Nowadays Product & Process Risk assessment and analysis is one of the most impotent methods in kinds of business. Because of the risk analysis, we can know what kinds of possible risks can occur in the full of manufacturing process and service which is a barrier to achieving the ultimate goal. As we can all possibly risk through the risk-based analysis, we can take easily preventive action in every occurring area involve all related people to acknowledge, train up, awareness and provide process and procedure for implementing and follow in the whole process of manufacturing service. Also, we make sure fewer error products, high efficiency, wastage control, defective rate control, and on-time shipment by performing risk base analysis and implementing accordingly. This content is about Product & Process Risk assessment in Garments Industry.
Details of Product & Process Risk assessment
| Name of Material /Process | Identified Risks/ Potential Hazard | Possible Risk | Measure to Overcome Risk | |
| Fabric | Chemical Hazard | Shade Variation and Defect | Follow 4 point Inspection system and Shade blanket with buyer approval lab dip | |
| Thread | Chemical Hazard | Shade Variation | Thread check with buyer approval trim card | |
| Labeling | Physical Hazard | info wrong /Missing & colour fastness | proper inspection Countable item as per AQL 1.5 and Non countable Item 10% check with po sheet as per buyer instruction | |
| Button | Physical Hazard | Shade Variation/poor Quality | Proper inspection as per AQL and check asper client standard | |
| Hangtag And others tag | Physical Hazard | Missing information & wrong barcode | Propper inspection as per AQL & check with PO sheet | |
| All machine must be Calibration of Equipment (Fabric Inspection machine,GSM Shinkage Template,Light Box) | Physical Hazard | Customer Complant & product safety,risk assessment. Damage Machine & Wrong inspection machine | Calibration machine during production operation and calibration all equipment on regular basis as per buyer standard | |
| Price ticket | Physical Hazard | wrong Barcode | proper inspection as per AQL and check as per buyer instruction | |
| Marking | Physical Hazard | Twisting ,Measurment | Follow marking properly without bias & jumping mark | |
| Spreading | Physical Hazard | Twisting ,Measurment | Follow spreading properly without bias layer | |
| Number & Building | Physical Hazard | Shading,part mistake,mismatch stripe | Follow shade wise spreading as per shade band report & ensure numbering and bundling all cut pannel | |
| Cut panel check | Physical Hazard | Fabric Defects,Dirty & oil stain | Conduct 100% cut pannel inspection as QA Manager singed approved reference sample which display at cutpanel inspection area. | |
| Calibration of Equipment (Fusing Machine bon Test machine) | Physical Hazard | Customer Complaint & Product Safety ,risk assessment | Calibration machine during production operation and calibration all equipment on regular basis as per buyer standard | |
| Garments Performance test (GPT) Extarnal | Chemical Hazard | Very Important for review garments performance | S/b be testing by buyer approved extranal lab as buyer requirment | |
| PH Test & Color Fastness,Dimensional change test, pilling test (Extrnal) | Chemical Hazard | Garments | S/b be testing by buyer approved extranal lab as buyer requirment | |
| Uneven tension & SPI | Physical Hazard | Machine adjusting problem | Adjust properly tension & spi as per buyer approvel sample then spi dial s/b lock during production | |
| Twisting | Physical Hazard | Twisting at Lower placket,sleeve gamble & bottom rolling due to handling problem and do not follow during production | If the operator stitches the fabric equally while sewing | |
| Oil Control | Chemical Hazard | Un-even SPI & Oil Mark | Maintain oil control procedure as per sop | |
| Un-even Foundtion at CF placket | Physical Hazard | As per buyer requirement un-even foundation is criticsal for button attaching | carefully handlaing when cf placket stitching for aviod uneven foundation | |
| Labeling | Physical Hazard | Info wrong/ missing & style wrong, wrong size attaching | 100% inspection check by sewing QI ,Label not issuing more then 10 style , display approved trims card. | |
| Part Assembling | Physical Hazard | Shading ,part mistake,missmatch stripe,symmetrical,seam joint | First check with all part ok issue card declear qty,only one size issueing per operator’s,hang the approved sample must be in the sewing section | |
| All machine s/b calibration as per sop and adjustment during lay out time.(Heat Seal Machine ,measurement Tape, ) | Physical Hazard | Customer Complaint & Product Safety ,risk assessment | Calibration machine during production operation and calibration all equipment on regular basis as per buyer standard | |
| Washing | Chemcial Hazard | PH valuer Increase | Before start washing must becheck water PH before and after wash | |
| hydrostector | Chemcial Hazard | Low Hydro Increase mould | Flowing timing as formula provide | |
| Dyear | Chemcial Hazard | Over dry product braning and pilling /less dry increase mould | set the dyer temperature as per timing provide miniute. | |
| Ironing/ Pressing | Physical Hazard | Measurement and garments visual appearence | Used proper steaming | |
| Button Attach | Physical Hazard/Adjustment | Should be conduct pull test every two hours by using 15lbs stay 9 sec. | adjust the gudge with proper foundation to aviod uneven foundation check out 100% | |
| Wrong Hang Tag / price Ticket | Physical Hazard | size/color mistake during attaching | Follow buyer approvel packing method before attachment | |
| Machine calibratiopn,9 point system,quarantine area | Physical Hazard | Control Metal item /needle fragment | Follow the procedure as per buyer as like (Zara1.0 mm & Others buyer 1.2 mm) requirment | |
| Carton | Physical Hazard | insect,broken,Less Ply & damage | Carton S/B GLASS room | |
| Wrong assortment | Physical Hazard | Assortment mistake | Update asssortment check as display board | |
| Packing accuracy mistake | Physical Hazard | Mistake assortment/colour during re-pack buyer inspected carton | Inspected carton properly audit after complete re-pack | |
| Damage cargo | Physical Hazard | Carton should be damage due to damage cargo | Audit cargo during Load the cargo | |
| Button | Physical Hazard | Pull out Button | Should be conct pull test every two hours by using 15Lbs stay 10 second | |
| Finishing and Packing safety problem | Physical Hazard | Product safety and customer safety | Use of the pin must be empletdy banned infloor | |
| Needle size | Physical Hazard | Hi rate of needle brokerage | Use proper size of needle and thread during production | |
| Create Mould | Chemcial Hazard | Customer complaint | Check moisture from wash received to packed carton of garments at In-process & finished carton on regular basis | |
| All machine s/b calibration (Pull Test machine,Thread Suker,Needle Detector,Measurement Tape) | Pysical Hazard | Customer Complaint & Product Safety ,risk assessment | Calibration machine during production operation and calibration all equipment on regular basis as per buyer standard | |
| Carefully Handle cwith MSDS as per buyer requirmnent for avoid accident | Chemcial Hazard | For Prevention worker and consumers Physical risk | During Storage & use must be follow buyer sop and MSDS,PPE for avoid any kinds of workers Physical accident. | |
| Sore ,Sewing,Finishing and Packing,canteen, toilet | Chemcial Hazard | insect | Copnduct pest control programe periodically by extranally | |
| Winding to Shipment | Physical Hazard | Product Safety | Maintain sharp tools control register of all production operation where applicable and check on regular basis | |
| Spot remover safety problem | Chemcial Hazard | Product safety and customer safety | Use PPE with MSDS During spot removing | |
| Insect killer,Pest Control,Moisture check ,Huminity Check ,House keeping . | Physical Hazard | Product safety and customer safety | Check moisture from wash received to packed carton of garments at In-process & finished carton on regular basis | |
| Safety Problem/Housekeeping problem/Insect problem | Microbiological contamination | Product safety | DailyHouse keeping monitoring & Hand wash system monitoring | |
| Safety Problem | Physical Hazard | Product safety and customer safety | use appropriate PPE properly during production | |
| Sharptools .Knif & needle Control,Fusing record, Needle detector check | Microbiological contamination/ Physical Hazard | Product Safety | Maintain sharp tools ,Knif & Needle control register of all production operation where applicable and check on regular basis.Fusing match with data sheet.and Needle Detector monitoing record.Control Contol Point (CCP) is out of toterance. |
Product & Process Risk assessment in Garments Industry
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