Needle, Broken Needle, and Sharp Tools Control Procedure in the Apparel Industry │Textile Floor│

This procedure applies to all types of needles used in sewing machines, hand sewing, label applicator guns, staples, and other sharp tools such as knives, scissors, and cutters in the apparel industry. The article addresses the control of sharp items in two main parts: needle control and the control of other sharp tools. Needles are found in every sewing machine, so they are treated separately. In any garment industry, needles and sharp tools must be controlled individually for safety.

Needles are used for sewing garments, while scissors, cutters, and knives are used for cutting fabrics and threads. Staples should be eliminated from all areas, sections, raw materials (like supplier cartons), and processes of the factory. Loose sharp objects must not be present in any production area near fabric or garments and should be securely tied up.

General Procedure for Sharp Tool Control

·         Maintain a log for broken needles and ensure no needles are left on idle machines.

·         Eliminate sharp points and ensure scissors and cutters are secured.

·         Properly control blades.

Contents

·         List of Sharp Tools Used in Garments

·         Needle Control

·         Objectives of Needle Control

·         Application of Needle Control Procedure

·         How to Control All Sharp Tools Used in Apparel/Garments

List of Sharp Tools Used in Garments

·         Sewing Needle

·         Scissors

·         Cutter (Thread Trimmer)

·         Cutting Machine Knife

·         Cutting Clamps

·         Loose Metal or Machine Parts

Needle Control

A needle issue booth should be available on each production floor, and only one designated person in the relevant department should have the authority to manage the needle control procedure. The apparel industry must implement a needle control policy to ensure safety for both buyers and garment manufacturers. This procedure applies to sewing, embroidery, knitting, linking, or any area where needles are used or where metal contamination could occur in the manufacturing process.

 

Objectives of Needle Control

·         Ensure customer product safety

·         Guarantee employee safety

·         Ensure consumer safety

·         Maintain discipline in handling sharp tools

·         Create a safe working environment

Application of Needle Control Procedure

Idle Machines: Machines not in production should not have needles attached.

Needle Management: Mechanics should not leave spare needles with the machine after servicing. Only the needle in use should be kept at the sewing machine. Spare needles should be stored securely, and the keys to that storage must be kept by the person responsible for managing the needle control procedure.

Broken Needles: When a needle breaks, all broken pieces must be recovered and reported to the person in charge of needle control. Once recovered, the pieces should be attached to a control sheet with clear adhesive tape, allowing for the issuance of a new needle.

Unrecoverable Needle Parts: If any broken needle parts cannot be found, isolate the work area, place the items in a locked box, and use a metal detector to locate the missing needle pieces. If the detector fails to locate the pieces, the batch of work should be destroyed.

 

Needle, Broken Needle, and Sharp Tools Control Procedure in the Apparel Industry

If a needle piece is lost, handheld metal detectors are effective in quickly locating missing needles, and it’s recommended to have one detector in each factory location. If the broken needle parts cannot be found with a metal detector, the entire isolated batch of work should be destroyed. All control sheets and related records should be maintained securely in a locked location. Worn-out needles should be stored in sealed containers away from the factory floor and disposed of safely to avoid injuries.

Avoid placing glass items, such as bottles or paperweights, in production areas to prevent injury from glass splinters. Snap-off blade knives and disposable metal blades should never be used in production, packaging, or shipping areas.

 

Action to Follow for Needle Control

Needle Status: Mark broken needles with "B" and worn, twisted, or bent needles with "W."

Broken Needle Recovery: When a needle breaks, all parts must be recovered and submitted to the responsible person. The broken pieces should be attached to a control sheet with clear tape, and a new needle may be issued.

Unlocatable Needle Parts: If all parts of the broken needle cannot be located, use a metal detector to find the pieces. If the detector is unsuccessful, isolate the area and destroy the batch of work.

 

Control of All Sharp Tools Used in Apparel/Garments

·         Maintain records of all sharp tools by section.

·         Supply all necessary sharp tools at the start of the workday and collect them at the end.

·         Ensure no tools are lost during production.

·         Keep section-wise stock management reports.

·         Securely tie scissors and cutters to the relevant machine or table during operation.

·         Eliminate the use of staples anywhere in the production area as they are a safety hazard.

·         Metal or machine spare parts should not be kept in the workplace.

·         By adhering to these procedures, the garment industry can ensure the safety of workers, consumers, and products, while maintaining a safe and efficient working environment.