| Our operation is based mainly on a piece rate bundle system. We do employ the use of a line system in some cases depending upon the item and quantity of order. Our normal minimum order quantity is 10,000 pairs. We are completely computerized and use a sophisticated bar code system to track all production and payroll. Our turn time is generally three weeks on average from receipt of the goods or the date cut. This, of course, depends upon the style and its particular requirements. After receiving cut work, or cutting it ourselves, it is bundled, shade marked and made ready for small parts. Flies, belt loops, bands, and flaps are prepared in parts sections. From there it moves to the main production lines and then on to finishing where belt loops, buttonholes and buttons are attached. After finishing, the work is trimmed, pressed and baked (if required). Aside from the machine operators, each section has one supervisor who is responsible for the production and quality in his/her section. Each section has additional assistant supervisor, one or more distributors, two or more roving quality checkers, one person measuring bands at the machine, one person matching panels to insure proper shading, one person marking sizes before banding, one person checking the chained seams for skips and two final inspectors At the end of each section, we employ auditors that move from section to section doing random audits based on a 1.5 AQL. Work may not proceed to the next section unless it passes this audit. These auditors have independent authority to stop a line temporarily from producing if need be. All operators fix their own repairs at their own expense. All production can be traced to the original operator at any time in the production process. Our computer system also tracks operators and operations. Work in process moves on to the final inspection. We again 100% inspect every garment, measure every waist and inseam and check every label. Each pair that is passed contains the inspector’s number. A rejected garment is repaired, re-pressed and re-inspected. Once passed, garments move on to packing. We do all ticketing, tagging, bagging, hanging and prepacking there depending on the needs of the cut. After packing, a full audit based on a 2.5 AQL is done on each cut. If rejected, the cut goes back for 100% inspection and repair and is audited again. Quality is our main priority and we have an extended quality staff of checkers, inspectors and roving auditors in each section. All quality data is written down and kept on file for future reference. Quality Reports such as in-line and end- line quality reports, in-line and end-line repair reports, stitches per inch reports, final quality audits, spec reports, packing audits and irregular reports are obtainable through the Island Apparel Quality Control Guidelines. We do our utmost to make a quality garment as well as meet the delivery needs of our customers. |
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| ISLAND APPAREL S.A. Operations |
