control the quality of a clothing factory

7/28/2019 control the quality of a clothing factory

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Assignment 02

Bachelor of Applied Science (Textile Technology)-2012/2013Lasitha Nawarathna

TEXTILE QUALITY MANAGEMENT



Assignment 02

Think of a procedure or a method to control the quality of a clothing factory. Produce formats if

necessary.

Introduction

For every industry or business, to get increased sales and better name amongst consumers andfellow companies it is important to maintain a level of quality. Especially for the businesses

engaged in export business has to sustain a high level of quality to ensure better business

globally. Generally quality control standards for export are set strictly, as this business is also

holds the prestige of the country, whose company is doing the export. Export houses earn foreign

exchange for the country, so it becomes mandatory to have good quality control of their

products. In the garment industry quality control is practiced right from the initial stage of

sourcing raw materials to the stage of final finished garment. For textile and apparel industry

product quality is calculated in terms of quality and standard of fibres, yarns, fabric construction,

colour fastness, surface designs and the final finished garment products. However quality

expectations for export are related to the type of customer segments and the retail outlets.

There are a number of factors on which quality fitness of garment industry is based such as -

performance, reliability, durability, visual and perceived quality of the garment. At present many

firms around the world are practicing quality management to achieve those benefits in order to

be competitive in the market. It is accepted world-wide that one of the key factors for forms to be

successful in the global market is quality.



What is quality?

Quality has many connotations. 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.

The subjective definition of element of quality relation to the design, style, color, and aesthetics.

Objectively, quality is the ability to meet consistently the return and clearly started specification.

These aimed at producing a product suitable for end use and price.

According to (Garvin, 2007 ) four principal approaches to defining quality

1. Product-based quality view

2. User (customer) based quality view

3. Manufacturing based quality view

4. Value-based quality view

Product-based quality view

In this view, quality is determined as a precise and measurable variable and difference in quality

reflects differences in the quality of some ingredient or attitude seen to be possessed by a

product. In this view quality and quantity has direct relation

User (customer) based quality view

In this view, definitions are based on the premise that solely the user determined quality.

Individual customers are assumed to have different wants or needs and goods that best satisfy the

preference are the one they regarded, as having the highest perceived quality. Quality is fitness

for use that this view also reflects a highly personalized and subjective view



Manufacturing based quality view

This view focuses on manufacturing and engineering practices. It emphasis conformance to

specified requirements. The higher the degree that meets specified requirements the higher the

quality. This view seeks to ensure that the deviations from standards set design specifications are

minimized.

To achieve the quality of conformance means improving in the design of the

· Equipment

· Materials

· Supervision

· Control· Training

4. Value based quality view

The base for this view is physiological understanding of the meaning of value.

Consequently, customers have been conditioned to accept that the quality of product is

determined by the price. There for price and quality have a direct relation ship

Why quality is important

1. Greater market share

2. Higher growth rate

3. Higher earning

4. Premium price

5. Loyal customers

6. High motivated employs



Quality control

Quality control is concerned with the operational techniques for detecting, recording and taking

action to eliminate quality problems. It refers to all activities (process) and technologies that are

used to achieve or maintain the quality of a product or service.

Quality control focuses on finding and eliminating of source of defects and monitoring the

manufacturing process. Quality control consists of developing, designing producing, marketing,

service products and services with optimum cost- effectiveness and usefulness, which customers

will purchase with satisfaction.

For effective quality control, it is necessary to exercises control over the input material, process,

and employment of skilled labor, management techniques and use of appropriate tools,

equipment and machines Quality control in eliminating of material wastes and ensures in quality

product and full customers satisfaction.

In the garment industry quality control is practiced right from the initial stage of sourcing raw

materials to the stage of final finished garment. For textile and apparel industry product quality is

calculated in terms of quality and standard of fibres, yarns, fabric construction, colour fastness,

surface designs and the final finished garment products. However quality expectations for export

are related to the type of customer segments and the retail outlets.

Quality control and standards are one of the most important aspects of the content of any job and

therefore a major factor in training.



Procedure to control the quality of a clothing factory

Who shall be involved in the quality control procedure?

For controlling the quality have to involve top management to bottom level worker in that

organization. Especially individual machine operators should have good knowledge about

quality. Responsibility for the production of good quality lies with and in the hand of the person

teaching the job. Primarily by good communication by making new comer aware of

specifications, importance of right first time, faults themselves, their effect and the appropriate

action to take. Such communication or training if properly planned and executed (implemented)

will greatly assist in minimizing the cost of poor quality. If operators know important of right

first time concept organization can increase them quality level.

Give main place for individual operators. when recruiting new employees giving the effective

training about this factor and develop their mind.

Why is quality important,

Sewing Machine Checklist,

Operator's responsibilities,

Housekeeping,

Sewing defects

Colour effects

Sizing defects

Garment defects

Environmental effects

Do right first time how it can affect you and the company.



Main sections of quality control

01. Raw material inspection

02. Cutting room quality control

03. Sewing room quality control

04. Finishing department quality control

Raw material Inspection department

The quality of a final garment depends on the quality of a fabric when it is received as a roll.

After fabric is received, it should be inspected to determine its acceptability from a quality view point; otherwise, extra cost in garment manufacturing may be incurred due to either the loss of

the material or time, to say nothing of customer returns and dissatisfaction due to poor quality.

Some garment manufacturers rely on their fabric suppliers to perform fabric inspection and mark

fabric defects

Cutting room quality

In cutting section quality control in two stages

a) Spreading quality control: Following the point are checked during spreading

II. EndsIII. TensionIV. LeaningV. Narrow GoodsVI. CountsVI. Ply heightVII. RemnantsVIII. Fabric flawsIX. Market placing



b) After cutting quality control: After each cutting blocks and bundles are checks on the

following points.

I. Miss cutII. Ragged cuttingIII. Pattern checksIV. Matching PliesV. Notches

The main thing is the quality of the cut pieces to product the good and quality garments.

Therefore it is important to check quality and accuracy in the cut pieces before they used to the

production. For that panel inspection is carried out. All operators should trained about right fist

time concept Panel inspection is control by the lab and also quality peoples are there to ensure

the quality. Every 20% of the cut quantities are checked cutting room quality checkers.

Sewing room quality control

Defects found from sewing room

Common sewing defects

I. Open seamsII. wrong stitching techniques

III. Nonmatching threadsIV. missing stitches,V. improper creasing of the garment,

VI. Improper thread tension etc.VII. Variation of colour between the sample and the final Garment

VIII. wrong colour combinationsIX. Mismatching dyes.X. Wrong gradation of sizes (Difference in measurement of various parts of a garment

like sleeves of XL size for body of L size garment can deteriorate the garments beyond repair)



Production process quality control

Model line has (20-30) machine operators One in line quality checker End line quality checker

Machine operators approach of quality control

1. The operators and when recruiting new operators giving the effective training about

below factors and develop their mind.

Why is quality important, Sewing Machine Checklist, Operator's responsibilities, Housekeeping, How to identify Sewing defects How to identify Colour effects How to identify Sizing defects How to identify Garment defects Environmental effects Do right first time how it can affect you and the company.

.

2. Display operational wise guide card in front of each operator.

Example:-

O eration uide card

Sample of operation Critical points of that operations

1.

2.

3.

4.



Using above guide card operators can self-check them own operation under given

introductions. When change styles in line quality checker and supervisor responsible for

the change operations guide card.

3. Inspection of every 5th piece of operation by the operator. The operator should inspect

his part of operation, on every 5th piece to determine any faulty stitching.

In-Line Quality control

Recruiting one in-line quality checkers for every module. The in-line checker is the major

role to ensure the quality level in the garments. In line quality checker has been got the

information about the quality level in the ongoing garment style from the pre- production

meeting. She checks the quality level in the process is ongoing and also after the sewing

the full garment.

In-Line Quality Checker (QC) should be responsible to maintain the quality in her/him

module. He/she visited near to the every operator adjusted and checked the followings. Appearance

Is the operation balanced/ symmetric

Measurements to specifications

Stitches per inch (SPI)

Suggested monitoring system of in line quality checker

This system is based on three lights red, yellow and green. The lights are used to

symbolize the quality status at the operation and make supervisor aware of where

problems are occurring and give the in line controllers an idea where they have to spend

more time.

S.P.I:- …………..

Technician signature ………….. In line Q.C signature …………..



Approved sample should display in end of every production line

End line quality checkers should be maintain past defect records.

control the quality of a clothing factory

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