This document provides information about quality assurance processes at ChaityCompositeLtd. It discusses their 4 point grading system for fabric inspection which assigns penalty points for defects based on defect type and size. It provides examples of defect types and the associated points. It also discusses acceptance criteria, requiring average points per unit area to be below 28 for acceptance. Record keeping procedures for greige fabric quality are also outlined. Organizational structures and responsibilities within the quality assurance department are presented.
The Purpose of this presentation is to give knowledge about, how the different style garments should be inspected.
Prepared By Abdul Latif
Asst. Manager.QA
MTM Faisalabad Pakistan
4 Point Fabric Inspection System in Textile IndustryMd. Sirajul Islam
The most popular system for fabric inspection is 4 point system. Its very easy process. ASTM defines- It is a Standard Test Method for Visual Inspecting and Grading Fabrics.
The Purpose of this presentation is to give knowledge about, how the different style garments should be inspected.
Prepared By Abdul Latif
Asst. Manager.QA
MTM Faisalabad Pakistan
4 Point Fabric Inspection System in Textile IndustryMd. Sirajul Islam
The most popular system for fabric inspection is 4 point system. Its very easy process. ASTM defines- It is a Standard Test Method for Visual Inspecting and Grading Fabrics.
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Mainly we have done visual inspection first after fabric received commonly follow 4 point inspection system. It's cover count/construction, width, weight, color, shading, design, measurement specifications, hand/feel and other specific quality parameters laid down by the clients.
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Apparel Quality Control & Quality AssuranceSAMultimedia
Quality control of apparels or garments, garments quality assurance, garments inspection, fabric inspection. By this file easily understand about garments quality.
Quality is a relative term. It means customer needs is to be satisfied. Quality is of prime importance in any aspect of business. Customers demand and expect value for money. As producers of apparel there must be a constant endeavor to produce work of good quality. To assess the quality of textile product Textile Testing is very important work or process. Testing In response to ever-changing governmental regulations and the ever-increasing consumer demand for high quality, softlines testing and textile testing help to minimize risk and protect the interest of both manufacturers and consumers. It is important that testing is not undertaken without adding some benefit to the final product.
Mainly we have done visual inspection first after fabric received commonly follow 4 point inspection system. It's cover count/construction, width, weight, color, shading, design, measurement specifications, hand/feel and other specific quality parameters laid down by the clients.
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Quality management is a method for ensuring that all the activities necessary to design,
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This presentation is my graduation internship presentation at BSL (LNJ group) Bhilwara (Rajasthan).
In this presentation I describe BSL company profile, Process significance, all steps which use for fibre to fabric in textile.
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The details quality control system of woven garments with pictures. Some cased you need to add or ignore some checking points based on styling. Shirt, pant, top, bottom.
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Here we are presenting our work flow process.
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5. 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.
6. 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.
7. 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.
8. SOP Of Grey QC
1. Knitting Production
2. Inspection, 4 Point System
3. More then 28 points Reject
4. Major Problem Discuses with QAD Head
5. Keep Record in GPQ File
9. Grey Fabric Quality Section
Inspection Machine SOP
Power Swatch on
Set RPM
Set Light
Ready to Inspection Fabrics
M/c Run- 16/18 RPM
Check by 4 point System
Acceptable Range Not Acceptable range
Grey fabrics Store Temporally Reject Zone
Ready to Batch for Dyed
Permanent Reject Consideration Approved
10. Check point Of Grey QC
1. Order/Buyer wise Quality Check
2. 4 point system Check
3. Inspection –
I. Yarn Variation/Count Mix
II. Contaminations
III. Knitting Hole
IV. Jumping
V. Fly Contra/ Yarn Contra
VI. Sinker Mark
VII. Needle Mark
VIII. Set off
IX. Lycra Out
11. Greige Fabrics inspection
a) Two person together inspection continue maximum two hours &
combined take decision.
b) Another two person give to support fabrics for inspection &
keeping for storage which is inspection complete also reject
fabrics keeping Temporally Reject area for finial decision from
Head of Quality.
c) Keep record which person work two hours with sign
d) Machine Speed should be limit 16 to 18 RPM, Means per one
minute 16 to 18 meters inspection
e) Inspection Machine Light Value Minimum 1000+ lux & Expired
time one year or 1300 hours which is 1st valid
f) Light Day light, Need to Register log book for time maintain &
Lux Checking record
g) If any major problem first communicate with online Quality
controller
h) Major Oil Sport check from Light box with UV light
i) Yarn variation/ Patta & Hole, Oil spot check by back light
j) Back light lux value not limitation
k) Inspection 4 point system
l) Keep all record, take sign from Head of Quality
13. 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
14. SOP Of Knitting Online
1. Batch Card Check
i. Yarn lot
ii. Yarn Count
iii. Buyer Name
iv. Stitch Length Cross Check
v. GSM Check
vi. Yarn Brand Check- Combed/Carded
2. Fabric Quality
i. Loop
ii. Needle Brocken/ Mark
iii. Sinker Mark
iv. Count/Lot Mix
v. Oil Sport/ Mark
vi. Set off
vii. Contra- Fly/Yarn
viii. Lycra Out
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Definition of 4 Point
18. 4- Point Grading System Table
Fault Length Points to be assigned
(0 to 7.5) cm or less than 3″ 1 point
(7.5 to 15) cm or (3″ to 6″) 2 points
(15 to 22.5) cm or (6″ to 9″) 3 points
More then 22.5 cm or 9″ 4 points
4 Point System
19. Following formula is used to calculate the points to be assigned to the inspected fabric for
the existing faults in it. The calculated values are entered in the Finished Fabric Inspection
Form
Total point per 100 square yards
4 Point System
hinYardsTotalLengt
styPoTotalPenal int
thCutableWid
36= X
ChaityCompositeLtd
X 100
Length (Meter)= Weight x 1550/Actual Width / Actual GSM /39.37
Length (yardage)= Weight x 1550/Actual Width/ Actual GSM/ 36
20. 1. Band line – 4 points
2. Oil spots :
i) Up to 5 mm diameter = 1 point
ii) Up to 10 mm diameter = 2 points
iii) More than 10 mm diameter = 4 points
3. Slubs
i) Up to 10 mm. = 2 points
ii) Longer than 10 mm = 4 points
4. Embedded Fly = 1 point
5. The maximum penalty points for any running yds (36" fabric width)
must not be more than 4 points.
4 Point GradingSystem
21. 6. All holes regardless the size = 4 pts.
(There must be two or more yarn broken at the same place to be considered as a
hole)
7. Yarn Contamination according to the size.
(Up to 0.50" = 1 point ; Over 0.50" = 2 pts)
8. Neps = 1 point or according to the discussion with QC manager.
9. Crease mark
(Fabric with dark crease will be rejected; light crease may be considered based on
the discussion with QC manager)
10. Unlevelness
(Fabric with major unlevel in dyeing or finishing chemical will be reprocessed.
Minor unlevel in dyeing or finishing chemical may be considered based on the
discussion with QC manager)
4 Point GradingSystem
6. All holes regardless the size = 4 pts.
(There must be two or more yarn broken at the same place to be considered as a
hole)
7. Yarn Contamination according to the size.
(Up to 0.50" = 1 point ; Over 0.50" = 2 pts)
8. Neps = 1 point or according to the discussion with QC manager.
9. Crease mark
(Fabric with dark crease will be rejected; light crease may be considered based on
the discussion with QC manager)
10. Unlevelness
(Fabric with major unlevel in dyeing or finishing chemical will be reprocessed.
Minor unlevel in dyeing or finishing chemical may be considered based on the
discussion with QC manager)
4 Point GradingSystem
22. 11. Needle Line
(Fabric with major needle line will be rejected. But fabric with less visible
needle line may be considered based on the discussion with QC manager)
12. Dead Cotton & Hairiness
(Fabric with major dead cotton & hairiness will be reprocessed. But fabric
with minor dead cotton & hairiness may be considered based on the
discussion with QC manager)
13. Patches
(Patches will be reprocessed))
14. Barre Mark
(Barre mark will be rejected)
4 Point GradingSystem
23. 15. Crumple Mark
(Crumple mark will be reprocessed))
16. Water drops :
i) Up to 5 mm diameter = 1 point
ii) Up to 10 mm diameter = 2 points
iii) More than 10 mm diameter. = 4 points
17. Dye resist :
i) Up to 5 mm diameter = 1 point
ii) Up to 10 mm diameter = 2 points
iii) More than 10 mm diameter = 4 points
4 Point GradingSystem
24. 4 Point GradingSystem
18. Dye stain :
i) Up to 5 mm diameter = 1 point
ii) Up to 10 mm diameter = 2 points
iii) More than 10 mm diameter =4 points
19. Dirty mark :
i) Up to 5 mm diameter = 1 point
ii) Up to 10 mm diameter = 2 points
iii) More than 10 mm diameter =4 points
25. Acceptance
Generally any piece of fabric with less than 40 points
fault per 100 square yard is allowed to pass however for
a roll, the average value should not exceed 28 points per
100 square yard. More than 40 points fault per 100
square yard is recorded as reject.
4 Point GradingSystem
26. 4 Point GradingSystem
Formula,
A/B x 100 = Points par 100
yard
Here,
A= Total points in this roll
B= Length of this roll in Yard
1 miter = 1.09 yard
Classifications,
◦ ≤ 40 points = A
◦ 41 – 60 points = B
◦ 61 – 80 Points = C
◦ 80 Above = Reject
27. Rejection
Fabric is rejected in case of the followings:
1. Any roll having a running or repeating defect through more than
three continuous meters shall be rejected regardless of point count.
2. Big tear is rejected.
3. Dark crease is rejected.
4. Fabric with more than 1″ short in width is rejected. If the
shrinkage is within the range, the fabric should be returned to
finishing department for correction of width.
4 Point GradingSystem
28.
29. 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
32. Fabrics inspection
a) Two person together inspection continue maximum two hours & combined
take decision.
b) Another two person give to support fabrics for inspection & keeping for
storage which is inspection complete also reject fabrics keeping
Temporally Reject area for finial decision from Head of Quality.
c) Keep record which person work two hours with sign
d) Machine Speed should be limit 16 to 18 RPM, Means per one minute 16
to 18 meters inspection
e) Inspection Machine Light Value Minimum 1000+ lux & Expired time one
year or 1300 hours which is 1st valid
f) Light Day light, Need to Register log book for time maintain & Lux
Checking record
g) If any major problem first communicate with online Quality controller
h) Major Oil Sport check from Light box with UV light
i) Yarn variation/ Patta & Hole, Oil spot check by back light
j) Back light lux value not limitation
k) Inspection 4 point system
l) Keep all record, take sign from Head of Quality
36. 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
____________ x 100 =
Cuttable width
A Max %
Solid colours/Prints
Stripes/Checks
Rolls exceeding these tolerances have failed.
Fabric Types
Max % of fabric width
Woven Jersey
3% 5%
2% 4%
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.
38. Quality Inspection
Remove of Fault
Indicate of Fault
Inform must be concern person
Cause Indicate of Fault
Inspection
39. Objective of QualityObjective of Quality
Establish quality objectives at relevant functions and
levels.
Make sure they're measurable.
Include objectives needed to meet product requirements.
Communicate to all personnel the meaning of the
objectives and how each person helps to achieve them.
During management reviews, evaluate the need for
changes to quality objectives.
40. Assurance: The act of giving confidence,
the state of being certain
or the act of making certain.
Quality Assurance: The planned and systematic activities implemented in a
quality system so that quality requirements for a product or service will be
fulfilled.
Control: An evaluation to indicate needed corrective responses;
the act of guiding a process
in which variability is attributable
to a constant system of chance causes.
Quality Control: The observation techniques and activities used to fulfill
requirements for quality.
Type of Quality
49. Non Conformed
Process Flow Chart of Fabric Quality
Re-process Dyeing
Stenter M/c
Shade uneven
Not OK Spot, Hairiness,
Hand feel
Lab Test
Shrinkage, Fastness &
Others
Compacting
Dia & GSM
Not OK Check
Fabrics Inspection
4 point System
Shade Continuity
Finish Fabric Store
OK
OK
58. Shade Check in Light Box
1. Two person together shade Check Avoid the Wong Decision.
Because Two Person not Same Measurable Power, So combined take
decision.
2. Three Light Shade Check
3. Make Family Shade A&B
4. Light D65, TL 83, A-10
5. 1st Batch Shade check with Woven Standard & Counter Sample
6. Next Batch Check Batch to Batch
7. White & Grey Mell Must be Check with UV Light
59. 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)
60. Light Sourcing (Under Wear)
1. Shop Light (Primary ) - TL83 Lax Value 1000 to more
2. Home Light (Secondary) -A-10 Lax Value 800 to More
3. Day Light - D65 Lax Value 1000 to More
4. Morning Sun Light – Ultra Violet (UV)
61. Light Sourcing
1. Use able time, 1300 Hours or 1 year which is first valet
2. Started time & Calibrations time should be recorded
with Maintenance & User Sign in Resister with
Certificate
3. Two person together Check Or Inspection only two
hours then other two person another two hours.
4. Keep Resister with Name
62. Procedure of Delivery
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 from
3-4 rolls Check,
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 dying 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.
63. Date
Batch No:………………………
Colour:…………………….
Buyer:………………………….. L- W- Sp- R. DIA/GSM:………………
CCL:……………………………. Process
Avg Dia/GSM:……………
F/Type:………………………… Batch Qty:…………………
Yarn Count M/c Dia Process Loss:……………….Delivery Qty:……………...
Stitch Length Gauge Process Loss ……………….
Roll No A.Dia A.GSM Qty(kgs) Roll No A.DIA A.GSM QTY(kgs) Roll No A.DIA A.GSM Qty(kgs)
1 29 57
2 30 58
3 31 59
4 32 60
5 33 61
6 34 62
7 35 63
8 36 64
9 37 65
10 38
11 39
12 40
13 41
14 42
15 43
16 44
17 45
18 46
19 47
20 48
21 49
22 50
23 51
24 52
25 53
26 54
27 55
28 56
Prepare by Knitting GM Dyeing GM
Chaity Composite Ltd.
Chotto Shilmondy, Tripurdi, Sonargaon, Narayangong
Quality Department
Approved
Shrinkage
64. Date:
Body Rib S/J Total Body Rib S/J Total Length Width Spirality
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Check AGM GM
RemarksSL Buyer CCL Batch Shade F. Type R.Width Avg.Width R.GSM Avg.GSM
Chaity Composite Ltd
Chotto Silmondi, Tripurdi, Sonargoan, Narayanganj
Pr/ Loss
ShrinkageBatch/Qty Delivery/Qty
Dyeing Quality Department
Style
DAILY Delivery Statuses
80. Record in Quality Department
1. Shade Continuity
2. Batch to Batch Shade Continuity Card
3. Every Rolls Shade Brand
4. Every Rolls GSM Cutting
5. 4 points System
6. Lab Test Report
7. Accessories Match Keeping
81. Keeping in Quality Department
1.Lab Dip
2.Counter/PP Sample
3.Original Swatch
4.Fabric Technical Data/FTD
5.Booking Sheet
82. Sample Record
1. Yarn Test
2. Counter Sample
3. Pre production
4. Chemical Test
5. Development Sample
6. Color Test Sample
7. Quotations
8. Style
9. Size Set
10.Fashion Show
11.Improved
12.Photo Sample
13.First Fit Sample
14.Inline Sample
84. 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
86. Yarn Test Record
1. One Meter Fabrics Keeping With Knitting
Information
2. Inspection Report
3. Uster Report
4. Yarn Count Test
87. Online Inspection
1. Shade Confirm
2. Width Confirm with Required
3. GSM Confirm with Required
4. Running Shade
5. Hand feel
6. Crease Mark
7. Line/Sinker Mark
8. Hairiness
9. Pin Hole
10.Fabrics give to Lab For Shrinkage
88. Fabrics Delivery Procedure:
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
Without proper inspection not a single kg fabrics delivered
90. Benefit from Development
1.Continues production
2.GSM & Width Variation Control
3.Quality Consistence & Improved
4.Buyer Satisfaction
5.Product Development
6.Time saving
7.Cost Reduces
8.Wastage Reduces
9.Process Loss Control
10. M/c efficiency improved
91.
92. 1. QAD- Quality Assurance Department
2. QSR- Quality Standards & Requirement
3. TQM- Total Quality Management
4. SRM- Standard Reference Method
5. ISO- International Organization for Standardization
6. GSM- Gram Square Meter
7. RQS- Requirement for Quality System
8. QMS- Quality Management System
9. MMR- Minimum Manufacturing Requirement
10. AQL- Acceptable Quality Level
93. 11. QC- Quality Controller
12. NQC- Nominated Quality Controller
13. SOP- Standard Operating Procedure
14. CMC- Color Measurement Clarification
15. PC- Polyester of Cotton
16. CVC- Chief Value of Cotton
17. FTD- Fabrics Technical Data
18. PPE- Personal Protective Equipment
19. H&M- Hannes & Mauritz
20. EPZ- Export Processing Zone
151. 1. What about delivery, How much Complain from
Garments
a. Shade issue
b. Inspection
c. Width
d. GSM
e. Shrinkage issue
2. FTD submit vs Approved & Reject
3. Sample Submit vs Approved & Reject
4. Not delivery any wrong fabrics
5. Proper information's transfer to related department