inspection ii

8/2/2019 Inspection II

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International Textile Ltd. 2

Company Profile

International Textile (ITL) is a dynamic group of companies characterized byits integrity to customers that have made it legendary as a great value of

excellence in manufacturing of quality textiles. It has structured a

professional operation staff in which empowerment and sense of

responsibility is the key to organizational development.

I.T.L has state of the art machinery backed by a well equipped laboratory.

SPINNING

Murata Jet Spinning

AutoCoro Spinning

Uster Tenso Rapid Tester

Uster UT-4

Auto Shorter tester

Tensile Tester

WEAVING

Beninger Warping Machine

Zell Sizing Machine

Sulzer Projectile Looms

DynaTerry Vamatex

Rapier Looms

PROCESSING

Pad Steam

J-Box

Loop Dryer

STITCHING

GGT Pattern Maker

Accu Mark

Gerber Infinity Plotter

Single & Double Needle Machines

Feedo Machine

Waist Band kansai machine

Snap Button Machine

Range cutters

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The company is

C e r t i f i e dC e r t i f i e d

Company Profile Cont

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Quality Objectives

Quality Control & Assurance QC&A Dept.

monitor product from its very basic stage.

Highly capable quality and technical team.

Quality Management Team is involved at each

production stage.

Quality Targets for each function

Never compromise over quality standards.

To achieve the quality objectives company is

bringing in use

Machinery/Maintenance and Preventive

Maintenance

Best available Quality Raw Materials

Safe and healthy work environment

Skilled Competent Worker/EmployeesTraining ( On Job / Internal / External /

Awareness QMS)

Sub-Contractors are Selected by Company

Policy

Well Equipped Laboratory and Competent

Quality Controller.

Rejection reduced at minimum levelOn time delivery

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Quality Check/Stages

Each product is checked as its comes in factory.

No products/item is issued without internal QC approvals

Raw materials and intermediate products are checked for quality at following stages

before its issued for bulk use.

Spinning & Yarn receiving

Weaving In-line QC

Greige fabric inspection

Processing in-line QC

Finish fabric In-house inspection

Stitching in-line & off-line

Stitching intermediate Audits

Stitching final Audits

Laboratory testing (Physical and Chemical)

Each inspection and audit is followed by random audits by the Quality manager.

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Quality Check/Stagesweaving

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Quality Assurance Program (QAP)

A Quality Assurance Program (QAP) is an integrated mix of QA functions (testing, inspection, audit,

etc) applied in such a way as to ensure an appropriate level of confidence in the quality and safety of a

manufactured product starting from very basic raw material and accessories to finished products.

Pre Production Developments

Initial product developments are done in order to access the product requirements.

Product Assessment

Product assessments are designed, firstly, to identify and correct safety problems at as early a stage as

possible (at initial development stage) in the product life and, secondly, to flag any potential QA issue.

Products specs

Pre production evaluation and product study would be carried out to develop a detail productspecification sheet.

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Product Testing

Each merchandized product is tested at following stages.

Raw Material Testing

Raw materials are tested at early a stage as possible, to ensure that the best recommendedmaterials are used in the manufacturing.

Pre Production Testing

Pre-production testing is carried out on final prototype samples, typical in all respects ofthe product to be manufactured in bulk. QC&A maintains reference samples

In-Process Product Testing

All products are test against requirements for their physical and chemical characteristics.

Accessories Testing

All the accessories are inspected against standards or stated requirements. Criteria for eachitem would be different depending on the nature of the item.

Final Inspection Testing

Post-production testing is done at our lab after the products have been finished, packed andare ready for shipment.

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Inspections

In general, the essential quality performance of a product will have been established ahead of

production and the purpose of quality assurance during production will be to ensure that the

required quality level is maintained.

Initial Production Inspections

Each Product is inspected at prototype stage before production starts. QC&A keep onereference sample for counter check

In-Process Quality Check (IPQC)

During production QC continuously monitors on going manufacturing processes.

Final Inspections (FIs)

Finished fabric is inspected for quality at AQL level II for quality before it is shipped.

Loading Inspection (LIs)Loading inspection is meant to complete the QA process for every order.

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Yarn Receiving

As Yarn receive in mill it is checked for various parameters.

Yarn is tested for count, tensile strength, moisture contents, UsterUT-4 and uster tensorapid tests.

After complete testing Yarn is issued for production.

SAMPLE FROM : I.T.L , C/O ITL #0 1

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Weaving & Greige Fabric

Weaving is closely monitored by Quality Dept.

Quality inspected by QCs for defects

First meter lab testing for specification.

Inspection at 4 or 10 point American system

Based on the defect frequency number of defects /100 sq mtr is calculated, which leads to acceptance orrejection of fabric.

Random audits by Quality Officer to assureeffective QA procedure.

No fabric can be issued for next process without QCaudit and written approval.

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Fabric Inspection

Greige fabric inspection point out the defect level and frequency and based upon these observations preventiveand corrective action are taken.

Each quality issue is immediately discussed with the concern production person for immediate action and apreventive action is designed for future improved quality.

The following general fabric faults are monitored and minimized at weaving stage.

Each defect is evaluated on 4 or 10 point American grading system.

Wrong Yarn CountGuide Mark

Picks Per InchOil Stain

Ends Per InchFloat

Uneven WidthCrack

Sizing StainDouble End

Damaged FabricDouble Pick

Color flyMiss End

Design OutMiss Pick

Temple MarkSelvage Tail

Reed MarkUneven Salvage

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Fabric Inspection Systems

Every fabric shipment is inspected for quality at 4 or 10 point American system.

Note:

Dyeing

1 Point

1 Point

3 Points

FABRIC INS PECTION C RITERIA

10 P OINT SYSTEM

Width wise points criteria

1 Point Up to 3"

3 Points Over 3" to 1/4 of the w idth.

5 Points Over 1/4 of the w idth to half of the w idth.

7 Points Over half of the w idth to 3/4 of the w idth.

10 Points Full w idth defect.

5 Points Minor crack of full w idth.

Length wise points criteria

10 Points 21-40" or 1 meter

5 Points 11-20 "

3 Points 6-10"

1 Point 5" and low er

Three consecutive 10 points w ill result in cuttable fault.Floats 1X1 cm 3 Points

Hole 1X1 Broken end/pick 3 Points

Hole 2X2 Broken ends/picks 5 Points

Hole Over 2X2 Broken ends/pi 10 Points

Stains 1x1 cm 3 Points

2X2 cms 5 Points

Over 2X2 cms 10 Points

Greige fabric for Printing Bleaching

Slubs 10 Points 1 Point

Knots 10 Points 1 Point

Hanging Thread 10 Points 3 Point

Yarn V ariation/Beam Motion/ Barre' effec t

Minor 5 Points

Major 10 Points

Full length defects including short end, selvage loose, selvage damage, wrong count,

Wrong draw ing, Reed marks, Temple marks, damaged selvage, w rong selvage,

Wrong w eaver and Defects exceeding 10 points limit

Cuttable de fects

Patta

Count/composition variation

Roll Rejection defects:-

Note:

Dyeing1 Point

1 Point

3 Points

Bleaching1 Point

Yarn Variation/Beam Motion/ Barre' effect

Greige fabric for Printing

Slubs 4 Points

Wrong weaver and Defects exceeding 10 points limit

Count/composition variationRoll Rejection defects:-

Full length defects including short end, selvage loose, selvage damage, wronWrong drawing, Reed marks, Temple marks, damaged selvage, wrong selva

Major 4 Points

Cuttable defectsPatta

Minor 2 Points



3 Points


2X2 cms

Hole Over 2X2 Broken end 4 Points


Floats

Hole 2X2 Broken ends/pic 3 Points

1X1 cm 1 PointsHole 1X1 Broken end/pick 1 Points

1 Point 5" and lowerThree consecutive 10 points will result in c uttable fault.


2 Points 6-10"

3 Points 11-20 "

4 Points Over 12"


2 Points Over 3" to 6" of the width.

3 Points Over 6" to to 12"

FABRIC INSPECTION CRITERIA

4 POINT SYSTEM

Width wise points criteria1 Point Up to 3"

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Note:

Dyeing

1 Point

1 Point

3 Points

Bleaching

1 Point

Yarn Variation/Beam Motion/ Barre' ef ect

Greige fabric for Printing

Slubs 4 Points

Wrong weaver and Defects exceeding 10 points limit



Full length defects including short end selvage loose, selvage damage, wr

f

,

Wrong drawing, Reed marks, Temple marks, damaged selvage, wrong selv

Major 4 Points

Cuttable defects

Patta

Minor 2 Points



3 Points


2X2 cms

Hole Over 2X2 Broken end 4 Points


Floats

Hole 2X2 Broken ends/pic 3 Points

1X1 cm 1 Points

Hole 1X1 Broken end/ ick 1 Points

1 Point 5" and lower

Three consecutive 10 points will result in cuttable fault.

4 Points 21-40" or 1 mete

2 Points 6-10"

3 Points 11-20 "

4 Points Over 12"


r

p

2 Points Over 3" to 6" of the width.

3 Points Over 6" to to 12"


4 POINT SYSTEMWidth wise points criteria1 Point Up to 3"


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Note:

Dyeing

1 Point

1 Point

3 Points


10 POINT SYSTEM

Width wise points criteria

1 Point Up to 3"3 Points Over 3" to 1/4 of the w idth.

5 Points Over 1/4 of the w idth to half of the w idth.

7 Points Over half of the w idth to 3/4 of the w idth.

10 Points Full w idth defect.

5 Points Minor crack of full w dth.


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5 Points 11-20 "3 Points 6-10"

1 Point 5" and low er

Three consecutive 10 points w ill esult in cuttable fault.

Floats 1X1 cm 3 Points

Hole 1X1 Broken end/pic 3 Points

Hole 2X2 Broken ends/picks 5 Points

Hole Over 2X2 Broken ends/pi 10 Points

Stains 1x1 cm 3 Points2X2 cms 5 Points


Greige fabric for Printing Bleaching

Slubs 10 Points 1 Point



Yarn Variation/Beam Motion/ Barre' effect

Minor 5 PointsMajor 10 Points

Full length defects including short end, selvage loose, selvage damage, w rong count,

Wrong draw ing, Reed marks, Temple marks, damaged selvage, w rong selvage,

Wrong w eaver and Defects exceeding 10 points limit

Cuttable defects

Patta



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Processing

directly monitored by Quality department.

QC continuously monitors the fabric processingat different stages

Randomly audited by QC for quality.

Each lot is marked separately and properprocess tail and shade band is prepared to checkconsistency.

Fabric is tested for its physical and chemicalparameters including fastness tests at ITL lab

NO fabric is issued without lab testing and

QC&A approval

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Finished Fabric

This process takes place when the fabric is sent to our rolling department where it is checked by

our inspectors, defected areas are marked by stickers and sent to our stitching department for final

editing before production.

The fabric received in our rolling department after processing is inspected 100% on tables by our

inspectors. There are two inspectors assigned per table to ensure that every yard is evaluated

meticulously at our end. From there on, the fabric is rolled on a rolling machine and inspected asecond time by our well trained inspectors for any defects that may have been left out in the initial

checking

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Laboratory Testing

Fiber/Yarn Testing

Uster UT-4 for yarn testing

Uster Tenso Rapid for single yarn.

Uster AutoShorter Count tester.

Lea tensile strength tester.

Fabric Testing

DataColor Spectrophotometer

Pad steam for lab colour matching

Padder and curring machine

Lundro meter

Milnor Washer

Stiffness tester

Strength Tester (SDL) fabric

ITL has a well equipped laboratory in which tests facilitate our spinning and processingplant at all stages of production.

Other Equipment Include:

Dryer

Colour assessment light box (VeriVide)

Drying ovens

pH meterSoil release assessment board

Digital balance

Humidifier

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Cutting & Stitching

Fabric received from processing is inspected in finish fabric rolling dept.

Fabric physical and chemical (washing) testing is done in ITL processing lab.

Fabric inspected at finish fabric rolling dept. is 100% inspected by checkers and randomly by the QCs.

Each roll is checked for width, shade (lot to lot, roll to roll, side to side, and end to end)

Fresh fabric approved by QC is forwarded to cutting department.

Cutting department cut and sew one piece pattern initially for pattern approval from QA before bulk

production cutting.Cutting is done as per approved pattern and each cutting range is checked by QC.

Before forwarding fabric to stitching proper bundling and marking is done to group different parts.

Stitching department stitch the article before bulk production to approve the stitching and other accessories

requirements.

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Quality Conformance Sequence at cutting &

Stitching

Finished fabric inspection

Spreading & Cutting

Pattern marking

Initial production

sample approval from

QC

Inline inspection / audits

Final audits

Shipment audits

Fabric grading fromrolling dept.

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inspection ii

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