Transcript 슬라이드 1 - Blank Title

PIERO CO., LTD.
Aeropostacle
COMPANY PROFILE
MACY’S
1
FACTORY OVERVIEW
2
1. Company information
PIERO
VIETNAM CO., LTD
• Address
1B QUARTER, AN PHU WARD, THUAN AN TOWN,
BINH DUONG PROVINCE, VIETNAM
• Tel / Fax
+84-650-3715-378~380 / +84-650-3715-379
• Contact
General Director:
Mr. Kim Jae Seon
Managing Director: Mr. Lee Jun Ku
Factory Manager: Mr. Kim Young Ho
• History
DEC 22, 2007 GOT INVESTMENT LICENSE
FEB 10, 2008 STARTED OPERATION
• Key
members
Managing Director : Mr. Lee Jun Ku
Factory Manager:
Mr. Kim Young Ho
• Address
162-5, MUK-DONG, JUNGNANG-GU,
SEOUL, KOREA
• Tel / Fax
+82 2
• Contact
President : Mr. Jae Seon Kim
PIERO
KOREA CO., LTD
([email protected])
([email protected])
([email protected])
([email protected]
([email protected])
/ +82 2
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2. Factory Overview
Area
1200 square meters
Cutting Tables
15 (1.9 x 10 meters)
BIAS Cutting Machines
2 units
Area
1000 square meters
Fabric Locker
20 (12 x 2 x 3meters)
Fabric Inspection machine, Light box
1 unit, 1 unit
TRIM ACCESSORY
Stockroom Department
Area
250 square meters
Locker
8 (1.2 x 0.8 x 1.3 meters)
Sample Room
Area
150 square meters
Sewing Machines, Sewers
35 units, 15 sewers
Area
2800 square meters
Sewing Machines
640 units, 20 Lines
Area
100 square meters
Tables
20 (1.2 x 2.0 meters)
Cutting Department
FABRIC
Warehouse Department
Sewing Department
Trimmer Department
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Area
420 square meters
Pressing Vacuum Table
85 units
Area
210 square meters
Tables
20 (1.8 x 2.4 meters)
Area
420 square meters
Tables
20 (1.8 x 2.4 meters)
Area
1250 square meters
Tables
20 (1.2 x 10 meters)
Administration Office
Area
320 square meters
TOTAL LAND / BUILDING
Area
Pressing Department
End Line QC Department
Finishing QC Department
Packing Department
14,800 / 8,120 square meters
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3. Key Facts
Major Contractors
Sales by Country
(2010)
Main Factory in VIETNAM
Production Capacity
Production Category
VENDOR
HANSOLL
NOBLAND
EUHA
BUYER
GYMBOREE, JUSTICE, GIORDANO
DKNY/GUESS/ ARITZIA / RAC&BONE
JONES NEW YORK
Year
USA
2008
90%
CANADA
3%
OTHER
7%
2009
92%
3%
5%
2010
95%
3%
2%
2011
95%
2%
3%
2012
94%
2%
4%
Line (43 operators per line)
Total Output per Month
19 Lines
600,000 PCS
TTL Output Per Month
Annual Output
Knit tops
300,000 PCS
3,600,000 PCS
Jacket
130,000 PCS
1,560,000 PCS
Pants
120,000 PCS
1,440,000 PCS
Dress
50,000 PCS
600,000 PCS
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4. Machine Inventory (Jun, 2013)
Category
4 thread Over-lock
Machine
Units
263
Category
Cover Stitch Machine
Units
Category
Units
153
Single Needle Machine
280
Button Hole Machine
3
Double Needle Machine
8
Smocking Machine
2
Button Sew Machine
5
Snap Machine
3
Thread Re-winder
4
Bar tack Machine
8
Fabric Inspection Machine
1
Vacuum Table
90
Metal Detector,
2
Light Box
1
Cutting Machine
11
Band Knife
0
Fusing Machine
2
Fabric Auto Cutter
Vacuum Cleaner
4
Air Compressor
3
Other
9
118
Total 967 units
5. Manpower (Jun, 2013)
Department
No
Department
SEWER
570
PRESSER
HELPER
144
FINISHING
LINE LEADER
34
TECHNOLOGY
No
No
ADMINISTRATION
27
106
MECHANIC
27
IN LINE Q.C
18
STATISTIC
13
10
END LINE Q.C
46
CLEANER
17
CUTTING
65
FINISHING Q.C
46
MEDIC
WAREHOUSE
14
Q.A AUDITOR
7
SAMPLER
TRIM STOCK ROOM
13
CUTTING Q.C
3
KOREAN MANAGER
TOTAL
63
Department
2
13
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1245 PERSONS
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Factory Organization Chart
Mr. KIM JAE SEON
General Director
0902761011
Mr. Kim Young Ho
Production Director
0903306804
Mr. Lee Jun Ku
Managing Director
0908088469
FQA & QC
Mr Park Chel Woo
Cutting Manager
Mrs Kim Joung Hee
Sewing Manager
Mr. Sun Gwaeh
Young
Finish Manager
Ms Hien / Ms Dep
FQA Supervisor
6 FQA staff
Mr. Phuong /
Mr Thanh
Cutting Chief
Mr.Quy / Mr. Van
Sewing Supervisor
Mr. Tien
Finishing Chief
Mr. Jin Cheng Ri
MR Manager
Mr. J.Y SONG
Maint Manager
HR/Compliance
Ms.Anh HRM
3 HR staff
Maintenance Chief
Ms. Nhung
Compliance staff
Ms Dung / Ms Huong
QC nline leader
16 workers
19 LINES
Ms Dung / Ms Duyen
QC Endline leader
56 workers
Ms Thu / Ms Qui
QC Finishing leader
56 workers
66
WORKERS
3 CUTTING QC
570 SEWERS
63 Ironner
144 HELPERS
106 FOLDERS
+ PACKERS
40 LEADERS &
ASST.LEADERS.
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Merchandisers
&
Sample room
Ms Hong
Mr Tien
Export- Import
23 Mechanic
4 Electrician
Ms Ha
Accounting Chief
1 account staff
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QUALITY CONTROL ORGANIZATION CHART
QUALITY & TECHNICAL TEAM
FACTORY MANAGER
MR. KIM YOUNG HO
LAB. TEST
Ms. Thaém
Fabric Inspec.
Mr. Kieân
PRINT & EMB
Inspect
Ms. Haèng
Ms Baù
QC SUPERVISOR
(EndLine)
Ms. Dung
Ms Duyeân
QC SUPERVISOR
(InLine)
Ms. Dung
Ms Höông
QC SUPERVISOR
(Finishing )
Ms. Thu
Ms Quyù
LINE 2
INLINE
Maän
ENDLINE
Mô
Söông
FINISHING
Lieân
Ngoïc
LINE 3
INLINE
Ly
ENDLINE
Hoàng
Nguyeät
FINISHING
Nhung
Loan
LINE 4
INLINE
Thuùy
ENDLINE
Chaâu
Meán
FINISHING
Truùc
Giangù
LINE 5
INLINE
Thanh
ENDLINE
Thu Söông
Ngaân
FINISHING
Nhung
Haûi
LINE 6
INLINE
Haø
ENDLINE
Thuùy
Hieàm
FINISHING
Ñeøo
Phöông
LINE 7
INLINE
Kieàu
ENDLINE
Ñôû
Hoaøi
FINISHING
Oanh
Yeân
LINE B1 – B5
LINE B1
INLINE
Minh
ENDLINE
Baèng
Loan
FINISHING
Vaân
Thaûo
LINE B2
INLINE
Minh
ENDLINE
Ngaøn
Cô
FINISHING
Phöông
Höông
LINE B3
INLINE
Dieãm
ENDLINE
Laøi
Kieàu
FINISHING
Nöông
Lan
Ms. Hieàn
8 FQA staff
CUTTING
PANEL INS
Ms. Trang
LINE 6-10
LINE 1-5
LINE 1
INLINE
Nhaãn
ENDLINE
Thaûo
Na
FINISHING
Hoa
YÙ
FQA
LINE 8
INLINE
Phöôïng
ENDLINE
Laùnh
Duùng
FINISHING
Xuaân
Luïa
LINE 9
INLINE
Huyeàn
ENDLINE
Hoaøng
Loan
FINISHING
Trang
Thuùy
LINE 10
INLINE
Lónh
ENDLINE
Tuyeán
Vaân
FINISHING
Haø
Thaûo
LINE B6 – B10
LINE B4
INLINE
Dieãm
ENDLINE
Dieãm Haèng
Thuùy Haèng
FINISHING
Xoan
Loan
LINE B5
INLINE
Höông
ENDLINE
Haïnh
Chi
FINISHING
Traïng
Cö
LINE B6
INLINE
Höông
ENDLINE
Luyeán
CaåmTuù
FINISHING
Dung
Hoa
LINE B7
INLINE
Haèng
ENDLINE
Giaøu
Myõ Haèng
FINISHING
Döông
Thô
LINE B8
INLINE
Haèng
ENDLINE
Ngoïc Tuù
UÙt
FINISHING
Ñieäp
Bích
LINE B9
INLINE
Thi
ENDLINE
Höông
Linh
FINISHING
Baèng
Sen
LINE B10
INLINE
Thi
ENDLINE
Thaûo
Thô
FINISHING
Xuyeân
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ADMINISTRATION
1.
5 Merchandiser, 1 Compliance, 3
Human Resources, 2 Import-Export
staffs, 2 Accountant.
SAMPLE ROOM
1.
14 Skillful sample worker in the sample
room under 35 unit of machinery.
CAD ROOM
1.
1 pattern–maker and 2 assistants with
2 computers and 01 pattern table in
the CAD room.
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6. Factory Overview (photo)
FABRIC
WAREHOUSE
1.
Fabric was
stored lot
by lot and
color by
color.
2.
Fabric lot
swatch was
compared
with
approved
shade band
and actual
fabric then
posted on
the board.
3.Fabric should
inspect
more than
20% by
random. If
have a
problem
going to
100%
inspection.
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CUTTING SECTION /
FABRIC RELAX /
TRIMS
1.
Fabric was
separate issued to
cutting section by
lot
2.
Each cut panels
inspected by
inspector. They
inspection
minimum 20% of
each parts. If they
found serious
problem will
going to 100%
inspection.
3.
Fabric should
relax on fabric
relax lock. Cutting
dept. can issue to
cut after
minimum 24
hours
4.
Trims should
storage on the
lock .
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SEWING LINE
1.
Sewer can turn on the red light if they have any
machine trouble for machine technicians easily
and quickly found machine trouble.
2.
Every sewing machines was attached needle
detector.
3.
Every lines have a traffic light system. Sewing
supervisors and operators more easily and quickly
reflect to operation for improve sewing quality.
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IN LINE AND END
LINE Q.C
1.
Every sewing
lines was
checked by in
line Q.C and
end line Q.C
for production
quality. They
give to sewing
line every 2
hours for
improve
sewing quality.
2.
End line Q.C
table posted
comments and
detail sketch.
3.
Foreign and
loose thread
was removed
by sucking
machine
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IRONING & FOLDING AREA
•
8 Ironing vacuum set in a line
•
Pattern drawing on the vacuum dye for
the keep garment own shape and design.
•
We have enough storage area for finished
garments.
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PACKING AREA
1.
Packing area was blocked by the wall for
prevent from finished garments missing.
Authorized persons can entrance to packing
area.
2.
We have enough storage area for finished
garments.
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CLEANING ROOM
1.
Clean the dirty marks like a oil spot,
stains,
2.
Each section have fire drills and bell
CLINIC / PCCC
1.
Any employees can rest in clinic if when
they want rest or frail, sick, fever/ pale,
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Quality Control System
•
•
•
•
•
•
•
1. Laboratory inspection
2. Fabric inspection
3. Cutting inspection
4. In line inspection
5. End line inspection
6. Finishing inspection
7. Final audit.
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1. Laboratory inspection
•
•
This procedure is for check shrinkage of fabric. The inspector has to cut the fabric in size 20
* 20 inches. It will be washed 10 minutes into water. After drying and ironing, the inspector
check the shrinkage
Fabric shrinkage report
Fabric
color
Weight
lot
g/m2
Before wash
length
width
After wash
length
width
Reduced %
width
observation
length
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2. Fabric inspection
•
•
•
•
•
This inspection is necessary to know the quality of fabric and the percentage of fabric’s
waste. The fabric is inspected by PO# and the inspected quantity more than 20%. In case
not urgent time going to 100% quantity inspection.
The inspector has to measure the fabric weight by punch and weight scale. All weight
measurement should check by two way option as before steam ironing and after steam
ironing.
The inspector has to measure the length and the width of the fabric to know whether the
fabric has the correct measurements. All measurements are to be taken with garment laid a
flat smooth surface, in a natural position, free of tension and without wrinkles.
The inspector has to check more than 20% quantity of PO# or 100% quantity whole the
complete rolls of fabric in a light box they need to look for holes, shade, actual yds, actual
width, etc. each one is considered a point based on 4 point system.
Finally the inspector has to elaborate the fabric inspection report according to 4 point system.
(sample of 4 point system report form is attached )
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3. Cutting inspection
•
•
•
•
When a style is new one, the inspector has to measure the pattern with shrinkage report.
Then they have to compare with the fabric on the table, in that way they can observe
whether the fabric is according to the pattern or not.
Then they have to check the quantity of fabric on table. They observed the shade in fabric
with approved shade band.
When fabric is cut, the inspector has to measure each cut panels and they check the
tolerance with approved pattern.
Cut panels going to 100% inspection panels part by part. If they found some of defect panels
then they should be ask to cutting department for replace panels by same lot# end cuts
fabric.
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4. Line inspection
 Our company has twenty sewing lines
 Our quality control system is a mix of what is known as:
 on location inspection(in line inspector)
 100% inspection (table inspection)
On location inspection
 Is a periodic verification to assure us what we are into quality standards.
 Is a very important inspection because it helps us to detect quality problems before we get significant
bundled out of quality standards.
 There must be efficient communication between line inspectors and final inspectors. Line inspectors has
to ask frequently to final inspectors about whom operations are giving us more troubles and line
inspectors need to focus on those operations.
Procedure
•
•
•
•
The inspector has to check the measurements of the garments of the garments before sewing
The inspector has to count the stitches per inches all the time.
The inspector has to find out about the principal problems in line. The inspector can check the numbers
of garments that she considered necessary to understand the problem and gong to correction.
If the inspector found a sewing problem she has to write and mark on the daily report. If an operator
found a machine problem she has stop operation and call the supervisor with red light. The inspector has
to review if the correction was made.
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5. End line inspection
At the end of the process the table inspection has to classify the garments according to it’s defect. If the
garments doesn’t have defects, they send it to the pressing department.
•
Reports
•
•
The line inspector has to fill out the reports as attached form.
Every 2 hours they give comments to sewing line then operator going to correction.
6. Finishing section
•
This inspection is a second place to inspect 100% of out products. This inspection is doing after pressing.
If the inspector found regarding quality problem they have to reclassify all garments.
The measure inspector check all of measurement by random. If they found some of measurement
problems then write on reports and ask to sewing line for correction.
•
7. Final audit
•
This inspection is based on 2.5 AQL table(statistical procedure). They have to take a sample size from
the lot and accept or reject according to the same table. If something is wrong they have to inspect all of
lot again.
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FACTORY HAVE LEVEL
CUSTOMER
BRAND
GRADE
1 / JONES APPEREL
GROUP
: - JONES NEW YORK
GREEN
2 / GYMBOREE
: - GYMBOREE
PASS
- JUSTICE
PASS
3/ TWEEN BRANDS
FACTORY ID
4002179
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