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SOP on Snap Fastener

and sewn Button safety


SQAD Bangladesh
April 2016
SOP ON SNAP
FASTENER
SAFETY
Introduction
What would a small child do with a button or snap or any
small part that is found on the floor?

1. Throw it away

2. Give it to his or her mother

3. Put it in his or her mouth


Introduction to Children Wear Safety
So does the earlier video have anything to do with
our business?...... The small part shown could have
been any of the following..
- Snap
- Button
- Plastic clip
- Laundry stone
- Zipper pull etc
IMPORTANCE OF SNAP FASTENER SAFETY SOP
Why do we need snap fastener safety SOP ?
To ensure that our products are safe for
Children start fom 0-3 months up to age-12 -
14 years

To avoid product recalls & comply with all legal safety


requirements per CPSIA requirements.
To protect Gymboree brand image as safest kid brand with
fashionable products.
To ensure production premises know & follow as necessary
steps needed for snap button, hook & bur & rivets
attachments with correct machine & mold set-up
Case 1

Customer is
injured by the
sharp point on
snap.
Initial Discussion

Do you have an implemented snap control


policy?

How do you measure the effectiveness of the


implementation ?

If snap failure is found, what will be the


subsequent control process ?
Critical Area
Have you implemented a snap control policy?
Gymboree Corporations Snap Control Program
Snap purchase from Gymboree designated supplier
(YKK/PRYM/SCOVILL/ WING HING BUTTONS/YIK CHEONG
METAL)
Correct snap component and application must be determined
through designated supplier.
Submit sample of garment to designated snap supplier with Snap
Fastener Data Sheet.
No manual press. Only use pneumatic or electric press that is
coming from snap supplier.
Dies : must match with snaps / avoiding metal fatigue
Set pinch settings
Check and validate equipment by machine supplier technician before
production & have machine service report for every PO.
Check during production.
Record keeping.
Critical Area

How do you measure the effectiveness of the implementation ?


Follow snap suppliers recommendation for snap selection and
application
Check during production :
Check snap machine at least twice a day to ensure snaps are
secure and consistent
At least twice a day on every snap machines output with approved
Imada Pull Tester to measure attachment strength,
REQUIREMENT : 21 lbs. x 10 sec

Keep record of daily inspection (Snap Production Control.pdf)


100% inspection of all snaps at end of production lines. Unsnapped
and re-snapped every garment to insure attachment and push/pull
standards are met (Snap Audit Report.pdf)
Pull test Calibration
Pull Tester- Instrument used to Document time and date when
measure the pull force. calibration is performed, and name of
Gymboree Brand have adopted the person who performed calibration
AATCC standard -part1 and BS to
test attached sundries in Children
Wear product.

Report
Calibration verification test
procedure.-
Use a known or pre-measured weight
Set dial to Zero
Attach known weight to pull tester
Lift weight with pull tester
Pull tester dial should read the value
of the known weight being used.
If weight displayed in dial do not
match the known weight being lifted,
pull tester is out of calibration.
Calibration to be done and recorded
daily. Record readings in proper
Units.
Small Part Safety Tester

3 Prong Clamp Digital Caliper

Force Gauge
& Stop Watch

Long Nose Grip Round Head Grip


Gripper Pull Test Clamp

A B
Saf-Q Gripper
A : C rail hold the rim of gripper
Clamp
B : L jaw insert in between gripper
and garment (Not Recommended).
Pre-production attachment Control form
Snap Button Pull test report Bulk
MEASURE PINCH SETTING
PINCH SETTING SHOULD BE
MEASURED FROM RUNNING
PRODUCTION IN EVERY 02
HOURS INTERVAL TO
UNDERSTAND MACHINE SET-UP
IS OKAY. MEASUREMENT OF
PINCH SETTING IS VERY
IMPORTANT AS THIS IS THE
ONLY TECHNIQUE TO IDENTIFY
WHETHER BUTTON SET-UP IS
OKAY ON BULK PRODUCTION
PCS THAT WILL BE PACKED FOR
SHIPMENT.
Pinch-setting instruction
B + S = A

Fabric Actual Pinch


Foundation
Basic Pinch

Pandora Associates Ltd :


MEASURING OF PINCH SETTING

spring A

A
A
S-spring

A
Grip fix

A
Grip fix

A
Gripfix

Pandora Associates Ltd :


How to read datasheet and pinch setting
Prym Fashion Asia Pacific PRESSFASTENER / RIVETING
ARTICLE DATASHEET
GYMBOREE
Customer ABC Garment Address China
Phone 852-1234567 Contact person Esther Date 7 May 2011

Customer product PO# 191089 Style no GSH141

Recommended Pressfastener / LH 10mm Rhinestone Rivet w/ LH 8mm Machine Tolerance


+/-0.20mm
Riveting Article Capped Washer
Internal use pinch setting (confidential ),
Pinch setting ( mm )
A A

S S min max
Position on product Article Code no. Die No. S A
min max Remarks





10mm LH10MM9
D60630LH
Rhinestone Rivet 01
1 Shoe Position x 1 3.40 8.55 2.65 3.95 8.15 9.10
8mm Capped LH8MM06
D60338LH
Washer 4BURR

Recommended Assembly Machines Possibly Existing Machines


Machine Type PP5/ 600 Producer Prym
For the assembly of Bur & Rivet
Ensure even foundation snap attachment at mentioned position.
Prym Fashion will not take any responsibility in the quality of snap attachment if Prym die is not used.
Industrial washing and ironing not recommended after attachment to avoid reaction between snaps and washing chemicals & steam.
Pinch Measurements Comments
S B A
+ = Attaching pressure:
Rhinestone Burr ----2.5 bar.
S B A
+ = Step processing, put rhinestone rivet on pre-punched hole completely on attaching position then
stud & stud eyelet
insert capped burr on rhinestone rivet . Push down machine handle until upper die fit on capped
burr . Make sure alignment is good then step down foot pedal to process attachment .
S B A
+ =

stud & pronged ring

Checked by : Paul.Chan

Pandora Associates Ltd :


EXAMPLE OF DATA SHEET FROM YKK
EXAMPLE OF MACHINE SERVICE REPORT
100% Snap Audit Form
Critical Area
If snap failure is found, what will be the
subsequent control process?

Stop production
Isolate problematic production garment for rechecking.
For post type snap
Recheck process/machine setting, snap to identify
source of failure
Correct & validate the machine setting before restart of
production
Snap Pull Off

Attach on uneven thickness or too close to seam


Snap Uneven Thickness cause by sewing workmanship
Grippers Leg Out
Grippers Sharp
Point
Lock stitch
button machine
safety sop
Button is considered as a
small object.
If swallowed, that could
cause Choking &
suffocation - hence
potential life threat to kids

The regulator in USA-


CPSC, consider any small
object attached to
Childrens wear should be
well secured
Choking can be deadly

Lets help building a safe world for kids.!


Gymboree Safety standards on button
attaching

All 4 hole buttons must be cross and


lock stitched and all other button must
be lock-stitched using a polyester or
polyester cotton wrap thread
Must pass the pull test requirement 21
lbs 10 seconds
No hand stitch is allowed
The Failure Missing Cross Stitch
From Jan 2015 Oct 2015, Gymboree has rejected 25
POs globally based on DC audits, as buttons MISSED
CROSS STITCH on attachment.
Over 1350 pcs did not meet the criteria.
Lockstitch vs Chain-Stitch Machine

LOCK STITCH MACHINE WITH CHAIN STITCH MACHINE-


BOBBIN CASE -ALLOWED NOT ALLOWED
Root Cause of Missing Cross Stitch
Lock stitch Buttoning machine is not used
Machine is faulty- not well maintained
Appropriate thread is not used
Button Operators are not well trained
Button operators are not checking or has no commitment to
check
The button attachment SOP is not followed
End of the line QCs & final auditors have failed to detect.
Machinery
Only Lockstitch machines are allowed for button
attachment
Sufficient no of lockstitch machine should to be
available. (Hourly output is a good measure)
Machinery list with Model/Year/Serial No
Routine (Periodic) servicing and recording
Machine Suppliers should be called in to review
the status of machines and to educate factory
maintenance team
Daily maintenance by factory mechanics
Daily Maintenance
Daily Machine and bobbin Cleaning.
Thread tension, Bobbin Tension
Checking.
Use correct Types of Needle (#11-
#16)

Needle change every 4


hours
No bent or tipped needle in
use
Daily activity should be
recorded
Button pull test
Random pull out 20 pcs from every 5,000 pcs of bulk for
internal pull test
All the testing record must be documented
At any failure, must stop the bulk production immediately
Create a unique team

All Button Operators


Mechanics
Button Checkers
Auditors

Pick up, train and register.


They should understand their responsibility,
importance of their work and the accountability.

Special attendance record


Trained Pool- to cover absenteeism
Re-training to be done every six months
Process -Pre-Production Control

Verify Foundation Thickness


Apply 25 buttons in a mock seam
Verify button attachment strength (Pull Test)
First Button attach in a mock seam and also at every
bobbin re-fill.
Remove the last Button from body at every bobbin
depletion.
PRE- PRODUCTION CONTROL CHART LOCK STITCH BUTTON ATTACHMENT
PROCESS PRODUCTION CONTROL

Collect every 2 hours production, count,


record with machine no before start checking
Construction and Complete stitch pattern
Review
Clearly Visible rabbit Ear and Knot
Pull test (21 lbs / 10 sec) with record
Daily Production Control chart By Visual check on Rabbit Ear ,
Complete Stitch Pattern
Process PSOs role
Cross check the record book of the
mechanics checklist
Ensure the button operator follow the
SOP when buttoning
Check the mock up in every 2 hours
Educate the trimmers dont treat the
Rabbit Ear as an uncut thread ends
Process Operators Role
Clean the buttoning machine everyday
Do not allow button operator to adjust the thread tension on
the bobbin case
Call out the mechanic to adjust the thread tension when
the button is too loose or too tight
Remove the last attached button when bobbin is empty
Attach the first button at the mock up after refill the bobbin
Process DQAs Role

Check PSO record book and buttoning mock up record in


every factory visit
Random pull 50 pcs of garment to review the performance
of the button attached
Evaluate the entire button operation process
Pull out 20 pcs of garment for internal pull test in every
5,000 pcs of button attached
Bobbin changing 1st button attachment form
LOCK STITCH MACHINE DAILY CLEANING REPORT
Pull test record on Daily Production Lock stitch button
Initiative taken with all factories to train all concerns to avoid Button
safety Failure
Initiative taken with all factories to train all concerns to avoid Button
safety Failure