Quality control in apparel industry of bangladesh

1.
QUALITY
CONTROL
IN
APPAREL
INDUSTRY
OF
BANGLADESH

2.
Arnab
Shahriar
Nirjhor
Department
of
Textile
Engineering

3. TABLE
OF
CONTENTS
1.INTRODUCTION:
5
2.MEANING
OF
QUALITY:
5
3.DIMENSION
OF
QUALITY
CONTROL:
6
4.QUALITY
MANAGEMENT
SYSTEM
EVALUATION:
6
5.QUALITY
ASSURANCE
FOR
THE
RETAILERS:
6
6.PRINCIPLE
OF
TOTAL
QUALITY
MANAGEMENT:
7
7.QUALITY
MANAGEMENT
CONTROL:
8
8.IMPORTANCE
OF
QUALITY
MANAGEMENT
CONTROL:
8
9.KIND
OF
QUALITY
CONTROL
8
10.QUALITY
DETAILS
IN
APPAREL:
11
11.THE
COST
OF
ACHIEVING
GOOD
QUALITY
MANAGEMENT:
12
12.CONCLUSION:
13
13.REFERENCE
14

4. Abstract:
Quality may be defined as the level of acceptance of a goods or services. For the textile
and apparel industry, product quality is calculated in terms of quality and standard of
fibers, yarns, fabric construction, color fastness, designs and the final finished garments.
In Bangladesh, different garments factory follow different quality control and
management systems especially different inspection systems for garment inspection. In
good management, every fault will get published and good quality product will be
produced. If managing plan is very good, organization will grow up quickly with good
quality products or service. This article contains the quality control processes as well as
quality management procedures followed by different garment factory of Bangladesh and
the feasibility of these processes.

5. Quality
Control
in
Apparel
Industry
of
Bangladesh
5
1.INTRODUCTION:
“What is quality?” The oxford American dictionary defines quality as “a degree or level
of excellence”. Obviously quality can be defined in many ways, depending on who is
defining it and to what product or service it is acceptable. To some people, quality is
goodness or luxury. To other, quality is durability, beauty, labels or high prices. Clearly,
consumers rely on a wide variety of cause to determine whether products meet their
quality standers. To confront the challengers the apparel industry could integrate by way
of major technology breakthroughs.
Quality means customer needs is to be satisfied. It helps the customers to get quality
products or goods. At this the customer is satisfied. Customer always wants new products
or goods through the processes of design, specification, controlled manufacture and sale.
There are a number of factors on which quality fitness of garments industry is based such
as - performance, reliability, durability, visual and perceived quality of the garment.
Quality needs to be defined in terms of a particular framework of cost. Garment industry
collected raw materials for final finished garment. For textile and apparel industry
product quality is calculated in terms of quality and standard of fibers, yarns, fabric
construction, color fastness, surface designs and the final finished garment products.
2.MEANING
OF
QUALITY:
Quality means customer needs is to be satisfied. Failure to maintain an adequate quality
standard can be unsuccessful. But maintaining an adequate standard of quality also costs
effort. From the first investigation to find out what the potential customer for a new
product really wants, through the processes of design, specification, controlled
manufacture and sale.
There are a number of factors on which quality fitness of garment industry is based such
as - performance, reliability, durability, visual and perceived quality of the garment.
Quality needs to be defined in terms of a particular framework of cost.
Objectives:
I. To maximize the production of goods within the specified tolerances correctly the
first time.
II. To achieve a satisfactory design of the fabric or garment in relation to the level of
choice in design, styles, colors, suitability of components and fitness of product
for the market.

6. Quality
Control
in
Apparel
Industry
of
Bangladesh
6
3.DIMENSION
OF
QUALITY
CONTROL:
The dimension of quality for a service differs somewhat for those of a manufactured
product. There are discussed following below. These are
Time and timelines: How long must a customer wait for service and is it completed on
time? For example, is an overnight package delivered overnight?
Completeness: Is everything the customer asked for provided? For example, is a mail
order from a catalogue company complete when delivered?
Consistency: Is the same label of service provided to each customer each time? Is your
newspaper delivered on time every morning?
4.QUALITY
MANAGEMENT
SYSTEM
EVALUATION:
The rising sub-contracting issues and improper quality processes are bringing more
obstacles to improving transparency and more reliable production processes.
As an accredited third-party service provider, we offer independent evaluation that helps
your garment manufacturers to develop a quality management system that meets
international standards and best practices.
Our QMS audit standard and scheme were developed through long-term collaborations
with leading players in the global textile and apparel markets.
5.QUALITY
ASSURANCE
FOR
THE
RETAILERS:
Retailers sell a variety of consumer products and rely on their suppliers to provide them
quality products. However, retailers must have some way of verifying that they are
receiving products at quality levels they planned or specified. Retailers also should be
able to specify quality levels, if necessary. This book outlines various approaches
available to retailers to assure product quality. The book also covers other important
topics like product safety, product testing, end item inspection, product recalls, product
liability, standards and specifications, supplier quality system evaluation, supplier rating,
supplier partnership, customer returns and customer satisfaction.

7. Quality
Control
in
Apparel
Industry
of
Bangladesh
7
6.PRINCIPLE
OF
TOTAL
QUALITY
MANAGEMENT:
The Quality System Requirements are based on the principle of PDCA Cycle.
6.A.Process Cycle:
1. Understanding the customers' quality requirements.
2. Organizing & training quality control department.
3. Ensuring proper flow of quality requirements to the QC department.
4. Ensuring proper flow of quality requirements to the Production Department.
5. Establishing quality plans, parameters, inspection systems, frequency, sampling
techniques, etc..
6. Inspection, testing, measurements as per plan.
7. Record deviations
8. Feed back to Production Department.
9. Plan for further improvement.
6.B.Establishing the Quality Requirements:
The first step for quality control is to understand, establish & accept the customers'
quality requirements. This involves the following steps.
1. Getting customers specifications regarding the quality
2. Referring our past performance
3. Discussing with the Quality Control Department
4. Discussing with the Production Department
5. Giving the Feed Back to the customers
6. Receiving the revised quality requirements from the customers
7. Accepting the quality parameters

8. Quality
Control
in
Apparel
Industry
of
Bangladesh
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7.QUALITY
MANAGEMENT
CONTROL:
It becomes necessary to maintain the quality right from the production stage in order to
deliver a satisfactory final product to the consumer with the right quality which in turn
results in getting continuous orders from the same customers.
8.IMPORTANCE
OF
QUALITY
MANAGEMENT
CONTROL:
Garment industry has a complex supply chain where garment makers source materials,
stitch garments and sell goods to retailers. Through buyers and retailers quality garments
reach to end user located all over the world. No wearers will buy a garment with poor
quality and visible defects. So buyers and retailer knowingly do not purchase a product
that does not meet the quality requirement. Quality conscious buyers have a strong
quality inspection system in place to avoid purchasing of defective goods.
• Factory may lose customers (buyers) as well as Brand Value
• Low motivated employees
• Need to work for extra hours
• Ultimately production cost will increase
9.KIND
OF
QUALITY
CONTROL
Quality is very important to buyer or user and it is increasing day by day. Mainly two
processes are followed to control quality
1. Testing &
2. Inspection.
Inspection in reference to the apparel industry can be defined as the visual examination or
review of raw materials (like fabric, sewing threads, buttons, trims, etc).
9.A.Quality Inspection System:
There are four systems to justify the quality of garments/fabric. They are given below:
1. 4 point system
2. 10 point system
3. Graniteville “78″ system.
4. Dallas system.
But among them four point system is widely used. In our previous article we have
discussed about 4 point system.

9. Quality
Control
in
Apparel
Industry
of
Bangladesh
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Process of Garment Inspection System:
Confirmation of Quantity
↓
Confirmation of accessories
↓
Size spec inspection
↓
in side Inspection
↓
Outside Inspection
↓
Final Inspection
↓
Packing
9.B.Various Steps of Inspection & Quality Control:
The following levels are discussed at the Garment Making Department assuming that this
department is receiving the ready to cut dyed & finished fabrics from the Dyeing &
Finishing Department.
9.B.(1)Before or Pre-production Inspection:
The following parameters & defects are checked prior to cutting.
Ø Shade Matching
Ø Fabric Construction
Ø Fabric Holes
Ø Vertical & Horizontal Stripes
Ø Knitting defects
such as missing loops
Ø Softness
Ø Shrinkage
Ø Matching of Rib, Collars & Cuffs
Ø Yarn Defects
such as thick & thin
Ø Dirt’s & Stains
Ø GSM (grams per square meter)
Ø Dyeing Levelness
9.B.(2)During Production Inspection:
Ø Fabric Defects
Ø Collars & Cuffs matching
Ø Stitching defects
Ø Sewing threads matching

10. Quality
Control
in
Apparel
Industry
of
Bangladesh
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Ø Dirt’s & Stains
Ø Measurements
Ø cutting patterns
Ø Cutting shapes
Ø Trims & Accessories
Ø Labels
9.C.Before Production Inspection:
There are Many of the important parameters of Pre-productions, during productions &
Final inspection parameters. This is to ensure that wrong or major defective garments are
not packed.
9.C(1)PACKING & ASSORTMENT
Ø Wrong Model
Ø Wrong Quantity
Ø Missing labels & tags
Ø Wrong Size & Color assortment
Ø Wrong Folding
9.C(2) FABRIC DEFECTS
Ø Uneven dyeing
Ø Holes
Ø Wrong Shade
Ø Thick & Thin places
Ø Dirt & Stains
Ø Oil stains
Ø Poor softness
Ø Higher Shrinkage
9.C(3) SEWING DEFECTS
Ø Needle holes & marks
Ø Unbalanced sleeve edge
Ø Unbalanced placket
Ø Open seam
Ø Puckering
Ø Incorrect side shape
Ø Broken & Missing stitch
Ø Poor Ironing
Ø Bottom hem bowing
Ø Uneven neck shape

11. Quality
Control
in
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Industry
of
Bangladesh
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9.C(4) MEASUREMENT PROBLEM
Compare the garment measurements against the Customers' Measurement Charts.
Following are the some of the important garments' measurement aspects to be considered.
1. Garment length
2. Body width
3. Shoulder length
4. Arm hole
5. Arm Opening
6. Sleeve length
7. Placket length
8. Placket width
9. Neck width
10. Neck opening
11. Hemming width
12. Rib or Collar width
9.C(5) GENERAL DEFECTS
1. Shade variation within the garment parts
2. Shade variation between the garments
3. Defective printing
4. Defective embroidery
5. Defective buttons
10.QUALITY
DETAILS
IN
APPAREL:
There are following discuss about quality apparel. These are
1. Fabric is the basic foundation of apparel. Fabric is woven by yarns which run up
and down or across. When apparel is cut from the fabric.it should run up-down
and across. Sometimes apparel is not correctly, and actually causes clothing to
twist around body. This is called off-greensand cannot be corrected. Off-grain
apparel is result of quality control during the manufacturing process.
2. Manufactures sometimes use bias cut section cut costs. Bias cut apparel is
exceptionally difficult to sew, tends to stretch out of shape. Hang unevenly at the
hem, or sag, compromising quality.
3. Patterned fabrics should match along seemliness in both directions, across and up-
and-down. Aching indicates quality because of the additional fabric and labor
involved in cutting and sewing.

12. Quality
Control
in
Apparel
Industry
of
Bangladesh
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4. Colors should match between pieces and is not indictor of quality. Fabric, thread,
zipper, even elastic should match, function and be durable. Manufacturers know
the performances characteristics of each fabric and should base decagons on how
well these pieces perform in accordance with the fabric.
5. Seams within a garment should be securely sewn. Check to make sure threads
have not popped or ruptured along all seams. Seams with surging are more secure
and higher quality as long as the correct tension was used when sewn. Just be sure
you tag along a seam to see if it has enough tension to resist popping.
6. Design features within apparel can also help you judge quality.
7. Collars should be smooth as they lay against the body- corners should not roll or
pucker and each end of the collar the same length and shape.
8. Buttons should pass through the button the buttonhole, and be securely sewn to
the fabric
9. Hook and loop tape should be securely sewn. The coarser the hooks and loops are,
the better the holding power of the tape. Be sure to lock the tape together before
laundering to prevent damage to other apparel in the wash load.do not iron
10. Fit of the garment to the wearer is the final indicator of a quality to the wearer is
the final indicator of a quality decision. Alterations if needed can be an additional
expense. Be sure to check the fit by sitting, working and bending with the garment
on the body. If you have to pull or tug at any area of a garment after moving,
sitting or bending, the garment is improperly sized for the wearer. Check the
mirror looking at the front side and back for horizontal wrinkles in the garments.
There are no standard sizes in apparel sizes vary be style.
11.THE
COST
OF
ACHIEVING
GOOD
QUALITY
MANAGEMENT:
The cost of quality management program is prevention cost and appraisal costs.
Prevention costs are the costs of trying to prevent poor quality products from reaching the
customer. Example of prevention costs include:
Quality planning costs: The costs of developing and implementing the quality
management program.
Product design costs: The costs of designing products with quality characteristics.
Process costs: The cost expended to make sure the productive process conforms to
quality specification.

13. Quality
Control
in
Apparel
Industry
of
Bangladesh
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Training costs: The costs of developing and putting on quality training programs for
employees and management.
Information costs: The costs of acquiring and maintaining data related to quality and the
development and analysis of reports on quality performance.
12.CONCLUSION:
Wants, wants and more wants, every person say. Every person wants quality products or
services. For this, more company is ready to give quality product or service. If you want
to see your company, you need to give quality product. At this the company will stay
more days. If good quality products do not give, the company will lost. The managing
quality control gives always good quality product or service. Though total quality
management, Good quality products give possible. So quality management is not very
good, at this quality product or service get. So it is very important for apparel industry.

14. Quality
Control
in
Apparel
Industry
of
Bangladesh
14
13.REFERENCE
1. http://www.fibre2fashion.com/industry-article/8/800/quality-systems-for-
garment-manufacture1.asp
2. http://www.sgtgroup.net/pages/service_qe.aspx
3. http://textilelearner.blogspot.com/2011/08/quality-control-system-in-
garments_2589.html
4. http://www.garmentsmerchandiser.info/quality-inspection-system-in-garment-
industry/