Quality Management and

Control
(Teng 5205)

For: 5th Year Textile engineering

students

16-1
 Definition of Quality

• Definition of quality depends on the role of the people

defining it “I know it when I see it”

• There is no single universal definition of quality

 some of the more common definitions of quality:-

A. Conformance to specifications: How well a product

or service meets the targets and tolerances
determined by its designers and it is not goodness
(Crosby,1979). 16-2
Cont.d
B. Fitness for use: definition of quality that evaluates
how well the product performs for its intended use

(Juran,1995)

•Quality is meeting or exceeding customers’

expectations and requirements that are determined or
modified through continuous communication between
customers, front-line associates, and management
(Deming,1986;1939).
16-3
Cont.d

C. Value for price paid: Quality defined in terms of

product or service usefulness for the price paid

D. Support services: Quality defined in terms of

the support provided after the product or service is
purchased

16-4
Cont.d
E. Psychological criteria: A way of defining quality
that focuses on judgmental evaluations of what
constitutes product or service excellence

According to ANSI and ASQ quality is:

“The totality of features and characteristics of a

product or service that bears on its ability to satisfy
given needs.”

16-5
Cont.d
 The formal definition of quality as stated in ISO
(International Organization for Standardization)
9000 : 2000 is :-

Ability of a set of inherent characteristics of a

product, system or process to fulfill requirements
of customers and other interested parties.

16-6
Why Quality? (importance of quality)

• Competition – Today’s market demand high

quality products at low cost. Having `high
quality’ reputation is not enough! Internal cost of
maintaining the reputation should also be less.

• Changing customer – The new customer is not

only commanding priority based on volume but
is more demanding about the “quality system.”
16-7
Cont.d

• Changing product mix – The shift from low

volume, high price to high volume, low price have
resulted in a need to reduce the internal cost of
poor quality.

• Product complexity – As systems have become

more complex, the reliability requirements for
suppliers of components have become more
stringent. 16-8
Cont.d

• Higher levels of customer satisfaction – Higher

customers expectations are getting spawned by
increasing competition

16-9
Five Types of Product Quality
1. Transcendent Quality
(Superior)

- Judgmental perspective of “goodness of a

product.

– “absolute and universally recognizable, a

mark of uncompromising standards and high
achievement (Shewhart’s transcendental definition
of quality)
16-10
Cont.d

2. Product-Based Quality

– The presence or absence of a given product

attribute.

3. User-Based Quality

– its ability to meet the user’s expectations.

16-11
Cont.d

4. Manufacturing-Based Quality

– How well the product conforms to its design

specification or blueprint.

5. Value-Based Quality

– How much value each customer separately

attributes to the product in calculating their
personal cost-benefit ratio.
16-12
 Quality perspectives
 Typical points about the definition of quality include:
1. Perfection
2. Consistency
3. Eliminating waste
4. Speed of delivery
5. Compliance with policies and procedures
6. Doing it right the first time
7. Delighting or pleasing customers
8. Total customer satisfaction and service 16-13
Dimensions of product Quality

• Conformance - meeting pre-established

standards

• Performance —basic operating characteristics

eg. acceleration of a vehicle

• Reliability — that the product will function as

expected without failure

• features—the extras that are included beyond

the basic characteristics; 16-14
Cont.d
• Durability - expected operational life of the
product
• Serviceability - ease of getting repairs, speed &
competence of repairs
• Aesthetics - look, feel, sound, smell or taste
• Safety - freedom from injury or harm
• Other perceptions - subjective perceptions based
on brand name, advertising, etc
16-15
Cost Of Quality

• high cost of poor quality

• dissatisfied customers

• loss of business

 quality control costs: costs necessary for

achieving high quality

16-16
..
Prevention costs: Costs incurred in the process of preventing poor
quality from occurring

including:
 quality planning costs

 costs of product and process design

 employee training in quality measurement

• Appraisal costs: Costs incurred in the process of

uncovering defects, including:-

 cost of quality inspections, product testing, and

performing audits 16-17
Cont.d

 quality failure costs:- cost consequences of

poor quality i.e
a. Internal failure costs:- costs associated with
discovering poor product quality before the product
reaches the customer, including:-
Rework - cost of correcting the defective item
Scrap - costs material, labor, and machine

16-18
Cont.d

 cost of machine downtime due to failures

 costs of discounting defective items for

salvage value.

b. External failure costs:- costs associated with

quality problems that occur at the customer site

 damaging because customer faith and loyalty

can be difficult to regain

16-19
Cont.d

 customer complaints

 product returns and repairs

 warranty claims, recalls, and

 even litigation costs resulting from product

liability issues

 lost sales and lost customers

16-20
 Quality Management

 Quality management refers to systematic policies,

methods, and procedures used to ensure that
goods and services are produced with appropriate
levels of quality to meet the needs of customers.

 it is systematic effort of an organization to

• ensure that its products or services satisfy the

customer's quality requirements and
16-21
Cont.d

• comply with any regulations applicable to those

products or services.

• enhance customer satisfaction, and

• achieve continual improvement of its performance.

16-22
Textile Quality Characteristics

 Quality characteristics of textile products in

general include:-

• Physical characteristics - length, weight,

volume, thickness, air permeability

• Mechanical characteristics - Strength (tensile,

tearing, Bursting), extensibility, stiffness, etc.

16-23
Cont.d

• Chemical characteristics - color fastness,

water absorbency

• Geometrical characteristics - structure of

fibres, yarn and fabric

16-24
Quality Characteristics Textile Fibres

 Quality characteristics of cotton fibre:

• Colour - some fibres have enough pigment (eg.
Linen) yellow coloured – may interfere with
dyeing or printing – should be bleached

• Shape – cross sectional and longitudinal

circular, triangular or u shaped cross section

Affects – appearance, feel, surface texture and luster

16-25
Cont.d
• staple length - affects spinning limit, yarn
appearance, evenness, and strength

• Maturity - affects strength of yarn

• Fineness - appearance and strength of a yarn

• Moisture content - wet cotton – stronger

wet wool – weaker

Luster- its level can be monitored by titanium oxide

16-26
Cont.d
• lint content - a measure of efficiency of the
cleaning

• Fibre structure - a measure of maturity

• Strength – directly affects the strength of the

yarn and fabric

• Trash content – level cleanness

• Fibre characteristics are inter related

16-27
Cont.d
• A fibre may have good tensile strength but poor
abrasion resistance

• Less serviceable than a fibre with moderate

strength and better abrasion resistance

• The sum of qualities determines the usefulness of

the fibre

• Negative qualities can be overcomed by special

finishes or processing
16-28
 Quality Characteristics of cotton
Yarn
• Yarn count (Yarn numbering) – Tex

• Yarn strength

• Twist of cotton yarn - number of twists or turns per meter

of length

• Hairiness of yarn - protruding ends of single fibres or loops

• Yarn evenness - linear density of spinning products (sliver,

roving, and yarn)

16-29
Cont.d

• Cotton yarn tension – abnormal tension causes

internal deformation and leads to breakage

• Yarn abrasion – due inter fibre rubbing and fibre

and machinery surface rubbing

16-30
Quality Characteristics of a Fabric

• Strength – tensile, tearing and bursting strength

• Drapability - ability of fabric to form soft rounded

folds with a small radius of curvature or stand

• Stiffness - ability of textile fabrics to resist

changes in their shape at bending deformation

• Abrasion – wearing of part of a fabric due friction

16-31
Cont.d

• Pilling - tendency of a fabric to form rolled up

ends of fibres called pills on their surface

• Color fastness – fastness to washing, sunlight

• Crease resistance

• Air permeability

16-32