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Standard Operating Procedure of A Small Business

Standard Operating Procedure or SOP means is structured documentation that provides step-by-step guidelines and instructions on how to do a particular business activity, such as production or record keeping. We need SOP in a company with different operations in different areas.

Example of business operating procedure manual:

Standard operating procedures or SOP needs to develop as a structured documented office word or pdf file and manual printed copy for management approval. These procedures also need to approve by international verification companies like SGS, Intertek, Bureau Veritas, etc. The motto of developing a standard manual is to implement all standard procedures in every simple step in the factory or workplace. And finally, need to implement and follow all procedures written in the manual Company responsible personnel need to maintain all written SOP. SOP Auditor will verify all standard procedures are maintaining regarding policies and submit monthly or yearly reports to company top management. A standard procedures manual can change from time to time regarding the way of work system and supply chain. Today we will show you a written structured copy of the STANDARD OPERATING PROCEDURE SOP MANUAL of a small business. By this SOP manual copy, you can understand then how to create your own company written standard operating procedures step-by-step and a systematic way to implement and maintain this.

A Small Business Standard Operating Procedure

Document type: Standard operating procedure (pdf, office word)
Business Category: Manufacturing
Production type: Apparel and Fashion goods
Operating manual standard: International
Approve by: ISO
Area of implementation: Garment Sewing & finishing section operating manual

Index of SOP manual of Garment Sewing and Finishing:

Serial no.machine title
1 Vision statement3
2 Mission statement3
3 Policy statement3
4 Vision and latitude3
5 Organogram of Maintenance Department4
6 Working instructions of the Machine installation and production maintenance5-8
7 Different types of machine problem and corrective actions9-22
8 Standard work procedure23
8.1 Electrical equipment23-26
8.2 Generator26-29
8.3 Boiler29-33
8.4 Air conditioner 33-35
8.5 Compressor 35-36
8.6 Plumber36
8.7 Welder37
9 Immunological/Preventive Management38
9.1 Sewing machine38-52
9.2 Electrical equipment53-57
10 Job description58
10.1 Manager58
10.2 Assistant Manager58
10.3 Mechanics59
10.4 Mechanics In charge60
10.5 Senior Mechanics in charge61
10.6 Electrician 61-62
10.7 Generator operator62
10.8 Boiler operator62-63
10.9 Compressor operator63
10.10 Plumber 63-64
10.11 Welder64
Index of Course – A garment industry standard operating procedure
  1. Vision statement:

The garment industry has a friendly work environment, self-convinced workers, modern technology, and management authority promise to introduce as a dependable and best garments manufacturer. We are always concerned about betterment, growth up and expand our business for Buyers and Employers profit.

  1. Mission statement:

The garment industry is always committed to meet the Buyer’s requirements through gradual quality improvement, punctuality, and ethical materials pricing. We invest our Experts, Modern Machines and Materials to produce lofty products and fixed our mind to achieve our target very carefully.

Our quality system is established to achieve our goal. We have modern types of machinery, machine maintenance systems, and maintenance manuals. All maintenance policies, machines defect & proper solutions, generator, boiler maintenance system, preventive & corrective actions, and maintenance manuals are being described consecutively. 

  1. Maintenance policy:

A garment industry is committed to satisfy the buyer to produce qualified garments and gradual quality improvements.

  1. Vision and latitude:

The garment industry is always committed to meet buyers’ requirements. Maintenance Manual has a maintenance department and all other machine maintenance procedures which will help to meet buyer requirements through guaranteeing higher productivity and excellent quality.

Standard operating procedure (SOP) – Garment Industry

5. Organogram:
Here you need to attach your company organogram of your sewing and finishing department to identify each workspace to implement standard operating procedures.

Fig: Organogram model

6. Standard operating manual of Machine installation and production procedures:

6.1 Vision and latitude:

To maintain required quality and productivity with higher efficiency ensures the best result. To take preventive and corrective actions with creativity according to the root cause analysis. 

6.2 Responsibility:

Maintenance Manager is responsible for the whole department’s activities and Maintenance Supervisors are his coworkers. They are responsible for all corrective and preventive actions.

6.3 Procedures:

6.3.1 New machines installation procedure: 

6.3.1.1 Read the assembly instructions manual received from the supplier to familiarize the machine parts, table assembly instructions, belt installations, electrical wiring diagram etc.  

6.3.1.2 Initially check the defective parts and inform the relevant supplier.

6.3.1.3 Verify the functions of machine-like trimming, sensor tracking, machine class etc. is performing well or not. 

6.3.1.4 Numbering the machines according to the machine types and brands.

6.3.1.5 Machine brands, Production numbers, models, and machine types have to transcribe in Machine Registry.

6.3.2 Machines condition checking procedures:

6.3.2.1 Keep the machine’s records in every unit.

6.3.2.2 Keep records of the machines, excess machines, rental machines, receiving loan machines and   providing loan machines etc.

6.3.3 Pre-production preparation manual:

6.3.3.1 Maintenance Supervisor must present in Pre-Production meeting.

6.3.3.2 Maintenance Supervisor mentions the necessary attachments and folders in the pre-production meeting. The quantity and size of this folder must be noted in meeting minutes with signature.

6.3.3.3 If a sample room organizes any meeting without any sample, then Maintenance Supervisors can attend this meeting without signature in a meeting minute.

6.3.3.4 Maintenance Supervisor will check the correct folders and attachments after the pre-production meeting, separate the improper attachments and folders. Try to adjust the excess machines and inform the Maintenance Officer. 

6.3.3.5 Maintenance Officer must be informed by the Supervisor after the PP meeting if found insufficient folders and attachments. Maintenance Officer will make a requisition for the necessary folders and attachments through Managers direction.

6.3.3.6 If the Maintenance Supervisor is unable to understand the use of folders and attachments after the PP meeting, then they should take help from a sample room Technician. 

6.3.3.7 After the PP meeting, the Maintenance Supervisor notifies the Maintenance and Production officer about the insufficient machines found in line.

6.3.3.8 Maintenance Supervisor will attach the correct folder with the machine and use the correct elastic, fabric, piping etc. Then compare with the approved sample and make it clear to the Maintenance and Production officer. Maintenance and Production officers will issue the piping fabrics.

6.3.4 Production manual:

6.3.4.1 Machine operators will turn on the Red light due to random quality issues like puckering, thread breaking, skipping, oil spot, dirty spot etc. during the production period. Maintenance officers will be aware to see this Red light.

6.3.4.2 If need more time to repair the machine, then he will exchange it with another machine (depending on machine availability) to avoid production stoppage. He will inform his senior due to unavailability of an excess machine.

6.3.4.3 Maintenance officers will take help from their seniors if they are unable to meet the quality requirements. If unable to meet the quality, then he will take help from High officials (PM, GM, Technical Manager).

6.3.5 Layout: 

6.3.5.1 Production officers will provide the layout documents to the Maintenance Mechanics and Maintenance Mechanics will follow the layout directions to fix the right pressure foot and T-Guide.

6.3.5.2 Mechanics will manage the excess essential machines, bobbins, bobbin cases etc. during the layout period and deliver those items to the Line Supervisors. Line supervisors will hand over the excess machines bobbin, bobbin case, T-guide, needle etc. to the Mechanics and eliminate the machine from line.

6.3.5.3 Follow the machine operations manual carefully during machine layout.

6.3.5.4 Cleaning the needle plate, feed dog, pulley, pulley cover during layoff period.

6.3.6 General Maintenance: manual

6.3.6.1 Maintenance Manager will make a monthly time schedule for servicing manual and time limit.

6.3.6.2 Servicing record, service card and maintenance signature will be noted in the Service register.

6.3.7 Preventive maintenance procedures:

6.3.7.1 Maintenance Manager will provide a preventive maintenance time schedule for every three month having maintenance manual and time limit.

6.3.7.2 Maintenance time limit will depend on machine manufacturer recommendation and previous experience. 

6.3.7.3 Preventive Maintenance time schedule will be submitted by the Senior Manager and General Manager. All department heads will be informed about it.

6.3.7.4 Every machine’s preventive arrangement will be accomplished according to the preventive maintenance time schedule. Floor-in-charge (sewing) will not conduct any work with machines during that period.

6.3.7.5 Machines preventive maintenance job will be noted on machine card, machine registration book and care card.

6.3.8 Machine defects identification procedure:

6.3.8.1 Every worker will turn on the red light for defective machines during the production period and Maintenance Supervisors will notice the red light for urgent action. Sewing Supervisors tasks name, operator’s name, line number and machine stoppage time will be noted on Machine defects Register.

6.3.8.2 Maintenance Supervisor will send the Machine Defects register after verification. 

6.3.8.3 After machine adjustment, check the machines in running condition for proper verification. Machines defect description will be noted on register.

6.3.8.4 Maintenance Manager or Maintenance Head will receive the register every morning and they will keep all of that information.

7. Different types of machine defects and corrective actions procedures:

General problems of sewing machine:

Skip stitch removal manual:

Broken stitch removal manual:

Loose stitch removal manual:

Hard stitch removal manual:

Needle broken removal manual:

Feed Dog problem removal manual:

Body sharing/squeezing removal manual:

Body waving removal manual:

Auto machines problem: (reasons behind auto machine stoppage)

Servo Motor problems removal manual:

Power board problems removal manual:

Machine Synchronizer problem and corrective action procedures:

Lighting system in sewing floor for machines problem & solution:

There are two Mechanics lights (small lights) in every top of the sewing machine at every line of all floors. One light is green and the other is red. Every Red light is connected with Maintenance rooms nine light. Every sewing floor has nine lines which are connected with the Maintenance rooms nine light. One Maintenance light for one sewing line. If problems occur in a sewing machine at any line, then turn on a light in the Maintenance room. Machine operator will turn on the red light for machine problems and the operator will stop his/her operation (defective machine causes bad quality garments). A light is turned on in the Maintenance room due to the switch on the red light. Mechanics can understand sewing lines problems to see the light and he resolves the machine problem immediately.

Yellow light is only for the Supervisor to resolve the machine’s problem or for proper direction. Example: thread cut, needle problem, bad quality garments, cut panel problem, input problem etc. Supervisor will resolve those problems to see the green light. If he is unable to provide a solution, then he will inform Line Chief, PM, GM gradually.

Operation procedure of Metal Detector machine & broken needle handling in garments manufacturing:

Garment manufacturing is fully connected with sewing machines. Needles are a tiny part of sewing machines. Sometimes the needle is broken during the sewing operation and the broken parts of the needle are lost. Broken parts of the needle inside the garments are a critical issue and claim from the Buyer’s side is a compulsory matter for that issue. In that case, the operator must collect the broken needle parts to provide it to the Needle Operator. If he/she is unable to find all the broken needle parts, then use the magnet collected from the needle operator to find all the tiny needle parts. If he/she fails to find it, then she/he must return the magnet to the needle man. After that, he/she needs to collect the N.D.C-08 number form from Needle man and fill-up the form with the Supervisor’s signature. Then he/she will take all the garments from the table to the Metal Detector room and check out the garments properly with the signature of the N.D.M operator in N.D.C08 form. If the needle detector machine operator (N.D.M) found any broken needle inside any garments during checking, he (N.D.M) must keep those garments in a requisition box (never give those broken parts to the sewing operator). Without any needle parts inside the garments, the operator must take those garments in line and will start his/her work again.

  1. Cutting machines problem:

Description of cutting machines problem:

  1. Center knife problem

Causes:

Solutions:

  1. Knife supporter problem:

Causes:

Solution:

  1. Knife sliding problem:

Causes:

Solution:

  1. Sharpener shoe problem:

Causes:

Solutions:

  1. Sharpener shoe spring problem:

Causes:

Solutions:

  1. Spool gear problem:

Causes:

Solutions:

  1. Roll pin problem:

Causes:

Solutions:

  1. Front pulley problem:

Causes:

Solutions:

  1. Sliding pulley problem:

Causes:

Solutions:

  1. Knife sharpening problem:

Causes:

Solutions:

  1. Knife screw problem:

Causes:

Solutions:

Big/Special machineries problems and corrective actions:

Fusing machines problem:

Different types of problems found in fusing machines. These are given below:

  1. Incorrect temperature adjustment
  2. Incorrect pressure adjustment
  3. Incorrect speed adjustment
  4. Belt adjustment problem
  5. Moving roller adjustment problem
  6. Micro switch problem
  7. Output sharp roller problem
  8. Fusing temperature, pressure and fabrics are not delivered at the correct speed from roll.
  9. Power supply problem in-
  1.  Control sections problem in-

Solutions:

Metal detector machine:

Metal detector machine problems are given below:

  1. Garments passing problem
  2. Metals/broken needles are not detect properly
  3. Displaying limitless metal values

Causes:

Solutions:

Fusing machine:

Problems of fusing machine:

  1. Interlining or fusing fabrics/papers aren’t attached properly with base fabrics.
  2. Fabric shading occurs due to excess temperature

Causes:

Solutions:

Spreading machine:

Spreading machines problem:

  1. Normally round knife and bottom knife’s having problem
  2. Showing some error message
  3. Problem in power board

Causes:

Solutions:

Eyelet holing machine:

Eyelet machine problems: (during operation)

  1. Skip stitch
  2. Broken stitch
  3. Blunt needle head
  4. Broken spreader
  5. Broken looper
  6. Knife hammers problem

Causes:

Solutions:

8.1 maintenance system of electrical equipment: 

Daily operation procedure of Maintenance department:

Daily working procedure of Electrician about electricity supply, maintenance and protection-

  1. Electrician has to present his work station twenty minutes before the factory starts.
  2. Routine check-up of electric machine and materials in every floor
  1. Switch on the emergency I.P.S.
  2. Check all emergency lights and high beam flood lights working well or not.
  3. Check below issues of I.P.S. before turn into auto mode-
    1. Battery
    2. Water level
    3. Operation indicator lamp
  4. To confirm D.B. board routine check-up
    1. Clean up
    2. M.C.B & M.C.C.B
    3. Distribution connections follow up.
    4. Face detector
    5. Bus bar
    6. Distribution M.C.B switches off confirmation.
  1. Confirm the switch-on of main D.B’s M.C.C.B on each floor with proper observation of sparking and flashing voltage.
  2. Confirm the switch-on of every floor distribution M.C.B according to line wise before 10 minutes.
  1.  Every fan, light, sewing machine and M.C.B
  2. Official M.C.B
  3. A.C.
  4. Exhaust fan
  5. And others 
  1. Take approval of previous days all reports from Maintenance in Charge, Department Head and Maintenance Manager. Reports are-
    1.  Daily inspection and its solution
    2. Daily closing report
    3. Electric appliances weekly audit checklist
    4. Weekly D.B report and submit it after every three month
    5. Inform about the problem of electric repairing parts, tools, materials to the Maintenance In Charge & Department Head and to know about previous requirements
  2. Inspect all lights, sewing machines motor, LED, fan on every floor and make an instant solution.
  3. Inspect every electric iron correctly and to confirm its solution
  1. Security, awareness and emergency electrical appliances correct maintenance and proper corrective actions:
  1. Factory opening and closing:

Power on/ off manual of factory during opening and closing:

8.2 Generator maintenance system:

Generator maintenance manual-

  1. Vision: To confirm continuous electricity supply
  2. Latitude: Generator and related machineries, A garment industry.
  3. Responsible person: Generator operator
  1. Maintenance procedure (before generator starts):
    1. Generator operator has to present his work station 30 minutes before the flood starts.
    2. Firstly he has to check the generator switch is on/off.
    3. Check the generators radiator’s water level and indicators position.
    4. Check the generators lub oil level-

Generator lube oil amount will be checked with a Deep stick. Deep stick has measurement indication marks. Emerge the deep stick into the Lub oil container and check the status of Lub oil to see the surface oil of the stick. 340 litre Lube oil will be kept down the generator engine in a mentioned place. Full lub oil will be changed during the Maintenance period by means of changing 340 litre lube oil.

  1. Generator gas pressure checking-

Minimum gas pressure will be 2 PSI. For gas pressure checking, check the meter reading of Gas line.

  1. Generator air filter checking-

Oxygen is very much essential for ignition during the generator starting period. Generator takes this essential oxygen from the air. Air filters clean the air contamination like dust and dirt particles. Surface dirt/dust particle in air filter occurring jam. Check the air filter every day and observe the dust/dirt particles on the surface.  If dust/dirt particles are found, clean it by using a brush or Air blower.

  1. Generators battery voltage checking-

Check the generators Volt meter for 25-27 Volt. Make a proper solution if you find any problem or change the battery.

After the hundred percent confirmation of above checking-

  1. Maintenance procedure (after generator starts):
    1. Drive the generator at an idle and rated speed.

Drive the generator at 1100 rpm for full circulation of Lube oil after the generator starts. At that time, the generator didn’t supply any electricity. Generators idle speed found in that state. In that state electricity supply is confirmed with Diesel generators. Generator will run 3 to 5 min in that state.

After driving in the idle state, the generator will be run at rated speed. Then the Generator is run in 1500 rpm Rated speed. After that the generator starts to supply electricity when the temperature is 1450 to 1500 degree Fahrenheit. 

  1. Check the generators voltage and frequency in a corrective way.
    • Generator’s ideal voltage- 397 to 400 Volt
    • Generator’s ideal frequency- 48 to 50 Hertz
  2. Raise the generator temperature in 150 degree Fahrenheit 
    • Run the engine in unloaded condition to raise the temperature up to 150 degree Fahrenheit. 
  3. Check the generator’s cylinder temperature.
    • Ideal cylinder temperature- 500 to 650 degree Fahrenheit
  4. Switch on the Circuit breaker for electricity supply from the generator.
  5. Also switch on the L.T. breaker slowly.
  6. Then start the cooling tower pump and cooling fan.
    • Make sure that the cooling pump and cooling fan is working well after starts and is continuing the physical check on every half an hour later.
  7. Generator cleaning-
    • Clean the whole generator with Jhoot fabric and use an air compressor to clean where hand cleaning is not applicable.
  8. Check parameters of the generator every hour and write down the readings. 
  1. If there is any problem in Gas generator or insufficient supply of gases in Gas generator, start the Diesel generator instantly.
  2. Verbally informed to the Admin and Maintenance Manager during Diesel generator starting period.
  3. Collect and reserve diesel with contact with Admin.
    • Diesel required for emergency period- 1000 liter (for all time reservation)
    • Contract with Admin when 400 to 500 liter Diesel remains and makes a requisition for 1000 to 1200 liter Diesel. (Quoted by Mr. Mohammd Sattar, Head of Operation)
    • Daily Diesel and Gas report to the Maintenance Manager.
    • Check the reserve water level of the cooling tower house. Physically check the water level to see if the level is correct or not.
  4. Add 300 gram chemical (Bulab 7032) before water dosing in the tower house every morning.
    • Add a required amount of chemical into the generator cooling water house. The switch on the cooling house and start dosing.
  5. Add 50 gram chemical (Bulab 8012) every afternoon at 3.00pm into the water house.
  6. Add 500 gram chemical (Dioxide-8012) every afternoon at 3.30pm into the water house.

N.B.: slowly open the Blow down from morning to afternoon at 3.00pm

  1. Add 500 gram chemical (Bulab-6057) every Tuesday into the water house.
  2. Fully open the Blow down 1hr after chemical addition and fully close the Blow down 1hr after full opening. 

N.B.: above 24,25,26,27 and 28 no. procedures for keeping water well into the water house.

  1. Emergency generator room must be closed during Gas generator is running.
  2. Take gas reading and R.I.B. meter reading daily at 12.00pm.
  3. And after factory closing, turn off the factory electricity supply (unload electricity) and shutdown the generator.
  4. Finally, close the engine switch and gas bulb switch.
  5. Such information not required to maintain registry given below:
    • Parts registry
    • Lub oil registry
    • Chemical registry
    • Diesel collection registry
    • Schedule maintenance registry
    • Per day consumption registry
    • Diesel generator on-off registry
    • Work in holiday registry
    • Reading per hour registry
  6. Finally, lock the main door of the generator room and put down the key in the main gate.
  7. Preventive Maintenance of Gas generator will be done on an every 1000 hour later and for Diesel generator on an every 250 hour later.
  8. Overhauling will occur every 20000 to 22000 hour later.

8.3 Boiler Maintenance manual:
A garment industry has two type of boiler

1. 640 KG Boiler (HERTZ BOILER): Registration Number-BA:B:5374

2. 500 KG Boiler (Modern Erection Limited): Registration number-BA:B:3853

Vision: Continuous steam supply in sewing floor.

Latitude: A garment industry’s Boiler section

Responsible person: Boiler operator

Operation manual:

  1. Responsible operator has to present his work station 15 minutes before the flood starts.
  2. Clean the boiler, blower, and Gas filter, water Steiner, Deposer and ignition rod.
    • Blower net
      • Clean the usable boiler with steel brush and air.
    • Gas filter
      • Clean with round brush and air
    • Water stunner
      • Clean with WD 40 spray and brush
    • Deposer
      • Clean with series paper and brush
    • Ignition rod
      • Clean with series paper
  3. Identify the water lines non-return bulb and water stunner is working well or not.
    • Observe the pressure meter for water pressure is not less than 5kg in the water line and not more than 6.5 kg. If water pressure is not within tolerance then take necessary actions.

Necessary steps for water pressure out of tolerance are given below:

  1. Check the gas line Ball bulb, Gas Steiner, Gas pressure gauge, Gas regulator etc. for working well or not.
    • Justify the gas pressure is between 10 to 12 PSI with proper checking.
    • Check the electric voltage is between 210V-220V and 420V-440V (in applicable areas only) with Analog Volt meter.
  2. Check the Circuit board in boiler room according to the below procedure:
    • Check whether the auto circuit is working or not.
    • Check the right voltage supply in every circuit face (210v-220v and 420v-440v in some cases).
  3. Make it sure that 1/3 is air and 2/3 is water in water gas level before the boiler starts.
  4. Confirm the above issues and run the boiler in below procedures.
  5. Make it sure that the gases 2/3 is water and 1/3 is steam during the boiler running period.
  6. All switch and bulb will be turn on according to the below serial:
    • Gas main bulb and gas pilot main bulb.
    • Feed water pump main bulb
    • Main circuit breaker switch in D.B board
    • Circuit breakers switch in the boiler room.
    • Turn on the boiler panel board.
    • Turn on the feed pump switch.
    • Turn on the blower switch
    • Steam distribution main bulb.
  7. Checkout the steam and firing inside the boiler is correct or not and check it at the first time of starting period.

Check point-

  1. Turn on the steam header bulb five minutes before the floor starts and proper steam supply into the floor.
  2. Justify the water level, Gas pressure and electric voltage on every 10 minutes while the boiler is running.
  3. Justify the water softness according to the below procedure:
    • Water hardness checking procedure:

Check water hardness with a Hardness test tablet.

Check frequency: depends on production. Water check is begun again three days after Salt wash. After hardness checking, salt wash will begin.

640 kg Boiler: Washing Recipe given below-

Salt=35 kg

Water=150 Liter

Time=90 min

Procedure: Add 35kg salt with 150kg water and input it in the soft inner correctly for proper washing. Required time is 90 min.

500kg boiler:  Washing Recipe given below-

Salt=15kg

Water=70 Liter

Time=90 min

Procedure: as like the previous 640kg boiler procedure.

  1. Add 300ml water liquid chemical Bulab-9742 into the feed tank daily at 9.30am to 10.00am for maintaining the quality of water.

To calculate the monthly used gases amount, get regular reading from 9.45am to 10.30 am and accumulate all monthly readings to find out total uses of gas. Total reading will differentiate with previous months reading to find out the discrepancy and reporting accordingly.

  1. Cold water reading memo:

To calculate the monthly used water amount, get regular reading from 9.30am to 10.00 am and accumulate all monthly readings to find out total uses of water. Total reading will differentiate with previous months reading to find out the discrepancy and reporting accordingly

  1. Condense water house checking and cleaning:

Check the working condition of the condensed water hose and clean it properly. Also check the leakages, pressures, safety issues and pump for working well or not.

  1. Check the boiler steam pressure and temperature at every time during the starting period and inform the Maintenance Manager for any type of problem.

500kg boiler-

Steam pressure=60-70 PSI

Temperature=1400-1500 degree Celsius 

600kg boiler-

Steam pressure=70-80 PSI

Temperature=1500-1600 degree Celsius

  1. Boiler blowdown water T.D.S. and P.H. check:

T.D.S. (Total dissolved solid): keep the T.D.S. value will be within 2500-3500. Test T.D.S. through a TDS meter or send it to the lab.

P.H. (Pusan Hardness): keep the P.H. value within 7-8. Test P.H. value using P.H. paper.

If TDS and PH value isn’t correct then change the softener wash and Bulab-9742 chemicals amount for corrective actions.

  1. Check the boiler feed water temperature which ranges from 500-600 degree Celsius. If temperature isn’t within limit, then find out the problem for a proper solution.

Temperature correction: Boiler feed water temperature will be counted with a Temperature counting machine (Thermometer). Keep the temperature within 500-600 degree Celsius confirming with the mixture of condense tank water, steam and softener soft water.

  1. Indicate the sound of a boiler , water pump, blower and firing sound to find out its abnormality. Shutdown the boiler for any abnormal case.
  2. Boiler weekly, monthly, six monthly and yearly servicing will be completed within correct time.
  3. Confirm about the closing time of every unit and turn off the Header bulb five minute before closing.
  4. Boiler main gas bulb, water bulb, steam vulb, electric circuit will be turned off after factory closing.
  5. If two floors are being idle then one boiler will be turned off with Blow down and washing. Close the gas line, electricity line, water line, and steam line correctly.
  6. Shutdown the Boiler room’s doors, windows correctly and leave that workplace with a card punch. 
  7. Modern Erection the boiler supplier will provide their service every two month later.

8.4 Air Conditioner Maintenance manual:

Responsible Technician has to present his workstation 10-15 minutes before the office starts. 

Check the noticeable places in the air conditioner like Panel boards, Dyeing lab, Q.C lab, knitting collar, chemical store and administration office etc. 

Checking procedure:

  1. Ampere checking: 
    • Check the ampere with AVO Clamp meter.
  2. Air filter cleaning:
    • Open the front cover of AC’s indoor unit for air filter and fence cleaning.
  3. Air cooling checking:
    • Physical checking of air cooling using by hand feels in front of an indoor unit and ampere.
    • Split AC-Gas meter and AVO clamp ampere meter for cooling check and Ampere meter for amperage check.
  4. AC schedule servicing:
    • Clean the indoor front cover, air filter and fence
    • Clean Outdoor units like air line and air filters with using water if having too much dirt.
    •  For too much dust in the indoor unit, lock the indoor unit gas line. Then take it to the Maintenance Department for clean air and water. Again attach the indoor unit and check joint leakages slowly opening the gas line. For any leakage repairing is required. Otherwise recharge required gases for starting AC. Finally check the ampere and gas pressure.

Major problems of AC:

AC’s major problems are-

  1. Steiner filter block
  2. Capillary block
  3. Compressor change

Solutions given below:

  1. Steiner filter block:

Due to the Steiner filter block, the gas meter shows zero reading. Hold down the gas meter for a certain time to understand the filter blockage because gas pressure is increasing gradually. Firstly I need to release the gases from the Steiner filter and take it to the outdoor shop. Then wash the pipe line of the Steiner filter with Octane or air pressure after opening the pipe line from the filter by welding. After attachment, turn off the suction and discharge line in the outdoor unit. Then check the leakages in every joint area with sufficient air pressure. For any leakages, need to be repaired. Otherwise release the air pressure to make it vacuum. Then set up an outdoor unit and again check the leakage in the suction and discharge joint with air pressure. Repairing needed for any leakage. Otherwise recharge gases in vacuum. Then turn on the AC with Ampere and Gas pressure checking.

  1. Capillary block problem:

Capillary tube is a narrow pipe that circulates a certain amount of gases at a required speed. Compressors oil or dust creates blocks into the tube. In that case, open the tube by gas welding. Then clean the tube by air pressure or Octane and attach the tube in the required place. Finally set the outdoor unit and check the AC in running condition.

  1. Compressor change: 

Firstly, open the outdoor unit to check AC without gas pressure. If AC isn’t running, then open the compressor by gas welding and cleaning out the pipe. After that attach a new compressor and a new Steiner filter. Then attach an outdoor unit with necessary checking. Finally check AC with required gas pressure.

  1. Oil from discharge line:

Sometimes oil came out from the discharge pipe. Gas flow is required to clean the discharge pipe and attach it in the right place. Finally check AC in running condition.

On the other hand, indoor and outdoor board, fan and capacitor problems can occur. Due to these problems, repairing or changing is required.

AC gas pressure:

60-65 PSI gas pressure is required during running. Gas pressure depends on AC’s Ampere consumption.

Ton Ampere 
19-10
1.511-12
213-14
2.515-17
Table: Gas pressure

8.5 Compressor maintenance manual:

Responsible person: Compressor operator

Reporting person: Maintenance Manager

Procedure:

  1. Attend the office 15 minutes before it starts.
  2. Required parts to clean-
    1. Air filter
    2. Air cooler
    3. All machine
  3. Turn on the compressor and dryer 10 minutes before the office starts and fill up the reserve tank.
  4. Then open the bulb for air supply according to necessary.
  5. There are three compressors and turn on according to requirements.
  6. Compressor air pressure is using in-
    1. Sewing lines auto machine
    2. Spot cleaning
    3. Printing
    4. Fusing machine
    5. Finishing
  7. During lunch period, stop air supply in non-required places and start it after lunch period in required places.
  8. Daily cleaning the air filters with an air blower.
  9. Necessary maintenance procedures continue within schedule time.
  10. Turning off all machines, vulbs, dyer etc. before leave.

8.6 Plumbers working procedures:

Responsible person: Plumber

Work description:

  1. Attend office due time in the morning.  
    • Firstly, open main water line
    • Then others individual lines
  2. Turn on the necessary pumps and turn off unnecessary pumps.
  3. Checkout the bulb in the fire water pump.
  4. Then every kind of pipe fitting.
  5. Then repair the water line bulb, tape, basin line, shower line etc. if required.
  6. Plumber will do everything for pipeline maintenance.
  7. Also steam pipe line repairing and new steam pipe line set up.
  8. And fire water line repair and new line set up.
  9. That is to say, Plumber will do everything repairing related to the pipeline.
  10. Turning off all machines, motor switches, bulbs etc. before leaving.

8.6 Welders working manual:

Responsible person: Welder

Reporting person: Maintenance Manager

Work description:

  1. Always need to maintain office entry time in the morning.
  2. Welder will do everything related to welding.
  3. Welder will do welding related to every maintenance according to the time schedule.
  4. Repair and make small sized doors and windows.
  5. Machines stand welding.
  6. Contraction related welding.
  7. Boiler pipe line welding.
  8. Gas pipeline welding.
  9. Air pipe line welding.
  10. Hanger stands making and repairing.
  11. Table making
  12. Box making
  13. Partition making etc.

9.0 Preventive Management

9.1 Preventive maintenance (Sewing machine):

General servicing:

Machines nameCheck listResponsible person
Plain machineOverlock machineBar tack machineKansai special machineTwo needle overlock machineFeed of the arm machinePocket welting machineSaddle stitch machinePicoting machineSmoking machineBlind stitch machineRib cutting machineButton hole machineVelcro attach machineLoop making machineFlat lock machineEyelet hole machineZigzag machineBack tape machineWaist tag machineSnap button machineFusing machineThread sucking machineOils pump and pipeOil return pipe, oil plug and oil sealNeedle guard and eye safety guardThread and machine standMachine pulley & belt coverPaddle operationRed point oilingBase area oiling & greasingMotor cleanOil replacementThread tension releaser pin and thread tape up springRotary hook timingThread trimming systemWeeper system check Control box & machine loose wirePaddle rubber matNeedle bar & bar BoseBobbin winderVacuum systemShuttle hook timingNeedle and looper timingMouth coverMachine wheel and table topMachine post and super tension postService log card checkAssistant MechanicsMechanicsHelper
Table: Garment sewing machine maintenance

Preventive Maintenance (Sewing machine):

  1. Preventive Maintenance frequency of sewing machine according to time schedule given below:
    1. Knit-1: Daily 8 pcs machine maintenance and 50 days for total floors machine maintenance.
    2. Knit-2: Daily 8 pcs machine maintenance and 51 days for total floors machine maintenance.
    3. Knit-3: Daily 8 pcs machine maintenance and 50 days for total floors machine maintenance.
    4. Woven: Daily 12 pcs machine maintenance and 50 days for total floors machine maintenance.
  1. Special machine maintenance on an every one month later:
Serial No.Machine nameCheck listResponsible person
1Plain machineOil pump and oil pump lineOil return pipe, oil plug and oil sealThread tension releaser pin and thread tape up springRotary hook timingThread trimming systemWeeper system check Control box & machine loose wireNeedle guard eye safety guardMachine pulley coverPaddle rubber matThread standMachine standNeedle bar and needle bar BoseBobbin winderMachine wheel and table topTension post and super tension postService log card check-Line Maintenance-Maintenance in Charge
Table: Garment special machine maintenance
Serial No.Machine nameCheck listResponsible person
2Overlock machineOil pump and oil pump lineOil return pipe, oil plug and oil sealThread trimming systemControl box & machine loose wireNeedle guard eye safety guardMachine pulley coverMotor pulley coverPaddle rubber matThread standMachine standNeedle bar and needle bar BoseVacuum systemMachine wheel and table topTension post and super tension postService log card check-Line Maintenance-Maintenance in Charge
3Bar tack machineOil pump and oil pump lineOil return pipe, oil plug and oil sealThread tension releaser pin and thread tape up springThread trimming systemWeeper system checkControl box & machine loose wireNeedle guard eye safety guardMachine pulley coverMotor pulley coverPaddle rubber matThread standMachine standNeedle bar and needle bar BoseBobbin winderMouth coverShuttle hook timingMachine wheel and table topTension post and super tension postService log card check-Line Maintenance-Maintenance in Charge
Table: sewing machine maintenance
Serial No.Machine nameCheck listResponsible person
4Kansai special machineOil pump and oil pump lineOil return pipe, oil plug and oil sealThread tension releaser pin and thread tape up springControl box & machine loose wireNeedle guard eye safety guardMachine pulley coverMotor pulley coverPaddle rubber matThread standMachine standNeedle bar and needle bar BoseMachine wheel and table topTension post and super tension postService log card check-Line Maintenance-Maintenance in Charge
5Two needle lockstitch machineOil pump and oil pump lineOil return pipe, oil plug and oil sealThread tension releaser pin and thread tape up springRotary hook timingThread trimming systemWeeper system checkControl box & machine loose wireNeedle guard eye safety guardMachine pulley coverMotor pulley coverPaddle rubber matThread standMachine standNeedle bar and needle bar BoseBobbin winderMachine wheel and table topTension post and super tension postService log card check-Line Maintenance-Maintenance in Charge
Table: Garment lock-stitch sewing machine maintenance
Serial No.Machine nameCheck listResponsible person
6Two needle chain stitch machineOil pump and oil pump lineOil return pipe, oil plug and oil sealThread tension releaser pin and thread tape up springControl box & machine loose wireNeedle guard eye safety guardMachine pulley coverMotor pulley coverPaddle rubber matThread standMachine standNeedle bar and needle bar BoseMachine wheel and table topTension post and super tension postService log card check-Line Maintenance-Maintenance in Charge
7Feed of the arm machineOil pump and oil pump lineOil return pipe, oil plug and oil sealThread tension releaser pin and thread tape up springControl box & machine loose wireNeedle guard eye safety guardMachine pulley coverMotor pulley coverPaddle rubber matThread standMachine standNeedle bar and needle bar BoseMachine wheel and table topTension post and super tension postService log card check-Line Maintenance-Maintenance in Charge
Table: Garment chain-stitch sewing machine maintenance
Serial No.Machine nameCheck listResponsible person
8Pocket welting machineOil pump and oil pump lineOil return pipe, oil plug and oil sealThread tension releaser pin and thread tape up springRotary hook timingThread timing systemWeeper system checkControl box & machine loose wireNeedle guard eye safety guardMachine pulley coverPaddle rubber matThread standMachine standNeedle bar and needle bar BoseBobbin winderVacuum systemMachine wheel and table topTension post and super tension postService log card check-Line Maintenance-Maintenance in Charge
9Saddle stitch machineOil pump and oil pump lineOil return pipe, oil plug and oil sealThread tension releaser pin and thread tape up springControl box & machine loose wireNeedle guard eye safety guardMachine pulley coverPaddle rubber matThread standMachine standNeedle bar and needle bar BoseBobbin winderMachine wheel and table topTension post and super tension postService log card check-Line Maintenance-Maintenance in Charge
Table: Garment saddle stitch sewing machine maintenance
Serial No.Machine nameCheck listResponsible person
10Picoting  machineOil pump and oil pump lineOil return pipe, oil plug and oil sealThread tension releaser pin and thread tape up springControl box & machine loose wireNeedle guard eye safety guardMachine pulley coverPaddle rubber matThread standMachine standNeedle bar and needle bar BoseMachine wheel and table topTension post and super tension postService log card check-Line Maintenance-Maintenance in Charge
11Smoking  machineOil pump and oil pump lineOil return pipe, oil plug and oil sealThread tension releaser pin and thread tape up springControl box & machine loose wireNeedle guard eye safety guardMachine pulley coverMotor pulley coverPaddle rubber matThread standMachine standNeedle bar and needle bar BoseMachine wheel and table topTension post and super tension postService log card check-Line Maintenance-Maintenance in Charge
Serial No.Machine nameCheck listResponsible person
12Blind stitch machineOil pump and oil pump lineOil return pipe, oil plug and oil sealThread tension releaser pin and thread tape up springControl box & machine loose wireNeedle guard eye safety guardMachine pulley coverMotor pulley coverPaddle rubber matThread standMachine standNeedle bar and needle bar BoseMachine wheel and table topTension post and super tension postService log card check-Line Maintenance-Maintenance in Charge
13Rib cutting machineControl box & machine loose wireNeedle guard eye safety guardMachine pulley coverMotor pulley coverPaddle rubber matThread standMachine standService log card check-Line Maintenance-Maintenance in Charge
15Button hole machineOil pump and oil pump lineOil return pipe, oil plug and oil sealThread tension releaser pin and thread take-up springRotary hook timingThread timing systemWeeper system checkControl box & machine loose wireNeedle guard eye safety guard Thread standMachine standNeedle bar and needle bar Bose-Line Maintenance-Maintenance in Charge
Serial No.Machine nameCheck listResponsible person
Thread standMachine standNeedle bar and needle bar BoseBobbin winderMouth coverMachine wheel and table topTension post and super tension postService log card check
15Velcro attaching machineOil pump and oil pump lineOil return pipe, oil plug and oil sealThread tension releaser pin and thread tape up springThread timing systemWeeper system checkControl box & machine loose wireNeedle guard eye safety guardMachine pulley coverMotor pulley coverPaddle rubber matThread standMachine standNeedle bar and needle bar BoseBobbin winderMachine wheel and table topTension post and super tension postService log card check-Line Maintenance-Maintenance in Charge
16Loop making machineOil pump and oil pump lineOil return pipe, oil plug and oil sealThread tension releaser pin and thread tape up springControl box & machine loose wireNeedle guard eye safety guardMachine pulley coverMotor pulley coverPaddle rubber matThread stand-Line Maintenance-Maintenance in Charge
Serial No.Machine nameCheck listResponsible person
Machine standNeedle bar and needle bar BoseMachine wheel and table topTension post and super tension postService log card check
17Flat lockmachineOil pump and oil pump lineOil return pipe, oil plug and oil sealThread tension releaser pin and thread tape up springThread timing systemWeeper system checkControl box & machine loose wireNeedle guard Eye safety guardMachine pulley coverMotor pulley coverPaddle rubber matThread standMachine standNeedle bar and needle bar BoseBobbin winderMachine wheel and table topTension post and super tension postService log card check-Line Maintenance-Maintenance in Charge
18Eyelet hole  machineOil pump and oil pump lineOil return pipe, oil plug and oil sealThread tension releaser pin and thread tape up springLooper and spider timingThread timing systemWeeper system checkControl box & machine loose wireNeedle guard Eye safety guardMachine pulley coverMotor pulley coverPaddle rubber matThread stand-Line Maintenance-Maintenance in Charge
Table: Garment sewing machine maintenance
Serial No.Machine nameCheck listResponsible person
Machine standNeedle bar and needle bar BoseBobbin winderMachine wheel and table topTension post and super tension postService log card check
19Zigzag machineOil pump and oil pump lineOil return pipe, oil plug and oil sealThread tension releaser pin and thread tape up springRotary hook timingThread timing systemWeeper system checkControl box & machine loose wireNeedle guard Eye safety guardMachine pulley coverMotor pulley coverPaddle rubber matThread stand Machine standNeedle bar and needle bar BoseBobbin winderMachine wheel and table topTension post and super tension postService log card check-Line Maintenance-Maintenance in Charge
20Back tape machineOil pump and oil pump lineOil return pipe, oil plug and oil sealThread tension releaser pin and thread tape up springRotary hook timingThread timing systemWeeper system checkControl box & machine loose wireNeedle guard Eye safety guardMachine pulley coverMotor pulley cover-Line Maintenance-Maintenance in Charge
Serial No.Machine nameCheck listResponsible person
Paddle rubber matThread stand Machine standNeedle bar and needle bar BoseBobbin winderMouth coverMachine wheel and table topTension post and super tension postService log card check
22Snap button machineControl box & machine loose wireNeedle guard Eye safety guardMachine pulley coverMotor pulley coverPaddle rubber matThread stand Machine standVacuum systemMachine wheel and table topService log card check-Line Maintenance-Maintenance in Charge
23Fusing machineRed point welding and pinion greasingControl box & machine loose wireMachine side coverMotor coverPaddle rubber matThread standMachine standVacuum systemMachine wheelBelt check of up and downService log card check-Line Maintenance-Maintenance in Charge
24Thread sucking machineControl box & machine loose wireMachine side coverMotor coverPaddle rubber matMachine standMachine wheelService log card check-Line Maintenance-Maintenance in Charge
Table: Garment button attaching machine maintenance

A garment industry

Machine Log card and Machine S.O.P.

Regular correction and Preventive management Report

Unit:                             A garment industry                              M.N.T.: 05       Date:

Corrective ManagementPreventive Management
DateMachine NameMachine Serial NumberServicing descriptionSpare partsNext servicing dateServiced byremarks
Table: sewing machine maintenance table-corective and preventive maintenance

Maintenance in Charge               Maintenance Manager                 Production Manager

Special machines monthly correction and Preventive Management:

A garment industry

Preventive and corrective work procedure: Machine Maintenance Report

Servicing numberMachine nameMachine serial numberCorrective work procedurePreventive management
Table: sewing machine maintenance table-corective and preventive maintenance

Preventive Maintenance (Electrical Department)    

     Weekly machine audit report

  A garment industry

     Electrical appliances-Weekly audit checklist

Unit:                                                                                                                                                                                                 Date: 

Serial No.Audit pointLine-1/–Line-2/–Line-3/–Line-4/–Line-5/–Line-6/–Line-7/–Line-8/–Line-9/–Office/store/othersFinishing/sampleRemarks 
correctincorrectcorrectincorrectcorrectincorrectcorrectincorrectcorrectincorrectcorrectincorrectcorrectincorrectcorrectincorrectcorrectincorrectcorrectincorrectcorrectincorrect
1Fan sound/hook
2Fan blade E/L point
3Machine motor switch
4Machine motor switch
5Machine LED light
6All C.B. ux checked
7All speaker checked
8Main line cable tray
9E. sub D.B
10E. main D.B
11All E. channel
12All tube light
13Finishing iron/line
14Vacuum table/line
15All fire alarm/switch
16M.E. Ambulance light
17IPS and line
18Emergency light
19All exhaust fan
20All exit light
21All sodium light
22Yellow bulb
23Energy saving light
24Halogen light
25Others all E-point
26All E.A. cleanness
27All center table
Table: Electrical appliance checklist table

Checked by                    Electric in charge             Assistant Engineer             Maintenance Manager             G.M. Production           G.M. Admin

A garment industry

Monthly Maintenance Audit Checklist

Unit:                                                                                                                                                                                                                      date:

Serial No.Audit pointMachine nameRemarks
Local SL. No.
1Super tension post
2Thread take-up spring
3Thread take-up needle bar cap
4Bobbin tension (Bobbin case)
5Needle guard
6Eye guard
7Machine pulley cover
8Motor pulley cover
9Rubber mat
10Thread stand
11Bobbin winder
12Physical machine stand
13Oil check and oil pump
14Machine loose wire/switch
15Machine wheel
16Table top
17Service card check
18Panel board and wiring condition
19Vacuum system
20Air leakage
21
22
23
24
Table: Monthly maintenance audit checklist

9.2 Electric supply accuracy assessment manual:

  1. Every floors electricity supply level follow up procedure:
  1. Correct electricity supply level assurance routine:
    • Electricity checkout on an every one hour later
    • Voltage, ampere, hertz, kilowatt and k.v.a. rating check.
  2. Standard electricity supply level grading:
    • For three face: 880 volt, 50 hertz
    • For single face: 220 volt, 50 hertz
  3. Required steps to be taken due to incorrect supply of electricity (if differences between ideal electricity value and getting electricity value):

Reasons for electricity supply level fluctuation and necessary steps 

Reasons behind electricity fluctuation Necessary steps to be taken
Over voltageTo control electric voltage and hertz in the control board ensuring correct electricity supply from the generator.
If the electricity supplier is R.I.B., then inform the responsible authority of R.I.B. for any electric fluctuation problem.
Low voltage
Over frequency 
Low frequency
Table: Electricity level fluctuation causes in garment industry

Electrical equipment- Distribution board

  1. Any type of material kept in front of D.B. board is fully prohibited. 
  2. Rubber Mat must be used to stand in front of D.B. board.
  3. Keep a fire extinguisher (Carbon dioxide type) near about D.B. board.
  4. Keep circuit diagram on top of D.B. board.
  5. Keep a checklist on top of D.B. board. 
  6. Keep a smoke detector on top of or beside D.B. board.
  7. Keep hand gloves (fabric/plastic made) beside the D.B. board.
  8. Ensure sufficient air and light supply 
  9. Always keep Earth-in of D.B. board
  10. Excess load onto D.B. board is fully avoided.
  11. Every cable of D.B. board must be cable locked.
  12. Attach Probonite sheet onto the D.B. boards switch. It will help to stop sparks from coming outside. 
  13. Keep an urgent telephone number beside D.B. board.
  14. Keep numbering in every D.B. board.
  1.  Job description:

10.1/2 Maintenance Manager/Assistant Manager:

Main responsibilities:

  1. Keep proper maintenance and workable condition for every machine. 
  2. Take preventive actions for mechanical faults. For major problems, immediately inform the Maintenance Manager for a proper solution.
  3. Every 30 minutes later, clean every machine using vacuum and ensure proper oiling. 
  4. PM/Line Chief/Supervisor will ensure to provide machine layout. After layout, they will adjust every machine with workable condition.
  5. Ensure Machine needle, necessary folder, attachments and other necessary mechanical part with feed mechanism for proper use.
  6. Adjust proper thread tension. Regular checking of needle plate, rotary hook, looper and safety guard and take proper steps if required.
  7. Deposit every broken part or broken needle into the store during the machine repair period and ensure to collect new spare parts.
  8. Ensure proper register maintaining of machine repair, maintenance and inspection records.
  9. Turn off every electrical switch and machinery after the end of the day and before leaving from the factory.
  10. Proper maintain every rules and regulations provided by HR and compliance.
  11. Properly complete everything important whatever needed by top management.
  1. Mechanics responsibility:

Job description of Mechanics:

  1. Mechanics will be present in the office regularly 15 minutes before work starts.
  2. Check every machine’s oil leakage in every line.

Quality people will check every sewing machine’s oil paper for reporting and submit it to the Mechanics in Charge. Mechanics will take proper decisions according to requirements.

  1. Collect machine numbers which have oil leakage problems.

Make Machine Maintenance Report Q.A.-1 for proper reporting.

  1. Properly clean oil leakage machine.

After proper reporting from quality people, Mechanics will go to the defective machine and repair it properly. If the problem isn’t removed, then discuss with Mechanics in Charge/ Mechanics Manager and replace the machine with a new one.

  1. Acquire proper knowledge about all machines of every line.
  2. Discuss about machines with Mechanics in Charge for the new layout.
  3. Take proper steps for new jobs folder guide.

Folder guide is stored in Maintenance room. Otherwise collect it from others’ floors. If not found on others ‘ floors, make a requisition to buy it from the market.

  1. Checkout rejection garments every hour.

QI and QC will check product quality and inform Mechanics if any problem is found. Sometimes Mechanics will check output products for ensuring good quality.

  1. Inspect first complete garments from the new layout and check for any kind of defects.
  2. Take necessary steps if required.

After machine rectification, Mechanics will check output garments again for quality is ok or not. If ok, production will run again. Otherwise, take necessary steps to change the defective machine.

  1. For complex machine problems during the production period, change that machine if repairing isn’t possible on an urgent basis.
  2. For broken parts or other problems during production, inform Mechanics in Charge to change it and keep production running.
  1. Responsibility of Mechanics in Charge:

Job description of Mechanics in Charge:

  1. Check sewing machine oil paper every morning.

Quality people will check every sewing machine’s oil paper for reporting and submit it to the Mechanics in Charge. Mechanics will take proper decisions according to requirements.

  1. Take corrective action to clean oil leakage machines.

After proper reporting from quality people, Mechanics will go to the defective machine and repair it properly. If the problem isn’t removed, then discuss with Mechanics in Charge/ Mechanics Manager and replace the machine with a new one.

  1. After cleaning, make a proper report of oil leakage machines.

Make Machine Maintenance Report Q.A.-1 for proper reporting.

  1. Acquire proper knowledge about all machines of every line.
  2. Get proper information about new line layout required or not on the floor.
  3. Manage all machines for new line layout according to requirements.

Mechanics in Charge will stay in line until new line layout completion. IE will provide machine requirements to the Mechanics in Charge during new layout and Mechanics in Charge will manage those required machines (from idle machine, others line machine or others floors machine).

  1. Collect folder guide for new layout.

Folder guide is stored in Maintenance room. Otherwise collect it from others’ floors. If not found on others ‘ floors, make a requisition to buy it from the market.

  1. Check hourly requisition paper during production period.

QI and QC will check product quality and inform him if any problem is found. Sometimes he will check output products for ensuring good quality.

  1. Take proper necessary steps for a rejected body.

After machine rectification, he will check output garments again for quality is ok or not. If ok, production will run again. Otherwise, take necessary steps to change the defective machine.

  1. For complex machine problems during the production period, he will change that machine if repairing isn’t possible on an urgent basis.
  2. For broken parts or other problems during production, Mechanics in Charge will collect new parts through requisition in store and return the damaged parts into store.
  3. Spare parts will be noted in the register.
  1. Responsibilities of Senior Mechanics in Charge:

Main responsibilities:

  1. Make a proper solution of all types of necessary defective machines in all floors. If Mechanics and Mechanics in Charge are unable to make a proper solution, then they will come to the Sr. Mechanics in Charge for a proper solution.
  2. All cutting machine repairs.

Repairable machines in cutting section: straight knife cutter, Bend knife cutter, Round knife cutter etc.  Due to the problem of those machines, the cutting section will inform the Senior in Charge and he will try to make a proper solution.

  1. Monthly registers will be noted after cutting machine repair.
  2. Every type of finishing machine repair.
  3. And he will calibrate the Metal Detector machine according to buyer requirements.

Machine calibration depends on garments type-

For woven and heavy knit garments, test card signal will be 1.2mm

For lite woven and knit garments, test card signal will be 1.0mm

  1. He will check the supplier calibration format date of the metal detector machine.
  2. For the registered supplier calibration expired date, he will inform the supplier.
  3. Repairing waist tag pin machine.
  4. He will help to change the type of machine attachment in any floor during the new layout.
  5. He will make requisition for any spare parts in the factory.
  6. He will contact the head office purchase department for using spare parts.
  7. Spare samples sent to the head office if required.
  8. He will maintain the machine’s delivery register.
  9. And he will maintain the machine’s incoming register too.

10.6 Responsibilities of Electrician: 

Main responsibilities:

  1. Electricians will ensure a smooth, continuous and safe electricity supply. He will manage proper lightness in all units.
  2. He will check all electric connections, control board cables, circuit breakers, compressor machines, generators, water pumps, electric alarms, cutting machines, electric bulbs, fans, air conditioners, exhaust fans, emergency lights etc. regularly. And he will take immediate actions if any problem occurs. 
  3. He will accomplish open or hanging cable fittings and will check machines plug, sockets etc. He will be clipping all hanging wires properly.
  4. He will turn on all lights/ fans during factory starts in the morning and turn off unnecessary fans/lights during lunch or closing period.
  5. He will maintain routine wise servicing for machineries/generators and will maintain a register for record.
  6. He must abide Buyers compliances and companies all rules and regulations.
  7. He is also responsible for doing others’ jobs whatever top Management needs.
  1. Responsibilities of Generator Operator:

Main responsibilities:

  1. Generator operator is responsible to turn on/off the generator within the proper period for ensuring proper electricity supply into the factory.
  2. He will stock the necessary fuel for the generator (Diesel/Oil).
  3. Regular service and log sheet maintaining.
  4. Operation record maintaining.
  5. Generator cleaning.
  6. Proper generator maintenance and keep inspection records and maintain a register.
  7. He must abide Buyers compliances and companies all rules and regulations.
  8. He is also responsible for doing others’ jobs whatever top Management needs.
  1. Responsibilities of Boiler Operator:

Main responsibilities:

  1. Regular boiler turns on/off for ensuring proper steam supply into the floor.
  2. He will ensure to supply soft water in the boiler (using a soft inner water to make soft water from hard water).
  3. He will check the gas line, steam line, steam vulb, gas bulb, and water club regularly.
  4. Condense water system checking.
  5. Water hardness and PH checking for water quality controlling.
  6. He will maintain a boiler log sheet.
  7. He will ensure a timely blow down for every day.
  8. Boiler servicing.
  9. Boiler and inspection record/register maintenance.
  10. He must abide Buyers compliances and companies all rules and regulations.
  11. He is also responsible for doing other jobs whatever top Management needs.
  1. Responsibilities of compressor Operator:

Main responsibilities:

  1. He will turn on/off the compressor for ensuring proper air supply into the floor depending on requirements.
  2. Stock necessary oil for the compressor.
  3. Regular servicing and log sheet maintaining.
  4. Operation record maintaining.
  5. Compressor cleaning.
  6. Keep the compressor inspection record and maintain a register.
  7. He will ensure about the turned off machineries at the end of the day and will keep records. 
  8. He must abide Buyers compliances and companies all rules and regulations.
  9. He is also responsible for doing others’ jobs whatever top Management needs.
  1. Responsibilities of Plumbers:

Main responsibilities:

  1. He will provide a proper solution to the water lines problem in the factory.
  2. He will repair every water tape (bathroom, washroom, basin, canteen etc.) if he has a problem.
  3. He will ensure proper drinking water supply into the factory.
  4. Ensure fire hose pipe maintenance and proper water supply.
  5. Note daily using water reading into the register and top management must be informed.
  6. He will inform the top Management about his daily work.
  7. He must abide Buyers compliances and companies all rules and regulations.
  8. He is also responsible for doing others’ jobs whatever top Management needs.
  1. Responsibilities of Welder:

Main responsibilities:

  1. Welder must wear P.P.I. (Personal Protective Equipment) during welding period.
  2. He will weld anything whatever needed in the factory.
  3. He must inform his top Management about his daily work.
  4. He must abide Buyers compliances and companies all rules and regulations.
  5. He is also responsible for doing others’ jobs whatever top Management needs.

—————————–The End———————————

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