1 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 1 of 33 Chaity Composite Ltd
AGM (Quality & Product Development)
Cell: +880 1708 454 779
Email: mizan5379@yahoo.com
Skype: mizan_mehben
2 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 2 of 33 Chaity Composite Ltd
Quality Assurance Department
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Quality Assurance: Quality Assurance is a process focused concept, where
the processes are put in place to ensure the correct steps are done in the
correct way. If the correct processes are in place there is some assurance
that the actual results will turn out as expected.
Quality Control: Quality Control is a product focused concept, where checking
of the actual results are done to ensure that things are as expected. If the
correct controls are in place you can know for certain that the actual results
have been achieved because the actual results have been checked.
3 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 3 of 33 Chaity Composite Ltd
Procedure of Delivery (sop)
1. Without Test Result Please don’t Delivery Any Quantity of Fabrics.
2. Without Rib/Single Jersey/ Back neck tap, not delivery.
3. Any Measurable part, Like Collar & Cuff, Stripe Yarn dyed Fabrics
should be check as buyer requirement.
4. Inline Fabrics All test should be check & Shrinkage CHECK from 3-4 rolls
& Ensure Acceptable tolerance,
5. Width ± 1”, More than need to Approval from Related Person. Also
infirm to cutting department.
6. Before Delivery must be Re-check by Shift In-charge, Width, GSM,
Shrinkage delivery report with Batch information.
7. 1st Batch Shade check & crosses check for confirmation.
8. All Approved shade must be keeping before dyeing from related
Merchandiser
9. All shade check two person avoid the wrong decision. (Keep sign)
10. 1st Batch check with Booking All information, like width, GSM,
Accessories & Shade Reference.
11. Every day at 1st All delivered batches should be showing to
Responsible person & take Sign
12. Unacceptable Issue not delivery.
We have committed good quality fabrics delivery which is customer
Requirement
4 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 4 of 33 Chaity Composite Ltd
Definition of 4 Point:
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Procedure of Four Point System:
1. Fabric inspection is usually done on fabric inspection machineries.
2. These machineries are designed so that rolls of fabric can be mounted behind the inspection
table under adequate light and re-rolled as they leave the table.
3. Inspection machineries are either power driver or the inspector pulls the fabric over the
inspection table.
4. The defects are located, marked and recorded on an inspection form.
5. Some machinery is equipped to measure the length of each roll of fabric (meter/yard).
Fabric defects point values based on the following:
Length of defect in Fabric Points allotted
Up to 3 inch 1
Over 3 inch up to 6 inch 2
Over 6 inch up to 9 inch 3
Over 9 inch 4
Holes and Opening
1 or less 2
Over 1 inch 4
5 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 5 of 33 Chaity Composite Ltd
Defect Length Points Sticker Colour
Less then3” 1 White
3”-6” 2 Green
6”-9” 3 Yellow
Over 9” 4 Red
Hole Points Sticker Color
Less or equal to 2.5cm/1” 2 Green
Larger than 2.5cm/1” 4 Red
Example:
Defect should be marked with a coloured sticker. To show defect position the selvage should
be marked with the same colour of sticker or thread.
Defects in both warp/weft directions will be assigned points using the following criteria:
Defects and Penalty points
Fabric width
1. Total points awarded for first m/yd is 4.
2+4 points=6 points.
“Regardless of length/size or number of
defects, no more than 4 penalty points may
Be assigned on any linear meter/yard”.
1m/yd
10cm
1m
5cm
1m/yd
2. Total points awarded for second m/yd is 1.
15cm
1m/yd
3. Total points awarded for third m/yd is 3.
1m/yd
4cm hole
25cm
4. Total points awarded for fourth m/yd is 4.
4+4 points=8 points.
“Regardless of length/size or number of
defects, no more than 4 penalty points may
be assigned on any linear meter/yard”.
6 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 6 of 33 Chaity Composite Ltd
Calculations and Result:
Total defect points per 100 yard square are calculated.
If fabric rolls contains less than 40 points per 100 yard square are considered “first”
quality and as an Acceptance criteria.
If fabric rolls containing more than 40 points per 100 yards square are considered
“second”.
Example:
A fabric roll 130 yard long and 45 inch wide contains the following
defects:-
6 defects up to 3 inch- ................................... 6 X 1 = 6 points
5 defects over 3 inch but less 6 inch- ............. 5 X 2 = 10 points
2 defects over 6 inch but less 9 inch- ..............3 X 2 = 6 points
1 defects over 9 inch- .................................... 1 X 4 = 4 points
1 hole over 1 inch dimensions- ....................... 1 X 4 = 4 points
………………………………………………………………………………………
Total defect points................................................= 30 points
Therefore,
Points per 100 yard square =
Total points scored in roll X 36 inch
……………………………………………………………… X 100
Fabric width/inches X Total length yard inspected
30 X 36
= ……………………… X 100
130 X 45
= 18.4 (Defect points per 100 yard square.) So, the roll is accepted.
7 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 7 of 33 Chaity Composite Ltd
Colour and shades must be controlled by maintaining colour continuity records.
Dye lot to dye lot, within a dye lot and within a roll must be checked. Records must be
Available for H&M and kept for at least 6 month.
The swatches must be a minimum of 4x10 cm and be evaluated visually in a light box.
A close critical match to colour standard and approved fabric must be achieved in; TL83, D65
And display no dramatic difference in colour appearance in A-light (tungsten).
For more detailed information see Supplier Colour Guide Book.
For the use of ISO 105-A02: 1993 Grey scale for assessing change in colour there should not
Be a greater difference than 4-5 between any parts within a dye lot and roll.
Full width cutting:
Inspection procedures:
Colour continuity record:
At the beginning and at the end of each roll selected for fabric inspection, cut a 30 cm/6” full
width cutting. The look, hand feel, and colour must be compared in the light box against:
•Colour Standard
•Approved fabric
•Fabric Technical Data
Shade deviation within a roll must be checked by folding or sewing:
•Side to side
•Side-centre-side
•Beginning-end
If difference is more then 4-5 on the grey scale between any parts, the H&M local office must
be contacted.
Weight-
•Check weight on minimum 10% of the rolls chosen for inspection.
•Weigh a 100 cm² cutting; convert the weight into m²/yd².
•Weight should correspond to weight stated on Fabric Technical Data.
If the deviation is more then -5% / +7% the roll has failed.
Cuttable width-
The minimum Cuttable width, measured between needle holes at roll selvages, is stated on
The Fabric Technical Data, and must be checked at least 3 times on each roll at:
• Beginning.
• Middle.
• End.
Rolls where cuttable width is less, has failed.
8 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 8 of 33 Chaity Composite Ltd
Minimum splice length is 30 m/yds.
Splice location must be noted on the individual roll inspection report.
4 penalty points will be assigned for each splice/join.
roll is allowed to contain more than 1 splice/join.
Shade Check in Light Box
1. Two person together shade Check Avoid the Wrong Decision. Because Two
Person not Same Measurable Power, So combined take decision.
2. with Three Light Shade Check
3. Make Family Shade A&B
4. Light D65, TL 83, A-10
5. 1
st
Batch Shade check with Woven Standard & Counter Sample
6. Next Batch Check Batch to Batch with Counter
7. White & Grey Mélange Must be Check with UV Light
8. Metameric Check in A-10 Home Light
9. Shade Check in 45 degree Angle
Splices-
Roll length verification-
Roll length measuring less than 40 m/yds cannot be accepted, unless agreed.
Roll length stated on the roll ticket must be verified against the actual roll length
Measured by the fabric checking machine.
•If the deviation is 1% less, length should be double checked on a cutting table.
If difference remains, the roll has failed.
Fabric odours-
Roll that emit an unpleasant odour, has failed.
Roll that emit an unpleasant odour, has failed.
9 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 9 of 33 Chaity Composite Ltd
Light Sourcing (Knit)
1. Shop Light (Primary ) -TL83 Lax Value 1000 to more
2. Day Light (Secondary)- D65 Lax Value 1000 to More
3. Home Light - A-10 Lax Value 800 to More
4. Morning Sun Light – Ultra Violet (UV)
Light Sourcing (Under Wear)
1. Shop Light (Primary ) - TL83 Lax Value 1000 to more/18w
2. Home Light (Secondary) -A-10 Lax Value 800 to More/18w
3. Day Light - D65 Lax Value 1000 to More/40w
4. Morning Sun Light – Ultra Violet (UV)/18w
10 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 10 of 33 Chaity Composite Ltd
Fabrics Delivery Approval Authority:
1. Check Buyer Requirement, Width, GSM, Shade match, Shrinkage,
Accessories ( Rib, Collar & Cuff, Piping, Back neck tap with
Measurement)- Confirm from Online In-charge & Executive (Shade)
2. Test Result (Shrinkage, Twist, Rubbing, Pilling & Wash Fastness)- confirm
from Physical Lab Manager
3. Fulfil the Buyer Requirement then possible to Delivered
i. GSM- 5-7% Low from Required,
ii. Shrinkage L-4% W-7% Spirality 5%
iii. Width ±1 inch
iv. Test as Buyer Required
4. Approved by any problems fabrics–
i. GSM, Width & Shrinkage (Cotton) - Knitting GM & Manager,
Finishing AGM & Manager with Sign.
ii. GSM, Width & Shrinkage (Lycra)- Finishing AGM & Manager
with Sign
iii. Shade, Uneven, Hairiness- AGM(Dyeing) with sign
iv. Test (Color Fastness, Pilling, Rubbing)- AGM(Dyeing), also
Physical Lab Manager with sign
5. Over all if take Responsibility Related Merchandiser then we can
delivered any kind of problems fabrics but need to take sign.
6. Any person given the approval then we send mail to related person in the
department
7. Without proper inspection not a single kg fabrics delivered
11 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 11 of 33 Chaity Composite Ltd
Job Responsibility:
Md Mizanur Rahman- AGM (Quality & Product Development)
1. Planning & Monitoring of Production Target.
2. Ensure that the Quality Standard is being met by Forecasting &
reviewing the result.
3. Develop Discipline, by implementing the Rules &Regulation in
Department.
4. Ensure acceptable Quality level (AQL) in textile manner.
5. Give a continuous guidance to the Executive, along with others for
target fabric specification.
6. Supervision constantly to Grey & Final QC.
7. Give the full support the Research & Development Department.
8. Make a continuous study of work improvement & give report to the
higher authority.
9. Response & act in the customer complain & query.
10. Ensure that all safety followed by the team.
11. Continuously study the Cost saving of the Department.
12. Enthusiastic to wastage utilization.
13. Optimize Manpower Utilization.
14. Worker Turnover & Absenteeism control as per Plan.
15. Skill Development in the Floor.
16. Ensure that all Lab test Report (Physical) are recorded.
17. Follow the concept of Top Management.
18. Regularly held a meeting to all people once in a week/ Time to time.
19. Co-ordination with all departments all quality parameter inform
time to time all department.
20. Check the hold fabric & give decision quickly.
12 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 12 of 33 Chaity Composite Ltd
Mr Arafat Rahman Prience- Asst Manager (H&M GPQ)
1. Ensure the delivery target with Quality
2. RQS Audit,
3. Urgency of H&M
4. Sample (All Buyer)
5. H&M GPQ Audits
6. H&M Related Quality Issue,
7. Hold (H&M) Fabric inspection & Take decision immediately
8. All Audit Record & Keeping Documents
9. Audit Related all points need to be check & Confirm available as
Buyer Requirement
10. FTD Approval ensure & Product Match with FTD
11. Give Training as buyer requirements
12. Ensure the quality Standard which is delivered
Mr Monir Hossain- Asst Manager (QAD)
1. Planning & Monitoring of Delivery Target.
2. All Buyer fabrics inspection Without H&M
3. Fulfil the buyer wise quality requirement
4. Ensure the delivery target with Quality
5. Hold Fabric Take decision immediately
6. Inline fabrics ensure the Quality Requirement
7. Ensure the 4 point system reporting
8. Grey fabric inspection & give decision
9. Ensure the good house keeping
10. Manpower utilize
11.Recruited
13 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 13 of 33 Chaity Composite Ltd
Monowar Hossain Nahid- Executive (GPQ- H&M)
1. Mainly H&M GPQ Responsible
2. All sample check
3. Ensure the buyer requirement
4. Ensure the testing requirement
5. Yarn test
6. Support to PP Sample
7. FTD Approval
8. Resource & Development
9. On time delivery with Quality
10. Keep record Sample inspection & Yarn test
SM Younus Ali Ruble – Senior Executive (Shade)
1. Confirm the Shade as buyer concept
2. Approval taken from Buyer
3. Within short time shade confirm & Feedback to production
4. All Lab dip take from Lab Then Confirm with Related Merchandiser
5. Keep all approval Swatch
Md. Shafiqul Islam- Shift In-charge (Inspection)
1. Fulfil the delivery target with quality
2. Requirement wise delivery width, gsm shrinkage, Spirality & All
Accessories (Rib, Collar & Cuff, Back neck tap)
3. Check process loss
4. All testing confirm then delivered
5. Return for reprocess Dyeing & Finish, Keep Record.
6. Ensure the good house keeping
14 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 14 of 33 Chaity Composite Ltd
Jahirul: Data Entry Operators
1. Make Reports- inspection, Compact, Hand folding, Inspection M/c
2. Handover Record
3. Reprocess (Dyeing & Finishing)
4. Return to Dyeing & Finishing
5. Order Summary
6. Reject
Md Anower Hossain- Executive (H&M GPQ)
1. Ensure Audite Related Keep all documents
2. Uster Yarn Report
3. Yarn test Report
4. MR Ensure the Fulfil Buyer Requirement
5. Order Sheet
6. Shade Continuity Card
7. GSM Record
8. Inspection Report
9. Fabrics delivered with test & Necessary documents
10. Handle the H&M Buyer
Ahasan Kobir Sumon- GPQ-H&M (Sample)
1. All H&M Sample
2. Yarn test
3. Uster Report
4. FTD approval Ensure
5. Keep record Sample inspection & Yarn test
6. Keep File (Knitting, Dyeing & Finishing)
15 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 15 of 33 Chaity Composite Ltd
H&M Sample Documents File Keeping (Buyer Requirement)
1. FTD
2. Knitting Data
3. Grieg Swatch
4. Dyeing Recipe
5. Program Route
6. Finishing parameter
7. Test Report
8. Inspection Report
9. Uster Report
10. Yarn Test Report
11. Booking Sheet
12. Summary Sheet
H&M Production Documents keep in the File
1. Booking Sheet
2. Order Sheet
3. Rick Assessment Sheet
4. Counter Sample comments copy
5. FTD Sample Comments copy
6. Inspection Report (4 Points)
7. Packing List
8. GPQ Certificate
9. Lab Test Report
10. Summary sheet
16 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 16 of 33 Chaity Composite Ltd
Quality Policy (¸bMZ gvb bxwZ)
Vision: - To Achieve Continues improvement in garments product quality
fabrics & attain sustainability through united effort.
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Mission: - To understand the buyers demand & Fulfil their requirement by
producing better quality Fabrics.
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Policy:-
1. To build up a long lasting better Relationship with buyer by fulfilling the
their demands
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2. To improve employees skills through training & Evaluate/ Appreciate their
work
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3. To maintain a Cleaner workstations & to build up self-Motivated &
Responsible work force.
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17 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 17 of 33 Chaity Composite Ltd
Online Inspection Point
1. Shade Give to Light Box for Approved
2. Hand feel & Hairiness Check with FTD
3. 10% Rolls check table, Running Shade/Uneven
4. Naps, Hole, Patta Check, Line/Sinker Mark
5. Width & GSM confirm with Requirement
6. Within ½ inch pin in Selvage more than infirm to Finishing
7. Give to one meter fabrics Laboratory for Test, Shrinkage/Fastness
8. Accessories available or not (Rib, Collar & Cuff)
9. Check Measurement if Required Like Stripe Fabrics
10. Information should be write down in Batch Card Clearly & Online
inspection Loge book
11. If any unacceptable must be infirm to Shift In-charge
Inspection Machine Point
1. First Check online information
2. Two person Maximum two hours continue inspection
3. Note in Register loge book which person inspection with sign
4. 4 point system follows
5. Machine Speed Light Color 16/18 & dark Color 18/20 RPM
6. Lux value 1000+ & Light Expired time one year or 1300 hours which is
1st valid
18 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 18 of 33 Chaity Composite Ltd
Table Inspection Point
1. Two person together Inspection
2. Two person Maximum two hours continue inspection
3. Running Shade/ Uneven/ Hairiness
4. Hold Fabrics & Take Quick decision
5. Follow 4 point System
6. Result OK/ Reject
7. Lux value 1000+ & Light Expired time one year or 1300 hours which is
1st valid
Compactor M/c Inspection Point
1. Two person together Inspection
2. Two person Maximum two hours continue inspection
3. Machine Speed 16/18 RPM
4. Width & GSM check
5. Hole, Naps, Hairiness, Crease Mark, Compaction Mark, Any spot, Patta,
Lycra Missing/Out, Yarn/Fly Contra, Width Variation, Pin out, Jumping,
Recovery, Slanted, Bowing,
6. If any measurement like Stripe
7. Within ½ inch pin in Selvage more than infirm to Finishing
8. Roll to Roll Shade & GSM cut
9. Inspection as 4 point System
10, Maintain Register Loge book
19 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 19 of 33 Chaity Composite Ltd
Compact & Inspection M/c before starting Ensure the below issue-
1. Shade
2. Running shade
3. Dia ±
4. GSM ±
5. Enzyme Dust
6. Hairiness
7. Shrinkage
8. Spirality
9. Bowing
10. Angle
11.Any Measurable issue, Stripe
12. Accessories available with match (Rib, Collar & Cuff)
Any problem first take decision then started m/c otherwise hold
Out of 4 point System
1. Running Shade
2. Patta, Line Mark
3. Lycra Missing
4. Hairiness
5. Naps
6. Uneven
7. GSM issue
8. Width short/ Long
9. Brush Problem
Only need take decision Major or minor
20 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 20 of 33 Chaity Composite Ltd
Impotent Sample
1. Counter Sample
2. PP Sample (Pre-production)
3. Inline
4. Quotation Sample
5. Photo Sample
6. Development Sample
7. Yarn Test
8. Color Sample
9. First Fit Sample
10. Chemical Test
11. Style Sample
Need available in QAD Department:
1. Lab Dip
2. Counter/PP Sample
3. Original Swatch
4. Fabric Technical Data/FTD
5. Booking Sheet
Record Keeping in Department:
1. Shade Continuity
2. Every Rolls Shade Brand
3. Every Rolls GSM Cutting
4. 4 points System
5. Lab Test Report
6. Accessories Match Keeping
21 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 21 of 33 Chaity Composite Ltd
Sample Record Keeping:
1. Order Sheet
2. Standard Swatch
3. Shade Card
4. Inspection Report (4 Point System)
5. One Meter Fabrics
6. Accessories Match Keeping
7. Send mail to related person
8. Uster Report
Quality Related imported Shortcut
1. QAD- Quality Assurance Department
2. GPQ- Guideline for Production & Quality Control of Material.
3. H&M- Hannes & Mauritz
4. C&A- Collins & Aikman
5. GSM- Grams per Square Meter
6. QC- Quality Controller
7. NQC- Nominated Quality Controller
8. SOP- Standard Operating Procedure
9. CMC- Color Measurement Clarification
10. CVC- Chief Value of Cotton
11. FTD- Fabrics Technical Data
12. RQS- Requirement for Quality System
13. QMS- Quality Management System
14. MMR- Minimum Manufacturing Requirement
15. TQM- Total Quality Management
22 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 22 of 33 Chaity Composite Ltd
16. QA- Quality Assurance
17. ISO- International Organization for Standardization
18. EPZ- Export Processing Zone
19. HR- Human Resources
20. TBC- To be Confirm
21. AOP- All over Print
22. PC- Polyester of Cotton
23 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 23 of 33 Chaity Composite Ltd
Impact of Higher Quality Control
Less Wastage
Less Re work
Few Reject Lower Cost
Less Backlog High Productivity
Few Complaints
Few Returns
Quality Inspection
Remove of Fault
Indicate of Fault
Inform must be concern person
Cause Indicate of Fault
Inspection
24 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 24 of 33 Chaity Composite Ltd
OK
OK
Non Conformed
Process Flow Chart of Fabric Quality
Re-process Dyeing
Stenter M/c
Shade uneven
Not OK Spot, Hairiness,
Handfeel
Lab Test
Shrinkage, Fastness &
Others
Compacting
Dia & GSM
Not OK Check
Fabrics Inspection
4 point System
Shade Continuity
Finish Fabric Store
25 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 25 of 33 Chaity Composite Ltd
Standard Operation Procedure
Grey Inspection:
1. Knitting Production
2. Inspection, 4 Point System
3. More than 28 points Reject
4. Major Problem Discuses with QAD Head
5. Keep Record in GPQ File
Check Point for Griage Fabrics
1. Order/Buyer wise Quality Check
2. 4 point system Check
3. Inspection –
A. Yarn Variation/Count Mix
B. Contaminations
C. Knitting Hole
D. Jumping
E. Fly Contra/ Yarn Contra
F. Sinker Mark
G. Needle Mark
H. Set off
I. Lycra Out
26 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 26 of 33 Chaity Composite Ltd
Record Keeping Of GPQ
1. Booking Sheet Collect
2. FTD Collect
3. Counter Collect
4. Order Risk Assessment
5. Inspection Report (4 Point System)
6. Shade Continuity
7. Roll to Roll GSM Board
8. Roll to Roll Shade Board
9. Accessories Joint with Body
10. Test Report
11. GPQ Certificate
12. Packing List
13. Sample Process Record
14. Light Life time value Record
Knitting Online QC
1. Batch Card Check
a) Yarn lot
b) Yarn Count
c) Buyer Name
d) Stitch Length Cross Check
e) GSM Check
f) Yarn Brand Check- Combed/Carded
2. Fabric Quality
a) Loop
b) Needle Brocken/ Mark
c) Sinker Mark
d) Count/Lot Mix
e) Oil Sport/ Mark
f) Set off
g) Contra- Fly/Yarn
h) Lycra Out
27 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 27 of 33 Chaity Composite Ltd
Inspection Area-
1. Yarn Inspection
2. Grey Fabrics Inspection
3. Dyed Yarn Inspection
4. Printed Fabrics Inspection
5. After Dyeing Fabrics Inspection
Yarn Dyed Inspection:-
1. Color Bleeding
2. Measurement on Stripe
3. Any fly contaminations
4. Yarn Contaminations
5. Bowing
6. Angle/ Slanted
7. Twisted/ Spirality
8. Shrinkage
Print Fabrics Inspection:
1. Check with Stranded Swatch
2. Print Durability
3. Color Bleeding
4. Before & After Check any Change
5. After Finishing print any Change
6. Shrinkage
28 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 28 of 33 Chaity Composite Ltd
Fleece Fabric Inspection
1. Shade Check
2. Before & After Shade Check what about Change
3. Chemical Test
4. Hairiness
5. Re-tension / Stitch Recovery
6. Brush Fiber Migrations
7. Naps
8. Sinker/ Line Mark
9. GSM/ Width
Sueded Fabrics Inspection:
1. Shade Check
2. Before & After Shade Check what about Change
3. Line/ Sinker Mark
4. Naps
5. Hairiness
6. Hole before or After (Pin/ Sueded)
Fabrics Inspection-
1. Shade Check
2. Hairiness
3. Naps
4. Bowing/Slanted
5. Shrinkage
6. Twist/Spirality
7. Sinker/ Line Mark
8. Uneven Shade
9. Running Shade
10. GSM/ Width
29 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 29 of 33 Chaity Composite Ltd
Theory of Color-
 Pigment Theory:
1. Primary – Red, Yellow, Blue
2. Secondary – Orange, Green, Violet
3. Tertiary – Olive, Grey, Purple
Allowable Maximum Points
1.
2.
3.
4.
Accepted Average & Maximum:
Fabrics Type Avg/yards Max/yards Avg/Meter Max/Meter
Single Jersey 15 20 17 22
Double Jersey 18 24 20 26
Interlock 22 28 24 31
30 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 30 of 33 Chaity Composite Ltd
Date: 11-09-2017
Name of Test H & M Lidl (HK & B.C) Hema Sears GP US PoloTAKKO TEIJEN
Dimentional Stability to wash (Shrinkage)
Knit General ± 5%,
Rib+waffle+interloc
k L -5% & w +5%/-7%
2% to -5% ± 6 %
S/J L/w -6%,
Terry L -8%/w-
8%, Rib L -6%/w-
±5%
L -5%,
w -5%
± 5%
T/D -5%,
L/D
-5%/+2%
Twisting(Spirality)
5%(Trouser 8% &
Long Sleeve 1cm
5% 5% 5% 3% 5% 5% 5%
GSM ± 5% ± 5% ± 5% ± 5% ± 5% ± 5% ± 5% ± 5%
C/F to Rubbing--Dry 3 to 4 4 4 4 4 3 to 4 4 3 to 4
C/F to Rubbing--Wet 2 to 3 (CN shipment) 2 to 3 3 3 3 2 to 3 3 2 to 3
C/F to Wash --Color Staining 3 to 4 3 to 4 ≥ 4 3 to 4 4 3 to 4
C/F to Wash --Color Change 4 3 to 4 ≥ 4 4 4 4
C/F to Wash --Cross Staining 4 to 5 3 to 4 ≥ 4 4 to 5 4 to 5 4
C/F to Water-- Color Staining 3 to 4 3 to 4 ≥ 4 ( Baby item) 4 3
C/F to Water-- Color Change 4 3 to 4 ≥ 4 ( Baby item) 3 to 4 4
C/F to Water-- Cross Staining 4 to 5 3 to 4 ≥ 4 4 to 5 4 to 5
C/F to Perspiration(ACID)--Color Staining 3 to 4 ≥ 4 4 3 to 4 3 to 4
C/F to Perspiration(ACID)--Color Change 4 ≥ 4 3 to 4 4 4
C/F to Perspiration(ACID)--Cross Staining 4 to 5 ≥ 4 4 to 5 4 to 5 4
C/F to Perspiration(ALKALI)--Color Staining 3 to 4 ≥ 4 4 3 to 4 3 to 4
C/F to Perspiration(ALKALI)--Color Change 4 ≥ 4 3 to 4 4 4
C/F to Perspiration(ALKALI)--Cross Staining 4 to 5 ≥ 4 4 to 5 4 to 5 4
C/c to Saliva-- Color Staining 4 N/A 4 (Size≤36 months)4 4 to 5
C/c to Saliva-- Color Change 4 N/A 4 (Size≤36 months)4 4 to 5
C/c to Saliva-- Cross Staining 4 to 5 N/A 4 (Size≤36 months)4 4 to 5
C/F to Phenolic Yellowing 4 N/A 4 to 5 3 to 4 4
C/F to Light 3 to 4 3 to 4 ≥ 4 3 to 4 4 to 6 3
Pilling 3 (blended fabric) 4 (Martindale) ≥ 3(15000 Cycle) 4 3 to 4
Bursting 250 kpa (GSM≤200) N/A N/A N/A N/A
Fabric pH 4 to 7.5 4 to 7.5 4 to 7.5 5 to 7 4 to7.5
Appearance after wash No major change N.M.C N.M.C N.M.C N.M.C N.M.C N.M.C N.M.C
Dye transfer in storage--Color staining 4 N/A N/A N/A N/A 3 to 4 N/A N/A
Dye transfer in storage--Color Change 4 N/A N/A N/A N/A 3 to 4 N/A N/A
Dye transfer in storage--Cross staining 4 to 5 N/A N/A N/A N/A 3 to 4 N/A N/A
Note: CN-China , N.M.C-No major Change, T/D-Tumble dry, L/D-Line dry, N/A- Not Applicable, HK-Hongkong, B.C-BayCity, kpa- Kilo pascale
General 3 to 4, if
size ≤ 104 it should
be 5
General 3 to 4, if
size ≤ 104 it should
be 5 (Kids Item)
Chaity Composite ltd.
Sonargaon, Narayangonj
Buyers Requirments
31 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 31 of 33 Chaity Composite Ltd
AGM (Admin) GM (Fabrics) Director
Data Entry-1
ApproveredAsst Manager (QAD) AGM (Qality & Product Development)
Executive-3, Knitting,
Dyeing, Finishing
Inspector-4
Director
Inspector (GSM Cutting & Board)-5
Inspector (Machine)-4
Inspector (Dust remover)-2
Inspector (Hand Folding)-5
Inspector (Rib Collar & Cuff)-4
Inspector (Hold & Reject Check)-2
Inspector (Yarn Dyed & Subcontact)-1 (G)
Inspector (Report & Delivery Update)-2
Executive
Excutive/Incharge-1
Supervisor-2
Inspector-20, M/c-5
Sr Executive- G
Executive (Floor)-G
Executive (Shade)-3
Incharge-3
Supervisor-2
H&M (GPQ) R&DAsst Manager (others)
Lidl (GPQ) Grey Fabrics InspectionHema, Bay City & Others
Sr Executive Sr Executive
Executive (Shade)
Executive (Sample)
Sr Inspector (Stenter)-8
Sr Inspector/Inspector (Compact)-10
Inspector (teble Runn Shade Check)-4
Inspector (Documents)-3
Data Entry
Executive (Elastic)
Executive (Grey)
Sr Executive
Managing Director
AGM
Company Profile.
Quality Assurance Department
Chaity Composite Ltd.
32 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 32 of 33 Chaity Composite Ltd
Bowing/Skewing:
Bowing is the measurement of the bowing arc at the highest point of a line at right angles
Between the two selvages.
A Bow depth
Fabric width
Skewing/Twisting:
Skewing/Twisting is the measurement of the highest point between a weft thread/row and a
line at right angles between the two selvages/folds.
Skew depth -A
Fabric width
Tolerance Calculation
A
Max %____________ x 100 =
Cuttable width
Fabric Types Max % of fabric width
Woven Jersey
3% 5%
2% 4%
Solid colours/Prints
Stripes/Checks
Rolls exceeding these tolerances have failed.
Exception:
Skewing are characteristics for woven twill/satin constructions and for single jersey.
The skewing tolerance must therefore be agreed on each order separately, and stated on the
“Fabric Technical Data”. The H&M garment supplier must first check twisting and eventual
distortion on garment after:
•Eventual garment treatment.
•Washing according to care instruction.
In case of Inconsistent skewing/twisting in-between inspected rolls the inspection has failed.
33 | P a g e Q u a l i t y A s s u r a n c e D e p a r t m e n t
Page 33 of 33 Chaity Composite Ltd
Avgiv cªwZÁve×,
c‡b¨i ¸bv¸Y wbð©Z Kivi,
hvnv †µZvi Pvwn`v|

Quality manual

  • 1.
    1 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 1 of 33 Chaity Composite Ltd AGM (Quality & Product Development) Cell: +880 1708 454 779 Email: mizan5379@yahoo.com Skype: mizan_mehben
  • 2.
    2 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 2 of 33 Chaity Composite Ltd Quality Assurance Department (`ª‡e¨i ¸bv¸Y wbð©Z Kiv) ‡Kvqv‡jwU: ‡Kvb `ª‡e¨i KZ ¸‡jv ˆewkó¨ ev AvPiY hvnv †fv³v‡`i D‡Ïk¨ ev Pvwn`v c~i‡Y mÿg| ‡Kvqv‡jwU ‡KvȪj: ‡Kvb m~-m„•Lj e¨e¯’v hvnv †Kvb Kvw•LZ `ªe¨w` Drcv`‡b mÿg| ‡Kvqv‡jwU wbð©Z Kiv: cÖwµqv MZ fv‡e `ª‡e¨i ¸bv¸Y wbð©Z Kiv| Quality Assurance: Quality Assurance is a process focused concept, where the processes are put in place to ensure the correct steps are done in the correct way. If the correct processes are in place there is some assurance that the actual results will turn out as expected. Quality Control: Quality Control is a product focused concept, where checking of the actual results are done to ensure that things are as expected. If the correct controls are in place you can know for certain that the actual results have been achieved because the actual results have been checked.
  • 3.
    3 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 3 of 33 Chaity Composite Ltd Procedure of Delivery (sop) 1. Without Test Result Please don’t Delivery Any Quantity of Fabrics. 2. Without Rib/Single Jersey/ Back neck tap, not delivery. 3. Any Measurable part, Like Collar & Cuff, Stripe Yarn dyed Fabrics should be check as buyer requirement. 4. Inline Fabrics All test should be check & Shrinkage CHECK from 3-4 rolls & Ensure Acceptable tolerance, 5. Width ± 1”, More than need to Approval from Related Person. Also infirm to cutting department. 6. Before Delivery must be Re-check by Shift In-charge, Width, GSM, Shrinkage delivery report with Batch information. 7. 1st Batch Shade check & crosses check for confirmation. 8. All Approved shade must be keeping before dyeing from related Merchandiser 9. All shade check two person avoid the wrong decision. (Keep sign) 10. 1st Batch check with Booking All information, like width, GSM, Accessories & Shade Reference. 11. Every day at 1st All delivered batches should be showing to Responsible person & take Sign 12. Unacceptable Issue not delivery. We have committed good quality fabrics delivery which is customer Requirement
  • 4.
    4 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 4 of 33 Chaity Composite Ltd Definition of 4 Point: ‡Kvb wbw`©ó †d«we• Gi ΃wU ¸‡jv †K Bw‡Z cwigvc K‡i Pvi wU av‡c wef³ K‡i †kÖbx‡Z iæcvšÍi Kiv †K eySvq | Procedure of Four Point System: 1. Fabric inspection is usually done on fabric inspection machineries. 2. These machineries are designed so that rolls of fabric can be mounted behind the inspection table under adequate light and re-rolled as they leave the table. 3. Inspection machineries are either power driver or the inspector pulls the fabric over the inspection table. 4. The defects are located, marked and recorded on an inspection form. 5. Some machinery is equipped to measure the length of each roll of fabric (meter/yard). Fabric defects point values based on the following: Length of defect in Fabric Points allotted Up to 3 inch 1 Over 3 inch up to 6 inch 2 Over 6 inch up to 9 inch 3 Over 9 inch 4 Holes and Opening 1 or less 2 Over 1 inch 4
  • 5.
    5 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 5 of 33 Chaity Composite Ltd Defect Length Points Sticker Colour Less then3” 1 White 3”-6” 2 Green 6”-9” 3 Yellow Over 9” 4 Red Hole Points Sticker Color Less or equal to 2.5cm/1” 2 Green Larger than 2.5cm/1” 4 Red Example: Defect should be marked with a coloured sticker. To show defect position the selvage should be marked with the same colour of sticker or thread. Defects in both warp/weft directions will be assigned points using the following criteria: Defects and Penalty points Fabric width 1. Total points awarded for first m/yd is 4. 2+4 points=6 points. “Regardless of length/size or number of defects, no more than 4 penalty points may Be assigned on any linear meter/yard”. 1m/yd 10cm 1m 5cm 1m/yd 2. Total points awarded for second m/yd is 1. 15cm 1m/yd 3. Total points awarded for third m/yd is 3. 1m/yd 4cm hole 25cm 4. Total points awarded for fourth m/yd is 4. 4+4 points=8 points. “Regardless of length/size or number of defects, no more than 4 penalty points may be assigned on any linear meter/yard”.
  • 6.
    6 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 6 of 33 Chaity Composite Ltd Calculations and Result: Total defect points per 100 yard square are calculated. If fabric rolls contains less than 40 points per 100 yard square are considered “first” quality and as an Acceptance criteria. If fabric rolls containing more than 40 points per 100 yards square are considered “second”. Example: A fabric roll 130 yard long and 45 inch wide contains the following defects:- 6 defects up to 3 inch- ................................... 6 X 1 = 6 points 5 defects over 3 inch but less 6 inch- ............. 5 X 2 = 10 points 2 defects over 6 inch but less 9 inch- ..............3 X 2 = 6 points 1 defects over 9 inch- .................................... 1 X 4 = 4 points 1 hole over 1 inch dimensions- ....................... 1 X 4 = 4 points ……………………………………………………………………………………… Total defect points................................................= 30 points Therefore, Points per 100 yard square = Total points scored in roll X 36 inch ……………………………………………………………… X 100 Fabric width/inches X Total length yard inspected 30 X 36 = ……………………… X 100 130 X 45 = 18.4 (Defect points per 100 yard square.) So, the roll is accepted.
  • 7.
    7 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 7 of 33 Chaity Composite Ltd Colour and shades must be controlled by maintaining colour continuity records. Dye lot to dye lot, within a dye lot and within a roll must be checked. Records must be Available for H&M and kept for at least 6 month. The swatches must be a minimum of 4x10 cm and be evaluated visually in a light box. A close critical match to colour standard and approved fabric must be achieved in; TL83, D65 And display no dramatic difference in colour appearance in A-light (tungsten). For more detailed information see Supplier Colour Guide Book. For the use of ISO 105-A02: 1993 Grey scale for assessing change in colour there should not Be a greater difference than 4-5 between any parts within a dye lot and roll. Full width cutting: Inspection procedures: Colour continuity record: At the beginning and at the end of each roll selected for fabric inspection, cut a 30 cm/6” full width cutting. The look, hand feel, and colour must be compared in the light box against: •Colour Standard •Approved fabric •Fabric Technical Data Shade deviation within a roll must be checked by folding or sewing: •Side to side •Side-centre-side •Beginning-end If difference is more then 4-5 on the grey scale between any parts, the H&M local office must be contacted. Weight- •Check weight on minimum 10% of the rolls chosen for inspection. •Weigh a 100 cm² cutting; convert the weight into m²/yd². •Weight should correspond to weight stated on Fabric Technical Data. If the deviation is more then -5% / +7% the roll has failed. Cuttable width- The minimum Cuttable width, measured between needle holes at roll selvages, is stated on The Fabric Technical Data, and must be checked at least 3 times on each roll at: • Beginning. • Middle. • End. Rolls where cuttable width is less, has failed.
  • 8.
    8 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 8 of 33 Chaity Composite Ltd Minimum splice length is 30 m/yds. Splice location must be noted on the individual roll inspection report. 4 penalty points will be assigned for each splice/join. roll is allowed to contain more than 1 splice/join. Shade Check in Light Box 1. Two person together shade Check Avoid the Wrong Decision. Because Two Person not Same Measurable Power, So combined take decision. 2. with Three Light Shade Check 3. Make Family Shade A&B 4. Light D65, TL 83, A-10 5. 1 st Batch Shade check with Woven Standard & Counter Sample 6. Next Batch Check Batch to Batch with Counter 7. White & Grey Mélange Must be Check with UV Light 8. Metameric Check in A-10 Home Light 9. Shade Check in 45 degree Angle Splices- Roll length verification- Roll length measuring less than 40 m/yds cannot be accepted, unless agreed. Roll length stated on the roll ticket must be verified against the actual roll length Measured by the fabric checking machine. •If the deviation is 1% less, length should be double checked on a cutting table. If difference remains, the roll has failed. Fabric odours- Roll that emit an unpleasant odour, has failed. Roll that emit an unpleasant odour, has failed.
  • 9.
    9 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 9 of 33 Chaity Composite Ltd Light Sourcing (Knit) 1. Shop Light (Primary ) -TL83 Lax Value 1000 to more 2. Day Light (Secondary)- D65 Lax Value 1000 to More 3. Home Light - A-10 Lax Value 800 to More 4. Morning Sun Light – Ultra Violet (UV) Light Sourcing (Under Wear) 1. Shop Light (Primary ) - TL83 Lax Value 1000 to more/18w 2. Home Light (Secondary) -A-10 Lax Value 800 to More/18w 3. Day Light - D65 Lax Value 1000 to More/40w 4. Morning Sun Light – Ultra Violet (UV)/18w
  • 10.
    10 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 10 of 33 Chaity Composite Ltd Fabrics Delivery Approval Authority: 1. Check Buyer Requirement, Width, GSM, Shade match, Shrinkage, Accessories ( Rib, Collar & Cuff, Piping, Back neck tap with Measurement)- Confirm from Online In-charge & Executive (Shade) 2. Test Result (Shrinkage, Twist, Rubbing, Pilling & Wash Fastness)- confirm from Physical Lab Manager 3. Fulfil the Buyer Requirement then possible to Delivered i. GSM- 5-7% Low from Required, ii. Shrinkage L-4% W-7% Spirality 5% iii. Width ±1 inch iv. Test as Buyer Required 4. Approved by any problems fabrics– i. GSM, Width & Shrinkage (Cotton) - Knitting GM & Manager, Finishing AGM & Manager with Sign. ii. GSM, Width & Shrinkage (Lycra)- Finishing AGM & Manager with Sign iii. Shade, Uneven, Hairiness- AGM(Dyeing) with sign iv. Test (Color Fastness, Pilling, Rubbing)- AGM(Dyeing), also Physical Lab Manager with sign 5. Over all if take Responsibility Related Merchandiser then we can delivered any kind of problems fabrics but need to take sign. 6. Any person given the approval then we send mail to related person in the department 7. Without proper inspection not a single kg fabrics delivered
  • 11.
    11 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 11 of 33 Chaity Composite Ltd Job Responsibility: Md Mizanur Rahman- AGM (Quality & Product Development) 1. Planning & Monitoring of Production Target. 2. Ensure that the Quality Standard is being met by Forecasting & reviewing the result. 3. Develop Discipline, by implementing the Rules &Regulation in Department. 4. Ensure acceptable Quality level (AQL) in textile manner. 5. Give a continuous guidance to the Executive, along with others for target fabric specification. 6. Supervision constantly to Grey & Final QC. 7. Give the full support the Research & Development Department. 8. Make a continuous study of work improvement & give report to the higher authority. 9. Response & act in the customer complain & query. 10. Ensure that all safety followed by the team. 11. Continuously study the Cost saving of the Department. 12. Enthusiastic to wastage utilization. 13. Optimize Manpower Utilization. 14. Worker Turnover & Absenteeism control as per Plan. 15. Skill Development in the Floor. 16. Ensure that all Lab test Report (Physical) are recorded. 17. Follow the concept of Top Management. 18. Regularly held a meeting to all people once in a week/ Time to time. 19. Co-ordination with all departments all quality parameter inform time to time all department. 20. Check the hold fabric & give decision quickly.
  • 12.
    12 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 12 of 33 Chaity Composite Ltd Mr Arafat Rahman Prience- Asst Manager (H&M GPQ) 1. Ensure the delivery target with Quality 2. RQS Audit, 3. Urgency of H&M 4. Sample (All Buyer) 5. H&M GPQ Audits 6. H&M Related Quality Issue, 7. Hold (H&M) Fabric inspection & Take decision immediately 8. All Audit Record & Keeping Documents 9. Audit Related all points need to be check & Confirm available as Buyer Requirement 10. FTD Approval ensure & Product Match with FTD 11. Give Training as buyer requirements 12. Ensure the quality Standard which is delivered Mr Monir Hossain- Asst Manager (QAD) 1. Planning & Monitoring of Delivery Target. 2. All Buyer fabrics inspection Without H&M 3. Fulfil the buyer wise quality requirement 4. Ensure the delivery target with Quality 5. Hold Fabric Take decision immediately 6. Inline fabrics ensure the Quality Requirement 7. Ensure the 4 point system reporting 8. Grey fabric inspection & give decision 9. Ensure the good house keeping 10. Manpower utilize 11.Recruited
  • 13.
    13 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 13 of 33 Chaity Composite Ltd Monowar Hossain Nahid- Executive (GPQ- H&M) 1. Mainly H&M GPQ Responsible 2. All sample check 3. Ensure the buyer requirement 4. Ensure the testing requirement 5. Yarn test 6. Support to PP Sample 7. FTD Approval 8. Resource & Development 9. On time delivery with Quality 10. Keep record Sample inspection & Yarn test SM Younus Ali Ruble – Senior Executive (Shade) 1. Confirm the Shade as buyer concept 2. Approval taken from Buyer 3. Within short time shade confirm & Feedback to production 4. All Lab dip take from Lab Then Confirm with Related Merchandiser 5. Keep all approval Swatch Md. Shafiqul Islam- Shift In-charge (Inspection) 1. Fulfil the delivery target with quality 2. Requirement wise delivery width, gsm shrinkage, Spirality & All Accessories (Rib, Collar & Cuff, Back neck tap) 3. Check process loss 4. All testing confirm then delivered 5. Return for reprocess Dyeing & Finish, Keep Record. 6. Ensure the good house keeping
  • 14.
    14 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 14 of 33 Chaity Composite Ltd Jahirul: Data Entry Operators 1. Make Reports- inspection, Compact, Hand folding, Inspection M/c 2. Handover Record 3. Reprocess (Dyeing & Finishing) 4. Return to Dyeing & Finishing 5. Order Summary 6. Reject Md Anower Hossain- Executive (H&M GPQ) 1. Ensure Audite Related Keep all documents 2. Uster Yarn Report 3. Yarn test Report 4. MR Ensure the Fulfil Buyer Requirement 5. Order Sheet 6. Shade Continuity Card 7. GSM Record 8. Inspection Report 9. Fabrics delivered with test & Necessary documents 10. Handle the H&M Buyer Ahasan Kobir Sumon- GPQ-H&M (Sample) 1. All H&M Sample 2. Yarn test 3. Uster Report 4. FTD approval Ensure 5. Keep record Sample inspection & Yarn test 6. Keep File (Knitting, Dyeing & Finishing)
  • 15.
    15 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 15 of 33 Chaity Composite Ltd H&M Sample Documents File Keeping (Buyer Requirement) 1. FTD 2. Knitting Data 3. Grieg Swatch 4. Dyeing Recipe 5. Program Route 6. Finishing parameter 7. Test Report 8. Inspection Report 9. Uster Report 10. Yarn Test Report 11. Booking Sheet 12. Summary Sheet H&M Production Documents keep in the File 1. Booking Sheet 2. Order Sheet 3. Rick Assessment Sheet 4. Counter Sample comments copy 5. FTD Sample Comments copy 6. Inspection Report (4 Points) 7. Packing List 8. GPQ Certificate 9. Lab Test Report 10. Summary sheet
  • 16.
    16 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 16 of 33 Chaity Composite Ltd Quality Policy (¸bMZ gvb bxwZ) Vision: - To Achieve Continues improvement in garments product quality fabrics & attain sustainability through united effort. jÿ¨: HK¨e× cª‡Póvi gva¨‡g ‡cvkv‡Ki ¸bMZ gvb µgvMZ Dbœqb I `xN© ¯’vqxZ ¡ AR©b Kiv| Mission: - To understand the buyers demand & Fulfil their requirement by producing better quality Fabrics. D‡Ïk¨: †µZvi Pvwn`v eySv Ges DbœZ gv‡bi †cvkvK •Zixi gva¨‡g Zvnv‡`i Pvwn`v c~iY Kiv| Policy:- 1. To build up a long lasting better Relationship with buyer by fulfilling the their demands ‡µZvi Pvwn`v c~i‡Yi gva¨‡g `xN©¯’vqx m~m¤úK© ˆZix Kiv 2. To improve employees skills through training & Evaluate/ Appreciate their work cÖwkÿ‡Yi gva¨‡g Kgx©‡`i `ÿZv e„w× Kiv Ges Kv‡Ri g~j¨vqb Kiv| 3. To maintain a Cleaner workstations & to build up self-Motivated & Responsible work force. Kg©¯’‡ji cwi‡ek cwi”Qbœ ivLv I m¦cÖ‡Yvw`Z `vwqZ¡kxj Rbkw³ ˆZix Kiv|
  • 17.
    17 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 17 of 33 Chaity Composite Ltd Online Inspection Point 1. Shade Give to Light Box for Approved 2. Hand feel & Hairiness Check with FTD 3. 10% Rolls check table, Running Shade/Uneven 4. Naps, Hole, Patta Check, Line/Sinker Mark 5. Width & GSM confirm with Requirement 6. Within ½ inch pin in Selvage more than infirm to Finishing 7. Give to one meter fabrics Laboratory for Test, Shrinkage/Fastness 8. Accessories available or not (Rib, Collar & Cuff) 9. Check Measurement if Required Like Stripe Fabrics 10. Information should be write down in Batch Card Clearly & Online inspection Loge book 11. If any unacceptable must be infirm to Shift In-charge Inspection Machine Point 1. First Check online information 2. Two person Maximum two hours continue inspection 3. Note in Register loge book which person inspection with sign 4. 4 point system follows 5. Machine Speed Light Color 16/18 & dark Color 18/20 RPM 6. Lux value 1000+ & Light Expired time one year or 1300 hours which is 1st valid
  • 18.
    18 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 18 of 33 Chaity Composite Ltd Table Inspection Point 1. Two person together Inspection 2. Two person Maximum two hours continue inspection 3. Running Shade/ Uneven/ Hairiness 4. Hold Fabrics & Take Quick decision 5. Follow 4 point System 6. Result OK/ Reject 7. Lux value 1000+ & Light Expired time one year or 1300 hours which is 1st valid Compactor M/c Inspection Point 1. Two person together Inspection 2. Two person Maximum two hours continue inspection 3. Machine Speed 16/18 RPM 4. Width & GSM check 5. Hole, Naps, Hairiness, Crease Mark, Compaction Mark, Any spot, Patta, Lycra Missing/Out, Yarn/Fly Contra, Width Variation, Pin out, Jumping, Recovery, Slanted, Bowing, 6. If any measurement like Stripe 7. Within ½ inch pin in Selvage more than infirm to Finishing 8. Roll to Roll Shade & GSM cut 9. Inspection as 4 point System 10, Maintain Register Loge book
  • 19.
    19 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 19 of 33 Chaity Composite Ltd Compact & Inspection M/c before starting Ensure the below issue- 1. Shade 2. Running shade 3. Dia ± 4. GSM ± 5. Enzyme Dust 6. Hairiness 7. Shrinkage 8. Spirality 9. Bowing 10. Angle 11.Any Measurable issue, Stripe 12. Accessories available with match (Rib, Collar & Cuff) Any problem first take decision then started m/c otherwise hold Out of 4 point System 1. Running Shade 2. Patta, Line Mark 3. Lycra Missing 4. Hairiness 5. Naps 6. Uneven 7. GSM issue 8. Width short/ Long 9. Brush Problem Only need take decision Major or minor
  • 20.
    20 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 20 of 33 Chaity Composite Ltd Impotent Sample 1. Counter Sample 2. PP Sample (Pre-production) 3. Inline 4. Quotation Sample 5. Photo Sample 6. Development Sample 7. Yarn Test 8. Color Sample 9. First Fit Sample 10. Chemical Test 11. Style Sample Need available in QAD Department: 1. Lab Dip 2. Counter/PP Sample 3. Original Swatch 4. Fabric Technical Data/FTD 5. Booking Sheet Record Keeping in Department: 1. Shade Continuity 2. Every Rolls Shade Brand 3. Every Rolls GSM Cutting 4. 4 points System 5. Lab Test Report 6. Accessories Match Keeping
  • 21.
    21 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 21 of 33 Chaity Composite Ltd Sample Record Keeping: 1. Order Sheet 2. Standard Swatch 3. Shade Card 4. Inspection Report (4 Point System) 5. One Meter Fabrics 6. Accessories Match Keeping 7. Send mail to related person 8. Uster Report Quality Related imported Shortcut 1. QAD- Quality Assurance Department 2. GPQ- Guideline for Production & Quality Control of Material. 3. H&M- Hannes & Mauritz 4. C&A- Collins & Aikman 5. GSM- Grams per Square Meter 6. QC- Quality Controller 7. NQC- Nominated Quality Controller 8. SOP- Standard Operating Procedure 9. CMC- Color Measurement Clarification 10. CVC- Chief Value of Cotton 11. FTD- Fabrics Technical Data 12. RQS- Requirement for Quality System 13. QMS- Quality Management System 14. MMR- Minimum Manufacturing Requirement 15. TQM- Total Quality Management
  • 22.
    22 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 22 of 33 Chaity Composite Ltd 16. QA- Quality Assurance 17. ISO- International Organization for Standardization 18. EPZ- Export Processing Zone 19. HR- Human Resources 20. TBC- To be Confirm 21. AOP- All over Print 22. PC- Polyester of Cotton
  • 23.
    23 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 23 of 33 Chaity Composite Ltd Impact of Higher Quality Control Less Wastage Less Re work Few Reject Lower Cost Less Backlog High Productivity Few Complaints Few Returns Quality Inspection Remove of Fault Indicate of Fault Inform must be concern person Cause Indicate of Fault Inspection
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    24 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 24 of 33 Chaity Composite Ltd OK OK Non Conformed Process Flow Chart of Fabric Quality Re-process Dyeing Stenter M/c Shade uneven Not OK Spot, Hairiness, Handfeel Lab Test Shrinkage, Fastness & Others Compacting Dia & GSM Not OK Check Fabrics Inspection 4 point System Shade Continuity Finish Fabric Store
  • 25.
    25 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 25 of 33 Chaity Composite Ltd Standard Operation Procedure Grey Inspection: 1. Knitting Production 2. Inspection, 4 Point System 3. More than 28 points Reject 4. Major Problem Discuses with QAD Head 5. Keep Record in GPQ File Check Point for Griage Fabrics 1. Order/Buyer wise Quality Check 2. 4 point system Check 3. Inspection – A. Yarn Variation/Count Mix B. Contaminations C. Knitting Hole D. Jumping E. Fly Contra/ Yarn Contra F. Sinker Mark G. Needle Mark H. Set off I. Lycra Out
  • 26.
    26 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 26 of 33 Chaity Composite Ltd Record Keeping Of GPQ 1. Booking Sheet Collect 2. FTD Collect 3. Counter Collect 4. Order Risk Assessment 5. Inspection Report (4 Point System) 6. Shade Continuity 7. Roll to Roll GSM Board 8. Roll to Roll Shade Board 9. Accessories Joint with Body 10. Test Report 11. GPQ Certificate 12. Packing List 13. Sample Process Record 14. Light Life time value Record Knitting Online QC 1. Batch Card Check a) Yarn lot b) Yarn Count c) Buyer Name d) Stitch Length Cross Check e) GSM Check f) Yarn Brand Check- Combed/Carded 2. Fabric Quality a) Loop b) Needle Brocken/ Mark c) Sinker Mark d) Count/Lot Mix e) Oil Sport/ Mark f) Set off g) Contra- Fly/Yarn h) Lycra Out
  • 27.
    27 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 27 of 33 Chaity Composite Ltd Inspection Area- 1. Yarn Inspection 2. Grey Fabrics Inspection 3. Dyed Yarn Inspection 4. Printed Fabrics Inspection 5. After Dyeing Fabrics Inspection Yarn Dyed Inspection:- 1. Color Bleeding 2. Measurement on Stripe 3. Any fly contaminations 4. Yarn Contaminations 5. Bowing 6. Angle/ Slanted 7. Twisted/ Spirality 8. Shrinkage Print Fabrics Inspection: 1. Check with Stranded Swatch 2. Print Durability 3. Color Bleeding 4. Before & After Check any Change 5. After Finishing print any Change 6. Shrinkage
  • 28.
    28 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 28 of 33 Chaity Composite Ltd Fleece Fabric Inspection 1. Shade Check 2. Before & After Shade Check what about Change 3. Chemical Test 4. Hairiness 5. Re-tension / Stitch Recovery 6. Brush Fiber Migrations 7. Naps 8. Sinker/ Line Mark 9. GSM/ Width Sueded Fabrics Inspection: 1. Shade Check 2. Before & After Shade Check what about Change 3. Line/ Sinker Mark 4. Naps 5. Hairiness 6. Hole before or After (Pin/ Sueded) Fabrics Inspection- 1. Shade Check 2. Hairiness 3. Naps 4. Bowing/Slanted 5. Shrinkage 6. Twist/Spirality 7. Sinker/ Line Mark 8. Uneven Shade 9. Running Shade 10. GSM/ Width
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    29 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 29 of 33 Chaity Composite Ltd Theory of Color-  Pigment Theory: 1. Primary – Red, Yellow, Blue 2. Secondary – Orange, Green, Violet 3. Tertiary – Olive, Grey, Purple Allowable Maximum Points 1. 2. 3. 4. Accepted Average & Maximum: Fabrics Type Avg/yards Max/yards Avg/Meter Max/Meter Single Jersey 15 20 17 22 Double Jersey 18 24 20 26 Interlock 22 28 24 31
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    30 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 30 of 33 Chaity Composite Ltd Date: 11-09-2017 Name of Test H & M Lidl (HK & B.C) Hema Sears GP US PoloTAKKO TEIJEN Dimentional Stability to wash (Shrinkage) Knit General ± 5%, Rib+waffle+interloc k L -5% & w +5%/-7% 2% to -5% ± 6 % S/J L/w -6%, Terry L -8%/w- 8%, Rib L -6%/w- ±5% L -5%, w -5% ± 5% T/D -5%, L/D -5%/+2% Twisting(Spirality) 5%(Trouser 8% & Long Sleeve 1cm 5% 5% 5% 3% 5% 5% 5% GSM ± 5% ± 5% ± 5% ± 5% ± 5% ± 5% ± 5% ± 5% C/F to Rubbing--Dry 3 to 4 4 4 4 4 3 to 4 4 3 to 4 C/F to Rubbing--Wet 2 to 3 (CN shipment) 2 to 3 3 3 3 2 to 3 3 2 to 3 C/F to Wash --Color Staining 3 to 4 3 to 4 ≥ 4 3 to 4 4 3 to 4 C/F to Wash --Color Change 4 3 to 4 ≥ 4 4 4 4 C/F to Wash --Cross Staining 4 to 5 3 to 4 ≥ 4 4 to 5 4 to 5 4 C/F to Water-- Color Staining 3 to 4 3 to 4 ≥ 4 ( Baby item) 4 3 C/F to Water-- Color Change 4 3 to 4 ≥ 4 ( Baby item) 3 to 4 4 C/F to Water-- Cross Staining 4 to 5 3 to 4 ≥ 4 4 to 5 4 to 5 C/F to Perspiration(ACID)--Color Staining 3 to 4 ≥ 4 4 3 to 4 3 to 4 C/F to Perspiration(ACID)--Color Change 4 ≥ 4 3 to 4 4 4 C/F to Perspiration(ACID)--Cross Staining 4 to 5 ≥ 4 4 to 5 4 to 5 4 C/F to Perspiration(ALKALI)--Color Staining 3 to 4 ≥ 4 4 3 to 4 3 to 4 C/F to Perspiration(ALKALI)--Color Change 4 ≥ 4 3 to 4 4 4 C/F to Perspiration(ALKALI)--Cross Staining 4 to 5 ≥ 4 4 to 5 4 to 5 4 C/c to Saliva-- Color Staining 4 N/A 4 (Size≤36 months)4 4 to 5 C/c to Saliva-- Color Change 4 N/A 4 (Size≤36 months)4 4 to 5 C/c to Saliva-- Cross Staining 4 to 5 N/A 4 (Size≤36 months)4 4 to 5 C/F to Phenolic Yellowing 4 N/A 4 to 5 3 to 4 4 C/F to Light 3 to 4 3 to 4 ≥ 4 3 to 4 4 to 6 3 Pilling 3 (blended fabric) 4 (Martindale) ≥ 3(15000 Cycle) 4 3 to 4 Bursting 250 kpa (GSM≤200) N/A N/A N/A N/A Fabric pH 4 to 7.5 4 to 7.5 4 to 7.5 5 to 7 4 to7.5 Appearance after wash No major change N.M.C N.M.C N.M.C N.M.C N.M.C N.M.C N.M.C Dye transfer in storage--Color staining 4 N/A N/A N/A N/A 3 to 4 N/A N/A Dye transfer in storage--Color Change 4 N/A N/A N/A N/A 3 to 4 N/A N/A Dye transfer in storage--Cross staining 4 to 5 N/A N/A N/A N/A 3 to 4 N/A N/A Note: CN-China , N.M.C-No major Change, T/D-Tumble dry, L/D-Line dry, N/A- Not Applicable, HK-Hongkong, B.C-BayCity, kpa- Kilo pascale General 3 to 4, if size ≤ 104 it should be 5 General 3 to 4, if size ≤ 104 it should be 5 (Kids Item) Chaity Composite ltd. Sonargaon, Narayangonj Buyers Requirments
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    31 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 31 of 33 Chaity Composite Ltd AGM (Admin) GM (Fabrics) Director Data Entry-1 ApproveredAsst Manager (QAD) AGM (Qality & Product Development) Executive-3, Knitting, Dyeing, Finishing Inspector-4 Director Inspector (GSM Cutting & Board)-5 Inspector (Machine)-4 Inspector (Dust remover)-2 Inspector (Hand Folding)-5 Inspector (Rib Collar & Cuff)-4 Inspector (Hold & Reject Check)-2 Inspector (Yarn Dyed & Subcontact)-1 (G) Inspector (Report & Delivery Update)-2 Executive Excutive/Incharge-1 Supervisor-2 Inspector-20, M/c-5 Sr Executive- G Executive (Floor)-G Executive (Shade)-3 Incharge-3 Supervisor-2 H&M (GPQ) R&DAsst Manager (others) Lidl (GPQ) Grey Fabrics InspectionHema, Bay City & Others Sr Executive Sr Executive Executive (Shade) Executive (Sample) Sr Inspector (Stenter)-8 Sr Inspector/Inspector (Compact)-10 Inspector (teble Runn Shade Check)-4 Inspector (Documents)-3 Data Entry Executive (Elastic) Executive (Grey) Sr Executive Managing Director AGM Company Profile. Quality Assurance Department Chaity Composite Ltd.
  • 32.
    32 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 32 of 33 Chaity Composite Ltd Bowing/Skewing: Bowing is the measurement of the bowing arc at the highest point of a line at right angles Between the two selvages. A Bow depth Fabric width Skewing/Twisting: Skewing/Twisting is the measurement of the highest point between a weft thread/row and a line at right angles between the two selvages/folds. Skew depth -A Fabric width Tolerance Calculation A Max %____________ x 100 = Cuttable width Fabric Types Max % of fabric width Woven Jersey 3% 5% 2% 4% Solid colours/Prints Stripes/Checks Rolls exceeding these tolerances have failed. Exception: Skewing are characteristics for woven twill/satin constructions and for single jersey. The skewing tolerance must therefore be agreed on each order separately, and stated on the “Fabric Technical Data”. The H&M garment supplier must first check twisting and eventual distortion on garment after: •Eventual garment treatment. •Washing according to care instruction. In case of Inconsistent skewing/twisting in-between inspected rolls the inspection has failed.
  • 33.
    33 | Pa g e Q u a l i t y A s s u r a n c e D e p a r t m e n t Page 33 of 33 Chaity Composite Ltd Avgiv cªwZÁve×, c‡b¨i ¸bv¸Y wbð©Z Kivi, hvnv †µZvi Pvwn`v|