Training for quality in chaity

Mohammad Mizanur Rahman
AGM (Quality & Product Development)
Cell: +880 1708 454 779
Email: mizan5379@yahoo.com

Quality Assurance Department
ChaityCompositeLtd

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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.

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

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

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

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

Quality Improvement
ChaityCompositeLtd

Quality Inspection
Remove of Fault
Indicate of Fault
Inform must be concern person
Cause Indicate of Fault
Inspection

Definition of Quality
1. Conformance to specifications
2. The degree to which a product or service
meets the needs of the customer
3. Uniformity around a customer-defined target
4. Exceeding customer expectations
The customer is the most important part of the process.

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.

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

Inspection Areas
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

Printed Fabrics, Inspection
1. Check with Stranded Swatch
2. Print Durability
3. Color Bleeding
4. After Finishing print any Change
5. Shrinkage

Fleece Fabrics Inspection
1. Shade Check
2. Chemical Test
3. Hairiness
4. Naps
5. Sinker/ Line Mark
6. GSM/ Width

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

 Done through Fabric Inspection machine.
 Very important for every industries .
 In fabric inspection their checks several things i.e. in
fabric are there any defect available or not. In fabric, fabric
defects viz. off shade or shade variation, hole in fabric,
barre effect etc. can be visual after entering into the store
room. For those defects it will be problem able for making
garments making.
 In fabric inspection, also test fabric strength, color,
quantity
 To check fabric there are different system i.e. 4 point
system, 10 point system etc.
Fabrics Inspection

FEW
RETURNS
HIGHER
QUALITY
LESS WAIST
LESS
REWORK
FEW
REJECTION
LESS
BACKLOG
FEW
COMPLAINTS
LOWER COST
HIGH
PRODUCTIVIT
Y
HIGHER
VALUE

Theory of Color
 Pigment Theory:
1. Primary – Red, Yellow, Blue
2. Secondary – Orange, Green, Violet
3. Tertiary – Olive, Grey, Purple
 Light Theory:
1. Primary – Red, Green, Blue
2. Secondary – Yellow, Grey, Purple
3. Tertiary –

Finished Fabric Inspection Procedure
For each batch, the Finished Fabric Inspection Form has to
be filled up after the inspection. Here the inspector
measures the gm/ square meter (GSM) & width of each roll
and the inspection machine measures the length. If there
is any discrepancy it is mentioned against roll no.
Normally fabric faults are recorded using the 4 point
system given below:

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

 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

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

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)
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

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
13. Patches
(Patches will be reprocessed))
14. Barre Mark
(Barre mark will be rejected)

15. Crumple Mark
(Crumple mark will be reprocessed))
16. Water drops :
iii) More than 10 mm diameter. = 4 points
17. Dye resist :
iii) More than 10 mm diameter = 4 points

18. Dye stain :
iii) More than 10 mm diameter =4 points
19. Dirty mark :
iii) More than 10 mm diameter =4 points

1. Running Shade
2. Uneven
3. GSM High/Low
4. Width Short/Long
5. Line Mark
6. Brush Problem
7. Crease Mark

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.

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

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.

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

4 Point Grading Format
ChaityCompositeLtd

GPQ
Guideline for Production & Quality
Control

Properly Work in Inspection M/c

Directly Fabrics Keeping Floor

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

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
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)

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

Procedure of Delivery
1. Without Test Result Plea se don’t Delivery Any Qua ntity of
Fa brics.
2. Without Rib/ Single Jersey/ Ba c k nec k ta p, not delivery.
3. Any Mea sura ble pa rt, Like Colla r & Cuff, Stripe Ya rn dyed
Fa brics should be che ck a s buyer requirement.
4. Inline Fa brics All test should be check & Shrinka ge from
3- 4 rolls Chec k,
5. Width ± 1”, More tha n need to Approva l from Rela ted
Person. Also infirm to cutting depa rtment.
6. Before Delivery must be Re - c heck by Shift In- cha rge,
Width, GSM, Shrinka ge delivery report with Ba tch
informa tion.
7. 1st Ba tch Sha de check & crosse s check for confirma tion.
8. All Approved sha de must be keeping before dying from
rela ted Mercha ndiser
9. All sha de che c k two person a void the wrong decision.
(Keep sign)
10. 1st Ba tch che c k with Booking All informa tion, Like
width, GSM, Ac cessories.

Date
Ba tch No:………………………
Colour:…………………….
Buyer:………………………….. L- W- Sp- R. DIA/ GSM:………………
CCL:……………………………. Process
Avg Dia / GSM:……………
F/ Type:………………………… Ba tch Qty:…………………
Ya rn Count M/ c Dia Process Loss:……………….Delivery Qty:……………...
Stitch Length Ga uge 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
Qua lity Depa rtment
Approved
Shrinka ge

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
Ch ot t o Si l m on d i , Tr i p u r d i , Son a r goa n , Na r a ya n ga n j
Pr/ Loss
ShrinkageBatch/Qty Delivery/Qty
Dy ei n g Qu a l i t y Dep a r t m en t
Style
DAI L Y De l i v e r y St a t u se s

Batch to Batch Shade Variations

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

Keeping in Quality Department
1.Lab Dip
2.Counter/PP Sample
3.Original Swatch
4.Fabric Technical Data/FTD
5.Booking Sheet

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

Sample Record
1.Shade
2.Color Fastness
3.Rubbing Fastness
4.Shrinkage
5.Twisting/ Spirality
6.Width & GSM

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

Yarn Test Record
1. Yarn Contaminations
2. Fly Contaminations
3. Oil Stain
4. Think & Thin
5. Patta/ Yarn Variations
6. Hairiness
7. Naps

Yarn Test Record
1. One Meter Fabrics Keeping With Knitting
Information
2. Inspection Report
3. Uster Report
4. Yarn Count Test

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

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

1. Yarn Count Test
2. Knitting M/c Select
3. Machine Gauge Select as defend on Yarn Count/GSM
4. Stitch Length
5. Check Grey GSM with Dia
6. Check Wash for Shrinkage, GSM & Dia
7. If Lycra then Check %
8. Re-Check Stitch Length
9. Weight Check before Loaded in dyeing M/c
10.Set up Finishing Parameter

11. Temperature, Width, Speed & Overfeed
12. Check Width & GSM, Slanted or Bowing
13. Hairiness
14. Knitting Hole
15. Shrinkage & Spirality
16. Process Loss
17. Keep Record
18. Enzyme %
19. Total Dyeing Time
20. Match With Buyer Standard

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

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. ASTM- American Society of Testing & Materials
7. GSM- Gram Square Meter
8. RQS- Requirement for Quality System
9. QMS- Quality Management System
10. MMR- Minimum Manufacturing Requirement

11. AQL- Acceptable Quality Level
12. GSM- Grams per Square Meter
13. QC- Quality Controller
14. MPP- Mini Project Policy
15. NQC- Nominated Quality Controller
16.SOP- Standard Operating Procedure
17. CMC- Color Measurement Clarification
18. PC- Polyester of Cotton
19. CVC- Chief Value of Cotton
20.FTD- Fabrics Technical Data

21. PPE- Personal Protective Equipment
22.H&M- Hannes & Mauritz
23. C&A- Calzado & Aceesorios
24. TDS- Technical Data sheet
25. MSDS- Materials Safety Data sheet
26. LC- Latter of Credit
27. CM- Manufacturing Cost
28. CCL- Chaity Composite Ltd
29. GP- Golden Penney
30. M&S- Marks & Spencer

31.TOD- Time of Delivery
32. RFT- Right First Time
33. RFD- Ready For Delivery
34. PPC- Production Planning Centre
35. PMC- Production Monitoring Centre
36. CSR- Customer Specific Requirement
37. EPZ- Export Processing Zone
38. CTP- Certified third Party
39. CPQ- Configure Price Quote
40. CTX- Corporate Trade Exchange

41. VOC- Volatile Organic Compounds
42. QA- Quality Assurance
43. CAP- Compliance Audit Program
Corrective Action Plan
Common Audit Process
44. IE- Industrial Engineering
45. RMG- Ready Made Garments
46. HR- Human Resources
47. CSR- Compliance Social Reasonability
48. PV- Present Value
49. CAD- Computer Aided Design
50. ACTL- Advisory Committee on Trademarks & Licensing

51. CSR- Complies Social Responsibility
52. GOTS-Global Organic Textile Standard
53. ETP- Effluent Treatment Plant
54. WTP- Water Treatment Plant
55. RO-
56. TBC- To be Confirm
57. OK- Objection Killed
58. AM- Ante Meridiem
59. PM- Post Meridiem
60. PTO- Please Turn Over

61. LOGG- Label of Graded Goods
62. AOP- All Over Print
63. COC- Code of Conducts
64. MIS- Management Information System
65. BGMEA- Bangladesh Garments Manufactures & Exporters
Association's
66. BKMEA- Bangladesh Knitwear Manufactures & Exporters
Associations
67. BTMC- Bangladesh Textile Mills Corporations
68. BJMC- Bangladesh Jute Mills Corporations
69. CPI- Course Per Inch
70. WPI- Wales Per Inch

71. BSCI-Business Social Compliance Initiative
72. DA- Disciplinary Action
72. BSCIC- Bangladesh Small and cottage Industrial
Corporations
73. OBA- Optical Brighting Agents

Question ???
?
ChaityCompositeLtd

Our Expectation Quality as Buyer
Requirement with Quantity.

Quality is Customer Satisfaction & We Can do this.
Thanks to All For
Attend with Us

Training for quality in chaity

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