Idea of Product Safety

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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


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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


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REJECTED

AREAPASSED AREA

TO BE INSPECTEDAREA

Fabric /Accessories Ware House


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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.


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Cutting Room

Metal Object Controlling atCutting


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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 .


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Metal Contamination Controlling

Metal Object Controlling at Sewing


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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


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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.


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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.


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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


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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.


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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 ) .

Documents

Idea of Product Safety