Quality manual formal trouser

It includes market analysis, product development, production planning, statistical quality control, preventive maintenance, wastage control, inventory control, cost reduction and after s

Submitted by: Submitted to:

Vinay Prajapati

M.F.Tech, Sem-I,

NIFT, Gandhinagar

Ms Nupur Chopra Asst Professor NIFT, Gandhinagar

III. Organisational Structure and Responsibilities

IV. Job Description of Responsible Persons For Quality

5. Quality System

I. Purpose

II. Scope

III. Quality System Procedures

IV. Quality Planning

VI. Fabric Inspection Procedure - 4 Point System

VII. Rolls Selection Procedures

VIII. Acceptable Penalty Points

IX. Acceptable Point Count Level

III. Process Inspection

IV. Spreading Inspection

V. Cutting Inspection

VI. Sewing Inspection

VII. Table Inspection

VIII. Two Hourly Inspection

IV. Garment Inspection Procedure

V. Defects Classification List (Major)

VI. Defects Classification List (Minor)

9. Sampling Techniques

10. Pre-Shipment Survey By Acceptance Sampling

11. Control Of Non-Conforming Products

I. Purpose

II. Scope

III. Activities

12. Garment Taken: PETERENGLAND Formal Trouser

I. Sampling of Formal Trouser

II. Front View

III. Back View

IV. Parts of Formal Trouser

13. Conclusion

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Introduction Page

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With the increased demand of garments in the world wide, number of garments factories is growing rapidly but Q.A management system cannot be developed in the same speed due to the lack of Q.A management system Quality of product and service along with the efficiency of the work force is the foremost objective to produce products and service of the high standard, which meets all the specifications, including environmental concern and safety

Commitments to valued customer:

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Objective Page

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Objectives of these policies are:

value, respect, justice, cleanliness, discipline and equality between workers and others

efficient management, research, development and continuous improvement

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Cost and Quality

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Cost and Quality Page

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Cost and Quality

QUALITY: Quality is defined as “Totality of characteristics of an entity (product, service etc.) that

bears on its ability to satisfy stated and implied needs.”

QUALITY CONTROL: Is an effective system for interchanging the quality maintenance and quality

improvement efforts of various groups in an organization so as to enable production at the most economical levels which allow full satisfaction for the consumers

TOTAL QUALITY MANGEMENT (T.Q.M.): Is described as an all- inclusive fully integrated

productivity technique It helps to create new markets, expand existing markets and recapture lost markets by utilizing the optimum capability of man, machine, material, method and produces high and uniform quality of products with reduced costs Total quality control starts from market i.e from purchasing material and machine and ends in the market i.e selling the finished products in the market including after-sale service It includes market analysis, product development, production planning, statistical quality control, preventive maintenance, wastage control, inventory control, cost reduction and after sales service etc The ultimate goal of T.Q.M is to increases the quality/cost ration and continuous improvement It may be done by increasing the quality with same cost, decreasing the cost with same quality and increasing quality and decreasing coast at the same time

The basic quality problem is to set correct balance between the cost and quality i.e to find out a suitable quality/cost ration for the product which will satisfy the consumer both for cost and quality

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Management Responsibility

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This section covers the organizational structure and responsibilities of all personnel who supervises, perform and verify works at different stages for the improvement and maintenance of quality

ORGANIZATIONAL STRUCTURE AND RESPONSIBILITIES

The following positions play a managerial role in the maintenance of product quality and the quality control system through chain of command

JOB DESCRIPTION OF RESPONSIBLES PERSONS FOR QUALITY

1 MANAGING DIRECTOR: will ensure the absolute adherence to the quality control system by

exercising his authority through his channel of command

2 G.M.Q.A CENTRAL:

a) Preparing quality manuals for the group

b) Taking approval from the MANAGING DIRECTOR for implementation of the system stated in the manual

c) Implementation of statistical quality control system in the factories here it is applicable

d) Training of QC personals for continuous improvement to achieve zero defect level

e) Training of QC personals on statistical quality control system and graphical method for achieving target quality level desired by the buyer

f) Collections of buyer’s quality guide lines from buyer’s website or manual and convey it to Manager QA central, Manager QA factory and Monitoring for proper implementation to achieve buyer’s quality level

g) Maintain liaison with buyers QA team for technical problems for which their help is needed

and report it to concern authority

i) To help authority to recruit right person for right job of QA department

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j) To inform to concern directors and chairman of the group the overall quality position of the factories by MIS.

k) Inform the concern director if any factory is unable to perform up to the desired level of quality

by corrective action request or verbally

l) Study quality related books, journals, manuals and research for continuous improvement

3 MANAGER QA CENTRAL:

a) Collection of spec sheet, shade band card, trims card, fabric test report and approval sample from the concern merchandiser and compare production sample with the Approval samples as well as technical sheet

b) Not to allow any deviation from the approval sample if there is no written confirmation form the buyer

c) Collection of fabric inspection report to judge whether fabric is acceptable for production on the ground of shade, defect and other factors

d) In line inspection to see whether the garments quality is as per buyers requirement or not In case of any deviation, take corrective and preventive action

e) Briefly describe the buyer requirement and quality control procedure to Manager QA factory for proper monitoring to produce garments as per requirement of buyer

i) Allotment of his QC team to all mother and sub contract factories (if any), monitoring the quality

of production in all factories and subcontract factories

4 MANAGER QA:

a) Over All Administration of factories QA dep’t and monitoring the work of Sewing Q.C, Finishing

QC, Line QC, QI Cutting and all inspectors as well as evaluation of their performance

b) Conduct training and make all his sub ordinates accountable to him for their performance to achieve the target of quality level

c) Reporting day-to-day quality status and trend to factory GM/PM

d) Collection of approval sample, shade band card, trim card, spec sheet and go through these to compare first of production with the approval sample before going for bulk production

e) In case of any change in the style or design by the buyer he will communicate the floor people for the confirmation of change

f) Send samples of fabric, garments, and accessories to the concern merchandiser for lab test, if it

is required

g) Conduct day final inspection on the available quantity of ferments at the end of day in finishing

If the lost is not accepted go for correction Conduct pre shipment inspection after completion of the lot and take necessary corrective measures before buyer’s final inspection

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h) Details study of test cutting, sample, wash and non-wash and consult with Manager QA Central, GM/PM of the factory if there is any discrepancy to find out appropriate solution.

i) Keep close co-ordination with Manager and GM QA, central for continuous improvement

5 QC MIS & MONITORING: (Controlled by GM QA, CENTRAL)

a) Monitoring the job of MIS Asst./Inspector, and monthly MIS report to GMQA

b) Process capability study of every line by calculating C.V of lines defect percentage

with approved sample, with respect of technical sheet approved trim card and shade

e) Checking of line wise Monthly operator’s performance and Monthly table defect analysis

f) Monthly defect analysis, C.V of defects line wise and factory wise

g) Moving average line and factory wise to observe the trend of defect

h) Defect analysis after 100% process inspection in finishing

i) Monitoring accessories, fabric and cutting inspection

6 SUPERVISOR QC:

a) Carry out instruction receives from manager QA factory

b) Monitor the job of line QC’s in process 7pcs inspection, table inspectors and maintain liaison with cutting quality inspectors

c) Go through buyer’s approval sample, shade band card, trim card, spec sheet and supervise making garments as per style and measurement

d) Implementations of design change approved by buyer and instructed by Manager QA Factory.e) Management, administration, training, motivation of his stuff for of continuous improvement.f) Conduct daily inline inspection and fit audit and report to the manager QA

7 TWO HOURS Q.I (FINISHING):

of defects and re-inspection on same method

in finishing taking corrective and preventive action in sewing

8 Sr Q.I CUTTING:

a) He is responsible to Manager QA Factory

b) Monitor accessories inspection, fabric inspection, and cutting inspection

c) Submit all inspection report to Manager QA Factory

d) Collection of trim card and shade band card from Manager QA to compare the lot during inspection

f) Monitor spreading quality control and cutting quality control

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9 SR Q.I SEWING: Two/Three for each line (Depending on no of machines in line)

a) Carry out instructions of Manager QA Factory

b) Conduct process capability study of the Line by calculating C.V (Co-Efficient of variation) of hourly defect percentage

c) Monitor quality performance of operators for continuous improvement and incentives to operators for their performance

d) Supervise the cutting bundles numbering, size and serial for proper control in the sewing

e) Review the production sample according to approval sample and shade,

f) Check machine cleanliness, needle condition and size, proper thread count and shade

g) Conduct process inspection having idea from table inspection report and defect analysis, about the source of high ranking of defects

h) Observe the trend of defects from the moving average of defects in the table inspection and take special care in those particular processes in the line

10 ACCESSORIES INSPECTOR:

a) Sampling of accessories as per US-MIL-STD-105E Normal Inspection Level II AQL 2.5 or specified

by buyer

b) Inspection of accessories as per approved trim card by the buyer

c) Segregation of non- conforming accessories and keep it separately with non-conforming tags

d) Preparing inspection report and submit it to Manager QA, factory

11 FABRIC QUALITY INSPECTOR:

a) Random selection of rolls as per US-MIL-STD-160 5DE-1 05E to 10% of the lot

b) Shade grouping of all rolls, compare shades with approved shade

c) Side centre side, side-to-side, end-to-end and running shade check of individual rolls `

d) Preparing shade grouping report and submit it to Manager QA

e) Fabric inspection by 4-point system and making fabric inspection report

f) Segregation of non-conforming rolls with red tag and keep ii) a safe place

12 CUTTING QUALITY INSPECTOR:

a) Spreading checking on 10 points

b) Block and bundle check

c) Daily summary of cutting and spreading quality control report to manager A factory

d) Affix allotted QA numbered arrow sticker to mark all defects where applicable,

13 TARLE QI, OUTPUT: Number two/three for each line (inside and out side) 100 Inspection of outside and

inside of garments

a) Segregation of non-conforming garments and returns to line QC for taking corrective and preventive action

b) Re inspection of non-conforming garments after correction

c) Fill up the line wise hourly inspection format,

d) Affix allotted QA numbered arrow sticker to mark all defects where applicable

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14 FINISHING QI (Individual Process)

a) 100% inspection of individual process inside and outside

b) Segregate non-conforming garments in separate box and hand over to Finishing QC for correction.c) Re inspection of non-conforming garments after correction

d) Affix allotted QA numbered arrow sticker or mark all defects where applicable

15 FINISHING QI (Measurement)

a) Measurements of 100% garments on specified points shown by QA Manager

b) Segregation of non-conforming goods and hand over to QC Finishing for necessary correction.c) Re-measurement of non-conforming goods after correction

6 FINISHING INSPECTOR (Final)

100% inspections of garments get up (Overall appearance)

a) Segregation of non-conforming goods to QC Finishing for correction

b) Re- inspection of non-conforming goods after correction

c) Fill up the hourly inspection report

d) Affix allotted QA numbered arrow sticker to mark all defects where applicable

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Quality System

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QUALITY SYSTEM PROCEDURES

The Quality procedure of each factory will be reviewed by the concerned persons of Management

of that factory Describing the quality systems of all factories of XYZ, this manual includes a brief description of the functions and mode of operation of the factories management personnel with respect to quality

QUALITY PLANNING

Documented quality planning is stated by this manual, accompanying procedure and instructions and quality, all of which comprise the Quality System Thus, quality planning is, documented and implemented by all Executives and Managers playing a role in the maintenance of product quality and the quality management system

To achieve the goal of zero defect level following steps has been taken

concern people

taking preventive and corrective measures

accountable for effective control on process inspection with the help I-operators quality performance chart

improvement and trend of defect

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9. For graphical representation of hourly defect percentage in control chart to set upper control limit at 1.0%, central line is 0.65% and lower control limit at 0.0% to brine down defect level towards zero by continuous improvement

Quality planning also includes the following

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Receiving Inspection

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FABRIC INSPECTION

Fabric roll is selected on the basis of random sampling;

acceptance or rejection criteria are decided at prescribed label

on 4-Point system 10% of rolls -are inspected in this stage by

Fabric Inspector In case of rejection of lot on 10% of rolls, rest of

the rolls of the lot is inspected thoroughly Reject rolls are kept

separately with red flags

Inspection records are kept in inspection format

Summary of the fabric inspection is recorded in the summary

sheet, for management information

Conforming goods are kept separately with Green Sticker and

kept in stack named

READY FOR CUTTING

All rejected goods are treated as "NON-CONFORMING GOODS" and marked with red sticker.

Checking of s-lade and shade grouping

FABRIC INSPECTION PROCEDURE - 4 POINT SYSTEM

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The aim of fabric inspection is to check the quality, quantity and packing by visual, measurement a colour check confirming with the specification and general appearance of the approval sample given by buyer

INSPECTION PROCEDURE

PENALTY POINT EVALUATION

Fabric to of graded will be examined from a distance of approximately three feet while runner-Up

compatible with his ability to distinguish

POINT CALCULATION

INDIVIDUAL ROLL

Penalty points X 36X 100

-Total yards Inspected x Width of cloth in inch

= Points per 100 Sq Yard

AVERAGE POINTS PER SHIPMENT

Total Points per 100 Sq yard of all rolls Inspected

-Total number of rolls Inspected

= Average points per 100 Sq yard

PENALTY POINTS IN 4 POINT SYSTEM

The position of the defect in the fabric in either length or width

ROLLS SELECTION PROCEDURES

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2. The knit dyeing unit is required to present the inspector with a shipment packing list when 80% of the rolls are packed from which the rolls to be inspected will be chosen.

number of rolls to be inspected or to the rolls selected for inspection

recording and measuring shade tolerances

ACCEPTABLE PENALTY POINTS:

If no specifies standard provided for knit fabric, the average point value per shipment not exceeds

40 points per 100 linear yards Individual rolls exceeding 40 points shall be rejected

DEFECTS CONDITIONS

considered reject

SPLICE ALLOWANCE

ROLL LENGTH

deviates 1 % or more from the ticket yards

COLOR SHADING RATING

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2) Side center Side 4 – 5 or 5 (Accepted)

ACCEPTABLE POINT COUNT LEVEL

Various types of textiles are divided into the following five groups Individual rolls exceeding the specified point count level shall be graded as second quality A shipment shall fail the inspection if the shipment penalty count points exceed the specified point count level

REJECTION RATE

If total rejected inspection yardage is over 10% of total inspected yardage, then overall result is concluded as "Rejected"

RUNNING DEFECTS

defect All running defects must be assigned four points to every yard in the roll when the running defect occurs

shall be rejected regardless of point occurs

FULL WIDTH DEFECTS

1. No roll that contains more than four full width defects per one hundred linear yards shall be accepted as first quality

2. Any roll found to contain defects, in any increment of one hundred yards, with an average of more than one major defect per ten linear yards will be rejected

3. No roll shall be accepted that contains a major defect in the first or last three yards of the rolls A major defect is considered to be any three or four point defect

4. No roll shall be accepted as first quality that exhibits a noticeable of loose or tightness along either

or both selvedges or ripples, puckers, folds or creases in the body of the fabric that would prevent the fabric form lying flat when being spread in a conventional manner

FABRIC WIDTH

1. Fabric width will be checked a minimum of three times during the inspection of a roll, beginning, middle and end The roll width will be checked more often if the fabric is close to the specified minimum width of if the fabric width is uneven

2. Rolls paving a measurement of less than the specified width will not be accepted

3. For knit fabric, rolls having a measurement of 1" wider than the specified diameter will not be accepted But for the stretched woven fabric, it can be accepted 2" wider than the specified purchased width

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4. For knit fabric, rolls having a measurement of 2" wider than the specified purchased width will be accepted But for the Lycra knitted fabric, it can be accepted 3" wider than the specified width.

Process Inspection

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rejected parts are replaced by good parts In cutting inspection there are two types of check BLOCK CHECK

& BUNDLE CHECK Following points are inspected in block check such as Size, Parts, Pattern check, Mis cut,

Ragged cutting, Notches, Matching plies

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Following points are checked in the bundle check such as Size, Parts, Total quantity, Inspect quality, Defect quality However it is recommended to check 100% cutting parts under the light box table.

SEWING INSPECTION

a) The SR Line Q.I should audit completed finished bundles

b) He must select 7 pcs at random from the bundle

c) If the inspector finds defective unit, he will take following steps on operator’s duality Performance Chart.d) He will mark red in the room against date of inspection with defect code and frequency as a symbol for warning and recheck He will hand over remaining units of the bundle to supervisor for check and taking corrective action

e) He will inspect next three bundles as follow up audit of the same operator and mark yellow in three rooms if no defective units are found in next three bundles

f) He will mark green in the room against date if no defective unit is found in the bundle

g) The inspector will make operators monthly analysis to compare it with tables monthly defect analysis to find out whether there is any lacking in the sewing inspection procedure

h) QC Supervisor Sewing will monitor 7 pcs inspection, whether it is being done properly or not

TABLE INSPECTION

Table inspection is conducted by two/three/four inspectors (depends on hourly output) to inspect inside and outside of the garments They will record hourly inspected garments, defect found, defect percentage; also calculate average defect percentage, quality index of the day and CV of defects This will help to

represent the defects graphically with the help of MIS Inspector Monthly table defect analysis report is

prepared and to compare it with operators monthly defect analysis

TWO HOURLY INSPECTIONS

i) It is the responsibility of finishing unit TWO HOUR Q.I

ii) It is conducted every after two hour

iii) Both visual and fit audit is conducted on available garments received per two hoursat desired AQL.iv) If lot is acceptable than passed for poly packing

v) If not return back for correction

vi) After correction it is re inspected in the same way

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