APPAREL-INDUSTRY  
(FABRIC AND TRIM STORE)
                  Hello Everyone!!!! Today we will be going to discuss regarding Inventories of Apparel industry, You can also called it as Raw   Materials .  To produce  garments at regular intervals, It is necessary to maintain equivalent inventory  , Therefore Proper store is being developed for both fabric, trims and accessories. So lets start…..
FABRIC STORE
Before staring the garments production, required amount of fabric have to store in the garments. All the next processes such as spreading, cutting, sewing etc. have done by taking the fabric from here. As result, this department plays an important role to get smooth production. As its importance, this article has presented a details discussion on the activities of fabric store department in readymade garments sector.

Flow Chart of Fabric Store Department in Garment Industry:

Fabric dispatched from supplier
↓
Fabric receiving
↓
Fabric checking
↓
Fabric checking by security guards
↓
Shade checking
↓
Send to the merchandiser for approval
↓
Quality checking for defects
↓
Fabric lot rejection
↓
Kept in store







All the above activities have explained in the following:
1. Fabric dispatched from supplier:
Here, required amount of fabric dispatched from the definite fabric supplier.
2. Fabric receiving:
It is the second task of any fabric store department in garment manufacturing industry. Here, store in-charge receives fabric from fabric supplier by following invoice.
3. Fabric checking:
Here, fabric has checked by following four point system.
4. Fabric checking by security guards:
The quantity of fabrics should be confirmed here by security guards according to invoice. If it’s found short then immediately should inform to the garment merchandiser.
5. Shade checking:
It’s a very important task for fabric store department. Fabric shade should be checked here by following different types of shade which are already approved by the buyer. Here, various fabric shades have found which should be kept in lot wise.
6. Fabric lot rejection:
According to grading of fabric such as A, B, C, D etc. fabric lot has to reject here. This task is performed by Q.C (quality controller).
7. Send to the merchandiser for approval:
Here, apparel merchandiser receives all the information’s related with supplied fabric from the fabric store department. If found any major defects or faults then merchandiser discuss with the suppliers and takes necessary steps to solve those.
8. Quality checking for defects:
In this section, quality controller checks fabric quality according to the buyer’s quality recommendation.
9. Kept in store:
After completing all the above information’s, finally fabrics are kept in store for supporting into the next processes such as cutting, sewing etc.


Fabric 4 point system inspection method

4 Point system for fabric inspection is widely used in apparel industry for fabric quality inspection. To use this system you have to know following things.
1.      Fabric inspection method or preparation
2.      Criteria of giving penalty points based on defects and defect length.   
3.      Calculation method of total penalty points for total defects found in a fabric roll or thān
4.      A Check sheet or format for recording data
5.      Knowledge of different types of defects (how a defect looks and its appearance)

Fabric inspection method or preparation

Details of selection method of fabric rolls and checking of fabric have been explained in our previous post. Please read one of our guest articles for the method fabric inspection. Essential Fabric Quality Reports for Bulk Cutting Approval of Fabrics

Criteria for giving penalty points

In the following table the penalty evaluation points has been given for different length of fabric defect and dimension of holes.

Table -1

Size of Defect
Penalty Points
Length of defects in fabric (either length or width)
Defects up to 3 inches
1
Defects > 3 inches < 6 inches
2
Defects > 6 inches < 9 inches
3
Defects > 9 inches
4
Holes and openings(largest dimension)
1 inch or less
2
Over 1 inch
4

Calculation of total points per yards

In 4 point system fabric quality is evaluated by unit points/100 sq. yds.  
Points / 100 sq. yd. = (Total points in roll * 36 * 100)/ (Fabric length in yards * Fabric width in inches)
Normally fabric roll containing 40 points per 100 square yard are acceptable.

Also Read: 4 Point System - Acceptable Level

Example: A fabric roll 120 yards long and 46 inch wide contains following defects.

4 defects up to 3 inch length
3 defects from 3 to 6 inch length
2 defects from 6 to 9 inch length
1 defect over 9 inch length
1 hole over 1 inch
4 x 1
3 X 2
2 X 3
1 X 4
1 X 4
4 points
6 points
6 points
4 points
4 points
Total defect points
24 Points
Therefore,
Points/ 100 sq. yards
= (24 X 3600)/(120 X 46)
= 15.652 points


Also read: Acceptable level (Points per 100 square yards) in 4-point system

Check sheet or Inspection Format

To record or to collects defects during inspection you must use a simple check sheet. A check sheet includes general details, details of fabric lot, fabric defects according their sizes, summary of fabric defects, quantity inspected and total penalty points and result of the fabric lot after inspection. Use tally marking for recording of number of defects. A sample 4 point system fabric inspection format has been attached at the bottom.

Types of defects found in fabric

Fabric checker should know common defects found in fabrics and he must recognize defects on the fabric at the time of fabric inspection. A detailed list of fabric defects has been posted earlier. Open the link to read the post for your reference.

Image: Sample format for 4-Point system for fabric inspection. 


SOP of Fabric Warehouse

The quality of a final garment depends on the quality of a Garments Fabric when it is received as a roll. Even the most outstanding manufacturing methods cannot compensate for defective materials. Normally, we inspect 10% of the rolls we receive and evaluate them based on a four-point system.

Procedure

§  Key Points
§  Fabric Receipt from Nominated Supplier
§  Physical Counting of rolls
§  Compare the quantity with purchase order or invoice.
§  Any shortage/damaged packaging is informed to commercial dept, purchase dept and merchandiser.
§   To ensure each roll has got the Supplier Stamp at the Head end.
§  To cut 20” of the full Width Fabric from the Head End for testing in LAB.
§  To Write the following Details on Both parts  1) 20” Head End  2) Balance Fabric Roll
§  Give the Cut Head Ends to the Fabric Manager with memo mentioning the Invoice # & Qty.
§  Each Roll at the time of head end cutting has been given a unique software printed tag having specified information printed on it.
§  This code is referred as during further processes of Garments Fabric inspection, shade segregation, warehouse keeping, issuing, and cutting.
§  Fabric Inspection : Fabric Inspection is done by American 4 Point System
§  4 Point System of Fabric Inspection :  No of roll selection -  10% of the shipment.
§  Once the Garments Fabric inspection, shade segragation and lab testings are passed then the fabric is kept in ware house as per Auto wise, color wise and shade wise.
§  Shade wise inventory is maintained in register as well as in Computer system.





TRIMS STORE

To make a garment that you need except fabrics is Trims-Accessories, this writing is about the Warehouse Trims Handling Procedure in Garments Industry what store team has to do from receiving materials to issuing in the production floor.



Warehouse Trims Handling workflow

Receive material
↓
Inventory
↓
Quality inspection in AQL
↓
Inspection Pass
↓
Reporting
↓
System Update
↓
Issue/Release material to Production Floor
↓
Keeping Leftover materials in old stock

Receive material -Receiving Invoice & Packing list from merchandiser or software & along with Goods
Inventory -Physical verification counting by weight & Counting Machine Pcs to Pcs against Invoice & packing list.
Reporting -Anything short or damaged during inventory immediately inform merchandiser & Commercial for taking up with Supplier.
System Update -Update GRN & make an inventory report on ERP or OMSv2 software
Receiving Trims card & Production folder along with a cut plan
Issue to Production Floor-Receiving issue requisition form a production unit
cross-check stock Quantity, Counting issue quantity on Counting m/c & pcs to pcs. Issue to production as per Requisition with keeping a record on manual register & in a software system. Any extra requirement production comes with extra requisition if we have an extra quantity available.
Leftover materials -Any extra Goods left in the floor returning back to store to keep in old stock-keeping place with proper documen
Needle Issued for different Machine from Store

Table - List of Different types of Needle Issued from Store

Machine Type
Needle Type
Needle Size
Plain Machine
DB×1
11
Button hole & 2N Machine
DP×5
11,16,14
BTN stitch and Bartech Machine
DP-7
14
Chain Stitch Machine
TV-7
11,14,16
Feed Off The Arm machine
TV-64
11,14,16
Overclock Machine
DC-1
9,11,14,16


List of Trims and Acessories   used in Apparel Industry.
The raw materials used in sewing room other than fabric are called Trims.On the other hand, materials are directly attached to the fabric to make a garment are called trims. Like: Threads, buttons, lining, Interlining, zippers, labels, care labels, etc.(Interlining is used as shape forming/preserving materials.)
  • Labels
  • Buttons
  • Zippers
  • Padding
  • Interlining
  • Down
  • Elastic
  • Thread
  • Twill Tape
  • Stopper
  • String/Draw Cord
  • Piping Cord
  • Emblem
  • Logo Print
  • Swivel Hook
  • Eyelet/ Grommet
  • Collar Stay
  • Cord Bell
  • Buckle
  • Rivet
  • Weaving Belt
  • Hook and Eye
  • Velcro Tape
  • Seam Sealing tape
  • Shoulder pad
  • Cable (steel ware)
  • Adjuster
  • Recco
  • Elastic Threads
  • Shoulder Tape
Accessories
The materials, which are used to make a garment attractive for sale and packing, other than fabrics and trims, are called Accessories.
  • Polybag
  • Elastic bag
  • Mini Polybag
  • Master Carton
  • Inner Carton
  • Size Clip
  • P.P.Band
  • Tag Pin
  • Brass Pin
  • Collar Stand
  • Safety Pin
  • Gum Tape
  • Arrow Sticker
  • Scotch Tape
  • Barcode
  • Defect Indicator
  • Tissue Paper
  • Backboard
  • Neck Board
  • Butterfly
  • Numbering Stickers
  • Hanger
  • Size Stickers
  • Carton Pad
  • Both Side Tape
  • Plastic Staple
  • Iron Seal
  • Clip
  • Ball chain
  • Size Tag
  • Carton Sticker
  • Safety Sticker
  • Plastic Clip

SOP for Trims Store

§  1st thing is physically counting of the no. of packages  received e.g. No. Carton / Bales / Sacks received.
§  Then compare the quantity mentioned on the packs multiplied with number of packs, with the the quantity mentioned on packing list or invoice. Any loss, damage or open boxes is informed to commercial dept, purchase dept and merchandiser.
§  Store Keeper prepares and signs a Goods received note or GRN in which Name of the item, actual quantity received is clearly mentioned and also he mentions the identification mark of the shortage i.e. Carton No., Bale no. etc. and gives a copy to commercial dept.

SOP Of Trims Inspection

§  Trim Card : before starting inspection, QC in the store collects Merchandiser Approved Trim Card*    and compare the Trims with Trim Card
§  Trim Card is a collection of all the trims used in a particular style pasted together in a card board  for  approval and referance.
§  First QC checks and compares the trims with trim chart she checks the style no. Auto no. etc.
§  QC Randomly takes 10% of the trims and  transfers  to the trims inspection bin where QC is doing the inspection for quality of the trims.She compares the quality with merchandiser’s trim chart.
§  And prepares a quality inspection report duly signed by Store Manager and QA Manager.
§  If it is approved from the merchandiser then 6 pcs of each item is sent to merchandiser to prepare Trim chart for Production reference. And all the trims goes to inventory.
§  If the inspection is rejected re-inspection is done for 100% trims.If pass goes to inventory if not the whole lot is rejected and report is sent to merchandiser.

Quality Checks for Sewing Trims

             Zipper – color, length, puller, working condition etc
             Label – print quality, color, size etc
            Button – broken, without hole, color, size, thickness etc
            Thread – color, no. of ply, tkt no. etc
            Elastic – width, stretchability
            Twill Tape – width, weave structure, color

Quality Checks for Packing Trims

           Labels – size,color,print quality
           Hang Tags – size,color,print, string
           Stickers – gum strength, color, size print quality etc
           Sizer – Print quality, size.
           Polybag – measurement, print quality

Quality Check for Accessories  

Belt – length, width, color buckle quality etc. On receipt of goods they prepares inspection shortage report in case of no discrepancy in quantities is observed the inspection shortage report shall show the variance as nil. And forward the inspection shortage report to commercial and also to the concern merchandiser.



THE END


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