Date post: | 05-Apr-2018 |
Category: |
Documents |
Upload: | kunto-antariksa |
View: | 220 times |
Download: | 0 times |
of 13
7/31/2019 Idea of Product Safety
1/13
6/6/200
Best Practice for product safetyin part of 5S Implementation
By. Kunto Antariksa, AT.,MM
Istanto Atmodjo, AK3
Sky Consultant
2009
Why product safety ?
Think safety for our company ? No claim
Think safety on customer ? Satisfaction
Think safety for you ?
Safe on product can be provide by safework place and safe worker ?
Product safety = Money safety
7/31/2019 Idea of Product Safety
2/13
6/6/200
3
Result of Quality Management System
Return on assets (ROA) = Profit margin x Asset turnover
Assume COPG* = 10% of sales revenue
Profit margin = 7%
Asset turnover = 3.0
=> ROA = 7% x 3.0 =21%
Assume COPG reduced to 6% of sales revenue
=> Profit margin = 7% + (10% - 6%) = 11%
Asset turnover = 3.0
=> ROA = 11% x 3.0 = 33%
A 4% reduction in COPG results in a 12% increase in ROA!!
*Cost of Poor Garments
Safety on Material & Components storage
Specific storage area should be fixed andlabelled.
Amber area - For storage of incoming raw materialand finished for inspection then just waiting forfurther decisions .
Green area - For storage of raw materials whichpassed the inspection and accepted to cutting
Red area - For storage of raw materials which arerejected / failed the inspection.
TO BE
INSPECTED
PASS
REJECT
7/31/2019 Idea of Product Safety
3/13
6/6/200
REJECTED
AREAPASSED AREA
TO BE INSPECTEDAREA
Fabric /Accessories Ware House
7/31/2019 Idea of Product Safety
4/13
6/6/200
Safety Control at Cutting
Department No pins/staples are allowed for cutting.
All scissors/ straight knife/ any metal objects need to log in &out in a store room with record daily.
Workers are not allowed to operate the cutting with their feeton the cutting table.
Protective equipment like chain mail gloves required toprovide for workers and make sure the workers wear thegloves during cutting operation.
Safety Control at Cutting Department
Workers are not allowed tooperate the cutting with theirfeet on the cutting table.
Make sure the workers wearprotective equipment like metal chain
gloves during cutting operation.
7/31/2019 Idea of Product Safety
5/13
6/6/200
Cutting Room
Metal Object Controlling atCutting
7/31/2019 Idea of Product Safety
6/13
6/6/200
Safety Control at Sewing Area
The sewing section need to follow the rules and disciplinessame as cutting dept.
Metal templates must be logged in and out daily.
Only one spare bobbin to be kept by the sewer (2 pcs for twinneedle sewing machine)
Using staples or pins on working area is not allowed.
All small scissors, clippers and drills need to be fastened to thework station & any large scissors or metal objects need to be
recorded in & out daily to avoid metal objects trapped insidecarton box during delivery.
Safety Control at Sewing Department
Sewing area must be metal free environment then if possible put the metalcontamination box in that area . If any worker found any metal part as
clip/pin/staples then they know in which place must be drop that metal part .
Production floor must be neat and clean . If possible the house keeping
must be sweep and clean the production floor 2 times /day .
Fire exit direction also must clear and visible on production area .
7/31/2019 Idea of Product Safety
7/13
6/6/200
Metal Contamination Controlling
Metal Object Controlling at Sewing
7/31/2019 Idea of Product Safety
8/13
6/6/200
Safety Control at Sewing Department
Spare & broken needle Brokenneedle detection procedure mustbe implemented and logged in andout with record daily by supervisor.
In case all broken needle partscannot be found (after searchingwith magnet and hand held metaldetector), all the semi-finished &finished products including thegarments within the area of 1 meteras radius from the broken needleplace to be delivered to the metaldetector section and handle withspecific persons. During
transportation, all garments to beput into big polybags then into ared contamination box with lock.
Lockedspare
needles
Broken Needle Controlling
7/31/2019 Idea of Product Safety
9/13
6/6/200
Safety at Quality Control
Safety Control at Spot Cleaning Area
Spot cleaning area mustbe well ventilated withgas immediatelydischarged to outside.
Ventilator must be on.
Protective wear shouldbe provided to worker,such as gloves andmask, to a safe healthy
working environment.
7/31/2019 Idea of Product Safety
10/13
6/6/200
Safety at Pressing/Finishing area
Safety Control at PackagingDepartment
Broken/ useless Kimballneedle must be handledunder broken needlecontrol procedures.
All garments packed withpolythene bag must passthrough metal detectorprior to delivery for
detecting extraneous metalobject.
9 point system need toapply for metal calibrationtesting.
Non-metal area where all finishedgarments will be scanned thru and
packed immediately before delivery.
7/31/2019 Idea of Product Safety
11/13
6/6/200
Safety Control on Packaging Department( Cont )
Metal Detector calibration testingshould be tested every 4 hours using 9point system.
Merchandise passing thru metaldetector should be separated andmarked by hours intervals when theyare scanned. Traceable record shouldbe kept. Merchandise within thatinterval will need to be recheck in casethe machine alert with the reject beepwhen calibration testing.
Merchandise should be re-scanned if itwas rejected during first scan. In case,this is still being rejected, the
merchandise should be put into alockable container with traceable record.
Broken needle searches should besupervised by first line management.
If the product does not pass through the
metal detector and the broken needlepieces cannot be found
THE GARMENT MUST BE
DESTROYED..
Metal Detection Area
7/31/2019 Idea of Product Safety
12/13
6/6/200
Metal Detection Area
Safety Control atFinishing Department
Sufficient final checking procedures required. Ensurefor quantity, color, size, SKU, line and price must match
the packing list. Verify the scanned bar shown on boxmust matches the information printed on the Point ofSale (POS) ticket.
7/31/2019 Idea of Product Safety
13/13
6/6/200
Q & A
25
Thank You
Strong companies develop superior capabilities inmanaging core business processes such as newproduct realization, inventory management and
customer satisfaction . Managing this core processeseffectively means creating marketing network in which
the company work closely with all parties in theproduction , distribution chain , from supplier of material
to retail distributors .
( John F. Welch , Former CEO of GE ) .