SlideShare ist ein Scribd-Unternehmen logo
1 von 29
WELCOME
Abruan Group
Dept. of Industrial Engineering &
Planning
Training Program on
“QUALITY CONTROL SYSTEM in
Garments Industry”
Quality is the degree to which a commodity meets the requirements of
the customer at the start of its life. (ISO 9000)
What is Quality? What does Quality Mean?
So, Quality is……….
1. Degree of excellence
2. Conformance to requirements
3. Totality of characteristics which act to satisfy a need
4. Fitness for use
5. Fitness for purpose
6. Freedom from defects
7. Delighting customers
Joseph Juran says, quality is “Fitness for Use”. When “fitness for use”
concept applied to garment it must
According quality Guru Philip Crosby, Quality is “Conformance to
Requirements.”
Quality Assurance vs. Quality Control
•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.
Process Flow Chart of Garments Quality
Fabric Inspection (4 Point System)
Accessories Inspection (10% Inspection)
Shade segregation
Shrinkage test
Size set check
Marker check
Spreading quality assurance
Shade segregation
Cut Panel Inspection
Hard pattern check
Process Flow Chart of Garments Quality
Risk Analysis Meeting
Pre-production meeting
Quality Assurance when Line Feeding
In process audit Quality Assurance
Two time process check
Process Flow Chart of Garments Quality
Two time machine check
7 Pcs Check (Traffic light System)
100% Shell Check
100% Lining Check
100% Shell Lining Join Check
Process Flow Chart of Garments Quality
100% KANBAN Check
Button Pull Check
100% Metal Check
100% Lining Check
Pre Final Inspection
Process Flow Chart of Garments Quality
DHU & DEFECTIVE %
Defects
Defects are all those non-conformance that are not acceptable by end customer. Like imbalanced shape of the
garment, broken button or other trims, holes in fabrics, slip stitch, broken seam etc. In a defective garment
there may be more than one defect.
Defective Pieces
Defective pieces are those pieces, which are separated for alteration during checking may be for any causes.
For the quantitative measure there is two measuring unit as Defects per hundred units and percentage
defective.
Defects per hundred units (DHU) – number of total defects in 100 checked garments. The formula for
calculating DHU is
DHU = Total no. of defects found X 100 / Total pieces checked
Percent Defective (%) – total number of defective pieces in 100 checked garments.
Percentage defective = Total no. of defective pieces X 100 / Total pieces checked
Example: Suppose in a day one table checker checked 200 pieces. He found total 15 defective pieces and in
those 15 pieces total 60 defects were found. So, quality measure of that lot in terms of DHU is 30 (60*100/200)
and Percentage Defective is 7.5%.
How to change defective or damaged garment parts intelligently?
“Part changing” is not an intended process in garment manufacturing but this process is there
because there is certain reasons where we can’t control the cause of fabric damages in the
garments completely. However, where possible, we have to minimize short shipment and improve
our sales. Part changing is generally done in finishing stages. Most of the fabric defects that are not
acceptable in garments are removed during cutting and stitching processes. Still damaged part is
found in the sewn garment due to heavy washing, dyeing or other reasons.
Instead of rejecting the defective garment, only damaged part can be changed and converted it
into a quality garment. When part changing is necessary and main purpose of the part changing is
to improve ship quantity, part changing must to be done intelligently. It should not increase the
fabric consumption or produce further defective garment in the part changing process. You have to
think from where you will get fabric for part changing? How to remove damaged component and
re-stitch the garment maintaining sewing quality?
For the fabric usage you have multiple options – i) End bits of the cut layers, ii) using fresh fabrics
or iii) replacing damaged parts with good parts of another garment. Which option to be chosen is
depends on garment processing after stitching, fabric types, value added work or embellishment in
the garment.
End bit usage for part changing:
In the cutting room, during layering cutters store end bits that are not layered in the lay for a cutting. These end
bits are one type of cutting waste. So for the part change you can use those end bits without increasing fabric
consumption. But here you have to take care about shade matching or lot matching of the fabrics with the
damaged garments. If the garments were heavily washed, then it will be very difficult to match the garment
fabric shade. After changing the parts garment must be washed again to give matching finished look and similar
hand feel.
Fresh fabric usage for Part changing:
If you don’t have enough end bits to replace the damaged parts from the garment, use available fresh fabric.
When using fresh fabric, you may find problem with shade matching, extra fabric consumption for the order. Only
use fresh fabric if there is no problem with shade matching. But for solid colors and yarn dyed fabric there is no
issue related to shade matching.
Using good components from other damaged garments:
This option is chosen when garments are dyed and there are no fresh fabric or end bits or fresh fabric for that
order. The reason, instead of rejecting all garments, you can make some good garment losing few garments. Also
for the high value garment with fine hand embroidery work and where you have less time to complete the
shipment, this option is preferred. Like above options, you have to care about the garment component’s shade
matching.
Key Performance Indicators (KPIs) for Quality
Customer complaint:
When buyers received something wrong against the contract with suppliers in terms of product
quality they claim for the damages. It is huge money to pay back to the buyer. Even factory may
lose business relationship with those buyers due to poor product quality. So customer complaint
is considered as most important KPI.
• AQL levels:
It means when garments are inspected what AQL level is being followed as pass or fail criteria.
Though it may vary product to product but it gives clear idea about factory’s quality performance.
Lower the AQL you follow better is the quality performance.
• Percentage Defective level:
This term is also known as Defect %. It is measure of total defective garments founds and total
garments inspected in percentage. It can be calculated batch wise or on the basis of complete
order. Generally factory measure Defect percentage on daily and hourly basis of batch. Lesser the
defect% better is the quality performance.
• Defects per Hundred Units (DHU):
Factories measure Defect% but don’t track total number of defects found in inspected pieces.
Tracking of DHU is important because your rework time and work force required for repairing
defect directly linked with DHU number. Lesser the DHU better is the quality performance.
• Rework Cost:
Each rework is a cost to the company. The rework costs vary according to the process and types
of rework. It consumes extra time and increase factory overhead. Process wise and product
wise rework cost can be tracked to measure it. Lower the Rework cost better is quality
performance.
• Right First Time (RFT):
For garment manufacturer RFT quality is an ideal situation. It means whatever activities you do
to make the garment, quality of the garment should be correct at the first time. Data can be
captured for RFT at each process and it is expressed in percentage.
Garment Zoning for the Inspection of Visual Defects
Defect Zone of Vest Outwear
Defect Zone of Hooded Jacket
Defect Zone of Sports coat
Defect Zone of Sports coat
What are the Critical Defects for a Garment?
Definition of Critical defects:
According to Quality Assurance Manual of Gap Inc. "Anything which can harm the wearer of the
product are critical defects".
Critical defects are also defined as a defect that is likely to result in hazardous or unsafe conditions
for an individual in using the product and that does not meet the mandatory regulations.
A critical defect in clothes may cause accident to the wearer and may malfunction when wearer out
wearing a garment with critical defect.
Example of some critical defects:
•Loose components: Trims and fasteners those are used in the garment but not secure properly. For
example, buttons, snaps, stones etc.
•Sharp edges: During the processing of the garment it come in contact with various sharp metals
such as needles, staples. Broken needles, damaged or broken snap buttons, rivets, wire and pins.
•Drawstrings at head or neck for baby or kids products. Draw string must be avoided in kids clothes.
•Thread or trims which are extensively long or loose.
All the above critical defects must not be present in the product in any circumstances. In an audit if
inspector finds such defects in packed garments, he must fails the audit and ask quality checker for re-
inspection of all goods. For the factory, management should run awareness program on critical defects
and potential risk of the critical defects at end-user point.
Major & Minor Defect
Major & Minor Defect
Major & Minor Defect
Major & Minor Defect
Major & Minor Defect
Acceptable Quality Level
Consumer Product
Critical defects no critical defect is accepted
Major defects AQL 2.5
Minor defects AQL 4.0
AQL standard refers to the maximum number of defective that could be considered
acceptable during the random sampling of an inspection. The Defects that are found
during inspection are classified into 3 levels: Critical, Major and Minor.
The AQL level should be agreed between buyer and supplier before production
commences.
The following AQL standard are usually applied by Hong Kong Q. C. Center Ltd unless
otherwise instructed by customer.
How to Improve Apparel Product Quality?
• Specific steps that can enhance quality include:
Communicating the importance of quality, each worker’s role in achieving and maintaining right quality,
and expectations of worker performance
• Maintaining a clean and dry workplace, including storage rooms and shipping areas
• Selecting and utilizing proper equipment for each cutting and assembly step
• Providing the proper tools and training to each worker, and communicating management quality
performance expectations
• Planning and conducting an ongoing program of machine maintenance
• Establishing agreed-upon quality standards with all fabric and finding suppliers before purchase,
including procedures for rejecting/returning unacceptable goods
• 100% inspection of all incoming fabrics to include, at a minimum:
• Visual inspection by a trained inspector running every roll of fabric over a back-lit inspection frame to
identify fabric defects such as holes, tears, stains, stop marks, and width variations, and to compare
actual width and length to reported dimensions.
• Color shade check, compared to agreed-upon (or buyer imposed) shade tolerances under a five-light box
• Rejection and return of all fabric not meeting agreed-upon quality standards
• 100% inspection of value added processes like panel printing, machine embroidery, hand embroidery etc.
No defective panels or components should be sent to assembly. Defective component to be accepted
after corrective measure.
Corrective measures:
Replace – replace underperforming suppliers, equipment,
• Repair – repair ill-functioning equipment,
• Retrain – retrain underperforming workers and
• Reward – reward high performing workers
Implementing even a few of these steps will result in improved quality, but each additional
suggestion put into practice will yield significant improvements in product quality.
Traffic Light System
Roving QC
Internal AQL System
Quality control

Weitere ähnliche Inhalte

Was ist angesagt?

Garments & garment defects zubair lahore
Garments & garment defects zubair lahoreGarments & garment defects zubair lahore
Garments & garment defects zubair lahorezubairtex90
 
Defects of garment(print, fabric & sewing)
Defects of garment(print, fabric & sewing)Defects of garment(print, fabric & sewing)
Defects of garment(print, fabric & sewing)Rupak Barua,
 
Garments production system
Garments production systemGarments production system
Garments production systemamnapervaiz14
 
Quality assurance department (sop)
Quality assurance department (sop)Quality assurance department (sop)
Quality assurance department (sop)Mizan Rahman
 
Presentation On Marker Making
Presentation On Marker MakingPresentation On Marker Making
Presentation On Marker MakingMd. Sirajul Islam
 
Fabric inspection-system
Fabric inspection-systemFabric inspection-system
Fabric inspection-systemMuhib Limon
 
Sampling .presentration
Sampling .presentrationSampling .presentration
Sampling .presentrationahad003
 
Fabric defects in woven and knitted fabric - hitesh choudhary
Fabric defects in woven and knitted fabric - hitesh choudharyFabric defects in woven and knitted fabric - hitesh choudhary
Fabric defects in woven and knitted fabric - hitesh choudharyHitesh Choudhary
 
Fabric relaxation procedure
Fabric relaxation procedureFabric relaxation procedure
Fabric relaxation procedureMazharul Islam
 
Woven garments quality control system
Woven garments quality control systemWoven garments quality control system
Woven garments quality control systemHafij Uddin
 

Was ist angesagt? (20)

Garments & garment defects zubair lahore
Garments & garment defects zubair lahoreGarments & garment defects zubair lahore
Garments & garment defects zubair lahore
 
Quality systems for garment
Quality systems for garmentQuality systems for garment
Quality systems for garment
 
Defects of garment(print, fabric & sewing)
Defects of garment(print, fabric & sewing)Defects of garment(print, fabric & sewing)
Defects of garment(print, fabric & sewing)
 
Sample in garment industry
Sample in garment industrySample in garment industry
Sample in garment industry
 
Garments production system
Garments production systemGarments production system
Garments production system
 
Cutting department
Cutting departmentCutting department
Cutting department
 
Knitted fabric faults and their remedies
Knitted fabric faults and their remediesKnitted fabric faults and their remedies
Knitted fabric faults and their remedies
 
Quality assurance department (sop)
Quality assurance department (sop)Quality assurance department (sop)
Quality assurance department (sop)
 
Presentation On Marker Making
Presentation On Marker MakingPresentation On Marker Making
Presentation On Marker Making
 
Quality control
Quality controlQuality control
Quality control
 
Fabric inspection-system
Fabric inspection-systemFabric inspection-system
Fabric inspection-system
 
Sampling .presentration
Sampling .presentrationSampling .presentration
Sampling .presentration
 
Fabric & Garments Fault with its remedies
Fabric & Garments Fault with its remediesFabric & Garments Fault with its remedies
Fabric & Garments Fault with its remedies
 
Marker efficiency
Marker efficiencyMarker efficiency
Marker efficiency
 
Garment Faults
Garment  Faults Garment  Faults
Garment Faults
 
CUT ORDER PLAN SPREADING & CUTTING OF APPAREL PRODUCTS
CUT ORDER PLAN SPREADING & CUTTING OF APPAREL PRODUCTSCUT ORDER PLAN SPREADING & CUTTING OF APPAREL PRODUCTS
CUT ORDER PLAN SPREADING & CUTTING OF APPAREL PRODUCTS
 
Garment production systems
Garment production systemsGarment production systems
Garment production systems
 
Fabric defects in woven and knitted fabric - hitesh choudhary
Fabric defects in woven and knitted fabric - hitesh choudharyFabric defects in woven and knitted fabric - hitesh choudhary
Fabric defects in woven and knitted fabric - hitesh choudhary
 
Fabric relaxation procedure
Fabric relaxation procedureFabric relaxation procedure
Fabric relaxation procedure
 
Woven garments quality control system
Woven garments quality control systemWoven garments quality control system
Woven garments quality control system
 

Ähnlich wie Quality control

U 7 total quality management in garment industry
U 7 total quality management in garment industryU 7 total quality management in garment industry
U 7 total quality management in garment industrykibrom G
 
Important for RMG sector
Important for RMG sectorImportant for RMG sector
Important for RMG sectorImran Hasan
 
Guide lines to improve the garment quality
Guide lines to improve the garment qualityGuide lines to improve the garment quality
Guide lines to improve the garment qualityHindustan University
 
Apparel production process
Apparel production processApparel production process
Apparel production processravi kishore
 
Cost of Quality in Apparel Industry
Cost of Quality in Apparel IndustryCost of Quality in Apparel Industry
Cost of Quality in Apparel IndustryShubha Brota Raha
 
Richa Tilwani ,Second Year Fashion Design Student NSQF Level -6
Richa Tilwani ,Second Year Fashion Design Student NSQF Level -6Richa Tilwani ,Second Year Fashion Design Student NSQF Level -6
Richa Tilwani ,Second Year Fashion Design Student NSQF Level -6dezyneecole
 
Garment inspection and testing process or dyeing process
Garment inspection and testing process or dyeing processGarment inspection and testing process or dyeing process
Garment inspection and testing process or dyeing processNahar spinning mills bhopal
 
Apparel Manufacturing Methodology
Apparel Manufacturing MethodologyApparel Manufacturing Methodology
Apparel Manufacturing Methodologymustafa hussain
 
Apparelmanufacturingprocess 140214034521-phpapp01
Apparelmanufacturingprocess 140214034521-phpapp01Apparelmanufacturingprocess 140214034521-phpapp01
Apparelmanufacturingprocess 140214034521-phpapp01Rihazudin Razik MBCS
 
Apparelmanufacturingprocess 140214034521-phpapp01
Apparelmanufacturingprocess 140214034521-phpapp01Apparelmanufacturingprocess 140214034521-phpapp01
Apparelmanufacturingprocess 140214034521-phpapp01Rumali Sahanika
 
Garment-Manufacturing-Pro.7112349.powerpoint.pptx
Garment-Manufacturing-Pro.7112349.powerpoint.pptxGarment-Manufacturing-Pro.7112349.powerpoint.pptx
Garment-Manufacturing-Pro.7112349.powerpoint.pptxPravin Ukey
 
apparelmanufacturingprocess-140214034521-phpapp01
apparelmanufacturingprocess-140214034521-phpapp01apparelmanufacturingprocess-140214034521-phpapp01
apparelmanufacturingprocess-140214034521-phpapp01dilawar shaikh
 
Mamta Manwani. ,Fashion Design Second year Diploma Student of Dezyne E'cole C...
Mamta Manwani. ,Fashion Design Second year Diploma Student of Dezyne E'cole C...Mamta Manwani. ,Fashion Design Second year Diploma Student of Dezyne E'cole C...
Mamta Manwani. ,Fashion Design Second year Diploma Student of Dezyne E'cole C...dezyneecole
 
Week 2 importance of standards
Week 2 importance of standardsWeek 2 importance of standards
Week 2 importance of standardsMillicent Anyango
 
Apparel production overview
Apparel production overview Apparel production overview
Apparel production overview Fouzia Mirza
 

Ähnlich wie Quality control (20)

U 7 total quality management in garment industry
U 7 total quality management in garment industryU 7 total quality management in garment industry
U 7 total quality management in garment industry
 
Important for RMG sector
Important for RMG sectorImportant for RMG sector
Important for RMG sector
 
Ttqc 3
Ttqc 3Ttqc 3
Ttqc 3
 
Guide lines to improve the garment quality
Guide lines to improve the garment qualityGuide lines to improve the garment quality
Guide lines to improve the garment quality
 
Apparel production process
Apparel production processApparel production process
Apparel production process
 
Raw Material Of Quality Control
Raw Material Of Quality ControlRaw Material Of Quality Control
Raw Material Of Quality Control
 
Cost of Quality in Apparel Industry
Cost of Quality in Apparel IndustryCost of Quality in Apparel Industry
Cost of Quality in Apparel Industry
 
Richa Tilwani ,Second Year Fashion Design Student NSQF Level -6
Richa Tilwani ,Second Year Fashion Design Student NSQF Level -6Richa Tilwani ,Second Year Fashion Design Student NSQF Level -6
Richa Tilwani ,Second Year Fashion Design Student NSQF Level -6
 
Garment inspection and testing process or dyeing process
Garment inspection and testing process or dyeing processGarment inspection and testing process or dyeing process
Garment inspection and testing process or dyeing process
 
Total Quality Management in Apparel Industry of Bangladesh
Total Quality Management in Apparel Industry of BangladeshTotal Quality Management in Apparel Industry of Bangladesh
Total Quality Management in Apparel Industry of Bangladesh
 
Methodology
MethodologyMethodology
Methodology
 
Apparel Manufacturing Methodology
Apparel Manufacturing MethodologyApparel Manufacturing Methodology
Apparel Manufacturing Methodology
 
Apparelmanufacturingprocess 140214034521-phpapp01
Apparelmanufacturingprocess 140214034521-phpapp01Apparelmanufacturingprocess 140214034521-phpapp01
Apparelmanufacturingprocess 140214034521-phpapp01
 
Apparel manufacturing process
Apparel manufacturing process Apparel manufacturing process
Apparel manufacturing process
 
Apparelmanufacturingprocess 140214034521-phpapp01
Apparelmanufacturingprocess 140214034521-phpapp01Apparelmanufacturingprocess 140214034521-phpapp01
Apparelmanufacturingprocess 140214034521-phpapp01
 
Garment-Manufacturing-Pro.7112349.powerpoint.pptx
Garment-Manufacturing-Pro.7112349.powerpoint.pptxGarment-Manufacturing-Pro.7112349.powerpoint.pptx
Garment-Manufacturing-Pro.7112349.powerpoint.pptx
 
apparelmanufacturingprocess-140214034521-phpapp01
apparelmanufacturingprocess-140214034521-phpapp01apparelmanufacturingprocess-140214034521-phpapp01
apparelmanufacturingprocess-140214034521-phpapp01
 
Mamta Manwani. ,Fashion Design Second year Diploma Student of Dezyne E'cole C...
Mamta Manwani. ,Fashion Design Second year Diploma Student of Dezyne E'cole C...Mamta Manwani. ,Fashion Design Second year Diploma Student of Dezyne E'cole C...
Mamta Manwani. ,Fashion Design Second year Diploma Student of Dezyne E'cole C...
 
Week 2 importance of standards
Week 2 importance of standardsWeek 2 importance of standards
Week 2 importance of standards
 
Apparel production overview
Apparel production overview Apparel production overview
Apparel production overview
 

Mehr von zaman parvez

Cost Optimisation for Unilever.pdf
Cost Optimisation for Unilever.pdfCost Optimisation for Unilever.pdf
Cost Optimisation for Unilever.pdfzaman parvez
 
Digital marketing for online apparel brand
Digital marketing for online apparel brandDigital marketing for online apparel brand
Digital marketing for online apparel brandzaman parvez
 
Digital marketing for online apparel brand
Digital marketing for online apparel brandDigital marketing for online apparel brand
Digital marketing for online apparel brandzaman parvez
 
আল্লাহর ৯৯ টি নাম
আল্লাহর ৯৯ টি নামআল্লাহর ৯৯ টি নাম
আল্লাহর ৯৯ টি নামzaman parvez
 
32 lean tools applied in garments industry
32 lean tools applied in garments industry32 lean tools applied in garments industry
32 lean tools applied in garments industryzaman parvez
 
Application of Industrial Engineering in Garments Industry
Application of Industrial Engineering in Garments IndustryApplication of Industrial Engineering in Garments Industry
Application of Industrial Engineering in Garments Industryzaman parvez
 

Mehr von zaman parvez (8)

Cost Optimisation for Unilever.pdf
Cost Optimisation for Unilever.pdfCost Optimisation for Unilever.pdf
Cost Optimisation for Unilever.pdf
 
Digital marketing for online apparel brand
Digital marketing for online apparel brandDigital marketing for online apparel brand
Digital marketing for online apparel brand
 
Digital marketing for online apparel brand
Digital marketing for online apparel brandDigital marketing for online apparel brand
Digital marketing for online apparel brand
 
আল্লাহর ৯৯ টি নাম
আল্লাহর ৯৯ টি নামআল্লাহর ৯৯ টি নাম
আল্লাহর ৯৯ টি নাম
 
32 lean tools applied in garments industry
32 lean tools applied in garments industry32 lean tools applied in garments industry
32 lean tools applied in garments industry
 
Application of Industrial Engineering in Garments Industry
Application of Industrial Engineering in Garments IndustryApplication of Industrial Engineering in Garments Industry
Application of Industrial Engineering in Garments Industry
 
Skill matrix
Skill matrixSkill matrix
Skill matrix
 
ASd
ASdASd
ASd
 

Kürzlich hochgeladen

Call for Papers - Educational Administration: Theory and Practice, E-ISSN: 21...
Call for Papers - Educational Administration: Theory and Practice, E-ISSN: 21...Call for Papers - Educational Administration: Theory and Practice, E-ISSN: 21...
Call for Papers - Educational Administration: Theory and Practice, E-ISSN: 21...Christo Ananth
 
Top Rated Pune Call Girls Budhwar Peth ⟟ 6297143586 ⟟ Call Me For Genuine Se...
Top Rated  Pune Call Girls Budhwar Peth ⟟ 6297143586 ⟟ Call Me For Genuine Se...Top Rated  Pune Call Girls Budhwar Peth ⟟ 6297143586 ⟟ Call Me For Genuine Se...
Top Rated Pune Call Girls Budhwar Peth ⟟ 6297143586 ⟟ Call Me For Genuine Se...Call Girls in Nagpur High Profile
 
Booking open Available Pune Call Girls Koregaon Park 6297143586 Call Hot Ind...
Booking open Available Pune Call Girls Koregaon Park  6297143586 Call Hot Ind...Booking open Available Pune Call Girls Koregaon Park  6297143586 Call Hot Ind...
Booking open Available Pune Call Girls Koregaon Park 6297143586 Call Hot Ind...Call Girls in Nagpur High Profile
 
Call Girls Pimpri Chinchwad Call Me 7737669865 Budget Friendly No Advance Boo...
Call Girls Pimpri Chinchwad Call Me 7737669865 Budget Friendly No Advance Boo...Call Girls Pimpri Chinchwad Call Me 7737669865 Budget Friendly No Advance Boo...
Call Girls Pimpri Chinchwad Call Me 7737669865 Budget Friendly No Advance Boo...roncy bisnoi
 
Unit 1 - Soil Classification and Compaction.pdf
Unit 1 - Soil Classification and Compaction.pdfUnit 1 - Soil Classification and Compaction.pdf
Unit 1 - Soil Classification and Compaction.pdfRagavanV2
 
PVC VS. FIBERGLASS (FRP) GRAVITY SEWER - UNI BELL
PVC VS. FIBERGLASS (FRP) GRAVITY SEWER - UNI BELLPVC VS. FIBERGLASS (FRP) GRAVITY SEWER - UNI BELL
PVC VS. FIBERGLASS (FRP) GRAVITY SEWER - UNI BELLManishPatel169454
 
Bhosari ( Call Girls ) Pune 6297143586 Hot Model With Sexy Bhabi Ready For ...
Bhosari ( Call Girls ) Pune  6297143586  Hot Model With Sexy Bhabi Ready For ...Bhosari ( Call Girls ) Pune  6297143586  Hot Model With Sexy Bhabi Ready For ...
Bhosari ( Call Girls ) Pune 6297143586 Hot Model With Sexy Bhabi Ready For ...tanu pandey
 
FULL ENJOY Call Girls In Mahipalpur Delhi Contact Us 8377877756
FULL ENJOY Call Girls In Mahipalpur Delhi Contact Us 8377877756FULL ENJOY Call Girls In Mahipalpur Delhi Contact Us 8377877756
FULL ENJOY Call Girls In Mahipalpur Delhi Contact Us 8377877756dollysharma2066
 
Call Girls Wakad Call Me 7737669865 Budget Friendly No Advance Booking
Call Girls Wakad Call Me 7737669865 Budget Friendly No Advance BookingCall Girls Wakad Call Me 7737669865 Budget Friendly No Advance Booking
Call Girls Wakad Call Me 7737669865 Budget Friendly No Advance Bookingroncy bisnoi
 
UNIT - IV - Air Compressors and its Performance
UNIT - IV - Air Compressors and its PerformanceUNIT - IV - Air Compressors and its Performance
UNIT - IV - Air Compressors and its Performancesivaprakash250
 
Call for Papers - African Journal of Biological Sciences, E-ISSN: 2663-2187, ...
Call for Papers - African Journal of Biological Sciences, E-ISSN: 2663-2187, ...Call for Papers - African Journal of Biological Sciences, E-ISSN: 2663-2187, ...
Call for Papers - African Journal of Biological Sciences, E-ISSN: 2663-2187, ...Christo Ananth
 
Double rodded leveling 1 pdf activity 01
Double rodded leveling 1 pdf activity 01Double rodded leveling 1 pdf activity 01
Double rodded leveling 1 pdf activity 01KreezheaRecto
 
Double Revolving field theory-how the rotor develops torque
Double Revolving field theory-how the rotor develops torqueDouble Revolving field theory-how the rotor develops torque
Double Revolving field theory-how the rotor develops torqueBhangaleSonal
 
Call Girls Walvekar Nagar Call Me 7737669865 Budget Friendly No Advance Booking
Call Girls Walvekar Nagar Call Me 7737669865 Budget Friendly No Advance BookingCall Girls Walvekar Nagar Call Me 7737669865 Budget Friendly No Advance Booking
Call Girls Walvekar Nagar Call Me 7737669865 Budget Friendly No Advance Bookingroncy bisnoi
 
Generative AI or GenAI technology based PPT
Generative AI or GenAI technology based PPTGenerative AI or GenAI technology based PPT
Generative AI or GenAI technology based PPTbhaskargani46
 
Intze Overhead Water Tank Design by Working Stress - IS Method.pdf
Intze Overhead Water Tank  Design by Working Stress - IS Method.pdfIntze Overhead Water Tank  Design by Working Stress - IS Method.pdf
Intze Overhead Water Tank Design by Working Stress - IS Method.pdfSuman Jyoti
 
The Most Attractive Pune Call Girls Manchar 8250192130 Will You Miss This Cha...
The Most Attractive Pune Call Girls Manchar 8250192130 Will You Miss This Cha...The Most Attractive Pune Call Girls Manchar 8250192130 Will You Miss This Cha...
The Most Attractive Pune Call Girls Manchar 8250192130 Will You Miss This Cha...ranjana rawat
 

Kürzlich hochgeladen (20)

Call for Papers - Educational Administration: Theory and Practice, E-ISSN: 21...
Call for Papers - Educational Administration: Theory and Practice, E-ISSN: 21...Call for Papers - Educational Administration: Theory and Practice, E-ISSN: 21...
Call for Papers - Educational Administration: Theory and Practice, E-ISSN: 21...
 
Top Rated Pune Call Girls Budhwar Peth ⟟ 6297143586 ⟟ Call Me For Genuine Se...
Top Rated  Pune Call Girls Budhwar Peth ⟟ 6297143586 ⟟ Call Me For Genuine Se...Top Rated  Pune Call Girls Budhwar Peth ⟟ 6297143586 ⟟ Call Me For Genuine Se...
Top Rated Pune Call Girls Budhwar Peth ⟟ 6297143586 ⟟ Call Me For Genuine Se...
 
Booking open Available Pune Call Girls Koregaon Park 6297143586 Call Hot Ind...
Booking open Available Pune Call Girls Koregaon Park  6297143586 Call Hot Ind...Booking open Available Pune Call Girls Koregaon Park  6297143586 Call Hot Ind...
Booking open Available Pune Call Girls Koregaon Park 6297143586 Call Hot Ind...
 
Call Girls Pimpri Chinchwad Call Me 7737669865 Budget Friendly No Advance Boo...
Call Girls Pimpri Chinchwad Call Me 7737669865 Budget Friendly No Advance Boo...Call Girls Pimpri Chinchwad Call Me 7737669865 Budget Friendly No Advance Boo...
Call Girls Pimpri Chinchwad Call Me 7737669865 Budget Friendly No Advance Boo...
 
Unit 1 - Soil Classification and Compaction.pdf
Unit 1 - Soil Classification and Compaction.pdfUnit 1 - Soil Classification and Compaction.pdf
Unit 1 - Soil Classification and Compaction.pdf
 
PVC VS. FIBERGLASS (FRP) GRAVITY SEWER - UNI BELL
PVC VS. FIBERGLASS (FRP) GRAVITY SEWER - UNI BELLPVC VS. FIBERGLASS (FRP) GRAVITY SEWER - UNI BELL
PVC VS. FIBERGLASS (FRP) GRAVITY SEWER - UNI BELL
 
Bhosari ( Call Girls ) Pune 6297143586 Hot Model With Sexy Bhabi Ready For ...
Bhosari ( Call Girls ) Pune  6297143586  Hot Model With Sexy Bhabi Ready For ...Bhosari ( Call Girls ) Pune  6297143586  Hot Model With Sexy Bhabi Ready For ...
Bhosari ( Call Girls ) Pune 6297143586 Hot Model With Sexy Bhabi Ready For ...
 
FULL ENJOY Call Girls In Mahipalpur Delhi Contact Us 8377877756
FULL ENJOY Call Girls In Mahipalpur Delhi Contact Us 8377877756FULL ENJOY Call Girls In Mahipalpur Delhi Contact Us 8377877756
FULL ENJOY Call Girls In Mahipalpur Delhi Contact Us 8377877756
 
Call Girls Wakad Call Me 7737669865 Budget Friendly No Advance Booking
Call Girls Wakad Call Me 7737669865 Budget Friendly No Advance BookingCall Girls Wakad Call Me 7737669865 Budget Friendly No Advance Booking
Call Girls Wakad Call Me 7737669865 Budget Friendly No Advance Booking
 
UNIT - IV - Air Compressors and its Performance
UNIT - IV - Air Compressors and its PerformanceUNIT - IV - Air Compressors and its Performance
UNIT - IV - Air Compressors and its Performance
 
Call for Papers - African Journal of Biological Sciences, E-ISSN: 2663-2187, ...
Call for Papers - African Journal of Biological Sciences, E-ISSN: 2663-2187, ...Call for Papers - African Journal of Biological Sciences, E-ISSN: 2663-2187, ...
Call for Papers - African Journal of Biological Sciences, E-ISSN: 2663-2187, ...
 
Call Now ≽ 9953056974 ≼🔝 Call Girls In New Ashok Nagar ≼🔝 Delhi door step de...
Call Now ≽ 9953056974 ≼🔝 Call Girls In New Ashok Nagar  ≼🔝 Delhi door step de...Call Now ≽ 9953056974 ≼🔝 Call Girls In New Ashok Nagar  ≼🔝 Delhi door step de...
Call Now ≽ 9953056974 ≼🔝 Call Girls In New Ashok Nagar ≼🔝 Delhi door step de...
 
Double rodded leveling 1 pdf activity 01
Double rodded leveling 1 pdf activity 01Double rodded leveling 1 pdf activity 01
Double rodded leveling 1 pdf activity 01
 
Double Revolving field theory-how the rotor develops torque
Double Revolving field theory-how the rotor develops torqueDouble Revolving field theory-how the rotor develops torque
Double Revolving field theory-how the rotor develops torque
 
NFPA 5000 2024 standard .
NFPA 5000 2024 standard                                  .NFPA 5000 2024 standard                                  .
NFPA 5000 2024 standard .
 
Call Girls Walvekar Nagar Call Me 7737669865 Budget Friendly No Advance Booking
Call Girls Walvekar Nagar Call Me 7737669865 Budget Friendly No Advance BookingCall Girls Walvekar Nagar Call Me 7737669865 Budget Friendly No Advance Booking
Call Girls Walvekar Nagar Call Me 7737669865 Budget Friendly No Advance Booking
 
Generative AI or GenAI technology based PPT
Generative AI or GenAI technology based PPTGenerative AI or GenAI technology based PPT
Generative AI or GenAI technology based PPT
 
Intze Overhead Water Tank Design by Working Stress - IS Method.pdf
Intze Overhead Water Tank  Design by Working Stress - IS Method.pdfIntze Overhead Water Tank  Design by Working Stress - IS Method.pdf
Intze Overhead Water Tank Design by Working Stress - IS Method.pdf
 
The Most Attractive Pune Call Girls Manchar 8250192130 Will You Miss This Cha...
The Most Attractive Pune Call Girls Manchar 8250192130 Will You Miss This Cha...The Most Attractive Pune Call Girls Manchar 8250192130 Will You Miss This Cha...
The Most Attractive Pune Call Girls Manchar 8250192130 Will You Miss This Cha...
 
Water Industry Process Automation & Control Monthly - April 2024
Water Industry Process Automation & Control Monthly - April 2024Water Industry Process Automation & Control Monthly - April 2024
Water Industry Process Automation & Control Monthly - April 2024
 

Quality control

  • 1. WELCOME Abruan Group Dept. of Industrial Engineering & Planning
  • 2. Training Program on “QUALITY CONTROL SYSTEM in Garments Industry”
  • 3. Quality is the degree to which a commodity meets the requirements of the customer at the start of its life. (ISO 9000) What is Quality? What does Quality Mean? So, Quality is………. 1. Degree of excellence 2. Conformance to requirements 3. Totality of characteristics which act to satisfy a need 4. Fitness for use 5. Fitness for purpose 6. Freedom from defects 7. Delighting customers Joseph Juran says, quality is “Fitness for Use”. When “fitness for use” concept applied to garment it must According quality Guru Philip Crosby, Quality is “Conformance to Requirements.”
  • 4. Quality Assurance vs. Quality Control •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.
  • 5. Process Flow Chart of Garments Quality Fabric Inspection (4 Point System) Accessories Inspection (10% Inspection) Shade segregation Shrinkage test Size set check
  • 6. Marker check Spreading quality assurance Shade segregation Cut Panel Inspection Hard pattern check Process Flow Chart of Garments Quality
  • 7. Risk Analysis Meeting Pre-production meeting Quality Assurance when Line Feeding In process audit Quality Assurance Two time process check Process Flow Chart of Garments Quality
  • 8. Two time machine check 7 Pcs Check (Traffic light System) 100% Shell Check 100% Lining Check 100% Shell Lining Join Check Process Flow Chart of Garments Quality
  • 9. 100% KANBAN Check Button Pull Check 100% Metal Check 100% Lining Check Pre Final Inspection Process Flow Chart of Garments Quality
  • 10. DHU & DEFECTIVE % Defects Defects are all those non-conformance that are not acceptable by end customer. Like imbalanced shape of the garment, broken button or other trims, holes in fabrics, slip stitch, broken seam etc. In a defective garment there may be more than one defect. Defective Pieces Defective pieces are those pieces, which are separated for alteration during checking may be for any causes. For the quantitative measure there is two measuring unit as Defects per hundred units and percentage defective. Defects per hundred units (DHU) – number of total defects in 100 checked garments. The formula for calculating DHU is DHU = Total no. of defects found X 100 / Total pieces checked Percent Defective (%) – total number of defective pieces in 100 checked garments. Percentage defective = Total no. of defective pieces X 100 / Total pieces checked Example: Suppose in a day one table checker checked 200 pieces. He found total 15 defective pieces and in those 15 pieces total 60 defects were found. So, quality measure of that lot in terms of DHU is 30 (60*100/200) and Percentage Defective is 7.5%.
  • 11. How to change defective or damaged garment parts intelligently? “Part changing” is not an intended process in garment manufacturing but this process is there because there is certain reasons where we can’t control the cause of fabric damages in the garments completely. However, where possible, we have to minimize short shipment and improve our sales. Part changing is generally done in finishing stages. Most of the fabric defects that are not acceptable in garments are removed during cutting and stitching processes. Still damaged part is found in the sewn garment due to heavy washing, dyeing or other reasons. Instead of rejecting the defective garment, only damaged part can be changed and converted it into a quality garment. When part changing is necessary and main purpose of the part changing is to improve ship quantity, part changing must to be done intelligently. It should not increase the fabric consumption or produce further defective garment in the part changing process. You have to think from where you will get fabric for part changing? How to remove damaged component and re-stitch the garment maintaining sewing quality? For the fabric usage you have multiple options – i) End bits of the cut layers, ii) using fresh fabrics or iii) replacing damaged parts with good parts of another garment. Which option to be chosen is depends on garment processing after stitching, fabric types, value added work or embellishment in the garment.
  • 12. End bit usage for part changing: In the cutting room, during layering cutters store end bits that are not layered in the lay for a cutting. These end bits are one type of cutting waste. So for the part change you can use those end bits without increasing fabric consumption. But here you have to take care about shade matching or lot matching of the fabrics with the damaged garments. If the garments were heavily washed, then it will be very difficult to match the garment fabric shade. After changing the parts garment must be washed again to give matching finished look and similar hand feel. Fresh fabric usage for Part changing: If you don’t have enough end bits to replace the damaged parts from the garment, use available fresh fabric. When using fresh fabric, you may find problem with shade matching, extra fabric consumption for the order. Only use fresh fabric if there is no problem with shade matching. But for solid colors and yarn dyed fabric there is no issue related to shade matching. Using good components from other damaged garments: This option is chosen when garments are dyed and there are no fresh fabric or end bits or fresh fabric for that order. The reason, instead of rejecting all garments, you can make some good garment losing few garments. Also for the high value garment with fine hand embroidery work and where you have less time to complete the shipment, this option is preferred. Like above options, you have to care about the garment component’s shade matching.
  • 13. Key Performance Indicators (KPIs) for Quality Customer complaint: When buyers received something wrong against the contract with suppliers in terms of product quality they claim for the damages. It is huge money to pay back to the buyer. Even factory may lose business relationship with those buyers due to poor product quality. So customer complaint is considered as most important KPI. • AQL levels: It means when garments are inspected what AQL level is being followed as pass or fail criteria. Though it may vary product to product but it gives clear idea about factory’s quality performance. Lower the AQL you follow better is the quality performance. • Percentage Defective level: This term is also known as Defect %. It is measure of total defective garments founds and total garments inspected in percentage. It can be calculated batch wise or on the basis of complete order. Generally factory measure Defect percentage on daily and hourly basis of batch. Lesser the defect% better is the quality performance.
  • 14. • Defects per Hundred Units (DHU): Factories measure Defect% but don’t track total number of defects found in inspected pieces. Tracking of DHU is important because your rework time and work force required for repairing defect directly linked with DHU number. Lesser the DHU better is the quality performance. • Rework Cost: Each rework is a cost to the company. The rework costs vary according to the process and types of rework. It consumes extra time and increase factory overhead. Process wise and product wise rework cost can be tracked to measure it. Lower the Rework cost better is quality performance. • Right First Time (RFT): For garment manufacturer RFT quality is an ideal situation. It means whatever activities you do to make the garment, quality of the garment should be correct at the first time. Data can be captured for RFT at each process and it is expressed in percentage.
  • 15. Garment Zoning for the Inspection of Visual Defects Defect Zone of Vest Outwear
  • 16. Defect Zone of Hooded Jacket
  • 17. Defect Zone of Sports coat
  • 18. Defect Zone of Sports coat
  • 19. What are the Critical Defects for a Garment? Definition of Critical defects: According to Quality Assurance Manual of Gap Inc. "Anything which can harm the wearer of the product are critical defects". Critical defects are also defined as a defect that is likely to result in hazardous or unsafe conditions for an individual in using the product and that does not meet the mandatory regulations. A critical defect in clothes may cause accident to the wearer and may malfunction when wearer out wearing a garment with critical defect. Example of some critical defects: •Loose components: Trims and fasteners those are used in the garment but not secure properly. For example, buttons, snaps, stones etc. •Sharp edges: During the processing of the garment it come in contact with various sharp metals such as needles, staples. Broken needles, damaged or broken snap buttons, rivets, wire and pins. •Drawstrings at head or neck for baby or kids products. Draw string must be avoided in kids clothes. •Thread or trims which are extensively long or loose. All the above critical defects must not be present in the product in any circumstances. In an audit if inspector finds such defects in packed garments, he must fails the audit and ask quality checker for re- inspection of all goods. For the factory, management should run awareness program on critical defects and potential risk of the critical defects at end-user point.
  • 20. Major & Minor Defect
  • 21. Major & Minor Defect
  • 22. Major & Minor Defect
  • 23. Major & Minor Defect
  • 24. Major & Minor Defect
  • 25. Acceptable Quality Level Consumer Product Critical defects no critical defect is accepted Major defects AQL 2.5 Minor defects AQL 4.0 AQL standard refers to the maximum number of defective that could be considered acceptable during the random sampling of an inspection. The Defects that are found during inspection are classified into 3 levels: Critical, Major and Minor. The AQL level should be agreed between buyer and supplier before production commences. The following AQL standard are usually applied by Hong Kong Q. C. Center Ltd unless otherwise instructed by customer.
  • 26.
  • 27. How to Improve Apparel Product Quality? • Specific steps that can enhance quality include: Communicating the importance of quality, each worker’s role in achieving and maintaining right quality, and expectations of worker performance • Maintaining a clean and dry workplace, including storage rooms and shipping areas • Selecting and utilizing proper equipment for each cutting and assembly step • Providing the proper tools and training to each worker, and communicating management quality performance expectations • Planning and conducting an ongoing program of machine maintenance • Establishing agreed-upon quality standards with all fabric and finding suppliers before purchase, including procedures for rejecting/returning unacceptable goods • 100% inspection of all incoming fabrics to include, at a minimum: • Visual inspection by a trained inspector running every roll of fabric over a back-lit inspection frame to identify fabric defects such as holes, tears, stains, stop marks, and width variations, and to compare actual width and length to reported dimensions. • Color shade check, compared to agreed-upon (or buyer imposed) shade tolerances under a five-light box • Rejection and return of all fabric not meeting agreed-upon quality standards • 100% inspection of value added processes like panel printing, machine embroidery, hand embroidery etc. No defective panels or components should be sent to assembly. Defective component to be accepted after corrective measure.
  • 28. Corrective measures: Replace – replace underperforming suppliers, equipment, • Repair – repair ill-functioning equipment, • Retrain – retrain underperforming workers and • Reward – reward high performing workers Implementing even a few of these steps will result in improved quality, but each additional suggestion put into practice will yield significant improvements in product quality. Traffic Light System Roving QC Internal AQL System