Quality control system_in_garments_industry__quality_control_system_in_apparel_industry__quality_contDocument Transcript
t ext ilelearner.blogspot .com http://textilelearner.blogspot.com/2011/08/quality-control-system-in-garments_2589.htmlQuality Control System in GarmentsIndustry | Quality Control System in ApparelIndustry | Quality Control System for KnittedGarment IndustryShare on facebook Share on twitter Share on email Share on print More Sharing Services 2Quality means customer needs is to be satisfied. Failure to maintain an adequate qualitystandard can therefore be unsuccessful. But maintaining an adequate standard of quality alsocosts effort. From the first investigation to find out what the potential customer for a newproduct really wants, through the processes of design, specification, controlled manufactureand sale.There are a number of factors on which quality fitness of garment indust ry is based such as -performance, reliability, durability, visual and perceived quality of the garment. Quality needs tobe defined in terms of a particular framework of cost.In the garment industry qualit y cont rol is practiced right from the initial stage of sourcing rawmaterials to the stage of final finished garment. For textile and apparel industry product qualityis calculated in terms of quality and standard of fibres, yarns, fabric construction, colourfastness, surface designs and the final finished garment products. However qualityexpectations for export are related to the type of customer segments and the retail outlets.Objectives: 1. To maximize the production of goods within the specified tolerances correctly the first time. 2. To achieve a satisfactory design of the fabric or garment in relation to the level of choice in design, styles, colours, suitability of components and fitness of product for the market.Requirements:The Quality System Requirements are based on the principle of PDCA Cycle.1 Understanding the customersquality requirements.2 Organizing & training qualitycontrol department.3 Ensuring proper flow of qualityrequirements to the QCdepartment.4 Ensuring proper flow of qualityrequirements to the ProductionDepartment.5 Establishing quality plans,parameters, inspection systems,frequency, sampling techniques,etc.. Process Cycle6 Inspection, testing,measurements as per plan.
7 Record deviations8 Feed back to Production Department.9 Plan for further improvement.Establishing the Quality RequirementsThe first step for quality control is to understand, establish & accept the customers qualityrequirements. This involves the following steps.1 Getting customers specifications regarding the quality2 Referring our past performance3 Discussing with the Quality Control Department4 Discussing with the Production Department5 Giving the Feed Back to the customers6 Receiving the revised quality requirements from the customers7 Accepting the quality parametersVarious Steps of Inspection & Quality ControlThe following levels are discussed at the Garment Making Department assuming that thisdepartment is receiving the ready to cut dyed & finished fabrics from the Dyeing & FinishingDepartment.Bef ore or Pre Production InspectionThe following parameters & defects are checked prior to cutting.1 Shade Matching2 Fabric Construction3 GSM (grams per square metre)4 ( whales & courses if required)5 Diameter6 Dyeing Levelness7 Ecological parameters if required8 Softness9 Shrinkage10 Matching of Rib, Collars & Cuffs11 Fabric Holes12 Vertical & Horizontal Stripes13 Knitting defects such as missing loops, sinker lines, etc.14 Bowing15 Skewing16 Yarn def ect s such as thick & thin places17 Dirts & StainsDuring Production Inspection1 Verify cutting patterns2 Cut components measurements3 Cutting shapes4 Fabric def ect s5 Other specific parameters as required by the customers Rib, Collars & Cuffs matching6 Stitching defects7 Sewing threads matching8 Dirts & Stains9 Measurements10 Labels11 Trims & AccessoriesBef ore Production Inspection
Many of the important parameters of Pre-productions, During productions & Final inspectionparameters. This is to ensure that wrong or major defective garments are not packed.Final InspectionA. PACKING & ASSORTMENT1 Wrong Model2 Wrong Quantity3 Missing labels & tags4 Wrong Size & Colour assortment5 Wrong FoldingB. FABRIC DEFECTS1 Wrong Shade2 Uneven dyeing3 Holes4 Knitting stripes5 Thick & Thin places6 Dirt & Stains7 Oil stains8 Sinker line9 Poor softness10 Higher Shrinkage11 Crease MarksC. WORKMANSHIP DEFECTS1 Open seam2 Puckering3 Needle holes & marks4 Unbalanced sleeve edge5 Unbalanced placket6 Insecure shoulder stitch7 Incorrect side shape8 Bottom hem bowing9 Uneven neck shape10 Cross labels11 Broken & Missing stitch12 Insecured buttons13 Untrimmed threads & fabrics14 Poor Ironing15 Double stitchD. GENERAL DEFECTS31 Shade variation within the garment parts2 Shade variation between the garments3 Defective printing4 Defective embroidery5 Defective buttonsE. MEASUREMENT DEVIATIONSCompare the garment measurements against the Customers Measurement Charts.Following are the some of the important garments measurement aspects to be considered.1 Garment length2 Body width3 Shoulder length
4 Arm hole5 Arm Opening6 Sleeve length7 Placket length8 Placket width9 Neck width10 Neck opening11 Hemming width12 IRib or Collar widthAQL ( Acceptable Quality Level )A certain proportion of defective will always occur in any manufacturing process. If thepercentage does not exceed a certain limit, it will be economical to allow the defective to gothrough instead of screening the entire lot. This limit is called the "Acceptable Quality Level" (AQL )Considering the practical & economic aspects, Sampling Techniques are adopted to Accept orReject a Lot on the basis of the Samples drawn at Random from the lot. It has been found andaccepted that a scientifically designed sampling & inspection plan protects a Manufacturer aswell as the Buyer economically.American Military Standards known as MIL-STD-105A to 105E is accepted world-wide forsampling sizes. It has the following sample size levels. Normally for Garment Industry 105D or105E are followed.1 Special Inspection Levels ( S1, S2, S3 & S4 )2 General Inspection Levels ( I, II & III )3 It has various AQL levels from 0.040 to 25 for Accepting or Rejecting the lots. Normally forGarment industry, the AQL levels of 2.5, 4.0 and 6.5 are followed.Ecological Parameters:Now all the Customers are asking for Ecological Parameters. Now European Buyers arestressing this. Following are main Ecological Parameters to be considered.1 pH range2 Formaldehyde levels3 Extractable heavy metals4 Chlorinated phenols ( PCP, TeCP)5 Forbidden Amines of MAK III A1& A2 categories6 Pesticides7 Chlorinated Organic carriers8 Biocide finishes9 Flame retardant finishes10 Colour fastness to Water11 Colour fastness to acid & alkali perspiration12 Colour fastness to wet & dry rubbing13 Colour fastness to saliva14 Emission of volatile chemicals15 Other specific parameters as required by the customers 3 0 2 0 1 347