SOP on sewn Button & snap fastener safety .pdf

SOP on Snap Fastener and sewn Button safety SQAD Bangladesh April 2016

SOP ON SNAP FASTENER SAFETY

Introduction What would a small child do with a button or snap or any small part that is found on the floor?

1.

Throw it away

2.

Give it to his or her mother

3.

Put it in his or her mouth

Introduction to Children Wear Safety

• So does the earlier video have anything to do with our business?...... The small part shown could have been any of the following….. - Snap

- Button - Plastic clip - Laundry stone - Zipper pull etc…

IMPORTANCE OF SNAP FASTENER SAFETY SOP • Why do we need snap fastener safety SOP ? • To ensure that our products are safe for Children – start fom 0-3 months up to age-12 14 years • To avoid product recalls & comply with all legal safety requirements per CPSIA requirements. • To protect Gymboree brand image as safest kid brand with fashionable products. • To ensure production premises know & follow as necessary steps needed for snap button, hook & bur & rivets attachments with correct machine & mold set-up

Case 1

Customer is injured by the sharp point on snap.

Initial Discussion •Do you have an implemented snap control policy? •How do you measure the effectiveness of the implementation ? •If snap failure is found, what will be the subsequent control process ?

Critical Area • Have you implemented a snap control policy? • Gymboree Corporation’s Snap Control Program • Snap purchase from Gymboree designated supplier (YKK/PRYM/SCOVILL/ WING HING BUTTONS/YIK CHEONG METAL) • Correct snap component and application must be determined through designated supplier. • Submit sample of garment to designated snap supplier with Snap Fastener Data Sheet. • No manual press. Only use pneumatic or electric press that is coming from snap supplier. • Dies : must match with snaps / avoiding metal fatigue • Set pinch settings • Check and validate equipment by machine supplier technician before production & have machine service report for every PO. • Check during production. • Record keeping.

Critical Area  How do you measure the effectiveness of the implementation ?  Follow snap supplier’s recommendation for snap selection and application  Check during production :  Check snap machine at least twice a day to ensure snaps are secure and consistent  At least twice a day on every snap machine’s output with approved “Imada Pull Tester” to measure attachment strength, REQUIREMENT : 21 lbs. x 10 sec  Keep record of daily inspection (Snap Production Control.pdf)  100% inspection of all snaps at end of production lines. Unsnapped and re-snapped every garment to insure attachment and push/pull standards are met (Snap Audit Report.pdf)

Pull test Calibration • •

Pull Tester- Instrument used to measure the pull force. Gymboree Brand have adopted the AATCC standard -part1 and BS to test attached sundries in Children Wear product.

• •

Report Calibration verification test procedure.– – – – –

Use a known or pre-measured weight Set dial to Zero Attach known weight to pull tester Lift weight with pull tester Pull tester dial should read the value of the known weight being used. – If weight displayed in dial do not match the known weight being lifted, pull tester is out of calibration. – Calibration to be done and recorded daily. Record readings in proper Units.

Document time and date when calibration is performed, and name of person who performed calibration

Small Part Safety Tester

3 Prong Clamp

Digital Caliper

Long Nose Grip

Round Head Grip

Force Gauge & Stop Watch

Gripper Pull Test Clamp

A Saf-Q Gripper Clamp

B

A : “C” rail hold the rim of gripper B : “L” jaw insert in between gripper and garment (Not Recommended).

Pre-production attachment Control form

Snap Button Pull test report – Bulk

MEASURE PINCH SETTING PINCH SETTING SHOULD BE MEASURED FROM RUNNING PRODUCTION IN EVERY 02 HOURS INTERVAL TO UNDERSTAND MACHINE SET-UP IS OKAY. MEASUREMENT OF PINCH SETTING IS VERY IMPORTANT AS THIS IS THE ONLY TECHNIQUE TO IDENTIFY WHETHER BUTTON SET-UP IS OKAY ON BULK PRODUCTION PCS THAT WILL BE PACKED FOR SHIPMENT.

Pinch-setting instruction B

+

S

Fabric Foundation

=

A

Actual Pinch

Basic Pinch

Pandora Associates Ltd :

MEASURING OF PINCH SETTING spring

A

A A S-spring

Grip fix

Grip fix

A

A

A Gripfix

Pandora Associates Ltd :

How to read datasheet and pinch setting Prym Fashion Asia Pacific 普利民亚洲太平洋

PRESSFASTENER / RIVETING ARTICLE DATASHEET 钮扣数据表

GYMBOREE Customer 客户

ABC Garment

Phone 电话

852-1234567

Customer product 客户产品

Address 地址 Contact person 联络人 PO# 191089

Recommended Pressfastener / Riveting Article 成衣上使用钮扣建议

Esther

Date 日期

Style no 款号

GSH141

LH 10mm Rhinestone Rivet w/ LH 8mm Capped Washer

China 7 May 2011

Machine Tolerance 可接受偏差

+/-0.20mm

Internal use pinch setting (confidential )內部文件,只供普利民公司內 用

Pinch setting 钮扣数据 ( mm 毫米 ) Position on product 钮扣位置

Shoe Position x 1

1

Article 钮扣

Code no. 钮扣编号

Die No. 模具编号

10mm Rhinestone Rivet

LH10MM9 01

D60630LH

8mm Capped Washer

LH8MM06 4BURR

D60338LH

S 净布 厚度

A 总厚 度

S min 最低 布厚

S max 最高 布厚

A min 最低 总厚 度

A max 最高 总厚 度

3.40

8.55

2.65

3.95

8.15

9.10

Remarks 备注

2

3

4

5

6

Recommended Assembly Machines 建议打钮机类型 PP5/ 600 Machine Type 钮机类型 Bur & Rivet For the assembly of 钮扣类别

Possibly Existing Machines 现存打钮机类型 Prym Producer 钮扣供货商



Ensure even foundation snap attachment at mentioned position.



Prym Fashion will not take any responsibility in the quality of snap attachment if Prym die is not used.



Industrial washing and ironing not recommended after attachment to avoid reaction between snaps and washing chemicals & steam.

Pinch Measurements S

B

+

S

A

=

B

+

A

=

stud & stud eyelet

S

B

+

Comments 建议 Attaching pressure: Rhinestone Burr ----2.5 bar. Step processing, put rhinestone rivet on pre-punched hole completely on attaching position then insert capped burr on rhinestone rivet . Push down machine handle until upper die fit on capped burr . Make sure alignment is good then step down foot pedal to process attachment .

A

=

stud & pronged ring

Checked by 检查人员:

Paul.Chan

Pandora Associates Ltd :

EXAMPLE OF DATA SHEET FROM YKK

EXAMPLE OF MACHINE SERVICE REPORT

100% Snap Audit Form

Critical Area If snap failure is found, what will be the subsequent control process? – Stop production – Isolate problematic production garment for rechecking. For post type snap – Recheck process/machine setting, snap to identify source of failure – Correct & validate the machine setting before restart of production

Snap Pull Off

Attach on uneven thickness or too close to seam

Snap – Uneven Thickness cause by sewing workmanship

Grippers Leg Out

Grippers Sharp Point

Lock stitch button machine safety sop

•

Button is considered as a small object.

•

If swallowed, that could cause Choking & suffocation - hence potential life threat to kids

•

The regulator in USACPSC, consider any small object attached to Children’s wear should be well secured

Choking can be deadly

Lets help building a safe world for kids….!

Gymboree Safety standards on button attaching •

• •

All 4 hole buttons must be ‘cross and lock – stitched’ and all other button must be lock-stitched using a polyester or polyester cotton wrap thread Must pass the pull test requirement 21 lbs 10 seconds No hand stitch is allowed

The Failure – Missing Cross Stitch From Jan 2015 – Oct 2015, Gymboree has rejected 25 POs globally based on DC audits, as buttons ‘MISSED CROSS STITCH’ on attachment. Over 1350 pcs did not meet the criteria.

Lockstitch vs Chain-Stitch Machine

LOCK STITCH MACHINE WITH BOBBIN CASE -ALLOWED

CHAIN STITCH MACHINE-

NOT ALLOWED

Root Cause of ‘Missing Cross Stitch’ Lock stitch Buttoning machine is not used Machine is faulty- not well maintained Appropriate thread is not used Button Operators are not well trained Button operators are not checking or has no commitment to check The button attachment SOP is not followed End of the line QCs & final auditors have failed to detect.

Machinery • Only Lockstitch machines are allowed for button attachment • Sufficient no of lockstitch machine should to be available. (Hourly output is a good measure) • Machinery list with Model/Year/Serial No • Routine (Periodic) servicing and recording • Machine Suppliers should be called in to review the status of machines and to educate factory maintenance team • Daily maintenance by factory mechanics

Daily Maintenance • • •

Daily Machine and bobbin Cleaning. Thread tension, Bobbin Tension Checking. Use correct Types of Needle (#11#16)

• Needle change – every 4 hours • No bent or tipped needle in use • Daily activity should be recorded

Button pull test Random pull out 20 pcs from every 5,000 pcs of bulk for internal pull test All the testing record must be documented At any failure, must stop the bulk production immediately

Create a unique team • • • •

All Button Operators Mechanics Button Checkers Auditors

Pick up, train and register. They should understand their responsibility, importance of their work and the accountability. • Special attendance record • Trained Pool- to cover absenteeism • Re-training to be done every six months

Process -Pre-Production Control • Verify Foundation Thickness • Apply 25 buttons in a mock seam • Verify button attachment strength (Pull Test) • First Button attach in a mock seam and also at every bobbin re-fill. • Remove the last Button from body at every bobbin depletion.

PRE- PRODUCTION CONTROL CHART – LOCK STITCH BUTTON ATTACHMENT

PROCESS – PRODUCTION CONTROL

• Collect every 2 hours production, count, record with machine no before start checking • Construction and Complete stitch pattern Review • Clearly Visible rabbit Ear and Knot • Pull test (21 lbs / 10 sec) with record

Daily Production Control chart – By Visual check on Rabbit Ear , Complete Stitch Pattern

Process – PSO’s role • Cross check the record book of the mechanic’s checklist • Ensure the button operator follow the SOP when buttoning • Check the mock up in every 2 hours • Educate the trimmers don’t treat the “Rabbit Ear” as an uncut thread ends

Process – Operator’s Role Clean the buttoning machine everyday Do not allow button operator to adjust the thread tension on the bobbin case Call out the mechanic to adjust the thread tension when the button is too loose or too tight Remove the last attached button when bobbin is empty Attach the first button at the mock up after refill the bobbin

Process – DQA’s Role Check PSO record book and buttoning mock up record in every factory visit Random pull 50 pcs of garment to review the performance of the button attached Evaluate the entire button operation process Pull out 20 pcs of garment for internal pull test in every 5,000 pcs of button attached

Bobbin changing 1st button attachment form

LOCK STITCH MACHINE DAILY CLEANING REPORT

Pull test record on Daily Production –Lock stitch button

Initiative taken with all factories to train all concerns to avoid Button safety Failure

Initiative taken with all factories to train all concerns to avoid Button safety Failure