and approval of fabric and accessories 13
7.5 Mandatory fabric tests 15
7.6 Testing laboratories 18
8.0 GARMENT CONSTRUCTION 18
8.1 Manufacturing process inspection
Spreading
Cutting 18
Sewing
Finishing
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9.0 LABELLING AND PACKAGING 22
9.1 Compliance guidelines 23
9.2 Label approvals and testing 24
9.3 Packaging approvals and testing 25
9.4 Label attachment 27
9.5 Shipment packing 28
10.0 FINAL INSPECTION TO AQL STANDARD 30
11.0 COMPLIANCE WITH LAWS 34
11.1 Employment contract 34
11.2 Labor 34
11.3 Occupational health and safety 35
11.4 Machine/equipment and safety 35
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1.0 SCOPE
1.1 POLICY
1.2 APPLICATION
The quality System described here is mandatory for all activities performed at VASTRAM
EXPORTS to assure product conformance to the applicable drawing, catalog item
specification and/or contract requirement.
This manual will be revised by Quality Assurance as required. Whenever revisions occur, all
holders of controlled copies will be distributed copies of the application revised pages,
including a new revision page describing the changes.
2.2 REVIEWS
Management reviews of operations are continuous and any problems indicated with the Quality
Program or its implementation will be addressed and corrected as directed by Management.
3.0 ORGANIZATION
The Quality Manager reports directly to the President and is delegated authority and
organizational freedom to identify and evaluate quality problems and to initiate, recommend
or provide solutions.
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3.2 RESPONSIBILITIES
The Quality Manager is responsible for:
Update and distribution control of the Quality Manual as required.
Planning to meet customer's quality requirements.
Approval of quality work instructions.
Directing inspection activities.
Approval of Suppliers.
Maintaining a listing of approved suppliers.
Monitoring procedures to assure compliance
Reviewing and maintaining Quality Records.
Approval of disposition of Nonconforming Articles
Corrective action coordination.
4.1 PLANNING
The Quality Program is planned to control products from the requirements of a customer
order to include procurement practices, receipt of material, receipt inspection of supplier
material, handling and storage to the eventual shipment of an article to our customer.
Employees are indoctrinated and trained, as necessary, to assure that suitable proficiency is
achieved and maintained throughout our operation systems. Training is performed as "On
the Job Training" under the direct supervision of management.
Procurement documents are manually generated and include appropriate technical and quality
requirements. When a customer has special requirements, such as a Certified Material Test
Report, our program is designed to include the requirement into our procurement documents.
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5.2 REVIEW AND APPROVAL
Procurement documents are reviewed and approved by the Purchasing Manager. The Quality
Manager performs random surveillance of procurement documents semiannually and
documents the results.
Changes to procurement documents are subject to the same level of control as in preparation of
the original document.
6.0 SAMPLING
What to submit?
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SAMPLE SWINGTICKET
Print strike-offs are approved by the Buyer for colour and design only. All quality aspects of
print strike-offs must be approved by QA.
Lab Test
Third party lab test are required on fabrics. Details of the test requirements can be found in
Testing of Fabric, Accessories and Labeling.
The purpose of this sample is to issue final approval pending the commencement of production.
Any fit or construction amendments requested in the 1st approval report must have been made on
this sample made by approval.
Fabric and accessories must also receive final approval at this stage. All colourways on order to
be submitted. The sample must be measured prior to submission and measurements noted on the
accompanying copy of size chart.
Pre production samples must be made up in the actual bulk fabric with the actual bulk
accessories, labels, swingtangs, bar codes stickers etc.
If fabric testing has been requested the lab test report must accompany this sample. An email
copy of the invoice is acceptable
.
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What sizes to be submit?
What to submit ?
Note that two garments are to be sent at the shipping sample stage.
These two samples must have been taken randomly from the bilk production bulk. The
samples must be measured prior to submission and measurements noted on the
accompanying copy at the size chart.
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7.0 FABRICS AND ACCESSORIES:
This Section provides guidelines for the Warehouse’s requirements in terms of quality and
functionality of fabrics and accessories, including the fabric test requirements.
This table the table below gives the guidelines for quality requirements for various fabric types.
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matched to the fabric type.
Fabrics to be used for children’s Fabrics, accessories and trims for this
nightwear and other daywear category of apparel must comply with all
the necessary standards that the buyer’s
specify and The Country Regulations
specify
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Elastic There must be no run-back of elastomeric
yarn at the cut ends.
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studs and poppers must be applied using a
compressed air machine- these accessories
must not be applied by hand. Plastic
washers MUST be used in infants; and
children’s wear and may be used if needed
on Adult’s wear
Satin ribbon bows Ends of these components must be out by
hot-wire, they must not be heat sealed with
open flame.
Thread For Lightweight Fabrics:
Polyester wrap core thread @ 24Tex
All Fabrics and accessories must be audited in garment, QA cannot approve fabrics as piece
goods or accessories if they are not applied or attached to the garment that they are intended for.
This is because the performance of a fabric or accessory may adversely affect the garment, and
this is impossible to predict unless QA audit the fabric and accessories in the garment’s finished
state.
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Visual Approval only:
QA approval reports will approve fabrics and accessories from a visual aspect only.
If a performance issue on an approval sample is obvious to QA the production department will
be advised to amend the issue.
Three testing levels: There are three levels of fabric, accessory that the warehouse require- they
are, General, Specific and Legal.
General: All fabric and accessories should be tested on a regular basis to ensure that they are
commercially acceptable as per the legal requirements of the legal standards and regulations
referred to in Compliance Guidelines of exporting country.
Specific: The fabric and accessories are to be tested by a third party to the performance levels
stated in the tables in the Mandatory Fabric Tests section.
Other responsibility:
Testing Laboratories that are to be used for apparel product are listed in this section.
All required testing must be carried out prior to submission of the sample for approval.
The lab test report must be an original document from the testing laboratory. Photocopies
or faxed copies of the lab test are not acceptable.
One report will suffice for multiple styles and orders per season. In this situation, all
styles numbers that the report pertains to must be listed on the report.
Tests reports must state the order numbers and style number and have relevant fabric
swatches attached.
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7.5 Mandatory Fabric Tests:
Testing will be required for all orders with a quantity of 2500 pieces or more.
For orders with a quantity of less than 2500 pieces, the quality department will conduct
random tests with available resources in the factory.
The table below denoted which tests are required to be performed on woven and knitted fabric
types.
The second table provides more information on the colourfastness tests that are required.
Woven Knitted
Dimensional stability** ✓ ✓
(shrinkage)
To washing All garments with fabric All garments with fabric
To dry cleaning that can be washed. that can be washed.
All garments which are All garments which are
categorised as dry categorised as dry
clean only. clean only.
Spirality N/A ✓
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Tear strength ✓ N/A
Colour Fastness ✓ ✓
Seam Slippage ✓ ✓
Pilling ✓ ✓
Colourfastness Tests:
Washing ✓
For all garments that can be washed
Light fastness ✓
Underwear/sleepwear not required
Dry Cleaning ✓
For garments which are categorised as dry clean only
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Print appearance after washing ✓ All garments with prints
Washing ✓ ✓
Light fastness ✓ ✓
Dry Cleaning ✓ ✓
All Sleepwear
Washing ✓ ✓
Light fastness ✓ ✓
Dry Cleaning ✓ ✓
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All Sleepwear
Nominated supplier:
For all fabric tests conducted in India, SGS is the nominated supplier. All the vendors/suppliers
will receive a 30% discount off the list price for tests being conducted for the warehouse (they
need to inform SGS that the tests are for the Vastram exports to receive the discount). SGS is
aware of our standards and familiar with what type of tests are to be conducted for the required
standards.
Office address:
134, Shivashaktinagar, College Road, Tripur, Tamil Nadu 641602
India
SPREADING
Table marking
Ends
Tension
Narrow goods
Remnants
Counts
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Ply height
Marker Placing
Fabric Flaws.
CUTTING
HOW TO MEASURE
Men’s wear
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KIDS WEAR
SEWING
Inspection in sewing involves the inspection of work from each operation, with a quality
standard established to limit the amount of bad work and a provision for operators to
re-inspect and repair entire bundles .
A complete manufacturing process chart should be made, Clearly identifying the
production or manufacturing steps for each type of garment made.
There should be a written quality specification for each job in the, manufacturing
process.
No operation should ever go longer than 3 hours without being inspected.
An independent audit team audits pieces after end line inspection at 1.5 AQL
Products should move to finishing only after their certification.
Feedback from audit on daily basis for further improvement.
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STITCHES PER INCH
The table below indicated the stitches required per inch (2.5) in various in various fabric
types:
FINISHING
Two hours inspection, visual and fit audit on the basis of buyers desired AQL.
Monitor the job off all finishing inspectors and report to manager QA factory.
Keep close coordination with sewing, rectifying defects in finishing and make defect
analysis in finishing to take corrective and preventive action in sewing.
Conduct training off finishing QA inspector for continuous improvements
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8.2 PRODUCT SAFETY AND ACCESSORIES RECQUIREMENT
Ensuring for the customer’s safety is not compromised in any way by the finished state of the
apparel product.
This covers the guidelines for the various types of labels that are required by the buyers
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o Requirements for label attachments.
o Care instruction.
o Labeling requirements.
It is the QC’s responsibility to ensure that the entire apparel product compiles with the most
recent versions of the following standards and regulations:
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ensure that product meets the requirement of
the following
Other standards will be followed according to buyer’s requirement and the requirement
of the Exporting Country Regulations.
Approvals:
Sew in labels must be submitted to the warehouse QA for approval prior to production.
If multiple garment styles use a common label then only one sample label is required for
approval.
On repeat orders the correct sew in labels should be submitted attached to the pre production
sample garment for approval.
Printed labels must remain legible for the life of the garment after continuous washing and
wearing.
Labels must have soft, smooth edges and must not fray.
For all outerwear bottoms-especially those with heavy fabrics, or any wash treatments- the
content/care/country of origin labels must be oven or as per buyer’s requirements.
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FIRE DANGER SEW-IN LABELS
Approvals
Fire danger labels for children’s night wear, and styles requiring these labels must be submitted
to the warehouse QA for approval. The labels must be accompanied by the lab test report
verifying that they have been tested for durability and comply with compliance guidelines of
exporting country. The lab test report must be an original copy.
Testing
Fire danger labels for children’s nightwear, and styles requiring these labels, must be tested for
durability and secure attachment to the garment. Samples of the labels must then be submitted
to the warehouse QA accompanied by the lab test report verifying that they have been tested
and comply with compliance guidelines of exporting country. The lab test report must be an
original cop y.
HANG-SELL PACKAGING
Materials
Approvals
Hang sell packaging must be submitted to the warehouse QA for approval prior for production.
Printed details on the packaging must be carefully checked pririor to submission to ensure that
the details are as requested by the packaging artwork. If the details are incorrect the items
should not be submitted until the corrections are made.
Testing
Polybags must have securely welded sides and plastic hanger hooks so that the package
performs satisfactory in-store until the product has been store.
SWING TiCKETS
Approvals
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Swing tickets should be submitted to the buyer for checking barcode prior to production.
STICKERS
Approvals
Stickers should be submitted to the buyer for checking artwork prior to production.
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HANG SELL PACKAGING Country of origin
Fibre content
Care instructions
Price and barcodes There must be only one price stated on the
labeling. Suppliers must not place a
price/barcode sticker over the top of another
barcode.
The warehouse requires all labels, barcodes and swingtags to be sourced from their nominated
label supplier.
Sew in labels
All labels must be securely sewn so they remain permanently attached to the garment.
Labels must be attached so that none of the wording is concealed in the seams.
Each piece of a set must have labels stating brand, care, fibre content and origin.
Reversible garment must have the care, content, and origin labels sewn in a pocket. If
the garment does not have a pocket then the care, content, and origin details must be on
a swingticket attached to the garment.
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Additional attachment information
More detaile d illustrations of placement of labels will be provide according to the buyer’s
requirement, check with the QA team before submitting the sample.
Item Requirement
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packing, the tissues must be colourfast.
For products manufactured in Spain: voluntary to mention the industrial register number of the
national manufacturer. For products manufactured outside the EU: Mandatory to mention the
tax ID of the importer. Hazardous products Certain consumer chemical products require
danger, warning and caution labels for products that are corrosive, explosive, flammable or
poisonous.
The requirements regarding the labeling of textile in Europe are covered by the Regulation
(EU) No 1007/2011 (the “Regulation”) which replaced the EU Directive 2008/121/EC from 08-
05- 2011
This manual contains regulations for frequently exporting coutries, if there are any other
specifications it can be done as buyer’s requirement.
The full list and images of the symbols and its description can be found at the following
website: www.iso.org
http://www.sartex.ch/ginetex-switzerland/ or www.care-labelling.co.uk
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10.0 FINAL INSPECTION TO AQL STANDARD
Categorizing defects:
Defects are categorized as either Critical, Major, or Minor. A single critical defect will fail the
order. The number of acceptable Major and Minor Defects varies by sample size.
Critical Defect: A defect that is likely to result in a hazardous or unsafe condition for an
individual using the product or that contravenes mandatory regulations.
Major defects: A defect that is likely to result in failure in reducing the usability of the product
and obvious appearance defects affecting the salability of the product.
Minor defect: A defect that does not reduce the usability of the product but us nevertheless a
workmanship defect beyond the defined quality standard.
Before inspecting:
An inspection should only commence when all the following conditions are met:
1. An approval sample garment with all relevant attachments is available.
2. A sample/ approval report is available.
3. Order details are available.
4. Fabric and accessories test reports have been submitted and approved.
5. Print test report available.
6. 100% of the stock is completed and available.
It should be noted that all inspections should be done in a clean and well-lit area.
The number of inspectors need depends on total production, the lot size, the
complexity of the item made and present outgoing quality level.
The inspection time per unit varies depending on the number of operations in the item.
Statistical auditing involves selecting a few units from the whole lot, doing a very thorough
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inspections of those few and making a projection based on the results.
How to inspect?
The table below describes the basic procedure for carrying out the inspection.
STAGE DETAILS
1. Review of Technical File and The inspector must make sure he has the
Order Details following items available:
Purchase order
Packing list
Product specifications (size specs,
sketches etc.)
Defect classification
Special instructions
An inspection form to record the
outcome
Sample cards to accompany the final
selected samples
2. Inspection of Standard and Follow the AQL table
Sampling Critical defects- not allowed
Major and Minor defects
3. Carton selection Obtain and review packing lists
Estimate number of cartons/quantity
presented for inspection
Select cartons randomly for complete
style, colour and size range
4. Packing and Markings Check following against
specification/order:
Packing material
Packing method
Packing size
Inner and outer packing
Labelling and hang tags
Shipping marks
Packing condition
Packing dimensions
5. Quantity/ Assortment check Check the following:
Number of pieces per export
carton
Check style, size and colour of
assortment as per packing list
and carton marking
o Style
o Size assortment- solid or
assorted size ratio
o Colour assortment- solid
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or assortment size ratio
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9.Size Measurement Check size measurement against specification.
If measurement is based on the factory’s
specification, please attach the size
specification for reference. You must measure a
minimum of 3 pieces per size.
10.Weight Check weight of knitted garment, quilted
garment, bags, towel etc. Compare weight of
actual finding to specification and reference
sample.
Check workmanship according to the correct
sampling plan. Indicate all the defects in the
garment with the red arrow defect stickers.
Report one most serious defect per unit and
classify as major or minor defects.
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11.0 COMPLIANCE WITH LAWS
The facility shall operate in full compliance with all applicable laws, rules, and regulations
including those relating to labour, worker health and safety, and the environment.
The facility shall keep all applicable records and documentation referenced in this standard on-
site and available to company representatives for at least 12 months from termination date of an
employee.
11.2 LABOUR
CHILD LABOR:
At the facility, all workers shall be at least 18 years of age. No workers under the age for
mandatory schooling shall be employed by the facility.Facility management shall have a rigorous
age verification procedure that includes maintaining copies of official government-authenticated
documentation for every worker and confirmation of the worker’s date of birth.
The facility shall pay overtime and any incentive (or piece) rates that meet all legal requirements
or the local industry prevailing standard, whichever is greater. Hourly wage rates for overtime
must be higher than the rates for the regular work shift.
The facility shall ensure that overtime hours not be adjusted against leaves/holidays/absent days
unless permitted by local law.
The facility shall ensure that workers are paid directly and at least once per month within no
more than 31 days after the end of the previous month or within the legally mandated period,
whichever is earlier.
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The facility shall comply with all applicable laws, regulations, and industry standards on
working hours. The maximum allowable working hours in any week shall be the lesser of a)
what is permitted by national law or b) a total of 60 hours of work in any consecutive 7-day
period.
OVERTIME HOURS:
The facility shall ensure that overtime hours not exceed legal limits or 12 hours in a week,
whichever is lesser.
GENERAL SAFETY:
The facility shall comply with all applicable laws regarding risk protection.
VENTILATION:
The facility shall ensure that adequate and effective ventilation exists for the comfort of workers
and that there is proper circulation of air, especially in areas of frequent or heavy use of
chemicals and paints, or in areas with significant dust and material particles.
LIGHTING:
The facility shall ensure appropriate and sufficient lighting is installed so workers are aware of
their surroundings, are able to perform their work safely, and are able to see any potential
barriers or obstacles on their way to the nearest exits.
The facility shall ensure that appropriate personal protective equipment such as masks, gloves,
goggles, ear plugs and rubber boots are made available at no cost to all workers and instructions
for use are shared with the workers.
The facility shall comply with all laws regarding machine and equipment safety and take all
steps to ensure safety.
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FIRST AID AND MEDICAL FACILITY:
The facility shall ensure adequate arrangement for first aid and medical care
The facility shall comply with all applicable laws regarding fire safety.
The facility shall ensure there are sufficient, marked exits and clear routes from all areas of the
facility to support safe and smooth evacuation from the facility.
EMERGENCY LIGHTING:
The facility shall ensure that sufficient, powered back-up emergency lights are provided
throughout the facility.
FIREFIGHTING EQUIPMENT:
The facility shall provide appropriate firefighting equipment in sufficient number throughout the
facility. These shall be maintained in functional condition at all times.
The facility shall have a functional and well-maintained alarm system for early emergency
warning.
The facility shall have an emergency response system and team with defined responsibilities.
The facility shall ensure that emergency evacuation drills are conducted and recorded.
BUILDING SAFETY:
The facility shall comply with all applicable laws regarding structural safety. The facility shall
take all necessary steps to ensure that the facility is structurally safe and well-maintained.
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