trouser quality manual
DESCRIPTION
Trouser Quality Manual for Subject Apparel Quality ControlTRANSCRIPT
- 1. Submitted by:Submitted to:Vinay PrajapatiM.F.Tech,
Sem-I,NIFT, GandhinagarMs. Nupur ChopraAsst. ProfessorNIFT,
Gandhinagar
centercenter 2010Quality ManualFormal TrouserNational Institute of Fashion Technology, Gandhinagar9500095000 2010Quality ManualFormal TrouserNational Institute of Fashion Technology, Gandhinagar
Contents
- Introduction
- 2. Objective
3. Cost and Quality 4. Management Responsibility 5. Purpose 6.
Scope 7. Organisational Structure and Responsibilities 8. Job
Description of Responsible Persons For Quality 9. Quality System
10. Purpose 11. Scope 12. Quality System Procedures 13. Quality
Planning 14. Receiving Inspection 15. Purpose 16. Scope 17.
Receiving Inspection 18. Accessories 19. Fabric Inspection 20.
Fabric Inspection Procedure - 4 Point System 21. Rolls Selection
Procedures 22. Acceptable Penalty Points 23. Acceptable Point Count
Level 24. Rejection Rate 25. Running Defects 26. Process Inspection
27. Purpose 28. Scope 29. Process Inspection 30. Spreading
Inspection 31. Cutting Inspection 32. Sewing Inspection 33. Table
Inspection 34. Two Hourly Inspection 35. Final Inspection 36.
Purpose 37. Scope 38. Activities 39. Garment Inspection Procedure
40. Defects Classification List (Major) 41. Defects Classification
List (Minor) 42. Sampling Techniques 43. Pre-Shipment Survey By
Acceptance Sampling 44. Control Of Non-Conforming Products 45.
Purpose 46. Scope 47. Activities 48. Garment Taken: PETERENGLAND
Formal Trouser 49. Sampling of Formal Trouser 50. Front View 51.
Back View 52. Parts of Formal Trouser 53.
ConclusionIntroduction
Introduction
With the increased demand of garments in the world wide, number of
garments factories is growing rapidly but Q.A. management system
cannot be developed in the same speed due to the lack of Q.A.
management system. Quality of product and service along with the
efficiency of the work force is the foremost objective to produce
products and service of the high standard, which meets all the
specifications, including environmental concern and safety.
Commitments to valued customer:
- Maintaining the highest achievable quality possible
54. The most competitive pricing in the world market 55.
Shortest lead-time with on time delivery 56. The best environment
for ethical standard in accordance with world compliance
standardsObjective
Objective
Objectives of these policies are:
- To understand customers perspective of quality
57. To provide better quality of products and service 58. To
provide good and safe working environment to the workers, which
includes human value, respect, justice, cleanliness, discipline and
equality between workers and others 59. To implement quality
control system with the aim to achieve zero defect level through
efficient management, research, development and continuous
improvementCost and Quality
Cost and Quality
Cost and Quality
QUALITY: Quality is defined as Totality of characteristics of an
entity (product, service etc.) that bears on its ability to satisfy
stated and implied needs.
QUALITY CONTROL: Is an effective system for interchanging the
quality maintenance and quality improvement efforts of various
groups in an organization so as to enable production at the most
economical levels which allow full satisfaction for the
consumers.
TOTAL QUALITY MANGEMENT (T.Q.M.): Is described as an all- inclusive
fully integrated productivity technique. It helps to create new
markets, expand existing markets and recapture lost markets by
utilizing the optimum capability of man, machine, material, method
and produces high and uniform quality of products with reduced
costs. Total quality control starts from market i.e. from
purchasing material and machine and ends in the market i.e. selling
the finished products in the market including after-sale service.
It includes market analysis, product development, production
planning, statistical quality control, preventive maintenance,
wastage control, inventory control, cost reduction and after sales
service etc. The ultimate goal of T.Q.M. is to increases the
quality/cost ration and continuous improvement. It may be done by
increasing the quality with same cost, decreasing the cost with
same quality and increasing quality and decreasing coast at the
same time.
The basic quality problem is to set correct balance between the
cost and quality i.e. to find out a suitable quality/cost ration
for the product which will satisfy the consumer both for cost and
quality.
Management Responsibility
Management Responsibility
Section 1
PURPOSE
The organizations quality policy is documented and communicated to
each person in the organization. The organizational structure,
responsibilities and authorities have been described to ensure
every key personnel know his job and the same could be cross
checked by his higher management. To check the effectiveness of the
quality system, it has been suggested to conduct a meeting after
every fortnight with the responsible officers taking care of
quality system in their assigned position.
SCOPE
This section covers the organizational structure and
responsibilities of all personnel who supervises, perform and
verify works at different stages for the improvement and
maintenance of quality.
ORGANIZATIONAL STRUCTURE AND RESPONSIBILITIES
The following positions play a managerial role in the maintenance
of product quality and the quality control system through chain of
command.
JOB DESCRIPTION OF RESPONSIBLES PERSONS FOR QUALITY
1. MANAGING DIRECTOR: will ensure the absolute adherence to the
quality control system by exercising his authority through his
channel of command.
2. G.M.Q.A CENTRAL:
a) Preparing quality manuals for the group
b) Taking approval from the MANAGING DIRECTOR for implementation of
the system stated in the manual
c) Implementation of statistical quality control system in the
factories here it is applicable
d) Training of QC personals for continuous improvement to achieve
zero defect level
e) Training of QC personals on statistical quality control system
and graphical method for achieving target quality level desired by
the buyer
f) Collections of buyers quality guide lines from buyers website or
manual and convey it to Manager QA central, Manager QA factory and
Monitoring for proper implementation to achieve buyers quality
level
g) Maintain liaison with buyers QA team for technical problems for
which their help is needed
h) Monitoring the job of Manager QA central, Manager QA factory to
evaluate their performance and report it to concern authority
i) To help authority to recruit right person for right job of QA
department.
j) To inform to concern directors and chairman of the group the
overall quality position of the factories by MIS.
k) Inform the concern director if any factory is unable to perform
up to the desired level of quality by corrective action request or
verbally.
l) Study quality related books, journals, manuals and research for
continuous improvement.
3. MANAGER QA CENTRAL:
a) Collection of spec sheet, shade band card, trims card, fabric
test report and approval sample from the concern merchandiser and
compare production sample with the Approval samples as well as
technical sheet
b) Not to allow any deviation from the approval sample if there is
no written confirmation form the buyer
c) Collection of fabric inspection report to judge whether fabric
is acceptable for production on the ground of shade, defect and
other factors
d) In line inspection to see whether the garments quality is as per
buyers requirement or not. In case of any deviation, take
corrective and preventive action.
e) Briefly describe the buyer requirement and quality control
procedure to Manager QA factory for proper monitoring to produce
garments as per requirement of buyer
f) Report to Manager Quality, all his findings and inspection
report for taking corrective actions and monitoring
g) Collecting of buyers quality guideline documents, going through
these and explain these to manager Q.A. factory, and monitoring the
same for correct implementation.
h) Conduct pre-shipment inspection before buyers inspection to be
confirmed about the lots defect level, whether it is as per buyers
desired level or not. It not, sends the lot for recheck for
correction (alter) and re-inspect the same lot after
correction.
i) Allotment of his QC team to all mother and sub contract
factories (if any), monitoring the quality of production in all
factories and subcontract factories.
4. MANAGER QA:
a) Over All Administration of factories QA dept and monitoring the
work of Sewing Q.C, Finishing QC, Line QC, QI Cutting and all
inspectors as well as evaluation of their performance.
b) Conduct training and make all his sub ordinates accountable to
him for their performance to achieve the target of quality
level.
c) Reporting day-to-day quality status and trend to factory
GM/PM.
d) Collection of approval sample, shade band card, trim card, spec
sheet and go through these to compare first of production with the
approval sample before going for bulk production.
e) In case of any change in the style or design by the buyer he
will communicate the floor people for the confirmation of
change.
f) Send samples of fabric, garments, and accessories to the concern
merchandiser for lab test, if it is required.
g) Conduct day final inspection on the available quantity of
ferments at the end of day in finishing. If the lost is not
accepted go for correction. Conduct pre shipment inspection after
completion of the lot and take necessary corrective measures before
buyers final inspection.
h) Details study of test cutting, sample, wash and non-wash and
consult with Manager QA Central, GM/PM of the factory if there is
any discrepancy to find out appropriate solution.
i) Keep close co-ordination with Manager and GM QA, central for
continuous improvement.
5. QC MIS & MONITORING: (Controlled by GM QA, CENTRAL)
a) Monitoring the job of MIS Asst./Inspector, and monthly MIS
report to GMQA.
b) Process capability study of every line by calculating C.V of
lines defect percentage.
c) Study of Technical sheet and approved sample of buyer. Compare
first of production sample with approved sample, with respect of
technical sheet approved trim card and shade.
d) Monitoring in-process 7 pcs inspection, counter check table
inspection.
e) Checking of line wise Monthly operators performance and Monthly
table defect analysis.
f) Monthly defect analysis, C.V of defects line wise and factory
wise
g) Moving average line and factory wise to observe the trend of
defect.
h) Defect analysis after 100% process inspection in
finishing.
i) Monitoring accessories, fabric and cutting inspection.
6. SUPERVISOR QC:
a) Carry out instruction receives from manager QA factory.
b) Monitor the job of line QCs in process 7pcs inspection, table
inspectors and maintain liaison with cutting quality
inspectors.
c) Go through buyers approval sample, shade band card, trim card,
spec sheet and supervise making garments as per style and
measurement.
d) Implementations of design change approved by buyer and
instructed by Manager QA Factory.
e) Management, administration, training, motivation of his stuff
for of continuous improvement.
f) Conduct daily inline inspection and fit audit and report to the
manager QA.
7. TWO HOURS Q.I. (FINISHING):
a) Two hours inspection, visual and fit audit on buyers desired
AQL. If lot is not passed, correction of defects and re-inspection
on same method
b) Monitor the job of all finishing inspectors and report to
Manager QA Factory
c) Keep close co-ordination with Sewing for rectifying defects in
Finishing and make defect analysis in finishing taking corrective
and preventive action in sewing.
d) Conduct training of all finishing QC Inspectors for continuous
improvements.
8. Sr. Q.I. CUTTING:
a) He is responsible to Manager QA Factory.
b) Monitor accessories inspection, fabric inspection, and cutting
inspection.
c) Submit all inspection report to Manager QA Factory..
d) Collection of trim card and shade band card from Manager QA to
compare the lot during inspection.
e) Conduct cut panel inspection and accessories inspection as per
sampling inspection plan.
f) Monitor spreading quality control and cutting quality
control.
9. SR. Q.I. SEWING: Two/Three for each line (Depending on no. of
machines in line)
a) Carry out instructions of Manager QA Factory.
b) Conduct process capability study of the Line by calculating C.V
(Co-Efficient of variation) of hourly defect percentage.
c) Monitor quality performance of operators for continuous
improvement and incentives to operators for their
performance.
d) Supervise the cutting bundles numbering, size and serial for
proper control in the sewing.
e) Review the production sample according to approval sample and
shade,
f) Check machine cleanliness, needle condition and size, proper
thread count and shade.
g) Conduct process inspection having idea from table inspection
report and defect analysis, about the source of high ranking of
defects.
h) Observe the trend of defects from the moving average of defects
in the table inspection and take special care in those particular
processes in the line.
10. ACCESSORIES INSPECTOR:
a) Sampling of accessories as per US-MIL-STD-105E Normal Inspection
Level II AQL 2.5 or specified by buyer.
b) Inspection of accessories as per approved trim card by the
buyer
c) Segregation of non- conforming accessories and keep it
separately with non-conforming tags.
d) Preparing inspection report and submit it to Manager QA,
factory.
11. FABRIC QUALITY INSPECTOR:
a) Random selection of rolls as per US-MIL-STD-160 5DE-1 05E to 10%
of the lot.
b) Shade grouping of all rolls, compare shades with approved
shade.
c) Side centre side, side-to-side, end-to-end and running shade
check of individual rolls. `
d) Preparing shade grouping report and submit it to Manager
QA.
e) Fabric inspection by 4-point system and making fabric inspection
report
f) Segregation of non-conforming rolls with red tag and keep ii) a
safe place.
12. CUTTING QUALITY INSPECTOR:
a) Spreading checking on 10 points
b) Block and bundle check.
c) Daily summary of cutting and spreading quality control report to
manager A factory.
d) Affix allotted QA numbered arrow sticker to mark all defects
where applicable,
13. TARLE QI, OUTPUT: Number two/three for each line (inside and
out side) 100 Inspection of outside and inside of garments.
a) Segregation of non-conforming garments and returns to line QC
for taking corrective and preventive action.
b) Re inspection of non-conforming garments after correction.
c) Fill up the line wise hourly inspection format,
d) Affix allotted QA numbered arrow sticker to mark all defects
where applicable.
14. FINISHING QI (Individual Process)
a) 100% inspection of individual process inside and outside.
b) Segregate non-conforming garments in separate box and hand over
to Finishing QC for correction.
c) Re inspection of non-conforming garments after correction.
d) Affix allotted QA numbered arrow sticker or mark all defects
where applicable.
15. FINISHING QI (Measurement)
a) Measurements of 100% garments on specified points shown by QA
Manager.
b) Segregation of non-conforming goods and hand over to QC
Finishing for necessary correction.
c) Re-measurement of non-conforming goods after correction.
d) Fill up the measurement report and submit it to QC
Finishing.
e) Affix allotted QA numbered arrow sticker to mark all defects
where applicable.
6. FINISHING INSPECTOR (Final)
100% inspections of garments get up (Overall appearance)
a) Segregation of non-conforming goods to QC Finishing for
correction.
b) Re- inspection of non-conforming goods after correction.
c) Fill up the hourly inspection report
d) Affix allotted QA numbered arrow sticker to mark all defects
where applicable.
Quality System
Quality System
Section 2
PURPOSE
To document and maintain a quality system as a means to ensure that
product of all factories to specified requirement.
SCOPE
The quality system operated aims to ensure compliance to specified
requirements and is defined and driven by Quality Manual,
departmental procedures and work instructions, those are defined in
this section.
QUALITY SYSTEM PROCEDURES
The Quality procedure of each factory will be reviewed by the
concerned persons of Management of that factory. Describing the
quality systems of all factories of XYZ, this manual includes a
brief description of the functions and mode of operation of the
factories management personnel with respect to quality.
QUALITY PLANNING
Documented quality planning is stated by this manual, accompanying
procedure and instructions and quality, all of which comprise the
Quality System. Thus, quality planning is, documented and
implemented by all Executives and Managers playing a role in the
maintenance of product quality and the quality management
system.
To achieve the goal of zero defect level following steps has been
taken.
- For massive awareness building regular discussion and meeting are conducted with the concern people.
60. Regular training session is being conducted on Statistical
Quality Control System 61. Introduce it as a tool to achieve the
goal. 62. Introduce incentives for inspectors and operators for the
best performing line. 63. Introduce operators' quality performance
chart to find out source and type of defect for taking preventive
and corrective measures. 64. Reorganize process/7pcs inspectors job
allocation, work procedure to make them more accountable for
effective control on process inspection with the help I-operators
quality performance chart. 65. Weekly defect analysis of process
inspection, table inspection and final inspection to find out the
irregularities of inspection if any and. to take corrective
measures. 66. Monthly defect analysis and moving average, line and
factory wise, to monitor improvement and trend of defect. 67. For
graphical representation of hourly defect percentage in control
chart to set upper control limit at 1.0%, central line is 0.65% and
lower control limit at 0.0% to brine down defect level towards zero
by continuous improvementQuality planning also includes the
following
- Assignment of responsibility for conducting checks
68. Stages at which checks are to be carried out 69. Methods to
be followed in conducting the checks 70. Frequency of the checks
71. Criteria for acceptance/rejections 72. Related documents to be
checked 73. Documents to maintain as evidence of the checks 74.
Corrective & preventive action to be taken subsequent to the
checkReceiving Inspection
Receiving Inspection
Section 3
PURPOSE
To establish and maintain documented procedures for receiving
inspection in order to verify that the specified requirements for
the product are met.
SCOPE
This section applies to the product being produced in the garment
factories.
RECEIVING INSPECTION
ACCESSORIES
Before receiving accessories all necessary tests and inspection is
conducted lot wise by the accessories inspector under the guidance
of QA Manager at buyers desired AQL. If result found acceptable,
then the lot is accepted otherwise lot is rejected and kept in
marked area with a red tag for the safety. So that non-conforming
goods are not used in process.
44577002032000FABRIC INSPECTION
Fabric roll is selected on the basis of random sampling; acceptance
or rejection criteria are decided at prescribed label on 4-Point
system. 10% of rolls -are inspected in this stage by Fabric
Inspector. In case of rejection of lot on 10% of rolls, rest of the
rolls of the lot is inspected thoroughly. Reject rolls are kept
separately with red flags.
Inspection records are kept in inspection format.
Summary of the fabric inspection is recorded in the summary sheet,
for management information.
Conforming goods are kept separately with Green Sticker and kept in
stack named.
READY FOR CUTTING
All rejected goods are treated as "NON-CONFORMING GOODS" and marked
with red sticker.
Checking of s-lade and shade grouping.
FABRIC INSPECTION PROCEDURE - 4 POINT SYSTEM
OBJECTIVE
The aim of fabric inspection is to check the quality, quantity and
packing by visual, measurement a colour check confirming with the
specification and general appearance of the approval sample given
by buyer.
INSPECTION PROCEDURE
- Receive approved colour and quality swatches.
75. Check lot size and label against the submitted packing list.
76. Randomly draw 10% of the lot. 77. Delivery of less than 1000
yds 100% inspection 78. Delivery of 1000 yds to 10000 yds to
inspect at least* 1000 yds. 79. Shipment of more than 10000 yds
inspects 10% of the lot.PENALTY POINT EVALUATION
Fabric to of graded will be examined from a distance of
approximately three feet while runner-Up cover the perch of a
fabric inspection machine. The inspector will run the fabric at a
speed compatible with his ability to distinguish.
POINT CALCULATION
INDIVIDUAL ROLL
Penalty points X 36X 100
-------------------------------------------------------------------
Total yards Inspected x Width of cloth in inch
= Points per 100 Sq. Yard
AVERAGE POINTS PER SHIPMENT
Total Points per 100 Sq. yard of all rolls Inspected
-------------------------------------------------------------------
Total number of rolls Inspected
= Average points per 100 Sq. yard
PENALTY POINTS IN 4 POINT SYSTEM
The position of the defect in the fabric in either length or
width
ROLLS SELECTION PROCEDURES
- These rolls shall be selected for inspection on a totally random basis.
80. The knit dyeing unit is required to present the inspector
with a shipment packing list when 80% of the rolls are packed from
which the rolls to be inspected will be chosen. 81. Once the
inspector has selected the rolls for inspection; no adjustment may
be made to the number of rolls to be inspected or to the rolls
selected for inspection. 82. At no time during the inspection may
any yardage be removed from any roll other than for recording and
measuring shade tolerances. 83. All rolls inspected will be graded
and assigned penalty points.ACCEPTABLE PENALTY POINTS:
If no specifies standard provided for knit fabric, the average
point value per shipment not exceeds 40 points per 100 linear
yards. Individual rolls exceeding 40 points shall be
rejected.
DEFECTS CONDITIONS
- No more than 4 points will be penalized within one yard
84. Severe defects are assigned max 4 points for each yard 85.
Any hole and any running defect will be penalized 4 points 86.
Whole roll having running defect or continuous defects in more than
10 yard will be considered rejectSPLICE ALLOWANCE
- It will not be allowed more than one splice
87. No part of a spliced roll can be shorter than 40 yard except
specified by customerROLL LENGTH
- Roll found to deviate more than 2% from the roll ticket yards shall be rejected.
88. The entire shipment shall be rejected if the total measured
yards in the sample audit deviates 1 % or more from the ticket
yards.HAND FEEL
The hand feel will be checked between roll with a reference sample.
If there is a noticeable difference, the roll will be classified as
second quality.
SHADE HATCHING
Roll to roll with head to end, side to side, side center side will
be checked during visual quality inspection for preliminary. Final
checking will be taken in the light box against gray scale rating.
Under light source D-65.
COLOR SHADING RATING
1) Side to Side 4 5 or 5 (Accepted)
2) Side center Side 4 5 or 5 (Accepted)
3) End to End 4 5 or 5 (Accepted)
4) Lot to Lot 4 or 4 5 or 5 (Accepted)
5) Against approval sample 4 or 4 5 or 5 (Accepted)
ACCEPTABLE POINT COUNT LEVEL
Various types of textiles are divided into the following five
groups. Individual rolls exceeding the specified point count level
shall be graded as second quality. A shipment shall fail the
inspection if the shipment penalty count points exceed the
specified point count level
REJECTION RATE
If total rejected inspection yardage is over 10% of total inspected
yardage, then overall result is concluded as "Rejected"
RUNNING DEFECTS
- Any defect found to repeat and/or run in a continuous manner will constitute a running defect. All running defects must be assigned four points to every yard in the roll when the running defect occurs.
89. Any roll having a running or repeating defect through more
than three continuous yards shall be rejected regardless of point
occurs.FULL WIDTH DEFECTS
- No roll that contains more than four full width defects per one hundred linear yards shall be accepted as first quality.
90. Any roll found to contain defects, in any increment of one
hundred yards, with an average of more than one major defect per
ten linear yards will be rejected. 91. No roll shall be accepted
that contains a major defect in the first or last three yards of
the rolls. A major defect is considered to be any three or four
point defect 92. No roll shall be accepted as first quality that
exhibits a noticeable of loose or tightness along either or both
selvedges or ripples, puckers, folds or creases in the body of the
fabric that would prevent the fabric form lying flat when being
spread in a conventional manner.FABRIC WIDTH
- Fabric width will be checked a minimum of three times during the inspection of a roll, beginning, middle and end. The roll width will be checked more often if the fabric is close to the specified minimum width of if the fabric width is uneven.
93. Rolls paving a measurement of less than the specified width
will not be accepted. 94. For knit fabric, rolls having a
measurement of 1" wider than the specified diameter will not be
accepted. But for the stretched woven fabric, it can be accepted 2"
wider than the specified purchased width. 95. For knit fabric,
rolls having a measurement of 2" wider than the specified purchased
width will be accepted. But for the Lycra knitted fabric, it can be
accepted 3" wider than the specified width.Process Inspection
Process Inspection
Section 4
PURPOSE
To establish and maintain documented procedures for process
inspection in order to verify that the specified requirements for
the product are met.
SCOPE
This section applies to the product being produced in the factories
of XYZ.
PROCESS INSPECTION
Process inspection is conducted on following sages.
- Spreading Inspection
96. Cutting Inspection 97. Sewing Inspection 98. Table
Inspection 99. Two hour InspectionsSPREADING INSPECTION
Following ten points must be taken care of by the cutting quality
inspector at the time of spreading.
- Table marking
100. Ends 101. Leaning 102. Tension 103. Narrow goods 104.
Remnants 105. Counts 106. Ply height 107. Marker Placing 108.
Fabric FlawsCUTTING INSPECTION
Cutting inspection should be on the basis on random sampling on
desired AQL. If the lot is passed on sampling inspection then it is
send for sewing operation, if not passed the whole lot is
re-inspected and rejected parts are replaced by good parts. In
cutting inspection there are two types of check BLOCK CHECK &
BUNDLE CHECK. Following points are inspected in block check such as
Size, Parts, Pattern check, Mis cut, Ragged cutting, Notches,
Matching plies.
Following points are checked in the bundle check such as Size,
Parts, Total quantity, Inspect quality, Defect quality. However it
is recommended to check 100% cutting parts under the light box
table.
SEWING INSPECTION
a) The SR. Line Q.I should audit completed finished bundles
b) He must select 7 pcs at random from the bundle.
c) If the inspector finds defective unit, he will take following
steps on operators duality Performance Chart.
d) He will mark red in the room against date of inspection with
defect code and frequency as a symbol for warning and recheck. He
will hand over remaining units of the bundle to supervisor for
check and taking corrective action.
e) He will inspect next three bundles as follow up audit of the
same operator and mark yellow in three rooms if no defective units
are found in next three bundles.
f) He will mark green in the room against date if no defective unit
is found in the bundle.
g) The inspector will make operators monthly analysis to compare it
with tables monthly defect analysis to find out whether there is
any lacking in the sewing inspection procedure.
h) QC Supervisor Sewing will monitor 7 pcs inspection, whether it
is being done properly or not.
TABLE INSPECTION
Table inspection is conducted by two/three/four inspectors (depends
on hourly output) to inspect inside and outside of the garments.
They will record hourly inspected garments, defect found, defect
percentage; also calculate average defect percentage, quality index
of the day and CV of defects. This will help to represent the
defects graphically with the help of MIS Inspector. Monthly table
defect analysis report is prepared and to compare it with operators
monthly defect analysis.
TWO HOURLY INSPECTIONS
i) It is the responsibility of finishing unit TWO HOUR Q.I.
ii) It is conducted every after two hour.
iii) Both visual and fit audit is conducted on available garments
received. per two hoursat desired AQL.
iv) If lot is acceptable than passed for poly packing
v) If not return back for correction
vi) After correction it is re inspected in the same way.
Final Inspection
Final Inspection
Section 5
PURPOSE
To establish and maintain documented procedures for final
inspection in order to verify that the specified requirements for
the product are met.
SCOPE
This section applies to the product being produced in factory
facilities.
ACTIVITIES
Final inspection is the inspection which is conducted before
shipment or buyers inspection. It is conducted in two stages.
i) Day Final.
ii) Lot Final
DAY FINAL
Day final inspection is the responsibility of factory QA Manager.
He conducts this inspection daily on available garments which has
passed by TWO HOURLY inspection and is conducted on desired AQL. If
it is passed, garments are ready for Central Q C Inspection or
Buyers 0 C inspection
LOT FINAL
Lot final is conducted by Central QA Manager when the lot is passed
by Factory QA Manager before shipment or in case any buyer gives
the authority to the factory to conduct final inspection before
shipment. It is also conducted when buyers inspection is conducted
before shipment. It is conducted on desired AQL. If lot is passes,
they are ready for shipment and placed before buyer's
representative for final inspection before the shipment.
Garments Inspection Procedure
Garments Inspection Procedure
STEP-I
Inspector should collect the following before going for the
inspection.
a. Approved sample from the proper authority.
b. First of production (FOP) garments sample as per size and color
from the concern person or authority.
c. Approved colour swatches, shade band card, trim card from the
concern person or authority.
d. Garments and Fabrics test report from the factory or
agent.
STEP-II
a. Inspector should take the following items with him.
- Inspection report form
109. Spec sheet 110. Calibrated flexible fibre measurement
tapeSTEP-III
a. Collect packing list from the factory and check carton against
the packing list.
b. Compare FOP sample with the approval sample and find out if
there is any deviation.
c. Check the shipping mark with the work sheet.
d. Select the carton for inspection by square root of .the total
carton and select carton number with the help of random number
table illustrated in Sampling Technique chapter.
e. Put signature on both the side of carton opening.
f. Bring the carton in the inspection room which should be
sufficiently lighted, tidy and clean.
d. Unseal the carton and check assortment, poly packing, hang tag,
labels, colour tone etc.
e. Select the garments for fit audit size and color wise with
respect to prescribed AQL of fit audit. Conduct fit audit and
identify total major and minor defects.
g. The defects will be called major if it exceeds tolerance and
touch another size in case of measurement.
k. The defect will be called minor if it exceeds tolerance but does
not touch another size in case of measurement.
I. Major and minor defects criteria for Visual audit have been
illustrated below.
M. If the total points major and minor exceeds points as per
prescribes AQL, lot will be rejected for fit audit.
n. Select garments sample size for workmanship
- Inspect garments pcs by pcs.
111. Put arrow sticker on the defect position. 112. Classify
defects as major and minor and score accordingly. 113. If the total
points, each major=10 and minor=0.5 exceed the prescribed points as
per desired AQL reject the lot. 114. Complete data sheet of both
visual and fit, take signature from the factory representative on
the sheet. 115. Replace defective garments in the carton by
good-garments. 116. Collect some defective garments for reference
hand over these to the Person concern for corrective and preventive
action.Defect Classification List (Major)
Defect Classification List (Major)
FABRIC DEFECTS
1. Holes (yarns cut), broken ends, continuous missing yarn
2. Soil, oil spot, contrast visible at arms length / A-zone,
adversely affecting appearance.
3. Misweaves, mispicks (woven)
4. Slubs (Linen & Silk not included) distinguishable when
viewed at arras length A-zone
5. Colour bleeding (A-zone) colour combination not as
specified
7. Misprint, dye spot
8. Bow in knit/ to inch (A-zone)
9. Coating defect less than % inch round (All zones)
10. Shaded parts (conspicuous mismatched)
11. Hand feel different from approved fabric swatch
12. Permanent crease mark Streaks
COMPONENTS AND TRIMS
BUTTONS & BUTTON HOLES
1. Buttons sewing thread colour not as specified
2. Missing button or button hole
3. Broken, damaged, defective or inverted buttons
4. Buttons do not conform to specification
5. Britton insecurely sewn
6. Improper button or button hole
INTERFACING / LINING / PADS
1. Fusible interfacing must be compatible to garment without bubble
or pucker.
2. In a lined garment, the liner must not extend below hem of the
shell.
3. Interlining apparent from outside of garments.
4. Missing one or both pads.
ZIPPERS
1. Insecure bottom or top stops
2. Incorrect colour or tape (shade) of zipper
3. Faulty slider on zipper
4. Any missing or damaged teeth
5. Does not function without special effort
6. Zipper size and length should be appropriate to garment end use
or as specified not more than + inch from spec. Any cut in the
zipper tape. Tape stitched too loose or tight resulting in
excessive bulge on tape or placket when closed.
9. Any malfunction
10. Missing top or bottom stopper
11. Wavy zippers
HOOK AND YES
1. Omitted or sewn in wrong places
2. Hook and eyes misaligned when fastened causing bulge or twist at
the point of closure.
3. All metal parts (snap, hook and eyes, rivets etc) must be rust
proof, washable and dry cleanable
4. Improper type
5. Defective
BELT AND BELT LOOPS
1. Belt Loop not fully secure
2. Incorrect number of belt loops on garments as specified
3. Missing belt loop
POCKET AND F LAP
1. Missing or miss located bar tack
2. Wrong placement
3. Insecure opening
4. Pocket zippers and stress points no' as specified / bar
tacked
CARE LABEL
1. Incorrect fibre content, country of origin, RN number etc.
2. Maintenance instructions do not meet all federal
requirements
3. Not caught completely or not sewn securely
4. Missing/incorrect / illegible
5. Incorrectly attached
COMPRESSION ATTACHMENT OF HARDWARE
1. Clasp/snap, rivet which is defective, damaged incorrectly placed
or attached
2. Eyelet missing or misplaced
3. Velcro placement closure not within 50% of total area
mates
4. Draw cord not free to move as designed
5. Length of drawstring not as specified
6. Ends of drawstrings not secured (missing stopper)
PRINTING DEFECTS
1. Wrong colour, missing colour
2. Miss registered obvious from 6 inch
STITCHING
1. SPI in excess of more than 3 or less than 2 than the
specified
2. Ends of stitching (back tacked at least'/. inch/2 or 3
stitches)
3. Open seams more than 1/4 inch. On outside or'/2 inch on
inside
4. Any raw edges more than Y4 inch on outside
5. Run off stitch (conspicuous)
6. Needle holes.
7. Seams closure uneven, off more than 1/8 inch
8. Seam twisted, puckered or pleated (conspicuous)
9. Poor mending or repairing (conspicuous)
10. Gathered/ bunched stitching
11. Skipped stitch (401), one skipped stitch in a row permitted; no
more than 2 occurrences per seam (lock stitch - 301)
12. Button hole (skipped stitch, cut not securely caught in fabric,
incomplete stitch, uncut not aligned)
13. Button not securely sewn, not cross stitched when
specified
14. Bar tacks not as specified length, placement, width, stitch
count or completely missing.
15. Blind stitch (103,503) excessive pick through 3/32 inch or
more, or tight tension causing distortion or puckering.
16. Beaded stitching (loose top of bobbin thread)
17. Button or button hole not aligned, causing noticeable
bulge
18. Conspicuous high/low pockets (A-Zone)
19. F -ant legs uneven off more than 1/4 inch on any fabric
20. Part of garment caught in any unrelated operation or stitching
(unauthorized stitches)
21. Seams and stitching not as specified type
22. Tight/Loose tension
23. Top stitching not uniform greater than -3/4 inch affecting
appearance
24. Permanent needle hole (needle cut, burrs)
25. Seam allowance (All zones) - join seam < 1/2 inch. / Double
needle setting < inch. Zipper setting < inch
FINISHING AND PACKAGING
1. Not pressed / folded / hang / assorted as specified
2. Over pressing or under pressing/poor pressing defects
including-shine, colour change, scorching or any other conspicuous
"Hard" pressing defect
1. Labs, tickets, tags, logo, hanger size clip missing/incorrect,
illegible or not specified.
2. Item not dry when packed
1. Adhesive labels or adhesive residue visible from 3 inch. (2 inch
in any view)
2. Seam should be pressed open
3. Burn or scorch mark
4. Shine marks on the surface of the garment
5. Sweaters pressed out of size
PACKAGING
1. Merchandise folded or packed incorrectly, resulting in poor
appearance
2. SKU information on box not same as item in the box
3. Incorrect poly bag, box dimension
4. Size sticker, price tag, hanger, box labelling UPC code etc.
incorrectly placed, missing or not as specified
5. Printed information incorrect or missing
6. Poor or improper selling
7. Not packed or assorted as specified
8. Wrong carton marking (shipping mark)
BUCKLES AND SUSPENDER LOOP
1. Broken, rough or sharp edges
2. Coating omitted or thickness or coating/plating less than
specified
3. Wrong colour or metal type
4. Incorrect size or type
1. Oxidized or corroded
2. Misplaced
3. Not attached as specified
Defect Classification List (Minor)
Defect Classification List (Minor)
FABRIC
1. Broken yarn (one yarn) zone B/C.
2. Mispick (low contrast) zone C.
3. Barre (low contrast) zone B.
4. Needle hole (which holes do not run / enlarge).
5. Garment s not within specified shade range or shade band.
6. Printing defects:
i) Incomplete coverage of colour.
ii) Design and pattern direction not as specified.
7. Mismatched stripe/ plaid:
i) On side seam or seat seam when requested in construction
specification Over Y4 inch
ii) 1i ) On placket or pant fly Over 1/16 inch
iii) On centre front panels or placket Over '/8 inch
iv) On pocket or flaps Over 1/8 inch
v) Skewed, bowed or biased fabric, solid or stripe over 1/2 inch
side to side
vi) Shaded parts / thread / or visible components
COMPONENTS AND TRIM
1. Any component not of specified colour, dimension or
appearance
2. Hardware trim misaligned
3. Incorrect position of snaps in excess of 1/8 inch and the
specified
3. Untied cord
3. Velcro, placement (closure) not within 75% of total area
mates
INTERLINING AND PADS
1. Type of interlining or pad not as specified
2. Misplaced fused interlining or pad location
3. Insecurely attached pad
LABEL
1 Label must be positioned at specified location + 1/4 inch and
fully visible
2. Crooked label
THREADS
1. Outside, Uncut thread over 1/4 inch
2. Inside Uncut thread over 1/2 inch seen hanging below a hem or
visible as presented
STITCHING
1. Topstitching Single or double needle not overlapped, stitch on
stitch at start and finish.
2. Poorly objectionably mended (C-zone).
3. Gathering or bunched stitching (B & C zone)
4. Sewn in pleat over 1/4 inch. (C- Zone)
CONSTRUCTION
(FRONT, BACK AND ASSEMBLY DEFECTS)
1. Knitted only Insecure shoulder tape.
2. Fronts are uneven at the bottom in excess of 1/4 inch
3. Uncle- facing shows on the top side of the garment
4. Component to component or joining seams-seam - alignment worse
than % Inch
5. Darts uneven in length in excess of % inch
6. Darts poorly shaped with large bubbles at the end
7. Darts not properly located
8. Waistband irregular or not uniform in width in excess of 1/4
inch
9. Right versus left side seam / in seam difference not exceeds 1/4
-1/2 inch
10. Fly that gaps or doesn't lay flat, exposed zipper tape when fly
is closed
POCKET DEFECTS
1. Raw edge of pocket not square
2. Corresponding pockets horizontally uneven or misaligned in
excess of 1/4 inch
3. Flap and pocket pattern mismatched
4. Weight and colour of pocketing material not according to
specification
5. Dog ears at pocket corners, more than 1/8 inch above top of
pocket
6. Non-uniform shaped or biased pockets more than 1/4 inch, side to
side or top to bottom, noticeable at arms length
7. Pocket width bigger than flap in excess of 1/8 inch
BELT LOOP DEFECTS
1. Belt locos incorrectly placed in excess of 14 inch.
1. Colour c- shade of loop not as specified
2. Thread colour must be matching unless otherwise specified.
3. Conspicuously crooked belt loop.
4. Width of belt loop more than % inch too wide too narrow.
HEM DEFECTS
1. Excessively puckered or twisted hem
2. Open hem greater than 1/4 inch
3. Hem uneven, twisted or poorly sewn
4. High/lpN bottom hem difference greater than 1/4 inch side to
side, or back to front
5. Lining less than 1/2 inch below top edge of the shell hem turn
back
BUTTON/BUTTONHOLE DEFECTS
1. Improper button-hole size
2. Ragged edges caused by cut if dull knife causing fabric
pulls
3. Thread shade that does not match Specified colour
4. Incompatible density of stitching in relation to the
fabric
FINISHING
1. Draw cord length not as specified
2. Odours Offensive odour (Chemical odour)
3. Improper Sealing
SAMPLING TECHNIQUE
The purpose of sampling is to draw correct conclusion about the
population from the sample, now if the sampling is not proper, we
may be misguided for taking action on the basis of wrong sampling.
Again an inspector cannot check all the items produced in a factory
in the whole day, it will cause more man power, more cost, more
time and more labour. If proper, sampling technique is used to draw
sample, it will not only reduce these factors, will also reduce the
monotonousness of the inspector. One of the most important things
of sampling technique is the business of the inspector. Inspector
cannot take sample as per his wish; he must follow the random
number table and probability each item to be drawn is equal. There
are various types of sampling of which, sample random sampling,
stratified random sampling, systematic sampling are commonly
used.
SIMPLE RANDOM SAMPLING
Simple random sampling is a method of selection n units out of N,
such that every one of the Cn samples has an equal chance of being
chosen. It is the simplest type of probability sampling and is the
basis of most of the other sampling methods. In practice a single
random sample is drawn unit by unit. I he units of the population
are numbered I to N.A series of random numbers between I and N are
drawn with the help of random number table or computer which
produces such table.
USE A RANDOM NUMBER TO SELECT A SAMPLE
Use a random number to select a sample the RAND Corporation of USA
has published a random number table in 1955 in the name " A million
random digits with 100000 normal Deviates" To select a sample with
this table, let us consider we have 750 items numbered from 1 to
750 on each item and we want to draw a sample of size 5. For these
purpose we need to select three digits number 001 to 750.
First it is necessary to determine the starting point of the table.
The random number table contains 50 rows and 50 columns of digits.
We are starting from 8th row 39th column from there the first
number is 471, 098, 443, 3351 015 it we arrange them in order then
015, 098, 335, 443, 471. Again we want to select sample of seize 10
from a population 500, for this we have to select three digit
number i.e. from 001 to 500. Let us start from row 30 arid column
11 then our first number will be 732 but it is not in our serial no
so we will exclude it, by going down we will have 752, 640, we will
also exclude these.
Next 268, 454, 013, 201, 017, 194, 361, 452, 419, 312 excluding all
the numbers, which are out of serial. Arranging the numbers in
order 013, 017, 194, 201, 268, 312, 361, 419, 452, 454 these are
the sample numbers which we want to select randomly.
PRE-SHIPMENT SURVEY BY ACCEPTANCE SAMPLING
ACCEPTANCE SAMPLING
Acceptance sampling is the art or science that deals with
procedures in which decision to accept or reject lots or process is
based on- the examination of samples. 100% inspection is generally
not justified because of time and cost as well as for the shortage
of trained manpower. Good sampling inspection, where the items
inspected are examined carefully may even provide. Better assurance
of product quality than 100% inspection with carelessness. The
purpose of acceptance sampling is to specify course of action not
to control lot quality.
Acceptance sampling plan merely accepts c, rejects lots. Generally
we like to ensure that lots of manufactured goods do not contain an
excessively large portion of defective items. This is achieved
mainly through the technique of sampling inspection. Acceptance
sampling has indirect effect on improvement of quality through its
encouragement by high rate of acceptance of good quality and
through discouragement of bad quality by high rate of rejection. It
also reduces the risk of rejection of good lots and accepting of
bad lots on the basis of sample.
TERMINOLOGY OF ACCEPTANCE SAMPLING
LOTS SIZE:
Is the number of units in the lot and is denoted by "N"
SAMPLE SIZE:
The number of units in the sample and is denoted by "n"
LOT INSPECTION:
A specific quantity of similar material, or a collection of similar
units, offered for inspection and acceptance at one time.
SAMPLING INSPECTION PLAN:
A specific plan which states (a) the sample size (b) The criteria
for accepting, rejecting, or taking another sample, to be used in
inspecting a lot.
ACCEPTANCE NUMBER:
The large number of defectives (or defects) in the sample or
samples under consideration that will permit the acceptance of the
inspection lot is called acceptance number, and is denoted by
"Ac".
REJECTION NUMBER:
The smallest number of defectives (or defects) in the sample or
samples under consideration that will require the rejection of
inspection lot is called rejection number, and is denoted by
"Re".
PRODUCER'S RISK:
The probability of rejecting a lot under the sampling inspection
plan when the fraction defective in the lot is actually within
specified limit is called producer's risk and is denoted by
"Pp"
CONSUMER'S RISK:
The probability of accepting a lot with higher fraction defective
than the specified limit under the sampling inspection plan is
called consumer's risk and is denoted by "Pc".
SINGLE SAMAPLING INSPECTION PLAN:
Is the sampling inspection plan in which a decision to accept or to
reject a lot is reached after the inspection of a single
sample.
PROCESS AVERAGE QUALITY:
Expected quality of products form a given process, usually
estimated from first sample inspection results of past lots.
ACCEPTABLE QUALITY LEVEL:
The maximum per cent defective that, for purpose of sampling
inspection, can be considered satisfactory as a process average is
called acceptable quality level anti is denoted by AQL.
PROBABILITY OF ACCEPTANCE:
Probability that a lot or will be accepted is called probability of
acceptance and is denoted by "Pa"
OPERATING CHARECTERSTIC CURVE OR O.C. CURVE:
A curve showing the relation between the probabilities of
acceptance, either lot quality or process quality, whichever is
applicable is called O.C. CURVE. The stealer the O.C. CURVE, the
greater is the protector to the consumer against accepting a bad
lot.
AVERAGE SAMPLE NUMBER:
The expected value of the sample size required for coming to a
decision, i.e., for acceptance or rejection of a lot, under the
sampling inspection plan is called average sample number and is
denoted by ASN. The curve obtained by plotting ASN against "P" is
called ASN curve. Lower the ASN curve better is the sampling
inspection plan.
MAJOR DEFECT:
A major defect is a defect that is likely to result in failure, or
to reduce materially the Liability of the unit of product for its
intended purpose.
MINOR DEFECT:
A minor defect is a defect that i s not likely to reduce materially
the usability of the unit of product for its intended purpose, or a
departure from established standards having little bearing on the
effective use or operation of the unit. Minor defects may be
classified into two categories; more important minor defects may be
designated as Minor "A" and less important ones, Minor "B"
CRITORIA FOR SHIFTING TO TIGHTENED INSPECTION:
When normal inspection is on effect, tightened inspection to be
instituted when 2 out of 5 consecutive lots or batches have been
rejected on original inspection.
CRITORIA FOR SHIFTING TO NORMAL INSPECTION FROM TIGHTENED
INSPECTION:
When tightened inspection is in effect, normal inspection shall be
instituted when 5 consecutive lots or batches have been considered
acceptable on original inspection, criteria for shifter to reduced
inspection When normal inspection is on effect, reduced inspection
maybe institute when,
(a) The preceding 10 lots or batches have been on normal inspection
and has been accepted on original inspection.
(b) The total number of defects in the samples from the preceding
10 lots or batches are equal to or less than the desired
level.
(c) Production is at a steady rate.
(d) Reduced inspection is considered desirable by the responsible
authority.
CRITERIA FOR SHIFTING TO NORMAL INSPECTION FROM REDUCED
INSPECTION:
When reduced inspection is on effect, normal inspection must be
reinstated whenever a lot or batch is rejected or production
becomes in e-regular or delayed or other conditions warrant that
normal inspection shall be instituted.
Control of Non-Conforming Products
Control of Non-Conforming Products
Section 6
PURPOSE
To prevent the dispatch of non-conforming products to the
customer
SCOPE
This section applies to the products which do not conform the
require quality
ACTIVITIES
Non-conforming goods are identified during the checking of
receiving section. Process inspection or final
inspection:
- When a major non-conformance is discovered i.e. (one that requires a managerial/executive decision regarding its disposition) it is so identified and segregated," subject to the appropriate management decision, the defective goods are reworked, accepted on concession, re-graded or rejected.
117. Where appropriate, the customer is consulted concerning any
concession.Garment Taken
PETERENGLAND Formal Trouser
Sampling of Formal Trouser
Parameters
- No. of samples asked for size including counters
118. In Proto Sample 3-5in 32 Size
- 1-3 sample Buyer
119. 1 sample counter 120. 1-2 merchandiser counter In fit
Sample
3-5 in 32 Size
- 1-3 sample Buyer
121. 1 sample counter 122. 1-2 merchandiser counter In Size
set
3-5 in 32 Size
- 1-2 sample Buyer
123. 1 sample counter 124. 1-2 merchandiser counter In
Pre-production
3-5 in 32 Size
- 1-3 sample Buyer
125. 1 sample counter 126. 1-2 merchandiser counter In Design
sample
3-5 in 32 Size
- 1-3 sample Buyer
127. 1 sample counter 128. 1-2 merchandiser counter Fabric
Used
Cotton (2-ply Superfine Satin)
- Actual trims like, buttons used - 3
129. On waist band 130. 2-on side pocket & one back pocket
131. Zipper used 132. What actually being checked 133. In Proto
Sample 134. Styling 135. Pattern 136. Measurements 137.
Construction In fit Sample
- Measurements
138. Fit 139. Constructional features 140. Type of stitching
& quality 141. Position of accessoriesIn size set
- Measurements
142. Fit 143. Constructional features 144. Type of stitching
& quality 145. Position of accessories In pre-production
Reference sample for the production
- Comment sent by -mail
146. The process be eliminated altogether, depends upon buyer
requirement Comment from buyer for different sampling stage till
pre-production can be categorized under following heads
Style Details
Measurement
Fit
Design comment:
- Type and position of trims
147. Shape of critical areas like packet Construction
features:
- Type of stitches
148. Quality of stitches 149. Quality of seams
Front View
Back View
Parts of Formal Trouser
Waist band width1.5Waist band 28Front raise9Fly length6Fly
width1.6Position from Waist band 0, from side seam 6.2 Pocket
opening6.8Position from Waist band 0, from side seam 0 Thai
width21.5Leg opening18Welt 4.9*0.4 Back raise 14Back pocket
7.2*5Position from Waist band 2.5, from side seam 1.2 Belt loop
2.2*0.5Pocket bag9.7*6.7Zipper length 7Size label 0.5*0.5 On the
right side of the fly below the waist bandBrand label 1.1*0.51.5
inch below from waist band Wash care label1.5*1.2Right side of the
front part inside Total length 40
Conclusion
Conclusion
Quality has always been a primary requirement and considers being
the life of a garment. There is no denying the fact that we have
been following Quality Control System in the production process
since its birth but there might have been differences in those
applications in factories. Compiling this quality manual is a
humble effort to put almost all necessary details of Quality
Control System to ensure that all our factories have a written
Manual/ Guideline in black and white to follow. In the beginning we
will not concentrate on the statistical Quality Control System. We
will follow this after a while when we have enough and required
manpower to exercise that. Any positive inclusion in this manual
which will help the factories in improving quality is always
welcome; but has to done with prior approval from the Managing
Director. We all need to educate and train our work force in line
with this Quality Manual to try and streamline our quality system.
Our united and sincere effort only can help to improve in the
sector of quality.