The document outlines a proposed quality system for Stitched Up, a leading apparel manufacturing company. It discusses establishing procedures to ensure quality control at each stage of production. This includes pre-process, in-process, and final inspections of materials and garments. Defects would be documented and corrective actions implemented. Regular internal audits and management reviews are proposed to continually improve processes. Training of employees is emphasized to properly implement quality procedures and achieve customer satisfaction. The quality system aims to meet ISO 9001 standards and help Stitched Up maintain their business success.

1. RMIT
TOTAL QUALITY MANAGEMENT
ASSIGNMENT
MITHILA ERANDA LIYANAARACHCHI
STUDENT ID - 3570101
RMIT UNIVERSITY, MELBOURNE, AUSTRALIA

2. 2
Contents
Introduction....................................................................................................................................3
Who are our customers....................................................................................................................3
Product ranges................................................................................................................................3
What is a quality system..................................................................................................................3
Proposed Quality system .................................................................................................................4
Quality Manual...............................................................................................................................4
Operating Procedures......................................................................................................................4
Quality Planning.............................................................................................................................4
Quality policy.................................................................................................................................5
Organizational structure of Stitched Up. ...........................................................................................6
Authority and responsibilities ..........................................................................................................6
Internal audits.................................................................................................................................8
Design control ..............................................................................................................................8
Management review........................................................................................................................9
Documentation ...............................................................................................................................9
Purchasing....................................................................................................................................10
Supplied items by the buyer...........................................................................................................10
Process control / Inspection ...........................................................................................................10
Preventive & Corrective actions.....................................................................................................12
Records........................................................................................................................................13
Training .......................................................................................................................................13
END............................................................................................................................................14

3. 3
Introduction
Stitched up is a leading apparel manufacturing company which maintains a fair goodwill. This
company was established in 1994. Their aim is to satisfy customers with their clothing
requirements. Company’s buyers are not super brands but they are good quality brands with
good name. For last five years, this company has maintained their business rate at a stable
manner. Therefore they wish to proceed with a new quality system to retain in the current
business position.
Who are our customers
As mentioned in the introduction company is not dealing with top clothing brands. But they deal
with midrange brands which has good name. Buyers are specifically from US, UK, Canada.
Namely, M&S, VS, PINK, Etc.
Product ranges
Company stitched up is a production plant which produces Intimate wear, Lingerie, and Bras.
Etc. Therefore they really need to maintain utmost cleanliness inside production premises.
Furthermore, the company should maintain quality standards and quality levels which buyers
expect.
What is a quality system
This is a system established to ensure the quality level of products in order to make the
requirements of customer fulfilled and also to enhance their satisfaction. This system involves
organizational structure, policies, procedures, processes and resources.

4. 4
Proposed Quality system
This Quality Assurance System is developed to meet ISO 9001 standards. And this applies to all
the activities of the Company. The Quality Assurance System is fully documented and all the
documentation comes under several sections.
1. Quality manual 2. Operating procedures 3. Quality planning
Quality Manual
These documents include the quality policy and structure of the Company and Operating
Procedures.
Operating Procedures
These documents describe the methods of operations to all the activities come under the
company.
Quality Planning
Customer satisfaction and quality will be achieved with the quality system. Therefore it is critical
to note the specified requirements of customer. Their requirements get documented during the
time of placing the order. And accordingly the operations will be planned in the best way to
achieve those requirements and declared needs.

5. 5
Quality policy
Stitched up’s quality policy is to gain more profits while growing the company in a sustainable
manner by providing services which will satisfy customers expected needs.
The quality level of a company reflects the quality of their output. It is achieved through this
quality assurance system which includes certain procedures. It will convince all existing
customers and potential customers that there is no doubt against the quality of the out coming
products of the company.. The involvement of staff is really essential to achieve this quality
policy. They must be responsible for the quality of their own duties. That will result an
improved working environment within the company.
Objectives of this quality policy;
There are certain objectives coming under this quality policy. They are;
 Achieve and maintain a good quality level which improves the good name of company
among customers.
 To ensure the activities are meeting the relevant legal and safety requirements
 To maintain an effective quality assurance system which complies with ISO9001
 To maximize customer satisfaction

6. 6
Organizational structure of Stitched Up.
Authority and responsibilities
When it comes to authority all staff members are authorized to perform their given
responsibilities. Each employee is authorized to identify defectives and to make any
suggestions on improving production quality. Staff should record the founded defectives
to make required actions. Managing Director of the company will review the company's
resources eventually to make sure the work force, equipment and materials are sufficient
to make the customers satisfied.

7. 7
Following are the responsibilities of each staff member;
Designation Responsibilities
Managing Director
 Approval of the Quality Assurance System
 Management Review
 Design Control
 Supplier Selection & Purchasing
 Contract Management & Control
 Training
Quality Manager
 Internal Audits and inspections
 Resolution of Quality Assurance System Discrepancies
 Control & Maintenance of the Quality Assurance System
 Documentation & Change Control (Quality System
Documents)
Merchandising Manager
 Management & Co-ordination of Sales and Support Functions
 Contract Review
 Sales Order Processing
 Design Control
 Estimating
 Project Management
 Control of Contract Documentation
 Planning & organization
 Supplier Selection & sourcing
Production Manager
 Planning and Co-ordination
 Control of Production and Measuring Equipment
 Maintenance of Support Stores
 Processing of Sales Orders
 Estimating
 New Product Identification & Evaluation
 System Design
Administration Manager
 Planning & Performance of Installation, Technical Assistance,
 Repairs, Testing and Maintenance Activities
 Control of Equipment and Materials Allocated
 Sales Database Administration
 Checking of Sales Orders
 Allocation of Order Reference Numbers

8. 8
Finance Manager  Control of Finance, Accounts and Warehouse Operations
 Training
 Supplier Selection and Purchasing
Warehouse  Control of Stock
 Replenishment Recommendation
 Protection and Preservation of Stock
 Receiving Inspection
 Packaging and Dispatch
Mentioned / unmentioned all staff members should take responsibility of their own duties.
This Quality System is structured with policy statements relating to Operating Procedures
under compliance with ISO: 9001 standard.
Internal audits
A quality audit will be carried out at least once a year in order to verify that the quality functions
are done according to company procedures. Through these audits garments will be investigated
randomly and the audits will be done by auditors trained in auditing and not directly responsible
for the functions being audited within company. Auditors will directly identify the person
responsible for a particular defect and will provide with a corrective action to rectify the defects.
Design control
This is controlling quality from designing stage. That is to ensure that the design of output is
what customer expects. The designs will be checked by design specialists and are forwarded to
relevant parties for approval if there is any point to correct in given design. The relevant
documents will be kept for clarification and security purposes.

9. 9
Management review
A review from managers should take place once a year to consider whether the practicing quality
system is still suitable or should need to be upgraded.
Documentation
All the documents using within the Company are controlled in a proper manner to make sure the
production is done accordingly.
Types of documents which includes the quality system;
 Specifications
 Customer Orders
 Production plans
 Quality Manual
 Operating Procedures
 International Standards
Quality manager maintains quality manual, procedures and quality plans to ensure that every
employee is well equipped with things that they need in production. Administration manager will
maintain ISO standards within the organization by keeping required records correctly and safely.
When making a change in documents, it is strictly informed to get the approval of the
responsible person. After the change is made, the copies of those documents will be kept as
records of changes for clarification and security purposes.
Company will have all records relevant to each contract in separate files and in the computer
system for easy access.

10. 10
Purchasing
When sourcing raw materials and trims from suppliers, a quality inspection will be done. There
will be certain criteria’s to review when selecting suppliers to make sure the quality of output
product will be good
 Quality of previously supplied goods
 Stock maintenance
 Amount of defectives produced
 Compliance with an approved quality system
 Recommendations
 Samples for performance evaluation
After the above points are being satisfied a purchase order will be sent to the shortlisted suppliers
with all the required information.
Supplied items by the buyer
Trims or any other items provided by customers will be inspected thoroughly and if a defect is
found, the customer will get notified immediately.
Process control / Inspection
Each and every operation will be carried out in a correct and productive manner as instructed in
the agreed contract with the buyer and to control the manufacturing process within the company,
there are 3 inspections or audits at 3 stages.
 Pre-process inspection
 In-process inspection
 Final inspection/audit

11. 11
I. Pre- process inspection
This inspection is to ensure that all the received goods to the warehouse for production are free
from defects. For that, all the raw material will be inspected thoroughly to see whether the
suppliers have provided the right item with right quality and right quantity. Fabric will be
inspected under “4point system”. If the result is bad, the supplied items will be returned to
supplier to get fine replacements. Accessories will also get inspected 100% and returned if
defectives are found.
After inspecting is done a sample will be sewn with sourced materials. The samples must be
perfect in order to start manufacturing. Through making samples, the company can ensure that
there are no mistakes in patterns, designs and other data given in specification. If there are any
comments, they will be submitted to the buyer.
Checked items will be documented and, in case of finding defected items, they will be kept in a
reject area. The extent of the defective items will be noted and subjected to supplier for review.
II. In-process inspection
After the pre-process inspection there shouldn’t be any non-conforming items for production.
This inspection is done during the process of production.
Cutting department is the first place to be inspected under this inspection where the fabric
pieces are being cut according to the marker. Quality inspectors must make sure that marker is
drawn correctly without unwanted pieces and in given measurements. Afterwards should check
the fabric rolls are laid properly. Then pieces will get cut and randomly inspected for any
defectives. As the next step is numbering and bundling, the bundled pieces should be kept
properly. All activities will be recorded under this inspection.
Sewing section is the second place to inspect under this inspection. Objective here is to make
sure that there are no defects during sewing. There will be checkers at the end of line and they
will cross check whether the garment has achieved the requirements of buyer. And if not, they
will re-send it immediately to the line for re-work. A statistical process control chart will be used
for inspections.
III. Final inspection / audit
This final inspection is done at the end of production process and even after packing is done. The
quality checkers will randomly check garments to see whether they have met buyer’s
requirements including packing. To ensure the quality, Quality department will use DHU
(Defects per hundred units) method, AQL method (Accepted quality method) for quality
verification.
DHU – This system is checking 100 garments randomly and recording how many defected
garments were there out of 100 garments. If the defected rate is at a high level, the whole lot will
get rejected.

12. 12
This is calculated as; Defects per hundred units = (Total defects found * 100)/Total garments
inspected
AQL – Accepted quality level means deciding on the maximum number of defective units,
beyond which a batch is rejected. Importers usually set different AQLs for critical, major, and
minor defects. Garments will be chosen randomly.
1. Critical: Must be 100% accurate.
2. Major: Normally 2.5%
3. Minor : Normally 4%
If the rejects are at a higher level, then the whole batch will get rejected.
With results being documented, company should consider whether items to be accepted or not.
As for the contract with the buyer, company can repair an item for a certain extent. But all
repaired items must be re-inspected to make sure they are acceptable.
In addition Control charts are being used to control the process. A control chart is a graph which
helps to examine the changes occur in process over time.. A control chart has a central line for
the average, an upper line for the upper control limit and a lower line for the lower control limit.
Those lines are drawn using historical data. Therefore by comparing current data with lines on
this graph, company can conclude whether the process is under control or out of control.
Preventive & Corrective actions
When defectives are found they are kept separately to avoid mixing with good ones. All
defective items must be reviewed and rectified by responsible personnel. Those founded defects
must be kept noted in order to make corrective actions and to improve those defect areas in
future.
To prevent defects, there must be a corrective action. Therefore a corrective action will be
formulated, documented, and will be monitored after implementing. Re-work will always be re-
inspected to make sure the customer satisfaction.
Employees are free to make suggestions on improving production methods. However, the
research and development team will be evaluating new possible improvement for the production.

13. 13
Customer feedback
Customer feedback is requested from buyers after an order is being delivered. And after the
feedback is given, that will be used and kept for future orders and for the continuous
improvement of the company.
Records
All the records will be stored as spate files in an identifiable manner. However records will also
be maintained in a computer software and these data will be “backed-up" eventually therefore
company should not worry about losing important data. Records will be retained at least for a
period of 2 years.
Training
Training is really necessary for employees because things get updated within the time. “Stitched
up” is always looking forward to train its employees to make them perfect. Company’s policy is
to make sure that all employees are properly trained to fulfill their duties in the company in an
effective manner. Normally, the company is recruiting employees who are experienced, skilled
and employees with required educational qualifications.
Staff members are authorized to recommend theirs or any other employee’s training requirement
to the relevant parties. Then it is management’s responsibility to organize required training
sessions. The staff is also authorized to make suggestions on task allocation among the
employees. E.g. If a task is given to an employee without considering his/her experience,
qualified level, an employee can report it to the management. All the records regarding training
sessions of each employee will be maintained separately.

14. 14
END