Quality Manual- Control of nonconforming products

Control of nonconforming products

Purpose:

To prevent the dispatch of nonconforming products to the customer.

Scope: 

This section applies to the products which do not conform the required quality.

Nonconforming product

ACTIVITIES:

Non-conforming goods are identified during the checking of receiving section¬, Process inspection and final inspection.

• When a major non conformance is discovered i.e. (one that requires a managerial executive decision regarding its disposition) it is so identified and segregated," subject to the appropriate management decision, the defective goods are reworked, accepted on concession, re-graded or rejected.
• Where appropriate, the customer is consulted concerning any concession.

IN A NUT SHELL QUALITY IN PRACTICE:

In our company quality assurance activities start from forward looking design and guarded down to the inspection stage.

• During product development utmost care is taken both in terms of aesthetic and technical details.
• When ordering materials or components specifications are made known to the vendor. If necessary he is educated, materials are accepted after the necessary checking is OK.
• All equipment's, machine and instruments are maintained at top working condition.
• Trained operatives are organized before production is planned.
• Production file is prepared along with costing.
• Regular spot checking of key operations followed by final checking in
• Cutting of upper & bottom.
• Prefabrication of components.
• Compounding , rolling & moulding of rubber/crepe components
• Injection of TPR/PVC soles.
• Lasting conveyors.
• Shoe finishing and branding of socks.
• Packaging
• During in process control if anything is found below level of performance corrective actions are taken.
• End products are checked and inspected in three/ four stages:
• By checkers in lasting line.
• By inspectors at the end of lasting line
• By quality control  personnel at the warehouse
• Third party inspection as per buyer’s requirement.

Responsibility of “quality assurance” therefore, is shared by almost entire management of our company i.e 

1. Product development
2. Procurement
3. Store personnel
4. Floor supervisors/ production managers
5. Quality team
6. Buyer
7. Third party inspector (Wherever required).

Further to this we   statistically analyze the customers claim if any and corrective actions taken through P.D. Dept. and production floor.

To guard this, wear test of the product is regularly conducted by the P.D. Dept. at development stages and afterwards from regular production line.

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What is Productivity

Productivity is the ratio of product output to resources input, which is the degree of effectiveness of resources utilization.
In short, it is the measure of efficient utilization of the inputs in the conversion process.

Productivity= Output/Input

Input:
Material
Machine
Labour
Space
Expenses etc

Output:
Production Unit
Turnover
Service etc.

Productivity is an attitude of mind that strives for and achieves the habit for improvement, as well as the system and the set of practices that translate that attitude into action:

• In and by ourselves through constantly upgrading our knowledge, skill, discipline, individual effort and team work.
• In our work through better management, work methods, cost reduction, timeliness, better systems and better technology so as to achieve high quality products and services, a bigger market share and higher standard of living. 

Kurt Lewin's model for human behavior can be expressed by the following:
Formula, B=f (I,E) i.e behavior is a function of the individual and his environment.
This principle provides a corner stone to release untapped human potential.
This Lewin's model expands in case of the productivity.
The productivity P=f (I,G,E) i.e the productivity depends on the individual, the group and the environment.
To tap productivity, each must be understood and managed accordingly.

Take a tour to know more about productivity.

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Introducing Management Training- Motivation Final Part

This is the final part of the article. Here we see the motivation theories. Here you find the first part.

MOTIVATIONAL THEORIES

1. Abraham Maslow’s “Hierarchy of needs theory”.
2. Frederick Herzberg’s “Two factors theory” (motivation-hygiene theory)
3. Claton P. Aldafar’s “ERG theory”
4. MC Gregor’s “X” and “Y” theory.
5. J.K. Atkinson and David C. MC Clelland’s “Need theory of Motivation”
6. Viktor E Frankl’s “Will to meaning theory”
7. B.F. Skineer’s “Conditioning and Reinforcement theory”.
8. Victor H. Vroom’s “Expectancy theory”.

ABRAHAM MASLOW’S HIERARCHY OF NEEDS THEORY 

Abraham Maslow's Hierachy of Needs Theory

Physiological need or Biological Need: Hunger, thirst, sex, air, food, water and so on. (Bodily need fulfillment)

Safety needs: Protection against danger, threat, deprivation and  so on.

Social Needs: Belonging, association, acceptance by others, giving and receiving friendship and love.

Ego or Esteem Needs: Self esteem (Self confidence, independence, achievement, competence,  knowledge) and personal reputation (status recognition appreciation respect).

Self actualization or self fulfillment Need:  Realizing one’s own potential, continued self development, creativity.

CRITICAL FACTORS TOR TAKING BEHAVIORAL DECISIONS

• Net profit: Observed value of the reward minus observed cost of the reward.
• Cost of failing: Cost of trying plus penalties for failing.
• Perceived probability of success
• Confidence in calculation.

According to behavioral scientist another point is Emotions. This is the most powerful force that motivate us even if they are not particularly rational.

What is Emotion ?

     An Emotion may be defined as a stirred –up – state of the mind accompanied by the physiological changes.
Emotions result from need seeking activities and are, therefore, indirect cause of behavior.

Most human behavior has a motivational base which seeks to satisfy needs.
If an operating manager is to try to draw some level of activity from a subordinate, he must have an understanding or awareness of the specific human needs that must be satisfied if the stirred –up –state is to be eliminated.

Two- Factor Theory:
Herzberg categorized those variables directly related to motivation and those not directly related, which he called hygiene factors.

Motivation
Achievement recognition work itself responsibility advancement
Hygiene factors 
Company policy pay working conditions supervision benefits.

Victor H.Vroom’s-Expectancy Theory:


         Motivation is a product of three factors: How much one wants a reward(valance), one’s estimate of the probability that effort will result in successful performance(expectancy), and one’s estimate that performance will result in receiving the reward(Instrumentality). This relationship is stated in the following formula:
       
           Motivation  =    Valence    x    Expectancy     x     Instrumentality

The  three factors

Valence: Valence refers to the strength of person’s preference for receiving a reward. It is an expression of the amount of one’s desire to reach a goal.
       
Expectancy: Expectancy is the strength of belief that one’s work-related effort will result in completion of a task.
For example- a person selling a magazine subscriptions door-to-door may know from experience that volume of sales is directly related to the number of sales call made. Expectancies are stated as probabilities.
       
Instrumentality: Instrumentality  represents the employees belief that a reward will be received once the task is accomplished. Here the employee makes another subjective judgment about the probability.

J.K.Atkinson & David C.Mc-Clelland

 According to them the individual personality is assumed to be composed of a network of three basic motives.

1. The need for achievement.
2. The need for affiliation.
3. The need for power.
4. It is possible to think of specific type of behavour that are likely to be associated with each kind of motive.Mc. Clelland found that people with high need to achieve tend to
1. 1.Seek and assumed high degree of personal responsibility
2. Take calculated risk
3.  Set challenging but realistic goals for themselves.
4. Develop comprehensive plans to help them achieve their goals.
5. Seek and use concrete measurable feed back of the results of their actions
6. Seek out business opportunities where their desire to achieve will not be thwarted.

Viktor E Frankl

     The first two analytical motivational model dealt with the idea of motives and the type of motivated behaviour that manager may apply to other people. Frankl in his book Men’s search for meaning writes more directly to individual person and his own motivation. Frankl,  believes, for example, that a great deal of  man’s basic frustration from his inability to find what Frankl calls the “Will to meaning” . He believes that a people have a basic need to do meaningful things, and thus when put into an environment that does not allow for meaning people become frustrated and develop neurotic behavior.

Clayton Alderfer’s E-R-G model

       Clayton Alderfder proposed a modified need hierarchy-the E-R-G model with just 3 levels. He suggested that employees are initially interested in satisfying their existence needs, which combine physiological and security factors. Pay, physical working conditions, job security, and frienge benefits. Can all address these needs. Relatedness needs are at the next level. And these involve being understood and accepted by the people above, below and around the empolyee at work and away from it.

Growth needs are in the 3rd category, these involve the desire for both self esteem and self actualization.

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Introducing Management Training-Motivation first part

This article is holding with two parts. Today we discuss about the first part.

IMPORTANT IDEAS ABOUT THE NATURE OF HUMAN BEHAVIOR

1. People are wanting animals. As soon as one of man’s need is satisfied, another will appear in its place. This process is unending and continuous from birth to death.
2. Satisfied need do not motivate of cause behavior. Only those needs that has not been satisfied can exercise a great deal of influence over human behavior.  
3. The needs can be arranged in a hierarchy of importance. An individual has a pre-determined order of needs. Each needs having its own rank level of importance to each individual.

WHAT IS MOTIVATION

The word motivation refers to activation from within the organism. It is an internal drive that incites the individual to take some kind of action. It is a stimulation to satisfy a need.

MOTIVATIONAL PROCESS

The motivational process may be described as consisting of three stages:

Motivational process

1. There is a need caused by internal dis-equilibrium. 
2. There is a behavior caused by the need to established equilibrium.
3. There is a goal that satisfies the need.

HUMAN NEED STRUCTURE

There are countless ways to classify and arrange the human need structure.  One way is to classify and arrange the human needs into two categories-

1. Primary motive 
2. Acquired motives

PRIMARY MOTIVES

Primary  motives or lower level needs are those which arises from the nature of man as an animal and which do not originate in previous learning.

Among the most important lower level needs are hunger, thirst,  sex, pain avoidance, comfort, breathing etc.

ACQUIRED MOTIVES

Acquired motives result from the experience of an individual from the special instructions an individual has with his environment. These interactions usually cause learning to occur. Among these acquired motives are the higher level -  social needs as well as esteem needs and self actualization needs.

The final part is about motivational theories. Stay in touch.

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Introducing Interflow Management

Interflow Management is a most effective system for a manufacturing company. Here i discus about the system which already we maintain our factory. Hope this will helpful for your company.

The philosophy:
Good communication in any company gives employees at all levels a feeling of belonging by keeping people informed and by providing an opportunity to contribute to overall operation of the enterprise.
It is intended to exchange the ideas and concerns between the management and the workers. That is the two-way communication on an ongoing basis.
Planning includes the broad based participation in the preparation of strategic plan such as preparing of annual estimate, budgeting of departmental expenses etc.
Decision making ranges from determining the type of equipment use for a particular design, availability of cutting dies, last, repairing of any machine in the line, training for any particular skill etc.
To be able to achieve this it is essential that all necessary information be available to a broad spectrum of people.  Fear of damaging leakages of business information should not be allowed to create an environment of secretiveness and misinformation.
To make it possible to bring all these important people into the planning, information and decision – making process in a more formal way a system called “Interflow”. Especially it improves the relationship between the first line supervisor and the operators.

(A)Purpose:

1. To ensure that every one working in the company feels they are participating in the venture.
2. To make information relevant to the operation of the department and company available to all levels of management.
3. To create good two –way communication.
4. To strengthen the relationship between the first-line supervisor and his subordinates.

Why it is important:

1. In order to work to their peak potential, people need to communicate.
2. It gives a very large and important group of people, those operating the machines an opportunity to receive information and express opinions.
3. Interflow is an important part of the overall management of the company.

( B )Who should be selected?:

Efficient employees with leadership experience and respect of his peers should be selected.
 Number should be minimum 3 to maximum 6 employees depending on the number of people working in a dept.( as a general rule there should be 1 interflow team member for every 5 employees working in a dept.


Rotation of interflow members:

Member should serve for a limited period of time. Each member should serve for at least 6 months and one member could be replaced approximately every two months, to ensure a cycle of continuity. It may be beneficial to form a core of 1 or 2 key members who would serve for a longer period.


( C ) Location:

It can be decided by discussing to select a convenient place.

Principle to be followed:

1. A commitment to interflow.
2. A positive approach.
3. Address important issues.
4. Follow-up.

What are the steps to be taken?

• Pre-schedule meeting.
• Prepare agenda.
• Chair the meeting.
• Communicate information.
• Record items that arise.
• Initiate prompt action.
• Report back and follow-up.

Summary:

• Supervisor must be well trained in the techniques of Interflow management.
• There must be conscientious preparation for each meeting.
• Every one- Supervisors, team members, managers, - must adopt a positive approach.
• Every member must be willing to participate and contribute.
• There must be immediate follow-up and feedback on all points.

To conclude the session:

Interflow Management Format

(A)Responsibilities:

Department manager:

1. Organize interflow in his dept.
2. Be sure that the meetings are scheduled and held.
3. Channel relevant information from the management team to the interflow chairman.
4. Review records of meeting.
5. Take action on points that require his attention.
6. Pass information of interest from interflow meetings to higher levels of management.
7. Give support and recognition to interflow chairman and members.

Interflow chairman:

• Actively gather information of interest from all sources, including his superiors.
• Prepare and conduct meaningful meeting.
• Pass on and gather points from his team members.
• Report topics discussed to management.
• Ensure prompt follow-up on points raised.
• Actively create and reinforced team spirit in the interflow group and his dept. as a whole.

Interflow team members:

1. Collect ideas and concerns from fellow employees. 
2. Offer opinions and suggestions readily during interflow meetings.
3. Pass information discussed during meetings to their colleagues.

(B)“Remember – Interflow management is not just a separate group of meetings held for supervisors and their subordinates to communicate, but, in fact, it is an essential part of the overall management of the company and a crucial ingredient in the total human relations activity.”

“Interflow must therefore; be managed with as much care and commitment as all other aspect s of the business. Interflow is something that must be developed until it is a meaningful and vibrant part of working life.” 

Thanks.

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Standard Operating Procedure For Footwear Industry-In process Quality Control

Hello everyone. This is the quality final part of the SOP. Lets see the In Process Quality Control.

If you aren't read the quality first part click to read First part

Quality control is one of the most important function in production. It cannot be "inspected into shoe ate the end of the line."

Quality must be built into the shoes at every step in the manufacturing process. Substandard quality be identified and corrected when it occurs in the manufacturing process.

This process quality control concept rest on three basic principles.

1. Only good materials are used
2. Operations are performed correctly
3. Any defects are corrected when they occur during manufacturing.

This quality control system moves the quality checker into the main stream of production and makes him process quality controller.

The process quality controller makes a statistical quality control check at several critical check points in the process, at regular intervals. He measures and counts he does not guess.

In line with that Operator should

1. Receive good work
2. Perform good work
3. Supply good work

In-Line Inspection: During the production of shoe the operator's finished work is checked by line supervisor. A quality inspector moves from one operator to another at random inspecting a predetermined number of parts from a finished lot.

At the final stage checking by the quality checker after ration packing in the master cartoon as per AQL(Accepted Quality Level)  requirement and making report. To make recheck if the consignment fails AQL Requirement.

AQL Chart

All the above checking is carried out on the basis of approved reference sample. Besides that on the basis of the quality report preventive/corrective action are initiated the the quality dept. They also check the processing parameters such as time, temperature and pressure on daily basis.


Ok thats all. I think it will help a footwear manufacturer to help make their own company SOP.

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Standard Operating Procedure For Footwear Industry-Quality Department-01

Hello everyone. This is the Quality Part of the SOP. It is one of the most important department of a manufacturing company. There are no compromise about Quality. Lets see what quality dept. done.

Quality can be defined as the measure of excellence or state of being free from defects, deficiencies, and significant variations. It can be defined as “The totality of all features and Characteristics of a product or service that bears on its ability to satisfy stated or implied needs.”

Quality assurance:

All those planned and systematic actions necessary to provide adequate confidence that a product or service will satisfy given requirement for quality is called quality assurance.

Quality control:

The quality of product at every stages of manufacturing can therefore, be ensured by introducing some sort of controlling and monitoring mechanism in the production process. This controlling and monitoring mechanism is regarded as quality control system.

The word quality has multiple meanings. Two of those meanings are critical, namely, product performance and freedom from deficiencies '.


Product performance: Product Satisfaction

In the sense of performance, quality refers to the performance features of a product. Such features are decisive as to product performance and as to product satisfaction. Such features compete with each other in the market place. External customers, especially ultimate users, compare the competing performances. Their comparisons then become a factor in deciding whose product will be bought. Because of the competition in the market place, a primary goal for product performance is to be equal or superior to the quality of competing products.

Freedom from deficiencies: Product Dissatisfaction

The word quality also refers to freedom from deficiencies, which take many forms as late deliveries, customer claims and returns, high rate of rework and even cancellation of sales. These collectively are forms of product dissatisfaction.




Some deficiencies impact external customers and hence are a threat to future sales as well as a source of higher costs. Other deficiency impact internal customers only and hence are mainly a source of higher costs.

For quality in the sense of freedom from deficiencies, the long-range goal is perfection.


a. Objectives: 

• To ensure each and every pair of shoe is acceptable standard quality level. 
• To build and maintain a quality standard procedure so that it can earn customers confidence regarding the quality product.

Quality in Practice:

In a company quality assurance activities start from forward looking design and guarded down to the inspection stage.

A. During product development utmost care is taken both in terms of aesthetic and technical details.
B. When ordering materials or components specifications are made known to the vendor. If necessary he is educated, materials are accepted after the necessary checking is OK.
C. All equipments, machine and instruments are maintained at top working condition.
D. Trained operatives are organized before production is planned.
E. Production file is prepared along with costing.
F. Regular spot checking of key operations followed by final checking in

• Cutting of upper & bottom.
• Prefabrication of components.
• Compounding , rolling & moulding of rubber/crepe components
• Injection of TPR/PVC soles.
• Lasting conveyors.
• Shoe finishing and branding of socks.
• Packaging

G. During in process control if anything is found below level of performance corrective actions are taken.
H. End products are checked and inspected in three/ four stages:

• By checkers in lasting line.
• By inspectors at the end of lasting line
• By quality control  personnel at the warehouse
• Third party inspection as per Buyer/Customer’s requirement.

 Responsibility of “quality assurance” therefore, is shared by almost entire management of our company i.e.

1. Product development
2. Procurement
3. Store personnel
4. Floor supervisors/ production managers
5. Quality team
6. Buyer/Customer
7. Third party inspector.( Wherever required).

Further the company   statistically analyze the customers claim if any and corrective actions taken through P.D. Dept. and production floor.

To guard this, wear test of the product is regularly conducted by the P.D. dept.at development stages and afterwards from regular production line.

To continue the final part of Quality as well as SOP

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Standard Operating Procedure For Footwear Industry-Production Process(Lasting & Finishing)

Hello everyone. This is the Production part (Lasting and Finishing) of this SOP. If you don't read yet the Sewing parts you can read from the following links. In this part we are talking about Lasting and Finishing department where a shoe packed.

Standard Operating Procedure For Footwear Industry-Production Process(Sewing)

It is the process in which all the component parts of the upper and bottom are brought together to construct the shoe. Various construction processes are used for shoe assembling depending on the style.

a. Objectives: 

• To make shoe as per plan, style and size assortment within the stipulated time.
• To ensure the best utilization of the resources (man, machine and material).
• To ensure the making of right quantity of shoe of the right quality in the most efficient manner. 

b. Main Functions:

• To make an analysis of the file, production plan received from the planning Dept.  and the approved sample. In case of any deviation to be communicated to the person concern and get it corrected.
• To make sure that the necessary equipment, machinery and manpower are available well ahead of production start time for avoiding any sort of interruption during production.

Receiving of components: 

• Ready components (upper, insole, sole etc.) are checked, counted pair by pair as per style, approved sample, color, size assortment and receive from the sewing dept. as well as from the store. 

Receiving of auxiliary items.

• Requirement for the corresponding accessories such as, shank, welt, needle, thread, necessary chemicals, packing material etc.  is given to the store and received accordingly.

Click to Large View

Practical shoe making:

There are seven different types of construction are in practice in a standard company. Namely

• Moccasin Process
• Stitch Down Process
• Cemented Stuck-on Process
• California Process.
• Goodyear welt process
• Stitch & turn process 
• Espadrilles.

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Standard Operating Procedure For Footwear Industry-Production Process(Sewing)

Hello everyone. This is the Production part (Sewing) of this SOP. If you don't read yet the Cutting & Prefabrication parts you can read them from the following links. In this part we are talking about Sewing department.

Standard Operating Procedure For Footwear Industry-Production Process(Upper Cutting & Prefabrication)

Sewing Department: The Sewing Dept. plays a very important role in shoe making. It has an impact both in terms of functionality and outlook. Maximum value addition in a shoe making happens  in sewing Department. Both for functional and decorative feature , it is important to use number of stitches per cm. Therefore utmost care should be taken in the sewing operations. Besides that the maximum job content, workforce and machinery are involved in the sewing dept. Let's see sewing objective and main functions.

Objective: 

• To stitch the cut components of uppers as per plan, size assortment and approved sample within the stipulated time.
• To ensure the best utilization of the manpower and machinery.
• To ensure the stitching of right quantity of upper in the right quality in the most efficient manner.

Main Functions:

• TO make an analysis of the file(Production Guide), production plan received from planning and the approved sample. In case of any deviation to be communicated to the person concern and get it corrected.
• To ensure necessary equipment, machinery and manpower are available well ahead of production start time for avoiding any sort of interruption during production.

Receiving Components:

• Upper components are checked, counted pair by pair as per style, approved sample, color, size assortment and receive from the cutting dept.

Receiving of auxiliary items:

• Requirement for the corresponding auxiliary items such as needle, thread, buckle, eyelet, trim, necessary chemicals etc is given to the store and received accordingly as per approved sample. 

Practical Stitching:

• Preparation: Before starting the job, a preparatory check is done of the approved sample, component, related accessories, guides, gadgets, machinery and the required manpower. Thread color & number to be matched with the approved style. Needle to be set as per thread number, stitch length to be adjusted as per sample. marking ink & cleaner to be selected well ahead of production.
• Line Setting: Since every style have their uniqueness in sewing, it requires different setting in the sewing line for the sequential operation avoiding repetition of movement.
• One pair is stitched first following the approved sample to check every technical details.Consult with the product development dept. and get it approved after necessary correction if required.

After getting the approval, the volume production stats, components are sometimes reinforced, laminate and progressively stitched together such as collars are joined to quarters, tongue to vamps, vamps to quarters, eyelets to uppers and so on depending on the style using a wide variety of specialized sewing machines until the upper is completely stitched. Sequential operation of a typical sewing line shown bellow:

Each operator along with the helper is responsible for efficiently producing high quality work. They must follow the approved sample. Proper thread, needle, number of stitches per cm, distances from edges or other raws of stitches to be maintained. Loose threads to be trimmed, shoe components are straight and wrinkle free during attachment. Line supervisor check the quality different point and gives technical solutions.

• At the end of the sewing process the quality controller inspect the stitched upper pair by pair so that a standard of excellence is maintained. After completion of stitching, the stitched uppers are stored in the section.
• Delivery: Depending in the style, some of the uppers are directly delivered to the lasting line and some of them to the Hand Sewing for Moccasin Stitch.

Relation Between thread and Needle: Very important for sewing

 THREAD NEEDLE (LR/LL) NEEDLE (DP/PF)
  10               160-180                       22-24
  20               130-140                 20-22
  30               120-130                 20-22
  40               100-110                 18-20
  60                90-100                 12-14

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Standard Operating Procedure For Footwear Industry-Production Process(Upper Cutting & Prefabrication)

Hello everyone. This is the Production part (Upper Cutting & Prefabrication) of this SOP. If you don't read yet the first 6 parts you can read them from the following links. In this part we are talking about Procurement department.

Part -01

Part- 02 

Part- 03

Part- 04

Part- 05

Part- 06

Making Shoe is a Step-By-Step Process. Bellow chart is a shoe making process chart.

Production Process Flow Chart

Upper Cutting & Prefabrication:

First step in making shoe is to cut the upper material into shoe components as per the required style. There the cutter places the material on the clicking machine and cut it with the help of cutting die /knife to achieve the following objectives.

a. Objectives: 

• To cut the material into component as per plan, style and size assortment within the stipulated time.
• To ensure the best utilization of the material.  
• To ensure the right quality of the component in the most efficient manner. 

b. Main Functions:

• To make an analysis of the file, production plan received from planning and the approved sample. In case of any deviation to be communicated to the person concern and get those corrected.
• To ensure necessary equipment, machinery and manpower are available well ahead of production start time for avoiding any sort of interruption during production.

1) Receiving of material: 

• To place a material requirement (leather, synthetic and fabric etc) called SR as per style, type of material and prescribed quantity to the raw material store for the following day. 
• To receive material as per the approved swatch & quantity and to keep them in the mini store in the section.

2) Receiving of cutting knife:

            

         After receiving,   the cutting knives are checked with the pattern, a pair of component is cut, pasted in a board after all the prefabrication job called dummy test and get it approved by the sample dept. 

3) Practical cutting:

• To issue cutters ticket as per the cutting plan, style and cutters capacity.
• To check material with the sample/swatch board supplied by PD dept.
• To issue material as per cutters ticket and also the cutting knife.
• After the components are cut, the pieces are checked & counted first by the helper and then by the quality checker and put into poly bag pair by pair.  In case of nonconformity of the components, the bad components are dropped in a bag attached in the cutting table and make the necessary replacement.
• The bad components are used for cutting smaller components whichever possible avoiding defects.
• The supervisor collects the good components every hour and sends for pre-fabrication.
• The cutter has to complete the stipulated number of pairs within the prescribed quantity of material. In case of surplus, he /she has to returned the material. In case of any shortage he/she needs to give explanation justifying the need and get it approved by the planning dept.
• Surplus material to return to the store after   shipment of that particular style.

Upper Cutting & Prefabrication Process Flow Chart

Upper Cutting Process flow chart

NOTE:

Cutting leather: The method of cutting “uppers” from a leather is a great importance, and is necessary for cutter to know the structure of the skin. The cutter must know which parts of the skin have better physical properties, the direction of the stretch and the nature and origin of the various defects.  A good cutter will always be cost minded and get maximum utilization from a skin. A good cutter must know how to use to the maximum the various parts of the leather. 

Cutting synthetic and fabric: Synthetic material & fabrics are cut in layer.  Depending on the thickness and hardness of the material the number of layers is determined. Some times to maintain the design, particular direction need to be maintained. 

Knives: The knives are manufactured from steel.   Double edge cutting knives are in use wherever possible; this minimizes the number of knives required, so reducing cost.

Two heights: 19 mm. for leather
32 mm. for textiles and other multi layer cutting. 

Cutting Block: The blocks on which leathers cut are made of poly propylene or phenolic resin block, the cutter should always use the entire surface area of the block to wear it uniformly, this saves knives and improves cutting quality.

Machine:  Basically two types of cutting machines are in use 

1. Swinging  head cutting machine
2. Beam  head cutting machine

             2a. Fixed beam head
            2b. Travelling beam head.

Normally the swinging head cutting machines are used for cutting leather and Beam head cutting machines are used for cutting synthetics & Fabric.

Safety on Machines: The double control system on cutting machines requires both the hands of the cutter to be on top of the machine, so ensuring that he cannot get his hands caught between the cutting head and the knife.

4)Prefabrication:

Shoe components particularly shoe uppers, must be prepared for the sewing together of the component pieces. Although the operations performed varies from style to style, some of the process are

1. Splitting to bring components to desired even thickness as per the requirement of style.
2. Lamination for reinforcing certain parts of the upper to give strength and comfort. 
3. Embossing any decorative design, punching etc.
4. Re-cutting.
5. Skiving 
6. Stamping or Printing.
7. Cementing of socks etc.

Because of the number of processes involved in prefabrication it is important that there is as little handling between feeding and collecting the shoe components as possible. The quality of the prefabrication process can impact the quality of later processes.

Quality Inspection: After completion of all the operations in the cutting & prefabrication, each and every component are checked pair by pair, put in poly bag and store in the cutting dept. for delivery. In case of non conformity, respective components are replaced.

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Standard Operating Procedure For Footwear Industry-Part 6(Raw Material Store)

Hello everyone. This is the 6th part of this SOP. If you don't read yet the first 5 parts you can read them from the following links. In this part we are talking about Procurement department.

Part -01

Part- 02 

Part- 03

Part- 04

Part- 05

a.Objectives: 

• To store all necessary materials well ahead of production in order to give support whenever they need.
• To maintain optimum stock level to avoid over/under stock. 

b. Main Functions:

• To receive material as per purchase order in terms of quantity and quality as per approved swatch.
• To store the materials in such a way so that they can remain free from all possibility of damage and can be easily located whenever they are needed.
• To maintain a stock inventory as per item.
• To supply the material on FIFO basis as per requirement and record it properly.
• To monitor the stock level as per standard OTB (open to buy) and communicate with the purchase manager.
• To adjust the stock with the new purchase requirement.
• To increase the stock turn for regular items.
• To remain well informed regarding the stock positions of all the items and participate wherever needed.
• To monitor the old stock and propose for the suitable article to use it.

Continue for the next post

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Standard Operating Procedure For Footwear Industry-Part 5(Procurement Department)

Hello everyone. This is the 5th part of this SOP. If you don't read yet the first 4 parts you can read them from the following links. In this part we are talking about Procurement department.

Part -01

Part- 02 

Part- 03

Part- 04

Procurement plays a vital role in any manufacturing operation. It is more important in case of export oriented company where the quality and timeliness is a number one priority. Besides that the process ability and productivity also greatly depends on the quality of the raw material and the timely procurement.

a.    Objectives :

• To make all the necessary materials available well ahead of production freezing.
• To ensure the competitive price and quality as per approved swatch.
• To maintain a very minimum stock level to avoid over and under stock.

b.    Main Functions:

• To receive the material requirement just after the production plan.
• To make adjustment with the available stock.
• To select the best possible supplier considering the price, timely delivery and consistency in quality.
• To maintain the suppliers data base.
• To make purchase order with the appropriate supplier for the particular material.
• To monitor their processing to ensure timely receiving.
• To visit the supplier time to time to see their facility and educate them as per our requirement.
• To invite suppliers to built good relationship.
• To receive material as per approved quality and receiving date.

Thanks.
Click to continue for the next post 

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Standard Operating Procedure For A Footwear Industry-Part 4(Planning Department)

Hello everyone. This is the 4th part of this SOP. If you don't read yet the first 3 parts you can read them from the following links.

Part -01

Part- 02 

Part- 03

Planning in its broader sense means systematic preparation for action. To decide before start where a company want to go and how they are going to get there.

Therefore, planning is a rational process characteristics of all human behaviors for actions individually or collectively to accomplish certain objectives.


a.    Objectives:

• To produce and deliver the right quantity of shoes,   
• Of the right quality,
• At the right time as required by the customer,
• In the most economical and efficient manner.

Make Plan

b.    Main Functions:

• To take export order considering the production facility regarding the technicality, capacity and the timing.
• To consult with the sample dept. regarding the approved sample, specifications and technical details of the ordered articles.
• To make a production file along with PD(Product Development) dept. detailing the specifications and the required quantities of material and issue to the concern dept. after necessary approval.
• To study the consumption of material.
• To make production plan to facilitate the operation to take necessary preparation in terms of machinery, manpower and material.
• To give material requirement to the procurement dept.
• To test material as per Buyer/Customer’s requirement.
• To consult with the Production Managers regarding the machinery and manpower.
• To make a checklist for all the necessary items such as equipment, material, accessories, auxiliary chemicals, packing materials etc. and update on daily basis to follow-up and ensure the availability on time. 
• To maintain liaison with the customer, PD(product development) and make necessary adjustment.
• To communicate with the customer and provide the necessary service to satisfy them.
• To conduct a pre-production meeting with the concern people for ensuring un-interrupted production.
• To give production schedule to the customer as well as the production people and follow it up to maintain.
• To visit production floor for having a track whether the things are moving in the right direction or not. If not to co-ordinate among the persons concern for necessary adjustment.
• To give inspection report to the customer for shipment approval.
• To conduct the third party inspection where ever necessary.
• To communicate with the shipping dept. for final shipment.
• To confirm the shipment status to the customer after passing the final inspection.

To be continued............

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