Welcome to our presentation

Prepared by Md.RayhanParvez------------ 091-23-1309 Md.Mirajul Islam------------- 092-23-1465 KabirMurad---------------------092-23-1470

Study on Quality Control Aspects in Woven

Garments Industry

What is quality
Quality refers to the characteristics of a product or service that defines its ability to consistently meet or exceed the customer demand.

Quality Control
Quality control is a process that is used to ensure a certain level of quality in a product or service.

Quality Assurance
The decisions, plans and actions those are necessary to provide adequate confidence that a product or service will satisfy given requirements for a particular quality.

Comparison chart of QC & QA

Improve this chart Focus on: Quality Assurance QA aims to prevent defects with a focus on the process used to make the product. It is a proactive quality process. Goal: The goal of QA is to improve development and test processes so that defects do not arise when the product is being developed. The goal of QC is to identify defects after a product is developed and before it's released. Quality Control QC aims to identify defects in the finished product. Quality control, therefore, is a reactive process.

Organogram of QC department
AGM

Manager cutting

Manager sewing

Manager washing

AQM

AQM

AQM

AQM

AQM

AQM

LQC (2)

LQC (2)

LQC (2)

LQC (2)

LQC (2)

LQC (2)

PQI (3)

PQI (3)

PQI (3)

PQI (3)

PQI (3)

PQI (3)

Factors affecting quality control

Customer: Process: Employee: Materials (Suppliers):

Types of QC
1. Product control: 2.Process control: a. Online quality control: Example: In line inspection b. Offline quality control: Example: Check the shade variation of fabric during dyeing.

Quality control flow chart at store

All incoming good at store
Accessories Fabrics Other materials Inspection

Trims

Inspection Sort out defective fabric Accept quality fabrics If any defects are found inform supplier and buyer

Inform supplier and Defects:

buyer

Types of garments in terms of level of quality

In terms of quality level buyers classify garments in 3 categories, such as 1st quality A grade 2nd quality B grade

3rd quality C grade

Quality Control flow chart of Garments section

Fabric Inspection QC Cutting Section QC Embroidery& Screen Print Section QC Sewing Section QC Washing Section QC Ironing Section QC Finishing QC Packing Section QC

Quality control in fabric

There are different types of fabric inspection system, but we followed the 4 point system (in standard group) to control the fabric quality of this pant of project, and the acceptable rang up to 28 points per 100 square yds.'

4 point system
Length of defect Up to 3 inches 3-6 inches 6-9 inches Over 9 inches Holes and Openings (1 inch or less) Holes and Openings over 1 inch Penalty points Allotted 1points 2points 3points 4 points 2 points 4 points

The formula to calculate penalty points per 100 square yards is given by:

Fabric inspection report of Standard Group

Different types of fabric defect

Different fabric test

Fabric Test: There are various types fabric test in Standard Group for getting exactly quality of fabric, such as 1. Pilling Test 2.ColorFastness To Washing. 3. Rubbing Fastness

Pilling test

Martindale machine

Assessment
Rating Discretion Points to be taken into consideration

5
4 3

No change
Slight change Moderate change

No visual change
Slight surface fuzzing The specimen may exhibit one or both of the following: Moderate fuzzing Isolated fully formed pills

Significant change

Distinct fuzzing and/ pilling

Severe change

Dense fuzzing and/pilling which covers the specimen

Quality Control in Cutting Section:

Process flow Chart of Garment Cutting section: Fabric received from store Fabric Relaxation (If Needed) Pattern Design Marker Making Fabric spreading Setting Marker on fabric lay Cutting the lay Parts numbering Sorting & Bundling

Defects in cutting
Mismatching of stripes and checks. Mixing the cutting parts. Wrong numbering of the parts The edge of the parts a little bit is missing The parts are cut in the opposite direction of fabric grain line.

Acceptable Quality Level of cutting

Lot Size 1.5 Inspect Less than 151 151-280 280-500 501-1200 1201-3200 3201-10000 10001-35000 35001-150000 150001-500000 500001 & Over 8 8 32 32 50 80 125 200 315 500 Accept 0 0 1 1 2 3 5 7 10 14 2.5 Inspect 5 20 20 32 50 80 125 200 315 500 Accept 0 1 1 2 3 5 7 10 14 21 Inspect 5 20 20 32 50 80 125 200 315 315 4 Accept 1 1 2 3 5 7 10 14 21 21 6.5 Inspect 5 20 20 32 50 80 125 200 200 200 Accept 1 2 3 5 7 10 14 21 21 21

Cutting inspection report of Standard Group

Quality control at sewing section

Quality control flow chart at sewing

Quality control in sewing section

In line inspection Install traffic light system Inspect each good Identify defect Accept passed good

Inspection of sewn good

100% inspection good on table

Separate washable and repair garments Wash and repair garments

Wash and repair garments Passed the quality full good

Reject good

Provide mock up sample to operators

There are different types of sewing QC in standard group to make this pant
Table(In line & End line sewing) inspection Join stitch is not acceptable Broken stitch is not acceptable Oil and dirt spot is not acceptable Part shading not acceptable Hole is not acceptable Traffic light system Selection of sewing operator.

Defects found during sewing inspection:

Defects

Non sewing defects Defects due to substandard material Defects due to wrong pattern Defects due to wrong marker, spreading, cutting Defects due to poor handling of goods Defects due to oil mark Defects due to wrong ironing, folding, packing.

Sewing defects Wrong stitch formation

Fabric distortion

Fabric damage along stitch line

In process sewing inspection report of Standard Group

Quality control in washing

Definition
The technology which is used to modify the appearance, outlook comfort ability & fashion of the garments is called garment washing.

Types of washing
There are two types of washing Wet washing process Dry washing process

Wet washing
There are different types of wet washing process such as Normal wash / Garments wash/ Rinse wash. Chemicals: detergent, flax , acetic acid, Enzyme wash. Chemicals: desizing agent, detergent, acetic acid, anti back staining, acid enzyme, acid enzyme

Wet washing
Caustic wash. Chemicals: caustic soda, detergent, acetic acid, flax , silicon, Silicon wash. Chemicals: Desizing agent, detergent, acetic acid, cationic softener, silicon, Stone wash. Chemicals: Desizing agent, detergent, anti stain, bleaching powder, soda ash, pumic stone, acetic acid, cationic softener,

Wet process washing report of Standard Group

Dry washing process

Whiskering P P spray

Dry washing process

Destroy Tagging

Dry process washing report

Quality control in Finishing

Process flow chart of finishing
Input in finishing Initial quality check Spot removing Inspection Metal detector m/c check Hang tag Ready for shipment Cartooning Bar code (buyer wise sticker)

Poly
Folding Get up change

Finishing check list

As per buyer requirement wise sewing check As per buyer requirement wise measurement check Front part, back part, thread can contrast color. Oil spot or dirt spot check. Main label, care label, etc. check. Hang tag and price sticker check. Buyer requirement wise carton size, poly size and garments size check.

Finished garments quality audit report of Standard Group

Inspection

Flow chart of garments inspection

Confirmation of quantity

Confirmation of accessories

Packing

Size spec inspection

Final inspection

Inside inspection

Outside inspection

Types of inspection
Pre-Production check Ex- Shade Matching Fabric Constructions GSM(grams per square meter) EPI& PPI if required During production check Ex-Verify cutting patterns Cutting shapes Stitching defects Sewing threads matching Measurements Labels Trims & Accessories

Types of inspection
Final Random Inspection Ex-Carton strength Wrong Model Wrong Quantities Missing labels & tags Wrong Size &Color assortment Wrong Folding Workmanship inspection Ex-Open seam Puckering Unbalanced plackets Incorrect side shapes Insecure buttons Poor Ironing Double stitches

AQL (Acceptance Quality Level)

AQL (Acceptable Quality Level) chart

AQL (Acceptable Quality Level) chart

Final product of this project

Front side Back side

Thank You