Sewing Needle Control Procedure

 

In garments industry needle is an important part, after cutting of fabric, joining cut panel with needle by stitching we make garments. So, making garments without needle is really difficult/impossible. Use of needle without control can be harmful for the user of that garments. If any needle, needle parts or sharp metal object lies in garments during wearing it can hart the user which may cause infection or big damage, even death can happen also. So, needle should be with in strict control.

1.0   Purpose

The purpose of this procedure is to provide a guideline to all the employees of the organization about proper utilization of needle, prevent unauthorized use of needle and ensure no metal contamination of product. This is a part of quality assurance process.

2.0   Scope

This process applies to all over the operations where needle using takes place. Specially –

Main Store Needle Requisition

Needle in-house

Main store needle issue

Sub store needle distribution

- New Needle issue control Procedure

- Needle Replacement Control Procedure

- Broken Needle and contamination control procedure

- Idle machine needle control procedure

- Daily needle change control procedure

- Rented machine needle control procedure

- Machine transfer

Hand Needle Control procedure

Needle Inventory Management

Kimble/tag gun needle procedure

 

3.0   Responsibility

Store Manager, Maintenance manager, Quality Manager, Production manager, Product safety responsible, Head of QA/ Operation /Compliance and HR will be responsible for this procedure.

 

4.0   Requirements

4.1   Sufficient needle booth with line/ section allocation. 

4.2   Equipment’s for searching broken needle (Trolley Magnet, Pen Magnet etc.) 

4.3   Needle carry box magnet inside with identification (Line/ Section, Responsible person).

4.4   Needle/ Metal contaminated garments carry box.

4.5   Needle replacement calendar.

4.6   Sample needle card

4.7   Needle sharpness check tools

5.0   Process

5.1   Main Store Needle Requisition Procedure

5.1.1   Needle requisition from main store is done in two ways

5.1.1.1 Monthly – based on the stock balance, monthly a needle requisition is raised where requisition is made by needle type, size and quantity.

5.1.1.2 Special Requisition – based on the style and floor demand, sometime special requisition is raised. It is also raised by needle type, size and quantity.

5.1.2   Store concern will make a requisition and take approval from all relevant persons (Head of Mechanic, QA & Operation) and sent to purchase department for further action.

 5.2   Needle in-house Procedure

5.2.1 It is the responsibility of the main store needle responsible to collect needle from the factory gate, security along with all necessary documents like Challan, Inspection report, product certificate etc.

5.2.2 The store concern will ensure inventory checking physical quantity with the challan quantity.

5.2.3 If everything not ok as per the challan, then it is the concerns responsibility to send it back to the purchase department with a report.

5.2.4 Needles will be safely kept in locker by its type and size if everything found ok.

5.2.5 A stock register should be maintained in the store and all new needles received should be include in the register type and size wise.

 

5.3   Main Store Needle Issue Procedure

5.3.1   A stock register should be maintained in store and all new needle received should be include in the register type and size wise.

5.3.2   Store will issue needle to sub-store with exact replacement. Only for new imported machine, new needle can be issued without replacement, with the approval by mechanic manager, Quality Manager & product safety officer.

5.3.3   If any needle lost from production that must be investigate properly, legal action should be taken against the responsible person, then needle can be issued following missing needle procedure with approval from Mechanic manager, Head of QA, Head of Operation, Product safety officer and Compliance/ HR Head.

5.3.4   Same as main store, each sewing floor needle counter (Sub-store) maintain its own register where total counters needle count is present. When needle stock balance reaches a certain level, the concern needle counter responsible shall raise a SR and after taking approval from the safety officer, will bring necessary needles from the main store.

 

5.4   Needle Replacement

Under no circumstances this factory will make any product containing or possibly containing any foreign metal components or needle components or needle fragments, or other sharp objects. In an effort to monitor this, has implemented and enforced the following controlling procedures.  

5.4.1         Needles even if needle is not broken must be checked regularly (Twice a day) by the supervisor / operator to ensure that they are in good working condition.

5.4.2         If any needle is found not in good working condition need to be changed even if the needle is not broken.

5.4.3         No sewing operator should be in the possession of any spare sewing needles, used or new, other than the needle installed on the sewing machine.

5.4.4         All replacement / spare sewing needles must be secured in a locked cabinet accessible only by the Needle Issue controller/Authorized personal.

5.4.5         All new needles may only be replaced by the Supervisor, Mechanic or authorized personnel along with the operator of the particular machine.

5.4.6         Used sewing needles must thoroughly be checked and if found to be in good working condition, need to be segregated and add in the used needle stock for further usage and if found not in good condition to reuse, required to be attached by adhesive tape on the “Used Needle Disposal Log Sheet” with proper details.

5.4.7         All replacement needle issues to be made on the basis of “One Old Received and One New Issued” of same type and same size only with record in needle room and needle calendar.

5.4.8         If it is necessary to change the needle size reason of size change must be authorized by Quality controller in needle replacement calendar.

5.4.9         Factory Safety officer / Compliance manager / QC Head will review this log sheets regularly. Auditor will count the numbers of needles pasted in the Log sheet and use needle stock against issued record and stock records to confirm proper implementation.

5.4.10      All the related documents including the “Used Needle Disposal Log sheet” shall be preserved for a period of time minimum 18 months.

 

5.5   New Needle issue control Procedure

5.5.1                     When any new sewing machine is received always there is a Needle installed with the machine and few more spare needles are supplied by the machine company. As soon as a new machine is installed all those needles must be handed over to the main store / needle control department by concerned Mechanic so that all those new needles are being added to the existing needle stock.

5.5.2         Following the same method when an old / used machine goes out of the sewing line or that machines needle required to be replaced due to style change, fabric requirement, line feeding, for idle machine and all mentioned requirement, all needle must be handed over to the needle controller. He/she will check the condition of the needle, if it is found that the needle is not in suitable condition to reuse, Needle controller shall attach those used needles to the “Used Needle Disposal Log sheet” with necessary details mentioned.

5.6   Used Needle Stock and Issue Procedure

5.6.1         During the line change, style change, line feeding period, needles are replaced in good condition. When those needles are returned to the needle counter, the concern needle controller first must check the condition of the needle using the needle checking equipment made with mash fabric. If it is found that the condition of the needle is ok, that needle must be added to the used needle stock maintaining all necessary records and documents. Next whenever there is any requisition for this particular needle type, based on the fabric type and operation, first the used needle must be issued. If used needle stock doesn’t have that particular needle, only than new needle will be issued.

5.6.2         When sewing line requires those New / Old – idle machines to be re-used Sewing, Line Chief/Supervisor together with the Mechanic shall apply for new needle(s) by filling-up the particular “New Needle Issue application” with all necessary details and approvals.

5.6.3         Only the Plant Head / Senior authorized management member must approve this application and Needle issue controller may issue new needles as required only after receiving of the authorized application and keep records on “New Needle Issue Log”. Particular machine Operator and Supervisor must be present at the time of the new needle issue.

5.6.4         All the New needle request applications must be attached to the particular “New Needle Issue log” and preserved for minimum of 01-year period.

5.6.5         Factory Safety officer / Compliance officer / QA Head will review these applications and controlling process regularly to ensure a proper implementation of the system.

 5.7   Broken Needle Control Procedure:

5.7.1         When a needle is broken during sewing, Operator will not move from his/ her seat. He/ she will raise his/ her hand to call the supervisor.

5.7.2         Supervisor will remove broken needle from machine, put into plastic pot magnet inside & every effort must be made to locate ALL fragments of the broken needle in the garment(s); machine must be checked including such areas as the sewing machine throat plate, feed dogs, bobbin case, inside and outside of the oil bath and its edges, ……etc. use of magnet to locate / search all fragments of the broken needle is recommended in 1.5-meter area.

5.7.3         Operator must use two Plastic Container with mouth closed when carrying broken needle parts to the metal detection procedure and needle issue counter. One for the particular garments working on which needle was broken and another for the surrounding garments.

5.7.4         Any Needle breakage must be recorded in the “Broken Needle Log” and the broken fragments attached to the Log sheet by a self-adhesive tape along with proper details as required in full.

5.7.5         Needle issue controller should check the broken needle carefully by arranging all broken fragments together and comparing with a sample needle of the same type before attaching broken parts to the Log sheet.  This log sheet should be kept in the Needle Issue counter under the authorized person.

5.7.6         If all fragments cannot be found, then the bundle(s) of garments on which the operator was sewing, and any bundles in close proximity must be taken to a separate Bin/Bucket for further examination. Here they must use two separate plastic boxes with lid on top.

5.7.7         The bin/box may be in RED color for easy identification and need to have a cover/lid. Particular garments working on which the needle was broken, must be carried separately on one box and all the other surrounding garments must be carried in another box.

5.7.8         Under the supervision of Line Chief/Supervisor, all garments/parts in the bin/Bucket should be passed through the needle detector machine. The concern metal detector operator should first pass the specific garments on which the needle was broken and then the other.

5.7.9         If garments/parts are not being rejected by the Needle detector machine, by filling up the metal detection verification docket, the concern metal detector operator will release the garments for production again.

5.7.10      If any garment/part is rejected, it must be searched for contamination either by visual inspection or by hand-held metal detector. If the needle fragment is found and removed, the garment/part must be passed through the needle detector again. If garment/part is not being rejected again may be accepted and released for production. The needle fragment found during the check must be handed over back to the Supervisor/Operator so that they can submit all broken needle fragments to the Needle Issue controller. Needle controller should follow the procedure and issue a new needle.

5.7.11      If Garment/Part is not being passed the detector check and the broken needle fragment is not found yet, it cannot be released back to the production and must be rejected. In that case the particular garment/part must be indicated with all the details such as Order No Color, Line No. Operation name in which the needle got broken, Date & Time, Machine No. and the Name & ID # of the operator and pack & seal in a poly bag and put in to the Contaminated Garments Destroy Box. Keep proper records on the “Metal Contamination Disposal Log Sheet”.

5.7.12      In the case of “Broken Needle Fragments missing/not found” …. Section /line supervisor must complete the above checking procedure and finally apply for a new needle by filling-up the particular “New Needle Application”. Only the Plant Head and in his absence the Senior Manager of the respective department is authorized to approve this application and once the duly filled and authorized application is received Needle issue controller may issue a new needle. Records must be kept on “Broken Needle Log Sheet” and the authorized Needle application shall be attached to the particular Broken Needle Log sheet for easy reference.

5.7.13      For full width quilted/ padded / allover embroidered fabric are having possibility of being contaminated by metal objects. In that case all the cutting panels must pass through the needle detection machine before putting through to the sewing line for assembling process.

5.7.14      Factory Safety officer / Compliance officer / QC Head will review this log regularly to ensure a proper implementation of the system.

5.8               Ideal Machine Needle Control Procedure.

5.8.1                     Machines which goes out of the layout or line, needles of those machines must instantly be removed and handover to the needle control room.

5.8.2                      Under no circumstances idle machine to have any needle.

5.8.3                     All idle & spare sewing needles must be secured in a locked cabinet in needle counter & there accessible only by the Needle Issue controller/Authorized personal.

5.8.4                      When those needles are returned to the needle counter, the concern needle controller first must check the condition of the needle using the needle checking equipment made with mash fabric. If it is found that the condition of the needle is ok, that needle must be added to the used needle stock maintaining all necessary records and documents. If it is found that the needle is not in suitable condition to reuse, Needle controller shall attach those used needles to the “Used Needle Disposal Log sheet” with necessary details mentioned.

5.8.5         This machine number & other information should be record in “Idle Machine Information Report “record file.

5.8.6         As needle are issued against specific idle machine number, it is the responsibility of concern needle controller to ensure without the return of previous needle, no new needle will issue against the same machine.

 

5.9               Rented machine needle control procedure

5.9.1         if any rented machine come to the factory in case of any emergency that must be registered first. Than need to identify them with an identification number.

5.9.2         Needle should be issue according to the identification no.

 

5.10           Machine Transfer

5.10.1      When need sewing machine transfer one line to another line or floor, there must be maintain below system,

a) Needles of those machines must instantly be removed and handover to the needle control room.

b) And another line responsible maintain “Application for new needle “form for new needle. So that line wise needle stock/balance maintain properly.

 

5.11           Hand Needle Control Procedure

5.11.1      Where hand-sewing / embroidery needles are used, they can be only used in the authorized quarantine zone. Hand needles can be issued only after verifying that it is a requirement of the process. It will be only issued after the concern quality manager and head of quality verify and sign the requisition. Stock must be maintained by strict follow up and check against “Issue and Receive” of every working shift by the Head / Supervisor / Authorized personnel of the concerned department. Proper records must be maintained. Under no circumstances hand needle can be issued for repair or mending. 

5.11.2 Where hand-sewing / embroidery needles are used, they can be only used in the authorized quarantine zone. Hand needles can be issued only after verifying that it is a requirement of the process. It will be only issued after the concern quality manager, Product safety officer and head of quality verify and sign the requisition. Stock must be maintained by strict follow up and check against “Issue and Receive” of every working shift by the Head / Supervisor / Authorized personnel of the concerned department. Proper records must be maintained. Under no circumstances hand needle can be issued for repair or mending purpose.

5.11.3 Hand needle should be used in separate/ isolated & secured area. No circumstances it should be used in production floor or any other working area where have the possibilities of contamination.

1.1.3         Each operator should have a closable box with pillow inside & box should be identified by operator name ID No & working area.

5.11.4         Box along with needle, should be issue daily when necessary, maintaining a register & return daily to needle room when not necessary.

5.11.5         If any needle broken/ lost, must follow organizations broken needle control procedure (5.7)

5.11.6         Factory Safety auditor / Compliance officer /any other authorized senior person shall conduct regular audits on all these controlling processes and records to ensure a proper implementation and maintenance of the system. 

5.11.7 Factory Safety auditor / Compliance officer /any other authorized senior person shall conduct regular audits on all these controlling processes and records to ensure a proper implementation and maintenance of the system.

5.12           Metal Contamination Control procedure

5.12.1      Any Metal Pins, Wires, Staples, Notice board pins, Paper clips and any other hazarded metal items are NOT ALLOWED to be used within the compound.

5.12.2      All these metal items must be completely avoided using in all Sampling, Production, Store and office rooms also.

5.12.3      Alternatives should be introduced such as Plastic clips, Self-adhesive tape, Glue, Plastic staples, Clamps, Binding threads…etc.

5.12.4      All incoming cargo, cartons, trims & accessories boxes, stationary items shall be routed through the Main Store. None of these items shall be directly delivered to the particular department or area.

5.12.5      All incoming documents shall be routed through Administration department.

5.12.6      An authorized person(s) in both store and administration departments will check all the incoming items for any prohibited metal objects and if found will remove the same and dispose in “Metal Disposal boxes” which are placed at particular areas.

5.12.7      If any metal items (Examples: Fabric clamps, Scissors, Trimmers, Clippers, Metal pointers, Screw Drivers, …etc.) must be used in a specific garment manufacturing process, such as fabric laying, cutting, in sewing lines, trimming areas and during machine maintenance, the factory/concerned department must maintain the documented record for controlling of those items.

5.12.8      Manual striping clips are not allowed at all for carton binding.

5.12.9      Scissors, Trimmers, Clippers and Pointers should be tied to the workplace to prevent the potential loss within a garment during the manufacturing process.

5.13           Needle Inventory Management

5.13.1      Main stores should maintain all Needles and Sharp metal items in such organized way where each item has got clear identification and updated bin card attached to it. All intact needles, Knives, Blades and other sharp metal items must be kept in a Safe cabinet with lock & key under the supervision of Store In-Charge/Manager.

5.13.2      Main Store shall maintain separate inventory records / registers individually for each item such as Sewing machine needles, Hand sewing needles, Scissors, Trimmers, Pointers, Clips, cutting clamps, cutting knives, Button hole blades etc. and all other sharp items being used in the factory Inventory Registers should indicate clear details as mentioned below

-    Item identification. (Name & Size/Length/model #)

-    Date of Receiving/Issuing

-    Opening balance / Previous balance

-    New receiving quantity

-    Cumulative Stock in hand

-    Issuing quantity per day

-    Cumulative stock in hand.

-    Issued quantity per day.

-    Stock balance in hand.

-    Signature of Store keeper.

-    Confirmation signature of factory safety/compliance auditor.

5.13.3               Store officer at the main store shall update the inventory records/registers at the main store based on the receiving and issuing which taking place on day-to-day basis.

5.13.4      Based on the balance inventory position store in-charge shall issue purchase requisitions with the concern of factory head and arrange the stock to be maintained in required level.

5.13.5      Mini store officer/needle controller shall follow the same way of working such as

-    Keep all intact needles safely under lock and key.

-    Keep only 01 – 02 packets of each needle in hand to be issued time to time.

-    Issue requisitions to the main store as necessary to get needles as per the daily consumption.

-    Update all particular registers and log sheets time to time following the procedure to be maintained.

-    Update all Mini Store Needle Management registers with correct details and maintain the needle inventory on daily basis.

-    Under any circumstance Store/Needle controller should not issue used needles, Used Cutting Knives or Button hole blades back to the production floor for any purpose.

-    All used needles and other sharp items must be disposed once in every 03 months under the permission and supervision of Factory management and Safety/compliance officers in a very safe manner. Proper records of each disposal must be maintained for minimum of 01-year period for further review.   

5.14           Kimble/ tag gun needle procedure

5.14.1       As like all other needles, this needle also must be issued from the needle counter.

5.14.2       In case of a new Kimble/tag gun, a needle must be issued against the new Kimble/tag gun requisition numbers and also its own identification number.

5.14.3       And when the Kimble gun is in use, every time when the needle gets old and loss it’s sharpness, the old needle has to be returned to the needle counter and the concern needle counter responsible will issue as per.

5.14.4       And in case of any needle breakage, the same broken needle procedure will be applied.

5.14.5       The concern must search the broken fragment with magnet, magnetic sweeper, hand held metal detector and finally they must gather all together and pass everything together in the conveyor type metal detector machine.

5.14.6       And after all this if still the broken fragment is not found, the concern must fill up broken needle format and taking all concern’s signature, submit to get new replacement needle.

5.14.7    And if the broken fragment is found, only the broken needle format must be filled and submit to get the replacement.

 

6.0                               Reference

6.1               New needle issue log

6.2               Used disposal needle log sheet

6.3               Application for new needle

6.4               Daily Needle issue summary

6.5               Monthly Consumption Report

6.6               Monthly missing needle fragment analysis report

6.7               Idle machine information

6.8               Mini store management register

6.9               Daily needle balance check report

6.10           Used needle stock and issue

 

7.0               Definition

 

8.0               Please follow the below flowchart for better understanding.