Product & Process Risk assessment in Garments Industry

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

Identified Risks/
Name of Material /Process Possible Risk Measure to Overcome Risk
Potential Hazard

Follow 4 point Inspection system

Shade Variation and
Fabric Chemical Hazard and Shade blanket with buyer
Defect
approval lab dip

Thread check with buyer approval

Thread Chemical Hazard Shade Variation
trim card

proper inspection Countable item as

info wrong /Missing & per AQL 1.5 and Non countable
Labeling Physical Hazard
colour fastness Item 10% check with po sheet as
per buyer instruction

Shade Variation/poor Proper inspection as per AQL and

Button Physical Hazard
Quality check asper client standard

Missing information & Propper inspection as per AQL &

Hangtag And others tag Physical Hazard
wrong barcode check with PO sheet

Customer Complant &

All machine must be
product safety,risk Calibration machine during
Calibration of
assessment. production operation and calibration
Equipment (Fabric Inspection Physical Hazard
Damage all equipment on regular basis as
machine,GSM Shinkage
Machine & Wrong per buyer standard
Template,Light Box)
inspection machine

proper inspection as per AQL and

Price ticket Physical Hazard wrong Barcode
check as per buyer instruction
 Follow marking properly without
Marking Physical Hazard Twisting ,Measurment
bias & jumping mark

Follow spreading properly without

Spreading Physical Hazard Twisting ,Measurment
bias layer

Follow shade wise spreading as per

Shading,part shade band report & ensure
Number & Building Physical Hazard
mistake,mismatch stripe numbering and bundling all cut
pannel

Conduct 100% cut pannel

Fabric Defects,Dirty & inspection as QA Manager singed
Cut panel check Physical Hazard
oil stain approved reference sample which
display at cutpanel inspection area.

Calibration machine during

Calibration of Equipment Customer Complaint &
production operation and calibration
(Fusing Machine bon Test Physical Hazard Product Safety
all equipment on regular basis as
machine) ,risk assessment
per buyer standard

Very Important for

Garments Performance test S/b be testing by buyer approved
Chemical Hazard review garments
(GPT) Extarnal extranal lab as buyer requirment
performance

PH Test & Color

S/b be testing by buyer approved
Fastness,Dimensional change Chemical Hazard Garments
extranal lab as buyer requirment
test, pilling test (Extrnal)

Adjust properly tension & spi as per

Machine adjusting
Uneven tension & SPI Physical Hazard buyer approvel sample then spi dial
problem
s/b lock during production

Twisting at Lower
placket,sleeve gamble &
bottom rolling due to If the operator stitches the fabric
Twisting Physical Hazard
handling problem and do equally while sewing
not follow during
production
 Maintain oil control procedure as
Oil Control Chemical Hazard Un-even SPI & Oil Mark
per sop

As per buyer requirement

carefully handlaing when cf placket
Un-even Foundtion at CF un-even foundation is
Physical Hazard stitching for aviod uneven
placket criticsal for button
foundation
attaching

100% inspection check by

Info wrong/ missing &
sewing QI ,Label not issuing
Labeling Physical Hazard style wrong, wrong size
more then 10 style , display
attaching
approved trims card.

First check with all part ok issue

Shading ,part
card declear qty,only one size
mistake,missmatch
Part Assembling Physical Hazard issueing per operator’s,hang the
stripe,symmetrical,seam
approved sample must be in the
joint
sewing section

All machine s/b calibration as Calibration machine during

Customer Complaint &
per sop and adjustment during production operation and calibration
Physical Hazard Product Safety
lay out time.(Heat Seal all equipment on regular basis as
,risk assessment
Machine ,measurement Tape, ) per buyer standard

Before start washing must

Washing Chemcial Hazard PH valuer Increase becheck water PH before and after
wash

Low Hydro Increase

hydrostector Chemcial Hazard Flowing timing as formula provide
mould

Over
dry product braning and set the dyer temperature as per
Dyear Chemcial Hazard
pilling /less dry increase timing provide miniute.
mould

Measurement and
Ironing/ Pressing Physical Hazard garments visual Used proper steaming
appearence

Should be conduct pull adjust the gudge with proper

Physical
Button Attach test every two hours by foundation to aviod uneven
Hazard/Adjustment
using 15lbs stay 9 sec. foundation check out 100%
 Wrong Hang Tag / size/color mistake during Follow buyer approvel packing
Physical Hazard
price Ticket attaching method before attachment

Follow the procedure as per buyer

Machine calibratiopn,9 point Control Metal item
Physical Hazard as like (Zara1.0 mm & Others buyer
system,quarantine area /needle fragment
1.2 mm) requirment

insect,broken,Less Ply &

Carton Physical Hazard Carton S/B GLASS room
damage

Update asssortment check as

Wrong assortment Physical Hazard Assortment mistake
display board

Mistake
assortment/colour during Inspected carton properly audit after
Packing accuracy mistake Physical Hazard
re-pack buyer inspected complete re-pack
carton

Carton should be damage

Damage cargo Physical Hazard Audit cargo during Load the cargo
due to damage cargo

Should be conct pull test every two

Button Physical Hazard Pull out Button hours by using 15Lbs stay 10
second

Finishing and Packing safety Product safety and Use of the pin must be empletdy
Physical Hazard
problem customer safety banned infloor

Hi rate of needle Use proper size of needle and thread

Needle size Physical Hazard
brokerage during production

Check moisture from wash

Customer received to packed carton of
Create Mould Chemcial Hazard
complaint garments at In-process & finished
carton on regular basis

All machine s/b calibration Calibration machine during

Customer Complaint &
(Pull Test machine,Thread production operation and calibration
Pysical Hazard Product Safety
Suker,Needle all equipment on regular basis as
,risk assessment
Detector,Measurement Tape) per buyer standard
 During Storage & use must be
Carefully Handle cwith MSDS For Prevention worker
follow buyer sop and MSDS,PPE
as per buyer requirmnent for Chemcial Hazard and consumers Physical
for avoid any kinds of workers
avoid accident risk
Physical accident.

Sore ,Sewing,Finishing and Copnduct pest control programe

Chemcial Hazard insect
Packing,canteen, toilet periodically by extranally

Maintain sharp tools control

register of all production operation
Winding to Shipment Physical Hazard Product Safety
where applicable and check on
regular basis

Product safety and Use PPE with MSDS During spot

Spot remover safety problem Chemcial Hazard
customer safety removing

Insect killer,Pest Check moisture from wash

Control,Moisture check Product safety and received to packed carton of
Physical Hazard
,Huminity Check ,House customer safety garments at In-process & finished
keeping . carton on regular basis

Safety Problem/Housekeeping Microbiological DailyHouse keeping monitoring &

Product safety
problem/Insect problem contamination Hand wash system monitoring

Product safety and use appropriate PPE properly during

Safety Problem Physical Hazard
customer safety production

Maintain sharp tools ,Knif &

Needle control register of all
production operation where
Sharptools .Knif & Microbiological
applicable and check on regular
needle Control,Fusing contamination/ Product Safety
basis.Fusing match with data
record, Needle detector check Physical Hazard
sheet.and Needle Detector
monitoing record.Control Contol
Point (CCP) is out of toterance.