Pearl Garments Company Ltd

Polash Bari, Nabi Nagar, Savar, Dhaka

Quality Manual
And
Format Sample

GENERAL OVERVIEW
Pearl Garments Company Ltd quality policy requires that the organization achieve total customer satisfaction by
meeting or exceeding customer, statutory and regulatory authority requirements by delivering products and
services on time and error free and by continuously improving the processes employed throughout the
organization. Commitment by each PCGL employee to this policy will ensure totally satisfied customers.
Pearl Garments Company Ltd has been established, documented, implemented and maintained the quality system
as a way to continually improve the performance of the organization. The quality manual describes out quality
policy and general company wide structure and procedure for maintaining the quality system that meets the
standards requirements.
Steering to Quality
In the merchandising path Pearl Garments Company Ltd integrated highly quality assured under & intimated
Garments with fashion spectrum. It spans both the quality & fashion designing. In Bangladesh, inaugurated with
highly calibrated personnel team & technical & technological improvement factory also contributing the national
economic growth.
PGCL maintain quality issues in every stage of production & meets buyer requirement as well as satisfy the
customer. PGCL implement the world best quality system.
PGCL is committed to producing quality product according to buyer requirements & style dedicated to continual
improvement through innovative & technical idea.

QUALITY POLICY
Pearl Garments Company Ltd quality policy and objectives for quality are displayed openly as a sign of our pride
and commitment and as a clear reminder of our focus and direction. The quality policy statement for PCGL is as
bellows:
1

We strive for excellence in all endeavors.

We set our goals to achieve customers satisfaction and to deliver defect free products on time.
It is our basic operational philosophy to concentrate on prevention method to make QUALITY a way of life
and perpetuate an attitude of DO IT RIGHT THE FIRST TIME. With this approach we will continue to
demonstrate to our customers that we are a reliable service provider.
Authority of Pearl Garments Company Ltd is committed to continuous improvement of its quality system.
Because the success of our quality system is essential for our competitiveness, it is vital that the employees of
Pearl Garments Company Ltd understand and adhere to our quality policy.
Top management ensures that the quality policy
a. Is appropriate to the purpose of the organization,
b. Includes a commitment to comply with requirements and continually improve the effectiveness of the
quality management system,
c. Provides a framework for establishing and reviewing quality objectives,
d. Is communicated and understood within the organization, and

e. Is reviewed for continuing suitability.

The quality policy is included in the quality manual.

QUALITY GOAL
The goals of our company are:
1. To achieve total customer satisfaction by:
1 Meeting or exceeding customer contract, statutory and regulatory requirements
2 Delivering defect free products
3 Zero-Late delivery
4 Eliminating errors
2. To become a preferred supplier to our customers.
3. To reduce customer complaints through continues improvement.
3. To practice continuous process improvement in order to continuously improve the way we do business.
4. To be a financially sound company and achieve continuous positive results by reduce process loss.
5. Training our peoples with new trend.

QUALITY PROCEDURE OF Pearl Garments Company Ltd

Inspection ProcedureWarehouseFabric inspection
Accessories Inspection
Cutting SectionLayer Inspection
Bundle inspection
Lace Inspection
Cut Panel Inspection

Sewing sectionSupervisor Sample inspection

First production Meeting
In process Inspection
Inspection of Shoulder strap line
Line table inspection
Random Inspection by Q.C Supervisor
Final Table inspection
Shipment sample inspection
Packing sectionIn-line inspection
Assort Table inspection
Pre-Final Inspection
Final/In-house Inspection

FABRIC INSPECTION
Upon received the fabric-packing list, start doing the inspection based on cut plan. Select sample lot of 10%, by
each color/pattern. Point system is depend on the length of the defect (0 to 3=1, above 3 but less than 6=2, above
6 but less than 9=3, over 9=4) inspection pass fail-margin is 40 points. While going ahead the inspection, check
color variation side-to-side; center to end by taking 6 width fabric strip by end.
And also as fabric inspector well aware about the nature of the fabric and the defects of the fabric, is taking fabric
swatch by every kind of defects to get a standard by merchandising dept to get guideline when proceed with
cutting and production.
All the defects should be documented. Inspection result decides based on point rate maximum is 40 point per 100
sq/yds... documented report to Q.A.M and to merchandising dept without delay.
Roll Fabric InspectionThe main purpose of this inspection is to assure the quality of received fabric before the supplying in cutting
section. To do the inspection we select 10% roll randomly. But for the accepted level for fabric we are following
FOUR POINT SYSTEM as world class standard.
The point of reject length is :
Length of the defect
Less than 3
3 to 6
6 to 9
9 to above

Penalty points
1.
2.
3.
4.

Formula:- Total penalty points x 100 x 36

Fabric Length (Inspected) x Fabric Width
Accepted level is Only major defect is considered such as hole, missing yarn, conspicuous yearn variation, end out, solid
yearn, dye spots, machine spots & shading.
Any hole other than shall be considered a major defect & assigned the maximum number of points
chargeable against a linear yards. Pinholes are not limited to those caused by tenter frame points.
All fabric must inspect on the face side for defects.
Defect must be measured lengthwise.
Maximum penalty points per leaner yards is 4.
Defects within of selvedge not considered
Accepted level upto 40 points/ 100 yards.
Defect must be marked by arrow sticker.
Fabric length, width, roll number, defect & other information must be recorded properly.
The reject roll is marked by red tag with all details.

SHRINKAGE TEST
Fabric is to check shrinkage prior to cut, avoid any shrinkage issue. This has to be grouped and documented
report to pattern making room to do patterns accordingly with shrinkage percentage.
ACCESSORIES INSPECTION
To produce a quality garment all the materials should be in good quality. So, it is better to have an accessory
inspection.
Take 10% sample lot by received quantity to inspect against approved sample. If damage percentage less than 5%
against to sample quantity is accepted. If it is more 5% it is fail. If fail then should be done another 10% and if
that also fail should do a 100% inspection and separate the defect quantity.
Or Quality people of the Warehouse who are responsible for the Quality ensure must the quality by JC PENNY
QUALITY system. As per Pearl Garments company Ltd policy they will must posted the JC Penny quality slave
in the inspection table & about this policy quality in charge must provide training to the people who work in the
respective area. After maintain the system Ware house in charge, Production GM & Quality GM must sign the
form after verifying the documents.
All the defects have to be documented and should be forward to QCM with some samples of defects to his review
and also to merchandising department.
FABRIC RELAXING
Fabric, which has stretch ability to have relaxing before cut the fabric.
QC should record the relaxing time and roll no. Relaxed rolls can do cut after the required relaxing time passed.
All the details are recorded and should be come to QCM for his understanding.
If buyer has any requirement about Fabric relaxation it will must follow by the PGCL quality team. Though we
are not producing Knit item thats why PGCL now not maintaining Fabric relaxation but if have any buyer have
any requirement then PGCL bound to do the Fabric relaxation before cutting minimum 48 hours.
MARKER LAYER CHECK
Q.A in charge in-cutting check marker drawing against the hard pattern, check size/ratio and marker placement
against the fabric selvedge.
Check alignment of the fabric edges and verify all the plies are extending beyond the marker ends. This is
documented and reports to cutting manager and to QAM.
All the marker layer check by the marker man & cutting in charge. After verifying the layer both the in charge
will sign in the layer paper it permit the cutter to cut the fabric. After verifying the layers concern people will
write their name & sign with date.

CUT PANNEL INSPECTION

A good sewing start with good cutting should have perfect inspection on cut panels. Thats why have stationed
removing Q.C in cutting. Roaming Q.C in the cutting department, check bundle for miss cut and for failure of
cutters tolerance is +/- 1/16, the top ply and bottom ply of the cut bundle check against the middle ply and
compare with hard pattern. The location check for panels by placing the hard pattern on the top ply. All the
defects are recorded with the identification number of cutter. Check 100% cut panels for fabric defect at AQL 1.5.
If any replacement need to be done by the cut balance of the same roll.
Quality people in the cutting section must ensure the quality of the cut panel & maintain all the quality format of
all cut panel.
PRE PRODUCTION MEETING
Pre production meeting to organize every department with new orders. Points of discussion- cutting, production,
fabric and trims, technical, quality, finishing, folding, packing and shipment along with p.o. breakdown. The
Factory Manager will chair this program and Concern Merchandiser, Technical Manager, Quality Manager,
Assistant Quality Manager, cutting manager, Production Manager, Finishing Manager will present at this
meeting.
Point, which discuss and agreed by all participants have to be documented and sign. PGCL have the policy of
monthly management review program on the last one month production. At this management review program
they will ensure what defect & problem found in last one month about quality & production. After discussing the
last one month problems they will analyse the root cause & decide how to solve the problem so that it not creat
again in future production.
SAMPLE
Once sample is made it is checked by QC to confirm fit, workmanship, appearance and the styling. This is
documented and report to QAM with samples, for his review and the documented report distribute to all relevant
personnel.
INTER DEPARTMENT PRE PRODUCTION MEETING
Prior to any style feeding QA department internal meeting to educate all relevant roaming QCs input, final,
measurement auditors and QA in charge. QA manager documents this.
The points discuss are:
1 P.P sample and sample comments
2 Construction details
3 Critical Operations
4 Measurements
5 Trim details
6 P.O breakdown
7 Input check table locations

PILOT RUN
As believe, in manufacturing process all depend on 4Ms (Man, Machine, Material, Method) we do pilot run to
identify the barriers at the earlier stage the quantity of the pilot run is 100pcs, including all the colors and the
sizes, with the first piece of feeding roaming Q.C and the QC in-charge follow machine to machine along with
QAM once the first operation set with the required standard only proceed to the next operation Mock-up has to be
made on every critical operation and it is to be hang on the machine along with the Q.A in-charges signature
input QC s location decided on the style QA in-charge gets initial produce pieces with comments to QAM to his

comments and to his approval all the initial out-put comments are documented and documented report distribute
to production managers, production line in-charge, roaming QC, QC in-charge and to all relevant department.
All the input checkers, final checkers, roaming QC, measurement auditor and QA in-charge are explained and
educated by QAM regarding all the quality issues.

IN PROCESS QUALITY CONTROLL SYSTEM IN SEWING

With the firm idea of critical operation roaming QC follow systems to control quality issues. Roaming QC takes
bundle from defect creative operation and takes 7 pieces to check if no damages QC can move to other operation.
But if found even one defect QC documented on report and take signature from machine operator on the report.
QC can move to other operation. The identical follow up cards give to machine operator to tie on the next three
bundles which is to be procedure and note down bundle numbers by compare with last bundle number and QC
continues with other operations. When QC comes to second check on follow up operation, take those identical
three bundles to find defects. If no defect, QC moves to other operation. If any defect QC put yellow light on the
operation with informing to production in-charge and does the same follow up procedure to 2 nd check. When QC
turn to 3rd check, if found any defect QC put red light and informed to production in-charge and stop the
machine. All the steps are recorded on the report. Once operation started to continue after corrected roaming QC
start continue to three checks in second session. If no damage, operation proceeds with on and off checks. If QC
found any defect, QC stops the machine with the same procedure. All steps are documented on the report and
inform to QAM to go head with the operation.
Roaming QC check input and end line final checkers documented report every hour to identify defects and the
percentage of the operation and attack to the problems accordingly.
The entire reject garments to keep in an identical place at the check table and QA in-charge review all the rejected
garments on daily basis and same way to the QAM to his review. Final rejected pieces are documented and send
to store through finishing department.
Sewing QC in-charge do hourly audit to end line pass garments based on AQL 2.5. If fail, recheck to be done for
hour pass quantity. Documents report to the QAM.

MEASUREMENT
Measurement auditors confirm fit by measuring each color, each size 3pcs, by each sewing lines, documented
report to line QA in-charge and to QAM.
BUTTON STRENGTH
Button attachments are to be checked randomly for strength. The details are documented. Report to maintenance
department and to QAM.
FINISHING
100% inside check carried out for all the garments and defects are documented and damages to rectification, pass
garment go forward with checker ID number. 100% check carried out to topside after pressing the garments.
Defects are documented and damages to rectification. Pass garments go forward with checker ID number.
Finishing defects findings segregate according to sewing line checkers accordingly.
Finishing QA in-charge dose line wise hourly random inspection to passed garments by checkers. This
documented and to QAM.

SHADE SEGREGATION
Finally shade segregation will be done before go to poly bag and identical shade lot number to avoid mixing
shades.
PACKING
Packing checkers will check packing accuracy. Check shade, size/ratio, poly bag, quantity, per cartoon mark and
number. This is documented and reported to packing manager, QA in-charge, AQL auditor for packed garments
and documented report to packing manager and QAM.
QAM do random inspection to packed garments and make comments on it. Documented report to packing
manager, finishing manager, QA in-charge.

STANDARD OPERATING PROCEDURE (SOP)

Cutting Quality Control

1.0 PURPOSE:
The purpose of this procedure is to verify the products for required standard of Customer and to ensure that
inspection have been performed to meet compliance to all contractual requirements.
2.0 SCOPE:
This procedure applies to all products that manufactured by Concorde Garments Limited and passed subsequent in
process inspection.
3.0 RESPONSIBILITY:
QA Manager or his representative will ensure that the control for achieving quality levels required by specification
is in place and that compliance to document is meet. QA Manager & Assistant QA Manager are responsible to
provide all necessary inspection standard, check list and standard operating procedure and to relevant staff. QA
Manager will ensure that inspection procedure is correctly understood, implemented, maintained by concerned
persons.

4.0 PROCEDURE:

4.01. Check the order sheet & ratio before marking.

4.02. Check the pattern & grading before sample cutting & trail cutting.
4.03. Check 10/o Fabric color wise as per 4 point system.
4.04. Check the fabric Shrinkage / Color Fastener / Mack Blanket for shad / Color variation.

4.05. Check the pattern cut mark / enter line / balance matching / border matching / measurement.
4.06. Check the marker & ratio & consumption.
4.07. Check the fabric status before cutting.
4.08. Check lay & spreading & pining.
4.09. Check the lay chart & keep record.
4.10. Check the cut pcs with pattern 10%.
4.11. Panel checks hourly with record.
4.12. Check the numbering / scissoring / bundling.
4.13. Check the fabric / interlining face / back with direction as per approval.

Sewing Quality Control

1.0 PURPOSE:
The purpose of this procedure is to verify the products for required standard of Customer and to ensure that
inspection have been performed to meet compliance to all contractual requirements.

2.0 SCOPE:
This procedure applies to all products that manufactured by Concorde Garments Limited and passed subsequent in
process inspection.

3.0 RESPONSIBILITY:
QA Manager or his representative will ensure that the control for achieving quality levels required by specification
is in place and that compliance to document is meet. QA Manager & Assistant QA Manager are responsible to
provide all necessary inspection standard, check list and standard operating procedure and to relevant staff. QA
Manager will ensure that inspection procedure is correctly understood, implemented, maintained by concerned
persons.

4.0 PROCEDURE:

4.01. Check the sewing accessories with trim card and order sheet for make & styling details.
4.02. Check the S.P.I & Stitch quality.
4.03. Check the approval sample with out put quality and lay out process wise and sewing details.
4.04. Check the measurement process wise.

4.05. Check the finished pattern for marking like pocket position, cuff, collar, band joint pattern.
4.06. Check the cut mark for sewing goods.
4.07. Check the Measurement complete garments.
4.08. Check the hole button position before hole making & button attaching.
4.09. Check the hourly report from Quality inspector.
4.10. Check the oil control report.
4.11. Make daily inline report.

Finishing Quality Control

1.0 PURPOSE:
The purpose of this procedure is to verify the products for required standard of Customer and to ensure that
inspection have been performed to meet compliance to all contractual requirements.

2.0 SCOPE:
This procedure applies to all products that manufactured by Concorde Garments Limited and passed subsequent in
process inspection.
3.0 RESPONSIBILITY:
QA Manager or his representative will ensure that the control for achieving quality levels required by specification
is in place and that compliance to document is meeting. QA Manager & Assistant QA Manager are responsible to
provide all necessary inspection standard, check list and standard operating procedure and to relevant staff. QA
Manager will ensure that inspection procedure is correctly understood, implemented, maintained by concerned
persons.

4.0 PROCEDURE:
4.01. Check the finishing accessories with buyer approval trim card.
4.02. Check the position of finishing accessories.
4.03. Check the packing instruction & ratio.
4.04. Check the sample ctn measurement / Quality before CTN order.
4.05. Check the shipping mark after sample CTN received.
4.06. Check the folding approval before finishing.
4.07. Preliminary check in side before iron.
4.08. Preliminary check topside before iron.
4.09. Set up Q.I for final check after iron.
4.10. Set up Q.I. for get up looking.
4.11. Set up Q.I. for finishing accessories checking like Hangtag / Price Ticket / UPC Code etc.
4.12. Set up Q.I. for ratio checking.
4.13. Set up Q.I. for export CTN & number checking.
4.14. Check the packing list.

JOB DESCRIPTION & RESPONSIBILITY OF QUALITY DEPARTMENT

Quality Assurance Manager

He has to response total quality management for develops a sustainable quality to meet all the respective
Customers / Buyer demands for product quality and safety and improve the quality standard for customer
satisfaction. He must approach the systems according to standard for develop the Q.C. department. He should
collect the entire order detail sheet / order sheet / trim card / sample / buyer comments or any revised or important
information should be dispatch to consignee as soon as possible with clear briefing.

Quality Assurance Manager

He has to responsible for the quality department and assisting for Q.A.M. by the required of factory manager and
nominate person. He must develop the Q.I. department and set up total quality system and make policy of
responsibility of quality department. He must collect all the necessary information from the Q.A.M. / F.M. and
communication with related person earlier.

Central Quality Controller

He is the responsible person of quality control for his section independently his department is separate from
production department. He always controls the quality inspector for inspection by the standard & reducing the
problem by his won responsibility to avoid the risk.

Line Quality Controller

A line quality control he is the responsible for his line quality control. He always monitoring the line and checks
the lay out from the starting time as per buyer approval sample & teaching Q.I. how to check the part /
component / his area. A line quality controller must approach the system of inspection to the Q.I. & brief them
how to measurement & check. A line Q.C. is the responsible person for his line quality control. He must follow
the quality control activities and collect all the necessary information and he should collect approval sample/
working details / measurement sheet from the C.Q.C./A.Q.A.M.

Quality Inspector
A quality inspector is the responsible person for the inspection for his job/Due. He must inspection his area
individually he is separate from the production. He should inspection by the standard & as per briefing of
management nominates person.
A quality inspector should be inspection properly. He never allows any defect for achivel00% quality. He must
short out all the defect & record keeping hourly defect %.

Finishing Quality Control

He is the responsible for finishing quality control maintains finishing quality control activities for sustainable
quality to improve customer satisfaction by reducing. Alteration and approach to achieve the world latest target in
ZERO ALTERATION by quality mission. Any confused then discus with Q.C.M / Asst. Q.C.M. to improving
system & procedure of finishing quality control (activities). He must arrange F.Q.S. (Finishing Quality
Supervisor) and training them for their job responsibility.

Finishing Quality Supervisor

(Pre-Final)
He is the responsible person for pre final quality inspection before iron. He must arrange the Q.I. for pre-final
inspection and training them about their job responsibility. How to check process wise for ZERO ALTERATION
any confused then discus with F.Q.C.
Wash / Spot Remove
He is the responsible person for the wash like spot removing. He must have knowledge about deferent color wise
spot removing chemical as production & laundering & flam mobility of deferent clothing. He should remove the
daily / Hourly spot and keep record any confused than discuss with F.Q.C.

Final
He is the responsible person for final quality inspection. He must arrange the final quality inspector and training
them how to check the final quality. Any confused than discuss with F.Q.C.
Get up
He is the responsible person for get up quality inspection. He must arrange the get up Q.I. and training them how
to check get up. Any confused then discuss with F.Q.C.
Packing
He is the responsible person for packing section. He must follow the packing quality control activities and
arrange Q.I. for packing section & training them how to check properly for good quality to success the final
mission without failure. Any confused then discuss with F. Q. C.

Line Quality Controller

One Line Quality Controller for each line. He is the responsible person for his sewing line quality control. He
must follow the sewing quality control activities. He monitoring in the sewing line Q.I. and briefing them arrange
Q.I. & training them him self as per quality management instruction. Any confused than should discus with
S.Q.C.

Quality Inspector (Q.I)

Make Section
He is the responsible person of make section. He always follows the L.Q.C. Instruction and checks process wise
and keep record hourly. His inspection area should be production floor. He should inspection properly never pass
any alteration and defect component must collect. All the information & measurement, pattern, sample and
necessary things which he need to ensure 100% quality any confused then he should discuses with L.Q.C.
Back Front
He is the responsible person of Back Front section inspection area. He should inspection properly. He must
inspection process wise & keep all record hourly. He should collect all the information & measurement, pattern,
sample for his inspection area. He needs to ensure 100% quality. Any information or suggestion he should meet
the L.Q.C as early as possible.
Slv / Cuff/Collar / Side Seam
He is the responsible Q.I. for the slv, gamble placket, cuff joint, collar joint, side seam & bottom hem area. He
should collect all the information, for his inspection area to ensure 100% quality. Don't pass any alter and defect
from his inspection area. If fell any confusion then discus with L.Q.C as soon as possible.
Inside preliminary checking
He is the responsible person for inside quality inspection. He should preliminary check inside all components at a
glance & check all the trim, stitch, LBL, spot, uncut thread & hole, BTN. Never passing any alteration from his
inspection area. He should collect all the information from the S.Q.C. Any confused then discus with S.Q.C.
To side preliminary checking
He is the responsible person for the topside preliminary inspection. He must collect all the information from the
S.Q.C. He must check the spec measurement of chest, collar, cuff, slv & top side all trim stitch & process wise
inspection & keep record. He check very strongly and never pass any alter & defect. He must short out the entire
defect garments hourly and hand over to the S.Q.C. for reducing the alteration and achieve the good quality.

IN COMING MATERIALS PROCESS

The items of in coming materials are mainly Fabrics & Accessories. We have some specified systems before
receive of these materials. The systems are following our factory as bellows:

For Fabric Receiving:

Normally the fabrics are coming from China. When the fabric cover van come in our factory, then fabric store in
charge check the document and open the cover van after checking the seal and lock along with the Security incharge. After opening the door he un-load the fabric from the cover van and verify with the mentioned quantity of
delivery challan. First the store in charge un-loaded the fabric by authorized loader in the designated quarantine
zone. From this zone 10% of fabric taken for inspection by AQL 4.0 system. If fabric passes by this inspection
then 100% fabrics send to pass goods area. If the fabric fail any lot or 100% then usually inform to the concern
merchandiser and merchandiser inform to supplier. Finally it depends on the negotiation with supplier how he
replaces the fabrics. Before that fabric will keep the reject zone. For pass fabric as per production plan taken by
cutting section by giving requisition and start the cutting procedure. Before cutting the fabric QC will make the
spreading report during lay distribution. After cutting defect parts are usually replaced by balance of same lay
fabric. After then work started on bundle checking and QC make the report of part checking and numbering
procedure completed after panel check. After completed the check procedure required bundle and parts send to
sewing line as per production plan.
Between these procedures Store in-charge submitted the fabric physical inventory report to concern merchandiser
mentioning the shortage and overage. Before bulk cutting, cutting in-charge collect the trial cutting fabric from
store by giving requisition.

For Accessories receiving:

Major items of accessories are coming from overseas source except some few items of local sources. Following
the same procedures of fabric all in coming accessories are un-loading through a prescribed procedure and after
then it keeps in a designated quarantine zone. From this zone 10% of goods for every items taken by IQC based
on order sheet and swatch card. If found the quality is as per swatch sample then the goods are allowed to keep in
pass area neither report to concern merchandiser for decision. Merchandiser checks the sample and he negotiate
with supplier for replacement or if he can take buyers approval until the goods are keeping in reject area. After
then physical inventory report usually submitted to the concern merchandiser for further action. Goods will issue
from accessories store as per production plan and by giving the requisition of concern section.
In a nutshell this is the material in coming procedure of Concorde Garments Ltd.

MACHINE MAINTENANCE POLICY

Concorde Garments Limited has various types of machine for operation. Have sufficient number of trained up
Mechanic to maintain these machine. To get the proper out put from machine, company announces the
maintenance policy for their machineries as bellow:
01. Within ones in a three-month each machine should be service;
.

02. A detail schedule should be announced as per machine number and date;
03. The schedule will prepare for three month and within this period each and every machine should complete the
service;

04. As per this service schedule and the findings of service; master register should be up dated accordingly for
each machine individually;
05. As per the service schedule if found any machine is keeping in a ideal area for no use in this style- also follow
the service procedure;
06. Each and every machine should have an emergency card for updating the informations at any times sudden
abnormality- rectified by mechanic;
07. In the same card service activities will be also up date and hung on the machine;
08. Another one daily check card will hung on the machine for up dating the daily check informations;
09. During the machine replacement time all of this check card will be available with the machine; doesnt matter
where it will keep and use;
10. Each and every machine will be fully equipped with all of his safety devices;
11. All operators will be fully updated about the machine operating system;
12. Machine will not carry without trolley in the floor;
13. Machine will make service out side of the sewing line (in the maintenance room);
14. In case of any rental machine need to use in the sewing line- need to check every point by check sheet and
add the safety guards if required before start production;
15. Each and every activities of machine maintenance should be documented.
Organ gram of PGCL-

Quality Flow chartPearl Garments Co. Ltd

QUALITY PROCESS FLOW CHART

Fabric/ Accessories in Store

Fabric/ Accessories Checking

(Before Sending to Cutting)

Sampling, Shrinkage &

Pattern Test

Drawing Marker, Layin

Cutting & Numbering

Table Inspection

In-Line Inspection (Sewing)

Cut Fabrics are Sent to

Sewing Line

Inspection on Cutting

Trimming & Inside/Outside

Inspection

Shade-wise Bundling for

Washing

Washing if Required

After Wash Inspection

Ironing, Where Required

Pre-Inspection

Finishing

Button/ Cording

Pre-Finish Inspection

Hang Tag, Price Ticket

Folding

Final OK Inspection

Assortment
Cartooning

Buyers/ Clients Final

Inspection

Final Getup Checking

Garments Insertion on P
Bag

Delivery

Drawstring maintain policy-Pearl Garments Company Ltd

Parameter

Requirement-Newborn /
Preemie Sizes under 3
months

Requirement-Infant /
Toddler Sizes smaller
than 2T

Requirement-Child
Sizes 4-20

Illustration

Hats

When ornamentation / decoration When ornamentation /

is applied on top of the hat,
decoration is applied on top of
chinstraps are not recommended. the hat, chinstraps are not
When no ornamentation /
recommended. When no
decoration is applied on top of the ornamentation / decoration is
hat, chinstraps can be used.
applied on top of the hat,
Chinstrap should not be a
chinstraps can be used.
continuous loop. Recommend a Chinstrap should not be a
breakaway such as hook and loop continuous loop. Recommend
fastener.
a breakaway such as hook and
loop fastener.

Gloves

Not recommended to use

drawstrings or ties. As an
alternative, it is recommended to
use hook and loop fasteners.

APPAREL
ACCESSORIES

When ornamentation /
decoration is applied on
top of the hat, chinstraps
are not recommended.
When no ornamentation /
decoration is applied on
top of the hat, chinstraps
can be used. Chinstrap
should not be a continuous
loop. Recommend a
breakaway such as hook
and loop fastener.

Not recommended to use

Not recommended to use
drawstrings or ties. As an
drawstrings or ties. As an
alternative, it is recommended alternative, it is
to use hook and loop fasteners. recommended to use hook
and loop fasteners.

RECOMMENDATIONS FOR DECORATIVE FEATURES

Feature

Allowance (Industry Practice)

Hazard

Decorative Bows

See TIES (Pre-tied bows are

permanently stitched, so that they
cannot be untied.)

Catch point

Allowed if they lay flat on the

Tabs (wide fabric pieces sewn to
garment so as to not create a catch
garment or attached with a closure) point. Maximum distance between
attachment points is 3.0 inches.

Ribbon/Tape woven through

openings (used around body)

Loops (cords or strings as

decorative loops, locker loops)

Catch point

Allowed, but must be tacked at every

entry and exit point or every 1.0
Circulation impairment
inches, whichever is less.

Allowed if they lay flat on the

garment so as to not create a catch
point. Cannot be elastic. Maximum
distance between attachment points
Strangulation
is 1.5 inches. Not allowed on the
back of garment between the neck
and shoulder blades.

Loops (fabric pieces as decorative

or functional loops)

Allowed if they lay flat on the

garment so as to not create a catch
point. Cannot be elastic. For
Catch point
footwear, fabric loops on the rear of
the shoe cannot exceed 1.0 inch in
length.

Sewn-in Labels (external)

Internal or external - no limit.

Circulation impairment

Illustration

RECOMMENDATIONS FOR DECORATIVE FEATURES

Feature

Allowance (Industry Practice)

Zipper Pulls

Maximum length is 3.0 inches. Must

be permanently attached to zipper
Catch point
and cannot be looped or tied such
that pull can be unlooped or untied.

Cordlocks

Drawstring and Tie Finishing

Hazard

Illustration

Under 36 months: Not

recommended. Over 36 months-16
years: Can be used for drawstrings
in loop configuration and soft cord
locks are recommended. Cordlocks Small part
should be permanently
attached/nonremovable.

Knots and plastic tipping are not

recommended on exposed ends.
Exposed ends should be finished
with bar tacking, stitching or heatsealing to prevent fraying.

Small part

ALTERNATE CONSTRUCTIONS
Feature

Interior Drawcord Holder (Uncinched)

Illustration

Interior Drawcord Holder (Cinched)

Drawstrings and Ties in Children's Apparel and Accessories

DEFINITIONS
Drawstring

A string, cord, tape, ribbon or bungee inserted into the hem or casings and intended to be drawn more than
1 inch. For use in closing a bag or controlling fullness of a garment.

Ties

A string, cord, tape, ribbon, sash used for fastening or uniting. Ties are not capable of controlling fullness.

Decorative Ties / Bows

A string, cord, tape, or ribbon that is stitched down in the middle to create a permanent non-functioning
pre-tied bow or tie.

Decorative Features

Tabs, woven ribbon / tape, loops, sewn-in labels, zipper pulls

Toggle

Toggle is generally threaded onto the cord, slides freely and usually stopped by a cordlock. If the
cordlock comes off, the toggle becomes free and poses a risk as a small part.

Cordlock

Cordlock is threaded onto the cord. It has a spring type of control that 'locks' them in place along the
cord. To move a cordlock, the mechanism of squeezing the lock and sliding it along the cord need to be
activated. The benefit to this is that, if the cord end has a knot that comes undone, the cordlock will not
fall off.

Fragile Trim

Decorative trim pieces such as jewels, sequins, beads, crystals and the like that are glued or sewn such that
they (a) do not meet a 15 lb tension requirement or (b) cannot be tested for mechanical properties without
crushing or compromising the integrity of the attachment.

PROCESS CONTROL CHART

Brand Style number Description Stud code Machine number Machine type Socket code Machine number Machine
type
Date
Press

Position

Specified pinch setting

Time

Average pinch setting

Pull test

Inspection
number

fastener

Average pinch setting

Press
fastener

Position

Specified pinch setting

Time
Inspection
number

Pull test

Sharpe Tools Control Policy

PGCL is committed to ship out metal free goods for all customers. In this regards, all operators, supervisors and
other concern persons shall follow the Sharpe tools (blade, tag gun & cutter) policy :
1. Sharpe tools (blade, tag gun & cutter) are issued to the operators from Store through indent duly
recommended by the Section In Charge and as well as approved by the concerned authority.
2. If any Sharpe tools broken, the operator is responsible to find out all broken parts to be get new
tool. Supervisor will issue the new sharp tool once get back all broken parts. And he is responsible
to post all broken parts onto the broken Sharpe tools register.
3. If any broken part not found the goods/ part of goods should be check trough metal / needle
detector machine. If still not found, the garments should be destroyed.
4. In exchange with the broken/ unusable replacement are made on free of cost basis to the operators
by the Needle in Charge as and when required.

5. Broken parts and replacement status of sharp tools should be properly recorded in the register
everyday.

Small Part safety policyTEST SPECIFICATION PHYSICAL AND MECHANICAL HAZARDS Specification No.:
Distribution: United States Date: TEST: Small Parts Page:
REQUIREMENT REFERENCE: U.S. Federal Hazardous Substances Act: 16 CFR 1501 ASTM
F963-07 Sections 4.6, 4.6.1, 4.6.3 and 5.11.2

METHOD REFERENCE: U.S. Federal Hazardous Substances Act: 16 CFR 1501 ASTM F963-07
Sections 4.6, 4.6.1, 4.6.3 and 5.11.2

PURPOSE: Articles intended for use by children under 3 years of age that presents a choking,
aspiration or ingestion hazard because of small parts are banned.
REQUIREMENTS: Samples (including removable, liberated components or fragments of toys or
trims) must not be small enough to fit entirely within the small parts cylinder under the force of its own
weight before and after appropriate use and abuse testing.
COMMENTS AND RECOMMENDATIONS: The CPSC requirement for all small parts and / or trim
components, functional and decorative, meets the standard attachment strength of: Age group of 18
months or less: 10 pounds (44.5 Newtons); and Age group over 18 months but not over 96 months: 15
pounds (66.8 Newtons) It is Dillards policy that all trim components must withstand a force of 17
pounds, applied within the first five seconds for the test and maintained for 10 seconds. An attachment
strength failure is defined as a complete detachment and / or tearing or rupturing of the fabric to which
the component is attached. . It is recommended that all trim components be sewn on to the fabric
instead of glued on or pinned on to the fabric. It is also recommended that buttons meet the following
minimum performance requirement: <14 ligne size 14 21 ligne size . 22 ligne size Center Breaking
Strength 17 lbs 17 lbs 22 lbs

Suggest: For components that are non graspable , testing should be performed by laundering the
product according to the recommended care instructions for a minimum of 10 home Launderings / 5
Drycleanings to determine of the component releases. If a release occurs then the product should fail
the requirement of no release for sizes under 3 years of age. This would include testing for all Heat
Transfer/Screen Print / Small Part For All Size Range.

a) Fragile Trims Certain trim components are too delicate and cannot meet the 17 lb minimum
attachment strength requirement. Such trims include beads, sequins, and rhinestones. It is
recommended that such trims not be included on garments and accessories intended for children under
the age of 3 (three) years. They may be used on garments and accessories for children aged 4 and
above. In order to assure the durability of fragile trims, it is recommended that the garments with
fragile trims be subjected to a number of cleaning cycles during development and production stages.
During development, 15 washing / drying cycles or five (5) dry cleaning cycles (if care instructions are
dry clean) and during production, 10 washing / drying cycles or three (3) dry cleaning cycles are
recommended. Trim that do not detach, break or discolor are considered acceptable. If fragile trims are
subjected to washing tests, attachment strength testing is not required. If appropriate, it is recommended
that garments with such trims also bear the warning hangtag.

b) Hasps and Sliders Hasps and slider failures cause the release of small parts that poses a choking
hazard for children under three (3) years of age. Therefore, it recommended that each production lot of
hasps and sliders is quality tested prior to shipment to garment manufacturer. A good quality hasp and
slider must meet or exceed the following performance requirements: Wire Diameter Hasp and slider:
2.6 mm (minimum) Lateral Pull 35 pounds (minimum) Vertical Pull 35 pounds (minimum) Opening
Tension 2 pounds (minimum) to 8 pounds (maximum) Closing Tension 8 pounds (maximum) Note:
Hasp sets: For domestic and foreign manufacturers, the only approved manufacturer to purchase hasps
from is Mississippi Trading Co.

c) Snap Fasteners It is recommended that all snaps be attached with a fully automated pneumatic or
electric press instead of manual presses. Light duty snaps (12-16 ligne) are not recommended for
children under 3 (three) years of age. It is also recommended that light duty snaps meet the
following performance requirements: Minimum Maximum Snapping Force 2 pounds 6 pounds
Unsnapping Force 2 pounds 6 pounds

d) Beads, Sequins and Pailettes Method of Attachment Sequins and beads must have knots behind
every third sequin / bead. This attachment method ensures that, if one sequin / bead breaks off, at
most only two additional sequins / beads will fall. Caviar beads must be attached by heat transfer.
Sequins must be applied in layers, one on top of the other, of at least two plies. It must have a
minimum of two stitches: edge to center and center to edge Thread Type Sequins, Beads and
Pailettes that are sewn on must be attached with thread that is polyester core-spun.

e)

Spherical Textile Trims and Tassels Method of Attachment All units must be sewn onto finished
product. Metal bands, glue, fusing or bonding are prohibited. Each unit must be individually
knotted. Thread Type Must confirm that thread is polyester core-spun. No monofilament thread
may be used in assembly or decorative stitching. Antenna Must confirm that stuffed antenna are
made from one continuous piece of fabric. If separate fabric pieces, the antenna must lie flat. No
wire or stiffener inserts are allowed.

g)
Method of Attachment Hand Stitching Ribbon: The hand stitching must be knotted at every seven inches
(7) of thread used. Thread: Hand crewel embroidery must be tied off after every inch of work. Machine or
hand embroidery floats or loose ends may not exceed one-quarter of an inch (), and are only acceptable on
the backside of artwork. All close-fitting garments with embroidery must have fusible backing. Any
embroidery in the chest or upper torso area will have fusible backing, regardless of the number of colors in
the embroidery. All-over embroideries do not require fusible backing; they must be fully lined. Cardigans, or
other layering pieces that do not touch the skin, do not require fusible backing unless floats or ends exceed
one-quarter of an inch ().

h)
Pompons and Tassels
The term pompon applies to lengths or strands of fiber, yarns or thread clamped or secured together at the
center and brushed to form a spherical ball. Spherical-shaped balls made of stuffed material are also
called pompoms. Tassels are defined as components comprised of lengths of string or yarn, bound together
and creating a spherical mass.
The following is quality performance and safety recommendations for pompoms and tassels:
Attachment Strength Preemie / Newborn: Infant / Toddler: 3 Child: 36 months
Under 3 Months
<36 Months
16 Years
Individual Yarns
Withstand direct pull Withstand direct pull Withstand direct pull
force of 17 lb / 10 sec force of 17 lb / 10 sec force of 17 lb / 10 sec
Individual yarns not Individual yarns not Individual yarns not
withstanding the
withstanding the
withstanding the
direct pull force of 17 direct pull force of 17 direct pull force of 17
lb / 10 sec, must
lb / 10 sec, must
lb / 10 sec, must
measure less than 12 measure less than 12 measure less than 12
inches in length.
inches in length
inches in length.
Must be sewn on to Must be sewn on to Must be sewn on to
the finished product. the finished product. the finished product.
Metal bands, glue,
Metal bands, glue,
Metal bands, glue,
fusing or bonding is fusing or bonding is fusing or bonding is
not recommended. not recommended. not recommended.
Attachment Strength Preemie / Newborn: Infant / Toddler: 3 Child: 36 months
Whole Pompom / Under 3 Months
<36 Months
16 Years

Tassel / Complete
Unit

Whole unit withstand Whole unit withstand Whole unit must

direct pull force of 17 direct pull force of 17 withstand direct pull
lb / 10 sec. Individual lb / 10 sec. Individual force of 17 lb / 10
yarns must meet 17 lb yarns must meet 17 lb sec. Individual yarns
/ 10 sec direct pull
/ 10 sec direct pull
not withstanding the
force. Individual
force. Individual
direct pull force of 17
yarns not
yarns not
lb / 10 sec, must
withstanding the
withstanding the
measure less than 12
direct pull force of 17 direct pull force of 17 inches in length.
lb / 10 sec, must
lb / 10 sec, must
measure less than 12 measure less than 12
inches in length.
inches in length.
Whole pompom must Whole pompom must
not pass through the not pass through the
pompom test fixture pompom test fixture
(diameter of 1.75
(diameter of 1.75
inches)
inches)
Must be sewn on to Must be sewn on to Must be sewn on to
the finished product. the finished product. the finished product.
Metal bands, glue,
Metal bands, glue,
Metal bands, glue,
fusing or bonding is fusing or bonding is fusing or bonding is
not recommended. not recommended. not recommended.

TEST SPECIFICATION CHEMICAL HAZARDS Specification No.: Distribution: United States Date: TEST:
Lead Content Page:
REQUIREMENT REFERENCE: U. S. Consumer Product Safety Act Regulation: 16 CFR 1303 Ban in Lead
Containing Paint and Certain Consumer Products Bearing Lead Containing Paint ASTM F963-03, Sections
4.3.5 and 4.3.5.1, Standard Consumer Safety Specification Toy Safety

METHOD REFERENCE: U. S. Consumer Product Safety Act Regulation: 16 CFR 1303 Ban in Lead
Containing Paint and Certain Consumer Products Bearing Lead Containing Paint ASTM F963-03, Sections
4.3.5 and 4.3.5.1, Standard Consumer Safety Specification Toy Safety

PURPOSE: Consumer Product Safety Commission has found that there is an unreasonable risk of lead poisoning
in children associated with lead content of over 0.06 percent (%) in paints and coatings to which children have
access.
REQUIREMENTS: Surface coatings such as paints, varnishes, lacquers, inks, etc. must not contain lead or lead
compounds in which the total lead content is in excess of 0.06 percent (%) (600 mg / kg or ppm) by weight of the
total non-volatile content of the paint or the weight of the dried paint film.
COMMENTS AND RECOMMENDATIONS: This test is recommended on all Trim Components, Painted
Hardware and Fabric Coatings.

TEST SPECIFICATION CHEMICAL HAZARDS Specification No.: Distribution: United States Date: TEST:
California Proposition 65 Page:

REQUIREMENT REFERENCE: California Safe Drinking Water and Toxic Enforcement Act of 1986
(Proposition 65); California Health and Safety Code, Section 25249.5, et seq.
METHOD REFERENCE: California Safe Drinking Water and Toxic Enforcement Act of 1986 (Proposition
65); California Health and Safety Code, Section 25249.5, et seq.
PURPOSE: This requirement is intended to advise the consumer of potential health hazards associated with
products that contain hazardous chemicals, as identified by California
REQUIREMENTS: All products manufactured, distributed or sold in California must comply with the exposure
and / or labeling requirements specified in Proposition 65. Californias Office of Environmental Health Hazard
Assessment (OEHHA) has identified and classified over 700 chemicals as either carcinogens or reproductive
toxins. If a product contains a listed substance that will release from the product over time in excess of the
Proposition 65 limits, then specified warning statements must appear on or near the product at the time of
purchase.

TEST SPECIFICATION CHEMICAL HAZARDS Specification No.: Distribution: United States Date: TEST:
Heavy Metals Page:
REQUIREMENT REFERENCE: ASTM F963-03, Section 4.3.5.2, Standard Consumer Safety Specification on
Toy Safety
METHOD REFERENCE: ASTM F963-03, Section 4.3.5.2, Standard Consumer Safety Specification on Toy
Safety
PURPOSE: Surface coating materials shall not contain heavy metals as there is an unreasonable risk of heavy
metal poisoning in children over the stipulated limit stated in ASTM F963-03.
REQUIREMENTS: Surface coating materials shall not contain compounds of Antimony, Arsenic, Barium,
Cadmium, Chromium, Lead, Mercury or Selenium in which the metal content of the soluble material is in excess
of the levels by weight of the contained solids. Soluble elements are extracted from toys under conditions that
simulate the situation in which the materials stay four (4) hours in the alimentary tract after swallowing.
ELEMENT LIMIT Antimony (Sb) 60 mg / kg Arsenic (As) 25 mg / kg Barium (Ba) 1000 mg / kg Cadmium (Cd)
75 mg / kg Chromium (Cr) 60 mg / kg Lead (Pb) 90 mg / kg Mercury (Hg) 60 mg / kg Selenium (Se) 500 mg / kg

COMMENTS AND RECOMMENDATIONS: While this voluntary specification is typically applied for Toy
Safety. It is recommended that testing be conducted for all Childrens Textile and Metal Trim Components in
accordance with the European Union Standard EN 71-3.

TEST SPECIFICATION CHEMICAL HAZARDS Specification No.: Distribution: United States

Date: TEST: Azo Dyes Page:

REQUIREMENT REFERENCE: European Commission Directive 2002 / 61 / EC, "Relating to

restrictions on the marketing and use of certain dangerous substances and preparations (azo colorants)"
European Commission Directive 2003 / 3 / EC, "Relating to restrictions on the marketing and use of
'blue colorant'"
METHOD REFERENCE: EN 14362 1, Textiles Methods for the determination of certain
aromatic amines derived from azo colorants Part 1: Detection of the use of certain azo colorants
accessible without extraction EN 14362 2, Textiles Methods for the determination of certain
aromatic amines derived from azo colorants Part 2: Detection of the use of certain azo colorants
accessible by extracting the fibers
PURPOSE: Specific azo dyes are not to be used in certain textiles and leather articles because they have
the capability to release certain arylamines, which may pose cancer risks.
REQUIREMENTS: All fabric and leather materials and toys, containing fabric and / or leather, are
prohibited from using azo dyes which are capable of decomposing into one or more aromatic amines
which have been identified as being carcinogenic. Finished textile products must not have amine levels
present in excess of 30 ppm. This directive applies to: -clothing, sleeping bags, bedding, towels, hair
pieces, hats, nappies and other sanitary items. -footwear, purses worn round the neck, gloves, wristwatch
straps, handbags, purses / wallets, briefcases and chair covers. -textiles or leather toys and toys which
include textile or leather garments. -carpets, excluding handmade oriental carpets.

The following chemicals have been identified as carcinogenic: 1) o-Aminoazotoluene (CAS 97-56-3) 12)
4,4-Dimethylenedi-o-toluidine (CAS 838-88-0) 2) 4-Aminobiphenyl (CAS 92-67-1) 13) 4,4-Methylenebis-2-chloroaniline (CAS 101-14-4) 3) 5-Nitro-o-toluidine (CAS 99-55-8) 14) 2-Napthylamine (CAS 9159-8) 4) Benzidine (CAS 92-87-5) 15) 4,4-Oxydianiline (CAS 101-80-4) 5) p-Chloroaniline (CAS 10647-8) 16) 4,4-Thiodianiline (CAS 139-65-1) 6) 4-Chloro-o-toluidine (CAS 95-69-2) 17) 4-Methyl-mphenylenediamine (CAS 95-80-7) 7) p-Cresidine (CAS 120-71-8) 18) o-Toluidine (CAS 95-53-4) 8) 2,4Diaminoanisole (CAS 615-05-4) 19) 2,4,5 Trimethylaniline (CAS 137-17-7) 9) 4,4-Methylenedianiline
(CAS 101-77-9) 20) 3,3-Dimethylbenzidine (CAS 119-93-7) 10) 3,3-Dichlorobenzidine (CAS 91-94-1) 21)
0-anisidine 2 methoxyaniline (CAS 90-04-0) 11) 3,3'-dimethoxybenzidine (CAS 119-90-4) 22) 4-amino
azobenzene (CAS 60-90-3) The directive also contains a list of azo dyes that may not be used in textile or
leather articles in concentrations higher than 0.1% by mass. Thus far, the list contains only one azo dye
(referred to as "blue colorant"). The blue colorant does not currently have a CAS number. This requirement
goes into effect July 1, 2004.

COMMENTS AND RECOMMENDATIONS: While azo dyes are regulated in the European Union, it is
not so in the United States and it is recommended that the industry take voluntary measures to restrict the
use of such azo dyes.

TEST SPECIFICATION CHEMICAL HAZARDS Specification No.: Distribution: United States

Date: TEST: Nickel Content Page:
REQUIREMENT REFERENCE: European Council Directive 94 / 27 / EC, "Relating to Restrictions
on the Marketing and Use of Certain Dangerous Substances and Preparations" (12th Amendment to 76 /
769 / EEC)
METHOD REFERENCE: EN 1810, Test method for release of nickel from products intended to
come into direct and prolonged contact with the skin EN 12472, Method for the simulation of wear
and corrosion for the detection of nickel release from coated items

PURPOSE: A number of consumer products including buttons, rivets, etc are made of nickel-containing
alloys that are capable of releasing significant amounts of nickel when they come into contact with
human perspiration and may result in the development of nickel allergy.
REQUIREMENTS: Rivet buttons, tighteners, rivets, zippers, and metal marks used on apparel must
comply with the following restrictions: Nickel is prohibited from use in parts of these products that
are in direct and prolonged skin contact if the rate of nickel release is greater than 0.5 micrograms per
square centimeter per week (g/cm2/wk); and Nickel is prohibited from use in parts of these
products that are in direct and prolonged skin contact unless these parts have a non-nickel based coating
that will prevent a rate of nickel release of greater than 0.5 micrograms per square centimeter per week
(g/cm2/wk) for a period of 2 years of normal use.
COMMENTS AND RECOMMENDATIONS: While nickel is regulated in the European Union, it is
not so in the United States and it is recommended that the industry take voluntary measures to restrict
the use of nickel in trim components such as metal zippers, buttons, snaps, belt buckles, eyelets, Drings, hasps & sliders, suspender clips, jewelry etc.

TEST SPECIFICATION CHEMICAL HAZARDS Specification No.: Distribution: United States

Date: TEST: Disperse Dyes Page:
REQUIREMENT REFERENCE: Section 30 of German Food and Commodities Law (LMBG)
METHOD REFERENCE: DIN 54231

PURPOSE: Disperse dyes are used to dye manufactured fibers (polyester, acetate, polyamide and
viscose / rayon. The dyes listed below are thought to be sensitizing and can cause allergic reactions.

REQUIREMENTS: No disperse dyes are specifically stated in the legislation. However, nine (9)
different disperse dyes have been enforced under 30 in a court of law. This applies to all dyestuff
with sensitizing, carcinogenic, mutagenic or reproductive toxic potential and must not be present. The
following disperse dyes are enforced under 30: 1) Disperse Blue 1 (CAS 2475-45-8) 2) Disperse Blue
35 (CAS 12222-75-2) 3) Disperse Blue 106 (CAS 12223-01-7) 4) Disperse Blue 124 (CAS 61951-517) 5) Disperse Orange 3 (CAS 730-40-5) 6) Disperse Orange 37 (CAS 12223-33-5) 7) Disperse
Orange 76* (CAS 51811-42-8) 8) Disperse Red 1 (CAS 2872-52-8) 9) Disperse Yellow 3 (CAS 283240-8) *previously designated Orange 37

COMMENTS AND RECOMMENDATIONS: While disperse dyes are regulated in Germany, it is not
so in the United States and it is recommended that the industry take voluntary measures to restrict the
use of disperse dyes on manufactured fiber fabrics.

TEST SPECIFICATION CHEMICAL HAZARDS Specification No.: Distribution: United States

Date: TEST: Cadmium Page:
REQUIREMENT REFERENCE: European Council Directive 91 / 338 / EEC, "Relating to
Restrictions on the Marketing and Use of Certain Dangerous Substances and Preparations" (10th
Amendment to 76 / 769 / EEC)
ASTM E1645: Standard Practice of Dried Paint Samples by Hotplate or Microwave Digestion for
Subsequent Lead Analysis ASTM E1613: Test Method for Determination of Lead by Inductively
Coupled Plasma Atomic Emission Spectrometry (ICP-AES), Flame Atomic Absorption Spectrometry
(FAAS), or Graphite Furnace Atomic Absorption Spectrometry (GFFAS) Techniques1
PURPOSE: Cadmium is typically used as a colorant in surface coatings on plastic products and there
are potential health hazards associated with the ingestion of cadmium in plastic trims and packaging.
REQUIREMENTS: Each surface coating and substrate of plastic products must not contain a total
cadmium concentration of 100 milligrams per kilogram (ppm) or more.
COMMENTS AND RECOMMENDATIONS: While cadmium is regulated in the European Union, it is
not so in the United States and it is recommended that the industry take voluntary measures to restrict
the use of cadmium in trim components with surface coatings, pigmented (colored) plastic and all PVC.

TEST SPECIFICATION CHEMICAL HAZARDS Specification No.: Distribution: United States

Date: TEST: Flame Retardants Page:
REQUIREMENT REFERENCE: EU Directive 2003 / 11 / EC of the European Parliament and
Council amending for the 24th time Council Directive 76 / 769 / EEC relating to restrictions on the
marketing and use of certain dangerous substances and preparations (PBDE, OBDE) EU Directive 76 /
769 / EEC on restrictions on the marketing and use of certain dangerous substances and preparations
Japanese Law for the control of household products containing harmful substances; Law 112

METHOD REFERENCE: Extraction method with GC/MS Analysis

PURPOSE: Bromintated flame retardants are a group of chemical compounds, that are added to
materials such as plastics and textiles to make them less flammable. These flame retardant chemicals
have the potential to disrupt thyroid hormone balance and contribute to a variety of developmental
defects.
REQUIREMENTS None detected for each of the following flame retardants: 1) Tris-(2,3,
-dibromopropyl)-phosphate (TRIS) (CAS 126-72-7) 2) Polybromobiphenyles (PBB) (CAS 59536-65-1)
3) Octabromodiphenyl ether (octaBDE) (CAS 32536-52-0) 4) Pentabromodiphenyl ether (PBDE)
(CAS 32534-81-9) 5) Tris (1-aziridinyl) phosphine oxide (TEPA) (CAS 545-55-1) 6) Bis (2,3dibromopropyl) phosphate (CAS 5412-25-9)

COMMENTS AND RECOMMENDATIONS: While the above mentioned flame retardants are
regulated in the European Union, there is no federal regulation banning these chemical in the United
States. Individual states have enacted legislation banning the use of PentaBDE and OctaBDE at levels
in excess of 0.1%: California, Hawaii, Illinois, Maine, Maryland, Michigan, New York. In addition,
Connecticut, Minnesota, Montana, Washington and Oregon have proposed bills to ban the use of
PentaBDE and OctaBDE. DecaBDE has been banned in Illinois; there is a proposed bill to ban in
Minnesota and Washington; possibility of an ban in California, Connecticut, Maine, Maryland, and
Oregon.
TEST SPECIFICATION OTHER HAZARDS Specification No.: Distribution: United States Date:
TEST: General Wearing Apparel Flammability Page:
REQUIREMENT REFERENCE: 16 CFR 1610: Standard for the Flammability of Clothing Textiles
METHOD REFERENCE: 16 CFR 1610: Standard for the Flammability of Clothing Textiles
PURPOSE: The standard provides methods of testing the flammability of clothing and textiles intended
to be used for clothing, establishes three (3) classes of flammability, sets forth the requirements which
textiles must meet to be so classified, and warns against the use of those textiles which have burning
characteristics unsuitable for clothing. In addition, Footwear, gloves, ( <14 in overall length) and Hats
(provided it does not cover the neck or face) are excluded.

REQUIREMENTS: The regulation defines which types of fabrics must be tested. Certain types of
fabrics and apparel accessories are exempt from testing as they are not considered to be dangerous.
Exemptions are as follows: Plain surface fabrics, regardless of fiber type, weighing 2.6 oz / sq yd or
greater Apparel manufactured with the following fibers, or blends of these fibers, regardless of
weight: Acrylic, Nylon, Polyester, Modacrylic, Olefin and Wool

COMMENTS: There are two major types of dangerous fabrics: -Plain Surface Fabrics weighing less
than 2.6 oz / sq yd -Raised Surface Fabrics (Brushed, Napped with Pile or Peached) which are made
wholly or partially of: Cotton, Linen, Acetate, Triacetate, Rayon, Ramie, Silk The above are called
Non-exempt Fabrics and must be tested for either Fabric weight or fiber to determine compliance to the
standard as an exemption.

The following light weight fabrics are considered suspect fabrics:

Cellophane Lawn Organdy Chiffon Leno Swiss Marquisette Crepe de Chine
Monie cloth Tissue Faille Crepe Crinoline Lingerie Batiste Tissue Gingham Gauze Moss
Crepe Tobacco Cloth Georgette Netting Tulle Laces Ninon Veiling
Voile
The following pile or raised surface are considered suspect fabrics:
Chamois Reverse Fleece
Chenille (cotton, rayon, acetate) Sherpa
Corduroy Terry Cloth
Flannel Velvet
Flocked Velveteen
Imitation Furs
While the standard is applicable to all wearing apparel, there are specific exemptions for which the standard does
not apply. These include:
Interling fabrics
Hats, gloves and footwear except:
a
b
c

o
o
o

Hats that form part of a covering for the neck, face and shoulders
Gloves that are more than 14 in length and form an integral part of another garment
Footwear that consists of hosiery and forms and integral part of another garment

COMMENTS AND RECOMMENDATIONS:

Use of feather trims on apparel: The method to test feathers (trims or boas) for flammability, as well as
classification of the results is not outlined under the Flammable Fabrics Act Regulations (16 CFR 1610, 1615 or
1616). It is the opinion of the CPSC that feathers used as an integral part of the garment, will have to meet the
regulation (in spite of the regulation not defining the way to test feathers). Therefore, they must be tested to the

standard.
TEST SPECIFICATION: Specification No: Distribution: United States Date: TEST: Childrens Sleepwear
Flammability Page:
REQUIREMENT REFERENCE: U. S. Flammable Fabrics Act (FFA) Regulation: 16 CFR 1615 (FF 3
71) Standard for the Flammability of Childrens Sleepwear: Sizes: 0 through 6X U. S. Flammable
Fabrics Act (FFA) Regulation: 16 CFR 1616 (FF 3 74) Standard for the Flammability of Childrens
Sleepwear: Sizes: 7 through 14

METHOD REFERENCE: U. S. Flammable Fabrics Act (FFA) Regulation: 16 CFR 1615 (FF 3 71)
Standard for the Flammability of Childrens Sleepwear: Sizes: 0 through 6X U. S. Flammable Fabrics
Act (FFA) Regulation: 16 CFR 1616 (FF 3 74) Standard for the Flammability of Childrens Sleepwear:
Sizes: 7 through 14

PURPOSE: The standards provide a test method to determine the Flammability of Childrens Sleepwear,
Sizes 0 through 14, and fabric or related material intended or promoted for use in such Childrens
Sleepwear.
REQUIREMENTS: The average char length of five (5) specimens must not exceed 178 millimeters (7
inches). In addition, no individual specimens shall have a char length greater than 254 millimeters (10
inches). The requirement applies to any product of wearing apparel up to Size 14 such as nightgowns,
pajamas, and similar or related items (robes) intended to be worn primarily for sleeping or activities related
to sleeping. Note: Separate regulations exist for different size categories as stipulated in the references.
Items excluded from this requirement include: a) diapers and underwear b) infant garments (9 months or
less), and c) tight-fitting garments For sleepwear to be considered in infant garment: a) must be sized for a
child nine (9) months of age or younger b) must not exceed 64.8 centimeters (25.75 inches) in length if one
(1) piece, or exceed 40 centimeters (15.75 inches) in length if it is two (2) pieces c) must bear a label
stating the size of the garment in terms of months of age. In addition, the article must comply with the
requirements of 16 CFR 1610 and / or 16 CFR 1611, whichever is applicable. For sleepwear to be
considered a tight-fitting garment: a) it must not exceed the maximum dimensions of each of the sizes
specified in the regulation b) have no ornamental trim extending greater than six (6) millimeters (1/4 inch)
from the garment c) meet other dimension requirements for the length of the sleeves and legs, and d) bear a
label stating the size of the garment in terms of age in months or by the child's size In addition, the article
must comply with all applicable requirements of 16 CFR 1610 and 16 CFR 1611. Children's Sleepwear
must also conform to specific labeling requirements stated in the above cited reference.

COMMENTS AND RECOMMENDATIONS:

a) Childrens Sleepwear Flammability
Childrens Sleepwear any product of wearing apparel, sizes over 9 months 14, such as nightgowns, pajamas,
or similar or related items, such as robes, intended to be worn primarily for sleeping or activities related to
sleeping. Not included in the definition: diapers and underwear; infant garments, and tight-fitting sleepwear.
Flame Resistant (FR) Sleepwear The testing specified for childrens sleepwear requires that all garments and

fabrics used in childrens sleepwear must not exceed maximum char lengths when exposed to a small, open flame
as specified in Code of Federal Regulations (CFR) 1615 & 1616. Unlike snug-fitting sleepwear, flame resistant
product has no fit restrictions.
Flame Retardant Sleepwear While the CPSC does not have a specific definition for flame retardant sleepwear,
Health Canada requires the use of the term flame retardant for chemically treated garments. Therefore, it is
recommended to use the term flame retardant to define chemically treated garments.
Tight-Fitting Sleepwear It is the Consumer Product Safety Commissions (CPSC) belief that tight-fitting
sleepwear is less likely to catch fire than loose fitting sleepwear. Therefore, the CPSC allows the sale of 100%
cotton sleepwear, for childrens sizes 0 through 6X and sizes 7 through 14, so long as the garments do not exceed
the maximum dimension specified in CFR 1615 & 1616, has no fabric or ornaments which extends more than
from the garment, meets flammability requirements of 16 CFR 1610 and bears a label stating size in terms of age.
Non-Sleepwear These are garments for non-sleeping purposes and include long johns, long underwear, and
loungewear. Historically these products were often displayed, marketed and sold to consumers as sleepwear.
Today, any product marketed for sleeping purposes must be in compliance with tight fitting requirements or the
flammability requirements of 16 CFR 1615 / 1616. There is no official loungewear category in the childrens
business. CPSC views loungewear equal to sleepwear. If the term loungewear is used, the product must meet all
sleepwear requirements.
Long underwear or long johns may still be manufactured, but they must be physically displayed in the underwear
section of the store and bear a label stating that the product is not intended for sleepwear.

Guidelines to Silhouettes Considered Sleepwear Silhouettes

Certain silhouettes, in childrens sizes 0 to 14, are automatically considered sleepwear (i.e.: footed garments for walking children, or gowns with
drawstrings at the bottom, are automatically sleepwear).
The following silhouettes are intended as guidelines, and are not all-inclusive:

For Cutting Section using the following Format

GLOBALATTIRE LTD.
Khaejurtek,Mirzanagar,Savar,Dhaka

CUTTING SECTION FORMAT

SRL #

NAME OF REPORTS

MARKER INSPECTION REPORT

SPREADING QUALITY CONTROL

LAY INSPECTION REPORT

CUTTING QUALITY CONTROL ( AUTO/MANUAL)

AFTER CUTTING INSPECTION SUMMARY-TOP/MIDDLE/BOTTOM

CUT PARTS INSPECTION REPORT

DAILY CUT PARTS REPLACEMENT REPORT

NUMBER & BUNDLE AUDIT REPORT

DAILY CUTTING WISE READY INPUT BUNDLE AUDIT REPORT

10

EMBROIDERY INSPECTION REPORT

11

DAILY FUSING MACHINE HEATING CHECK SCHEDULE

12

FUSING MACHINE QUALITY CONTROL

13

FUSING PANNEL CHECK REPORT

Marker Inspection

ORDER NO. #
STYLE #
MARKER LENGTH #
MARKER WIDTH #
MARKER QTY #
LIST OF PARTS
FRONT ( L)
FRONT ( R)
FRONT YOKE ( L )
FRONT YOKE ( R )
BACK
BACK YOKE
FRONT PLACKET
POCKET
SLEEVE ( L )
SLEEVE ( R )
COLLAR ( TOP )
COLLAR ( IN )
COLLAR BAND ( TOP )
COLLAR BAND ( IN )
SLEEVE CUFF ( TOP-L )
SLEEVE CUFF ( TOP-R )
SLEEVE CUFF ( IN-L )

DATE #
FABRIC WIDTH #

SLEEVE CUFF ( IN-R )

CUFF PLACKET- TOP
CUFF GAMBLE

Q.I SIGN

MARKER SUP. SIGN.

Q.C IN-CHARGE

CUTTING MANAGER

Spreading Inspection-

INSPECTOR NAME :
TABLE
CUT
LAY
MK
STYLE
MARKI
ENDS
NO. HEIGHT
PLACING
NG

SPLICES

NARROW LEANI
TENSION
GOODS NG

DATE :

COUNTS

REMNAN FABRIC
TS
FLAWS

Inspector

Incharge

Cutting Manager

QA Mana

Lay Inspection
TABLE NO :

COLOR :

DATE :

SHADE NO :

REF. :

CUT NO :

MARKER LENGTH :

MARKER WIDTH :

ROLL NO

ROLL LENGTH

NO OF LAY

TTL LAY

DEFECTS

ROLL WIDTH

BALANCE

STYLE

CUTTERMA
N

NAME OF

INSPECTOR NAME :

TTL CHECK
QTY

COLOR

BUNDLE
INSPECTED

Incharge

PATTERN
CHECK

NOTCHES

RAGGED
CUTTING

MATCHING
PLIES

MIS CUT

PANEL /
PARTS

TOTAL
BUNDLE

NO. OF LAY

CUT.
NUMBER

Inspector

Cutting Manager

QA Manager

Quality Inspection-

DATE :

REMARKS

INSPECTOR

Q.C SUPERVISOR

CUTTING MANAGER

Q.A MANAGE

After Cutting Inspection-

ORDER
NO.

CUTTING NO.

COLOR

SIZE

NAME OF PART

TYPE OF DEFECTS

REMARKS

AUDITED BY

Q.C MANAGER

CUTTING MANAGER

Cut part InspectionBUYER :

STYLE :
P.O :
SIZE

CUTTING NO.
COLOR :
ITEM :
NAME OF
PARTS
BACK
FRONT

FRONT

SLEEVE

SLEEVE

BACK
FRONT

FRONT

SLEEVE

SLEEVE

BACK
FRONT

FRONT

SLEEVE

SLEEVE

BACK

SERIAL
NUMBER

DATE :
PLY :
SHADE :
BUNDLE
QTY

DEFECTIVE
PANEL
NUMBER

NATURE OF
DEFECT

TOTAL
QTY

Q.C SIGN.

FRONT

FRONT

SLEEVE

SLEEVE

BACK
FRONT

FRONT

SLEEVE

SLEEVE

BACK

Q.C
Supervisor

FRONT

FRONT

SLEEVE

SLEEVE

Cutting inCharge

Quality inCharge

Q. A Manager

Cut Part Replacement-

BUYER #

CUT NO. #

STYLE #

DATE #

ORDER QTY #

COLOR #

CUT QTY #

LAY #

TTL CUTTING #

ITEM #

RATIO #
ROLL

SHADE

QTY

SERIAL
NUMBER
SIZE

SERIAL
NUMBER
SIZE

SERIAL NUMBER
SIZE

SERIAL
NUMBER
SIZE

SERIAL NUMBER
SIZE

Inspector

Incharge

Cutting Manager

QA Manager

Cut part AuditDATE :

CUTTING
NO.

ORDER NO.

BUNDLE NAME

COLOR

TYPE OF DEFECTS

REMARKS

TOTAL
TOTAL CHECK QTY
TOTAL DEFECT QTY
DHU %

Prepared By

Quality In-Charge

Q.A Manager

Ready Input
DATE :

ORDER NO.

CUT.NO.

TOTAL
BUNDLE

INSPECTED
BUNDLE

COLOR

BUNDLE
NAME

AUDIT RESULT

RE-AUDIT RESULT
SIZE

PASS

FAIL

PASS

FAIL

SIGN. OF
TYPE OF
SUPERVISO REMARK
DEFECT
R

Prepared By

Cutting Manager

Quality In-Charge

Q.A
Manager

Embroidery Quality InspectionBUYER #

STYLE #
COLOR #
PGCL NO. #
CUTTING
PART
NO.
DESCRIPTION

NAME OF INSPECTOR :
DATE :

INSPECTED
NO. OF PCS

FOUND NATURE
BUNDLE DEFECT
NO. OF
OF
QTY
QTY
DEFECT DEFECT

PASS QTY

SIZE

TOTAL CHECK QTY

TOTAL DEFECT QTY
DHU %
Prepared By

Quality In-Charge

Fusing Machine Heat CheckBUYER #

FUSING STANDARD

Q.A Manager

SIGNATU
RE

STYLE #
COLOR #
PGCL NO. #
DATE :

TEMP.
PRESURE
TIME

TIME

M/C

P/
CEDP

PRESURE
IBS

TIME/
SEC.

M/C
TEMP.

NOTE :

THERMO
PAPER
TEMP

FUSE
STRENGH

COLOR
CHANGE

PER DAY 02 TIME NEED TO FOLLOW

THIS.

MAINTAINANCE
MANAGER

SUPERVISOR

NAME
WF/QA

TACHNICAL
MANAGER

Machine ControlMACHINE NO. :

DATE :

BUYER

MACHINE NAME :
STYLE FAB COL

TIME

TEMP.

SPEED

PREASURE

QC SIGN.

SUP SIG

Inspector

Q.A
Manager

Quality In-Charge

Fusing Panel Check

DATE :
HOUR

QC NAME :
BUYER

Inspector

Summery Audit
DATE :

PO

COLOR

CUT NO

CUT
QTY

PANNEL
NAME

Quality In-Charge

FUSED
QTY

CHECKED DAMAGED
DHU REMA
QTY
QTY

Q.A
Manager

Auditor

Supervisor

In-Charge

Q.A Manager

Carton Audit
BUYER :

CONTRACT :

ITEM :

ORDER QTY :

DATE :

STYLE :

P.O #

LINE :

FOB :

PGCL #

COLOR :

PACK QTY :

CTN QTY :

FABRIC CONTENT :

CTN MARKING :

GR. WT :

FABRIC SOURCE :

CTN MEASUREMENT :

NT. WT :

WASHING :

PACKING RATIO :

PREPACK RATIO :

DEFECT %

TTL DEFECT

OTHERS

IRON

WASHING DEFECT

OIL STAIN

REJECTION

DAMAGES

FABRIC

HOLES

STAIN

BUTTON

RAW EDGE

SKIP STITCH

BROKEN STITCH

TTL INSP. QTY

LOT FAIL %

TTL LOT FAIL

TTL LOT PASS

TTL LOT

TTL OUTPUT

LINE

UNIT

TYPE OF DEFECT FOUND

ACCESSORY
CHECKLIST

MAIN LABEL

SEWING THREAD

EXPORT CARTON
SHAPE

SIZE LABEL

BUTTON

PACKING
ASSORTMENT

CARE LABEL

BUTTON HOLE

SHIPING MARK

HAND TAG

STREAMER

SKU

PRICE TICKET

INTERLINING

POLY BAG

ZIPPER

FOLDING

HANGER

SAMPLE PLAN
ACCEPTABLE
LEVEL

LOT SIZE

DEFECT UNIT ALLOWED

NO. OF CTN
TAKEN

2.5

THE CAPTIONED ORDER HAS BEEN

INSPECTION AND FOLLOWING
DEFECTS/DISCREPANCIES ARE FOUND

SL NO.

DEFECTS/ DISCREPANCIES

MINOR

MAJOR

1
2
3
4
5
6
7
8
9
10
TOTAL DEFECTS

PASS

FAIL

REWORK DUE TO

REMARKS :
3

BROKEN
PREPACK

WITHOUT P.
TKT

5
6
7
8

AUDITOR

Q.A IN-CHARGE

Q.A MANAGER

UNASSERTED
CTN

CLR TONE MIX

COPY TO :

End Line Inspection

PARTICULARS
ORDER NO

LINE 01 LINE 02 LINE 03 LINE 04 LINE 05

LINE 06 LINE 07 LINE 08

Total

BUYER
PRODUCTION
DEFECTIVE PCS
NO. OF DEFECTS
%OF DEFECTS
CODE

TYPE OF DEFECT

BROKEN STITCH

OVERLOCK BROKEN

SKIP STITCH

DOWN STITCH

RAW EDGE

JOIN STITCH

THREAD TENSION

PUCKERING

UNEVEN SHAPE

UP-DOWN POSITION

WRONG MEASUREMENT

SHADING

FABRIC FAULTS

HOLES/DAMAGES

POOR IRONING

STAIN/OIL STAIN

MISSING BARTACK

SPI

SLANTED

REJECT GMT

OTHERS
TOTAL

Quality in-Charge

Quality Manager

Quality
G.M

Hourly ReportPARTICULARS
ORDER NO
BUYER
PRODUCTION
DEFECTIVE PCS
NO. OF DEFECTS
%OF DEFECTS
CODE

TYPE OF DEFECT

LINE 01 LINE 02 LINE 03 LINE 04 LINE 05

LINE 06 LINE 07 LINE 08

Total

BROKEN STITCH

OVERLOCK BROKEN

SKIP STITCH

DOWN STITCH

RAW EDGE

JOIN STITCH

THREAD TENSION

PUCKERING

UNEVEN SHAPE

UP-DOWN POSITION

WRONG MEASUREMENT

SHADING

FABRIC FAULTS

HOLES/DAMAGES

POOR IRONING

STAIN/OIL STAIN

MISSING BARTACK

SPI

SLANTED

REJECT GMT

OTHERS
TOTAL

Quality in-Charge

Quality
G.M

Quality Manager

AlterationHANDED OVER TO
TIME

P.I NO.

COLOR

ISSUED

REC

NATURE OF ALTERATION
Prdn. SUP Q.C SUP

`-

DATE

TIME

DATE

End line Audit

Factory:
Adderess:

Inspection Date:
Sewing / Finishing Line #:
Inspector Name :
Defects category
Hour

1
2
3
4
5
6
7
8
9
10
11
12
13
14
Total
Total Defcts:

Fabrics

Trims

Construction

Stitch

Seam

Finishing/Packing

Thread

Total Defe

Percentage of defectives:

Inspector's Signature

QC Incharge

QC Manager

Endline Audit Summery

Pearl Garments Co. Ltd.

Palash Bari, Nabinagar,Savar, Dhaka-1349

Daily End line Inspection Summery Report

SEWING

DAT
Defects category

Line #

TTL Pcs
Checked

Fabrics

Trims

Construction

Stitch

Seam

Finishing/Packing

Thread

Total D

1
2
3
4
5
6
7
8
Total
FINISHING

9
10
11
12
13
14
15
16
Total
G.TTLKOHL'S
G.TTL- NON
KOHL'S

Prepared By

Audit M

Needle Detector
Remarks : Needle Detector must verify the calibration and accuracy 3 times per day at the beginning,
middle and end of a working period by using the 1.2 mm sphere ferrous checke cards to check machine sensitivity.

TOP

A7

A8

A9

CENTRE

A4

A5

A6

BOTTOM

A1

A2

A3

1. Switch on the machine and adjust sensitivity level to less than1.2 mm aphere.
2. Position the 1.2 mm sphere ferrous check card onto the conveyor belt at position A1,
let the test card passes through the search head.
3. The needle detection should be activated ( alarming ) also.
4. Repeat the procedure 1-3 with position the 1.2 mm sphere ferrous card onto the conveyor belt at position A2 & A3.
5. The needle detection should be activated ( alarming ) also.
6. Test A1, A2 & A3 with 1.2 mm ferrous check card only . No garment or paped os allowed to put together during testing.
7. Repeat the procedure 1-3 with position the 1.2 mm sphere ferrous check card on the top of the stand,
and placed the stand on to the conveyor belt at position A4,A5,A6,A7,A8,A9 and record

DATE

TIME

Operator's Signature

POSITION

BUYER
A1

A2

A3

A4

A5

A6

A7

A8

A9

FQA/F
Date

" = The needle detector activate ( alarming ) when 1.20mm ferrous check card pass through the search head.
" = The needle detector no reaction ( not alarming ) when 1.2mm ferrous ckeck card pass through the search head.

Metal Detector

DATE #

TIME

BUYER # STYLE #

PASS GMT

FAIL GMT

TTL PASS TTL FAIL

GMT
GMT

RE

Prepared By

Finishing In-Charge

Q.A M

Pull test machineDATE :

COLOR :
TIME

BUYER :
STRENGTH :
CHECKED
QTY

STYLE NO. :

DEFECT
QTY

MOCK UP

CHECKED BY

DHU

SIG

Q.A MANAGER

Cut Knife record

KNIEF
TYPE

DESCRIPTION

RCVD/ISSUE RCVD
CHALLAN NO. QTY

ISSUE
QTY

SIGN.

BALANCE REPLACE
QTY
QTY

REM

Store Manager

HOD

Needle Issue FormatFACTORY NAME :

NEEDLE TYPE :

COUNTRY :

SECTION :
BREAKAGE

SRL #

1
2
3
4

DATE

TIME

OPERATOR
NAME

I.D NO #

MACHINE
TYPE

NEEDLE SIZE

TAPE COMPLETE
NEEDLE PARTS

BROKEN FRAGMENT NOT

FOUND CORRECTIVE
ACTION

SUPERVISO
VERIFICATIO

5
6
7
8
9
10
11
12
13
14
15
16
17
18

Prepared By

Line
Manager

Production Manager

HOD

Snap Strength Test

VENDER :

FACTORY :

GARMENT DESCRIPTION :

MACHINE / MODEL NUMBER :

KOHL'S STYLE NUMBER/DIVISION :

OPERATOR :

SNAP DESCRIPTION / SIZE :

FOUNDATION THICKNESS :

NO. OF SNAPS GARMENT :

DATE :

NAME OF TASK FORCE COORDINATOR :

PRODUCTION CONTROL - MONITORING SNAPS ATTACHMENTSTRENGTH ( 5 READING ) TWICE PER EIGHT HOUR SHIFT, ONCE IN THE MORNING & O
MOCK/FAUX SEAM WHICH IS SAME CONSTRACTION AS THE PRODUCTION. NOTED : WASHED ITEMS MOCK UP SHOULD BE TESTED A

AM

PM

AM

Attachment Strength

PM
Attachment Strength

AM

PM
Attachment Strength

AM

PM
Attachment Strength

AM

PM

Attachm

DATE
TIME

9:00 AM

3:00 PM

9:00 AM

3:00 PM

9:00 AM

3:00 PM

9:00 AM

3:00 PM

9:00 AM

1
2
3
4
5
PASS
FAIL
NATURE OF
DETACHMENT
1
2
3
4
5
PASS
FAIL
NATURE OF
DETACHMENT

Prepared By

Checked By

Snap Product Safety

VENDOR :

FACTORY :

MODEL NO./ MACHINE NO. :

OPERATOR :

TASK FORCE COORDINATOR :

DATE :

STYLE NO. :

SNAP FASTENER TYPE :

PRODUCTION CONTROL - APPLY 100% CHECK EVERY TWO HOURS FOR A) SNAP FUNCTION - OPEN/CLOSURE PRESSURE, B)SNAP PLACEMENT/ SEATINGSEAT ON PARALLEL SURFACE, NOT OVER SEAMS. NO SPACE (GAP) BETWEEN MATERIAL AND COMPONENT C) VISUAL CHECK - EXPOSED PRONGS,

ROUGH SURFACES ON SNAPS.

TIME

OUTPUT

DEFECTIVES A DEFECTIVES B
( Units )
( Units )

Prepared By

DEFECTIVES C
TOTAL DEFECTIVES
( Units )

Checked By

ACTION TAKEN

HOD

Tag Gun Needle

MAINTENANCE DEPARTMENT
BREAKAGE
SRL #

STYLE
DATE

2
3
4

TAG GUN NEEDLE

TIME

OPERATOR
NAME

I.D NO #

MACHINE
TYPE
TYPE SIZE

BROKEN TAG
GUN NEEDLE

If any/ all parts

of a tag gun
needle cannot be SUPERVISOR
found, please
advise ACTION
NAME

5
6
7
8
9
10
11
12
13
14
15

Line
Manager

Prepared By

Production Manager

HOD

Button Hole Knife

MAINTENANCE DEPARTMENT

DATE #

BREAKAGE
SRL #

STYLE
DATE

BTN HOLE KNIEF

TIME

OPERATOR
NAME

I.D NO #

MACHINE
TYPE
TYPE

SIZE

BROKEN
KNIEF

If any/ all parts of a

knief cannot be found,
please advise ACTION

SUPERVIS

NAME SI

10

Prepared By

Line Manager

Production Manager

Sewing Line using FormatCover Page

PEARL GARMENTS CO. LTD.

Palash Bari, Nabinagar,Savar, Dhaka-1349

SEWING SECTION FORMAT

SRL #
1

NAME OF REPORTS
INLINE INSPECTION REPORT (HOURLY)

HOD

MOCK UP FORMAT

KILLED GARMENTS REPORT

HOURLY PRODUCTION REPORT

DAILY ALTERATION REPORT

END LINE INSPECTION SUMMARY REPORT

NEEDLE SWATCH

MINI-STORE NEEDLE ISSUE REGISTER

ENDLINE AUDIT REPORT- kohl's

10

ENDLINE AUDIT SUMMARY REPORT - kohl's

11

HOURLY AUDIT REPORT FOR FINISHED

12

SUMMARY OF FINAL AUDIT ( SEWING / FINISHING )

13

MAJOR 3 DEFECT OF THE DAY

14

7/0 SYSTEM ( OPERATION WISE INSPECTION )

15

HOURLY ALTERATION REPORT

16

DAILY QUALITY REPORT SEWING/ FINISHING

17
18

SIGNATURE
MR. MONIR & MR. KAMRUL ISLAM

End Line InspectionP.O NO. :

STYLE :

HOUR

8-9

9-10

10-11

11-12

BUYER :
ITEM :

INSPECTED QTY

TTL PCS

DEFECTIVE PCS

Q.C :

TOTAL

NO. OF DEFECTS

TOTAL

12-01

CODE

TYPE OF DEFECT

BROKEN STITCH
OVERLOCK
BROKEN

SKIP STITCH

DOWN STITCH

RAW EDGE

JOIN STITCH

THREAD TENSION

PUCKERING

UNEVEN SHAPE
UP-DOWN
POSITION
WRONG
MEASUREMENT

SHADING

FABRIC FAULTS

HOLES/DAMAGES

POOR IRONING

STAIN/OIL STAIN

MISSING BARTACK

SPI

SLANTED PARTS

OTHERS

COLLAR

COLLAR BAND

COLLAR
POINT

BOX
PLACKET

TOTAL

8-9 AM

9-10 AM
11-12 PM

10-11 AM

Prepared By

Q.C
Supervisor

4-5
PM
12-01
PM
3-4
2-3
PM
PM
5-6
6-7
PM
PM

Mockup
QUALITY SPECIFICATION SHEET
37
Buyer

VF

Order #

Pgcl- 07

Operation Name

T/St at Flap seam

Machine Type

2N4TLSUBT

Needle Size

Attachment

Thread Color

SPI

Foot Type

100 % Tgt

150

QUALITY OF THE OPERATION SHOULD BE CHECKED OPERATOR BY ITSELF BEFORE PASS IT TO THE NEXT WORK
STATION

Mockup
Killed GarmentsDATE :
BUYER

REF.

COLOR

XL

SIZE
2XL

3XL

DAY
TTL

G.TOTAL

REMAR

GRAND TOTAL

Prepared By

Checked By

Q. A Manager

Hourly Report
SECTION :

DATE :

1 st Hour2 nd Hour
1

TOTAL

Hour

TEAM #
3 rd Hour

4 th Hour 5 th Hour

6 th Hour 7 th Hour

8 th Hour

9 th Hour 10 th Hour

Reason For <

Productoin

10

Total

Supervisor

In-Charge

PM

G.M ( Production )

AlterationHANDED OVER TO
TIME

P.I NO.

ISSUED

RECIVED

COLOR NATURE OF ALTERATION

Prdn. SUP

`-

End Line inspection-

Q.C SUP

DATE

TIME

DATE

TIME

SIGNATURE

PARTICULARS

LINE 01

LINE
02

LINE
03

LINE 04 LINE 05 LINE 06

LINE 07 LINE 08

Total

DHU %

ORDER NO
BUYER
PRODUCTION
DEFECTIVE PCS
NO. OF DEFECTS
%OF DEFECTS
CODE
A

TYPE OF DEFECT

BROKEN STITCH
OVERLOCK
BROKEN

SKIP STITCH

DOWN STITCH

RAW EDGE

JOIN STITCH

THREAD TENSION

PUCKERING

UNEVEN SHAPE
UP-DOWN
POSITION
WRONG
MEASUREMENT

SHADING

FABRIC FAULTS

HOLES/DAMAGES

POOR IRONING

STAIN/OIL STAIN

MISSING BARTACK

SPI

SLANTED

REJECT GMT

OTHERS

TOTAL

Quality in-Charge

Quality
Manager

Quality
G.M

Needle Swatch-

SL NO.

MACHINE

NEEDLE

SIZE

SAMPLE

LENG

PLAIN MACHINE

DB X 1 ( 38 MM )

11

38 M

OVER LOCK MACHINE

DC X 1 ( 33 MM )

11

33 M

TWO NEEDLE / PLAIN

MACHINE

DP X 5 ( 38 MM )

14

38 M

BUTTON HOLE MACHINE

DP X 5 ( 38 MM )

16

38 M

BARTAC COMPUTERIZED

DP X 5 ( 38 MM )

14

38 M

BUTTON STITCH MACHINE

TQ X ! ( 40 MM )

14

40 M

FEED OF THE ARM ( 2 NDL )

TV X 64 ( 41 MM )

16

41 M

KANSAI SPECIAL

UO X 113 ( 41 MM )

11

41 M

VELCRO COMPUTERIZED

DP X 17 ( 44 MM )

14

44 M

10

PAGGOTON ( EYELET HOLE )

MACHINE

HA X 1 ( 38 MM )

11

38 M

11

FEED OF THE ARM ( 3 NDL )

UY X 128 GAS ( 45 MM )

11

45 M

12

FLAT LOCK

UY X 128 ( 45 MM )

14

45 M

13

BUTTON STITCH
COMPUTERIZED MACHINE

DP X 17 ( 44 MM )

14

44 M

14

SINGLE NEEDLE

DB X 7 ( 38 MM )

38 M

15

OVER LOCK

DC X 7 ( 34 MM )

34 M

16

OVER LOCK

DC X 14 ( 33 MM )

14

33 M

17

BUTTON STITCH

DP X 7 ( 38 MM )

38 M

Needle RegisterNEEDLE SIZE :

MONTH OF :

DATE

PREVIOUS
BALANCE

RCVD NEEDLES
FRM MAIN STORE

TOTAL
STOCK

NEEDLE
ISSUED

BALANCE

SIGN. OF STORE
KEEPER

SIGN. OF FT
MANAGER

COMMENTS :

End line Audit Summery-

Pearl Garments Co. Ltd.

Palash Bari, Nabinagar,Savar, Dhaka-1349

Daily End line Inspection Summery Report

SEWING

DAT
Defects category

Line #

1
2
3
4
5
6
7
8
Total
FINISHING

9
10

TTL Pcs
Checked

Fabrics

Trims

Construction

Stitch

Seam

Finishing/Packing

Thread

Total D

10

TOTAL

ACTION RECOMMENDED
UP-DOWN

SHADING

IRON/FUSING MARH

WRONG SIZE

FABRIC DEFECT

CUT HOLE

RAW EDGE

THREAD TENSION

PUCKERING

LINE :

SKIP STITCH

DATE :

BROKEN STITCH

MEASUREMENT
ATTACHED

PASS/FAIL

FOUND

ALLOWED

SAMPLE SIZE

LOT SIZE

HOUR

11

12

13

14

15

16

Total

G.TTLKOHL'S

G.TTL- NON
KOHL'S

Hourly Audit Report-

REF. :
BU

MAJOR
QUALI
AQL
TY
1.5/ AQL DEFEC
2.5
TS
ORDER QTY :
AU

WASHING DEFECT

OIL STAIN

REJECTION

InCharge

DAMAGES

FABRIC

HOLES

STAIN

BUTTON

RAW EDGE

SKIP STITCH

BROKEN STITCH

Supervis
or

TTL INSP. QTY

LOT FAIL %

TTL LOT FAIL

TTL LOT PASS

Auditor

TTL LOT

TTL OUTPUT

LINE

UNIT
7

10

Q.A
Manage
r

Audit Summery-

DATE :
TYPE OF DEFECT FOUND

Auditor

Supervisor

In-Charge

Major Defects
UNIT NO :
LINE

Inspector

DATE :
DHU %

BUYER

Supervisor

ORDER REF

TTL QC PASS MAJOR DEFECT FOUND

Incharge

QTY

Q.A Manager

REMARKS

HOUR

5
LINE :

COLLAR UN BAL.

PUCKERING

NUMBER MISTAKES

UNEVEN STITCH

OUT LINE WIDTH

DOWN STITCH

SKIP STITCH

THREAD TENSION

DATE :

SPI

OP NAME

OPERATION

Operation Wise Inspection-

SUPERVISOR
NAME :

Supervisor

Q.A
Ma

Incharge

Hourly AlterationLINE NO :

QC NAME :

TIME

QTY

ALTERATION
ON TOP

PROCESS NAME :
ALTERATION
INSIDE

SUPERVISOR
SIGN.

RECEIVED

BUYER :
QC SIGN.

08:00-09:00
09:00-10:00
10:00-11:00
11:00-12:00
12:30-02:00
02:00-03:00
03:00-04:00
04:00-05:00
05:00-06:00
06:00-07:00
TOTAL
G. TOTAL

DHU

Supervisor

Incharge

Daily Quality ReportLINE NO :

ORDER REF/ PO NO :
ITEM :

NO OF AUDIT
CONDUCTED :
NO OF FAILED
AUDITS :

INSPECTED QTY :

SUCCESS RATE :
MAJOR ISSUES
FOUND :

NO OF DEFECTIVE QTY:

QC CODE :

REM

NO OF DEFECTIVE PCS:

QC NAME :

DHU :

DATE :

MAJOR DEFECTS OF THE

LINE

PARTS

POSITION

DEFECTIVE QTY

BROCKEN STITCH
OVER LOCK BROCKEN
SKIP STITCH
RAW EDGE
JOINT STITCH
THREAD TENSION
PUKERING
UNEVEN SHAPE
UNEVEN OUT LINE
LABEL MISTAKE
UP DOWN
WRONG MEASUREMENT
SPOT/ OIL STAIN
MISSING BARTACK
SPI
SLANTED PARTS
INSECURE BUTTON
FABRIC DEFECTS
COLOR SHADING
WRONG UP RIGHT POSITION
MISSING PARTS/BUTTON

Supervisor

Incharge

Q.A Manager

Warehouse Using Format-

PEARL GARMENTS CO. LTD.

Palash Bari, Nabinagar,Savar, Dhaka-1349

WARE HOUSE FORMAT

DHU

SRL #

NAME OF REPORTS

FABRIC SWATCH BOARD

FABRIC INSPECTION REPORT

SHADE SEGREGATION REPORT

ACCESSORIES INSPECTION REPORT

SIGNATURE
MR. MOHSHIN ( BACCHU)

Swatch Card-

PALASH BARI, NABINAGGAR, ASHULIA, SAVER, DHAKA.

FABRIC SWATCH BOARD
FABRIC :

BUYER :

CONSTRUCTION :

STYLE :

SUPPLIER :

ORDER REF. :

COLOR :
BEFORE WASH

AFTER WASH

SHADE : A
SHADE : B
SHADE : C
SHADE : D
SHADE : E
SHADE : F

TOTAL :

Fabric InspectionFABRIC SUPPLIER :

DATE :

TTL YDS RCVD :

BUYER :

TTL ROLLS RCVD :

FABRIC WIDTH :

1" TO 3" DEFECT

TTL YDS INSP. :

ORDER NO :

3" TO 6" DEFECT

TTL ROLLS INSP. :

INVOICE NO :

6" TO 9" DEFECT

4 POINT

TTL PANELTY POINTS :

9" ABOVE DEFECT

POINTS PER SQUIRE YD :

PASS

FAIL

( TTL DEFECT POINT x 100 x36 / LENGTH / WIDTH ) = %

LENGTH

COLOR

ROLL NO

TKT
YDS

ACTUAL

MTS

YD
S MAX

WIDTH

SHADING

ACTUAL

MIN

WI
DT SLU CREA
SE
KNOTS
WIDTH/ H / B
MARK
WIDTH CE
NT
ER

HOLE

THICK YARN

FLY YARN

STO
MAR

TTL YDS

Q.I

Quality Supervisor

Q, C In-Charge

Q.A Manager

Shade CheckingBUYER #
STYLE #
COLOR #

I.D

SUPPLIER
ROLL ID

R
ACTUAL
QTY

LENGTH

WIDTH

LNGTH WIDTH
SHADE
SRNKG % SRKG %

REMARKS

I.D

51

52

53

54

55

56

57

58

SUPPLIE
ACTUAL
R ROLL
QTY
ID

59

10

60

11

61

12

62

13

63

14

64

15

65

16

66

17

67

18

68

19

69

20

70

21

71

22

72

23

73

24

74

25

75

26

76

27

77

28

78

29

79

30

80

31

81

32

82

33

83

34

84

35

85

36

86

37

87

38

88

39

89

40

90

41

91

42

92

43

93

44

94

45

95

46

96

47

97

48

98

49

99

50

100

Accessories InspectionBUYER #

STYLE #

PRODUCTION APPROVED TRIM

CARD AVAILABLE :
DESCRIPTION/
ITEM

SAMPLE OF
ITEM :

REFF/ORDER
NO.

PO NO. #
YES..
RCVD QTY

INVOICE NO :

NO..
INPSPECTED REJECTED REJECT SHADE/COLO
SIZE DESIGN
QTY
QTY
%
R

PA

PROCEDURE OF INSPECTION :

1. ONE PC OF CONSIGNMENT/LOT WILL BE A

2. AQL 1.5 FOLLOWED FOR SAMPLE SELECTI
3. WASH TEST TO BE CARRIED OUT FOR RES
SPECIAL COMMENTS :

Inspector

Incharge

Store Manager

QA Manager

PEARL GARMENTS CO. LTD.

NEEDLE POLICY
CRITICAL FOCUS MUST BE PUT ON ALL THESE AREAS:

USED NEEDLE CONTROL

FREQUENT AND ROUTINE CHECKS ARE DONE ON MACHINE NEEDLES FOR

DAMAGE. FREQUENCY DEPENDS ON TYPES OF GARMENTS/FABRICATION.

USED NEEDLE QUANTITY MATCHES QUANTITY ISSUED.

BROKEN NEEDLE CONTROL

EACH SEWING FLOOR HAS ITS OWN LOG NOT SHARED WITH OTHER

FLOOR.
ALL FRAGMENTS OF A NEEDLE ARE FOUND & ARE TAPED TOGETHER
IMMEDIATELY.
THE TYPE OF NEEDLE & THE FRAGMENTS MATCH IN LENGTH.
IF THERE ARE INCOMPLETE NEEDLE PARTS, THERE MUST BE REMARKS ON
WHAT CORRECTIVE ACTIONS TO ENSURE THAT FRAGMENTS ARE NOT ON
ANY PRODUCTION GARMENTS. FOLLOWING PROCEDUREMUST BE FOLLOW
TO SEARCH THE MISSING PARTS :
1. CHECK NEAR BY SURROUNDING AREAS BY MAGNET STICK.
2. IF NOT FOUND BY MAGNET THEN NEED TO PASS THE ENTIVE LOT OF

GARMENTS FROM NEEDLE DETECTION MACHINE.

3. AFTER PASSING FROM NEEDLE DETECTION MACHINE, IF NOT ABLE TO
TRACE OUT THEN NEED TO PASS THE 1ST FRONT & BACK MACHINE
GARMENTS FROM NEEDLE DETECTION.
4. IF AFTER THAT ALSO NOT ABLE TO TRACE OUT THEN NEED TO PASS THE
ENTIRE DAY PRODUCTION FROM THE NEEDLE DETECTION.
5. IF AFTER THAT ALSO NOT, THEN MUST BE PASS THE ENTIRE ORDER
GARMETS FROM NEEDLE DETECTION.

PEARL GARMENTS CO. LTD.

METAL DETECTION POLICY

THE FACTORY MUST KEEP AN ACCURATE RECORD OF ALL GARMENTS

THAT HAVE PASSED THROUGH NEEDLE DETECTION.
THE SHIPPED QUANTITY MUST NOT BE GREATER THAN THE QUANTITY
ALREADY NEEDLE DETECTED.
METAL CONTAMINATION FOUND MUST BE TAPED ON THE LOG AS
EVIDENCE.
THE RESPONSIBLE STAFF MUST SIGN ON THE LOG.

NEEDLE DETECTOR CALIBRATION

NO DAMAGED CALIBRATION CARD IS USED FOR CALIBRATION.

9 POINT SENSITIVITY CHECK IS DONE CORRECTLY ACCRORDING TO
PROCEDURES.
THE CHECK IS DONE THRICE/DAY AT THE BEGINNING, MIDDLE AND
END OF A WORKDAY.
COMMUNICATE WITH NEEDLE DETECTOR SUPPLIER IF THERE ARE
ANY CALIBRATION ISSUE SO THAT PROMPT ACTION IS TAKEN TO
RECTIFY THE PROBLEM.
THE NEEDLE DETECTOR IS CLEARLY LABELED AS OUT OF ORDER
AND NOT TO BE USED UNTIL THE PROBLEM IS RESOLVED.

PEARL GARMENTS CO. LTD.

SNAP ATTACHMENT POLICY

CRITICAL FOCUS MUST BE PUT ON ALL THESE AREAS:

SNAP ATTACHMENT STRENGTH TEST-PREPRODUCTION CONTROL

1. CHECK IS DONE PRIOR TO BULK PRODUCTION OF NEW ORDER.

2. A MOCK SEAM IS MADE UP WITH 10 SNAP ATTACHED. THE AIM IS TO VERIFY EACH SNAP
ATTACHMENT MACHINE IS CORRECTLY ADJUSTED AS PER SNAP FASTENER DATA SHEET.
THESE ARE CHECKED FOR:
1. EVEN FOUNDATION THICKNESS.
2. GOOD MACHINE PERFORMANCE.
3. SNAP ATTACHMENT STRENGTH.

SNAP ATTACHMENT VISUAL/PHYSICAL CHECK-DAILY PRODUCTION CONTROL

EVERY 2 HOURS 200 SNAPS ARE AUDITED FOR SECURE ATTACHMENT BY CHECKING:

1.
2.
3.
4.
5.
6.
7.

SNAP ARE ATTACHED ON EVEN FOUNDATION.

SNAP FUNCTION OPEN/CLOSURE PRESSURE.
SNAPS ARE NOT DEFORMED DUE TO POOR MACHINE ADJUSTMENT.
NO ROUGH SURFACE AND SHARP EDGES.
SNAP DO NOT SIT ON STITCH LINE.
PRONG LEGS DO NOT PROTRUDE.
SNAPS DROPPED ONTO THE FLOOR ARE NOT RE-USED.

SNAP ATTACHMENT STRENGTH TEST- DAILY PRODUCTION CONTROL

1.
2.
3.
4.

SNAP ATTACHMENT STRENGTH ARE CHECKED (5 READINGS) TWICE/EIGHT HOUR SHIFT.

ACCURATE RECORD OF RESULTS PER MACHINE ARE KEPT.
DATA ARE ANALYZE TO ENSURE SNAP ATTACHMENT STRENGTH MEETS STANDARD.
THE MINIMUM STANDARD TO BE MEET FOR STRENGTH IS 17 LBS PER 10 SECONDS.