Assignment on Quality and Quality Control Final

7/28/2019 Assignment on Quality and Quality Control Final

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Assignment on Quality&Quality Control

Course Title:Quality Control in Textile with lab

Course Code: TE-311

SUBMITTED TO:

Tanvir Ahmed Chowdhury

Lecturer in textile engineering department.

Daffodil International University

SUBMITTED BY:

Akter HossainID: 111-23-2533

Section: Evening

Department of textile engineering

Daffodil International University

DATE OF SUBMISSION :24-4-2013


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Quality & Quality control:

Introduction :Quality means customer needs is to be satisfied.Failure to maintain an adequate quality standard cantherefore be unsuccessful. But maintaining anadequate standard of quality also costs effort. Fromthe first investigation to find out what the potentialcustomer for a new product really wants, through

the processes of design, specification, controlledmanufacture and sale.There are a number of factors on which qualityfitness of garment industry is based such as -performance, reliability, durability, visual andperceived quality of the garment. Quality needs to bedefined in terms of a particular framework of cost.Quality Control:Quality is of prime importance in any aspect of

business. Customers demand and expect value formoney. As producers of apparel there must be aconstant endeavor to produce work of good quality."The systems required for programming andcoordinating the efforts of the various groups in anorganization to maintain the requisite quality". As


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such Quality Control is seen as the agent of QualityAssurance or Total Quality Control.In the garment industry quality control is practicedright from the initial stage of sourcing raw materialsto the stage of final finished garment. For textile andapparel industry product quality is calculated interms of quality and standard of fibres, yarns, fabricconstruction, colour fastness, surface designs andthe final finished garment products. However quality

expectations for export are related to the type ofcustomer segments and the retail outlets.Quality control and standards are one of the mostimportant aspects of the content of any job andtherefore a major factor in training.

Total Quality Control:"To ensure that the requisite quality of product is

achieved". This ensures customer satisfaction, but itleaves quality control as a necessary but expensiveevil.


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To ensure, at minimum practicable cost, that therequisite quality of product is being achieved atevery stage of manufacture from raw materials to

boxed stock

Objectives: To maximize the production of goods within the

specified tolerances correctly the first time. To achieve a satisfactory design of the fabric or

garment in relation to the level of choice indesign, styles, colours, suitability of componentsand fitness of product for the market.

Textile quality control experts:Quality Control :

AQM performs quality control and inspection services for

different customers from all over the world. Using

international standards such as ISO 2859, our Quality

Controllers (QC) method consists to check different

control points:

Conformity: The QC checks the conformity of the product

(design, colors, raw material) with the Pre-Production

Sample (PPS) and other technical files.


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Quality: Our QC checks for defects (fabric defects, colors

defects, accessories and label defects, manufacturing

defects) and classifies them accordingly.

Measurement: Following the measurement chart, our QC

checks the measures for each size of the product.

Packaging: Our QC checks the quantity of cartons, size of

cartons, their weight, shipping marks, etc.

Concept of Quality:Simply, quality refers to one or more desirable characteristics tproduct should possess.

Quality is inversely proportional to (unwanted) variability.


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Quality Characteristics:Every product possesses a number of properties that jointly des

what the user or consumer thinks of as quality. These propertie

known as quality characteristics.

For example, fiber length is known to be one of the important q

characteristics of a fiber.

Quality Cost :Preventing, detecting and dealing with defects cause costs that

called quality costs or costs of quality.

Quality costs can be broken down into four broad groups.

(1). Prevention Costs:product/process design.Process control.Burn-in.


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Training.Quality data acquisition and

analysis(2)Appraisal Costs:

Inspection and test of incoming material.

Product inspection and test.

Material and services consumed.

Maintaining accuracy of test equipment.

(3).Internal failure Costs:

Scrap

Rework

Retest

Failure analysis

DowntimeYield losses

Downgrading/ off-spacing

(4). External failure costs:

Complaint adjustment

Returned product/material

Liability costs

External costs


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Quality control in Garment Manufacturing proces

Quality is a relative term. It means customer needs is to

be satisfied. Quality is of prime importance in any aspectof business. Customers demand and expect value for

money. As producers of apparel there must be a constant

endeavor to produce work of good quality. In previous

article, I discuss about quality control system in garment

industry. Now I will give a short description of Quality

Control in Garment Manufacturing Process.

Quality inspection and control in RMG industry

The various Steps of Garments manufacturing where in-

process inspection and quality control are done are

mentioned below-

1.In Sample making section2.In- Marker making section3.Inspection in fabric spreading section4.Inspection in fabric cutting section5.Inspection in fabric sewn section
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6.Inspection in pressing & Finishing sectionQuality Control in Sample Section:

Maintaining buyer Specification standard Checking the sample and its different issues Measurements checking Fabric color, gsm, Fastness etc properties required

checking

Spi and other parameter checking

Quality Control in Marker Making:

To check notch or drill mark Fabric width must be higher than marker width Fabric length must be higher than marker length Matching of green line Check pattern size and dimension Matching of check and stripe taking into

consideration

Considering garments production plan Cutting table length consideration Pattern direction consideration

Quality Control in Fabric Spreading:

Fabric spreading according to correct alignment withmarker length and width

Maintain requirements of spreading Matching of check and stripe


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Lay contains correct number of fabric ply Correct Ply direction To control the fabric splicing Tension control

Quality Control in Fabric Cutting:

The dimension of the pattern and the cut piece shouldbe same and accurate

Cut edge should be smooth and clean

Notch should be cut finely Drill hole should made at proper place No yarn fraying should occur at cut edge Avoid blade deflection Maintain cutting angle More skilled operator using

Quality Control in Sewing Section:

Input material checking Cut panel and accessories checking Machine is in well condition Thread count check Special work like embroidery, printing panel check Needle size checking Stitching fault should be checked Garments measurement check Seam fault check


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Size mistake check Mismatching matching of trimming Shade variation within the cloth Wrong placement of interlining Creased or wrinkle appearance control

Quality Control in Finishing Section:

Proper inspection of the garments includingmeasurement, spot, dirt, impurities

Water spot

Shading variation check Smooth and unfold in pocket In secured or broken chain or button Wrong fold Proper shape in garments Properly dried in after pressing Wanted wrinkle or fold in lining Get up checking Collar closing Side seam Sleeve placket attach Cuff attach Bottom hem Back yoke Every parts of a body

Quality control of Sewing Thread And Zipper:


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Quality Control of Sewing Thread:

A slender, strong strand or cord, especially one designed

for sewing or other needlework. Most threads are made by

plying and twisting yarns. A wide variety of thread typesare in use today, e.g., spun cotton and spun polyester,

core-spun cotton with a polyester filament core, polyester

or nylon filaments (often bonded), and mono filament

threads.

Sewing thread

Following Features of Sewing Thread are Considered:

1. Thread Construction/Ticket number

Thread count Thread Ply Number of twist Thread balance Thread Tenacity Thread Elongation

2. Sew ability

3. Imperfection
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4. Thread finish

5. Thread color

6. Package Density

7. Winding8. Yardage

Quality Control in Zipper:

A zipper, zip, or zip fastener, is a commonly used device

for temporarily joining two edges of fabric. It is used in

clothing (e.g., jackets and jeans), luggage and other bags,

sporting goods, camping gear (e.g. tents and sleeping

bags), and other items.

Zipper

Following Factors are Considered in Zipper:

1.Proper dimension of zipper2.The top and bottom end should correctly sewn3.The tape and color of zipper should be uniform4.Slider has to be locked properly5.The slider should move properly
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On Line and off line Quality Control System:Quality Control System:

1.On- line quality control system2.Of line quality control system

On Line Quality control System:

This type of quality control is carried out without

stopping the production process. During the running ofproduction process a set up is automatically performs and

detect the fault and also takes corrective action.

Online quality control comprises with the raw material

quality control and the process control.

Raw Material Control :

As the quality product depends on the raw material

quality so we must be provided with the best quality raw

material with an economical consideration. The fabric

must be without fault, with proper absorbency, whiteness

as per requirement of the subsequent process. The Grey

inspection report gives the condition of the raw fabric.

Process Control :


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The method chosen for the process must be provided with

the necessary accurate parameters. Here the specific

gravity, water level, residual hydrogen per oxide etc. at

each stage is checked.

Laboratory :

Lab is the head of the textile industries. Higher precision

lab can aid easily to achieve the goal of the organization.

Before bulk production a sample for the approval from

industry is sent to the buyer. As per the requirement of the

buyer the shade is prepared in a lab considering the

economical aspects.

Lab Line:

1. Standard sample: The buyer to the industry gives the

standard sample. The sample is measured by the CCM to

get the recipe.

2. Lab trial: Getting the recipe the lab officer produce lab

trial and match with standard according to buyer

requirement. Lab trial is made by the AHIBA dyeing

machine.There are some programs for dyeing. The

programs are given below.

Off line Quality Control System:

Performed in the laboratory and other production area by

stopping the production process consisting of fabric

inspection and laboratory and other test. Correction steps


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are taken according to the test result.

Off-Line Tests: All the Off-Line tests for finished fabrics

can be grouped as follows:

A. Physical tests

B. Chemical tests

Physical Tests:

1.GSM test2.Shrinkage test3.Spirality test4.Tensile strength5.Abrasion resistance6.Pilling resistance7.Button Strength Testing8.Crease resistance9.Dimentional stability10. Brusting strength test

Chemical Tests:

1.Color Fastness to washing.2.Color Fastness to lighting.3.Color Fastness to heat.4.Color Fastness to Chlorinated water.5.Color Fastness to water spotting.6.Color Fastness to perspiration.


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2. Weight of fabric:

Weight per unit area.

Weight per unit length.3. Fabric strength and extensibility:

Tensile strength. Tearing strength.

4. Threads per inch of fabric:

Ends per inch. Picks per inch.

5. Yarn count:

Warp count Weft count.

6. Crimp:

Warp crimp Weft crimp.

7. Handle:.

Stiffness Drape.

8. Crease resistance and crease recovery.

9. Air permeability.


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10. Abrasion resistance.

11. Water resistance.

12. Shrinkages.

13.Different fastness properties:

Fastness to light. Fastness to wash. Fastness to perspiration. Fastness to Rubbing.

Quality Parameters of Knitted Fabrics:There are some quality parameters of knitted

fabric...............

1.Strength and extensibility.2.Course density.3.Wales density.4.

Lop length.5.Elasticity.

6.Deformation.7.Grams per square meter (G.S.M)8.Yarn count.9.Design.

Quality Parameters of Non-woven Fabrics:

There are some quality parameters of non-woven

fabric..................

1.Strength and extensibility of fabric.2.Weight.


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3.Thickness.4.Air permeability.5.Crease resistance.6.Stability of washing.7.Stability of dry cleaning.8.Dimensional stability.9.Elasticity.

Apparel Quality control System:

Some main quality aspects for export basis:

Below are some of the main quality aspects that are taken

into consideration for garment manufacturing for export

basis:

1.Overall look of the garment2.Right formation of the garment3.Feel and fall of the garment4.Physical properties5.Color fastness of the garment

Quality is a multi-dimensional aspect:

There are many aspects of quality based on which thegarment exporters are supposed to work.

1.Quality of production2.Quality of design of the garment


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3.Purchasing functionsquality should be maintained4.Quality of final inspection should be superior5.Quality of the sales also has to be maintained6.Quality of marketing of the final product is also

important as the

7.Quality of the garment itselfTo ensure quality:

To insure quality some factors are considered:

Recognize who the customer is

Build processes that anticipate and prevent defects Make a plan to achieve the desired quality level Set up ways to measure progress Work as a team to achieve goal

In this context, customer is the entity receiving a service

or product from our work. For example, we can take ashort production line.

Receiving Cutting Sewing Inspecting

Finishing

Quality problem in cutting may lead to problems in

sewing,inspecting and finishing. Its like garbage ingarbage out. In other words, one needs to have good

quality materials to produce good quality goods. So this

has to be applied to every process in the system to have a

total quality control.


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A good plan requires:

(a) A clearly defined objective

(b) Goals or expected results(c) The activities needed to achieve the desired results

(d) Defined roles and responsibilities for the activities

(e) Dates for beginning and completion of each activity

(f) An analysis of potential problems

Measurements are a vital part of any quality improvement

program. Anything that is not measured does not improve.

We need to establish these standard measures and

measure the progress periodically.

Team work is also an essential element for the success of

the program. Remember ONE of us is NOT better than

an All of US. The whole effort needs to have a directionthat a team leader will provide.

Way of control quality:

1.Have the proper approach toward operators.2.Train the operator to sew with good quality from the

beginning.3.Know quality specifications and tolerance. Be sureyou understand what constitutes good and poor

quality. Be consistent in your decisions toward

quality.


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4.Comment on both good and bad quality. We all havea tendency to be silent during good times and vocal

during the bad.

5.Be sure to check each operators work daily.6.Use a check list. Do not rely on memory of

specifications.

7.Do not rely on inspectors to tell you the quality levelof your operators, instead find out yourself.

8.Do not have a compromising attitude towardsproblem related to quality.

Basic quality inspection procedure in cutting area:

1.Marker is checked for all parts and for any variationagainst pattern.

2.Spreading has to be inspected3.During cutting:4.The marker line had to be followed5.All notches should be located correctly with even

depth say 1/8 in. ( 1/16). When cutting, care should

be taken not to shift the stack of parts to a side or cut

with the blade at an angle.

6.In bundling and shade marking, care should be takento ensure that the numbering is correct. For the final

audit process, the quality inspector will determinehow many bundles to check from every size

depending on the sample size.


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Basic quality control procedure in sewing line:

(a) 100% inline parts checking

The operations which are difficult to re-process afterassembling is checked 100% to avoid damages and waste

of time.

(b) Inline inspection

During the production of garments the operators finished

work is audited in an inline inspection. A quality

inspector moves from one operator to another at random

inspecting a pre-determined number of parts from a

finished bundle. This helps to control quality at needle

point.

(c) 100% end-line inspectionAt the end of a line or section there should be a checker to

inspect all the parts before they leave the section. The

inspections should be effective in identifying all defects in

a garment. The checkers should have their forms filled

correctly. A good source of information to determine the

quality performance of the section is the point of 100%

inspection. The section supervisor should check thequality level at the point of 100% inspection periodically.

With this information, the supervisor should address the

problems, correct the possible causes and make plans to

prevent them.


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(d) Pre-final audit

A pre-final audit should be performed on packed items on

a daily basis to ensure that the good packed items aremeeting the quality standards. Any problem seen can be

arrested at the early stage. If pre-final audits are done

properly, the final audit of the buyer should also be

carried out without any issues.

Quality Training:

The purpose of the training program is to train operators

to attain high speed and production together with good

quality work. Good quality comes from the consistent use

of correct methods

The steps to be taken to achieve good quality are as

follows:

1. Initial instruction

Point out the key points of method and quality to the

trainee and be sure that she understands them.

2. Trainee practice

When the trainee first practices an exercise, the instructorshould watch her methods very closely and correct any

incorrect methods immediately. The trainee should not be

timed or be permitted to start timing until she is doing the

exercise correctly. Even after starting her timing, the


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In SQC technique attempt is made to seek out systematic

causes of variation as soon as they occur so that the actual

variation may be supposed to be due to the guranted

random causes.

Statistical quality control refers to the use of statistical

methods in the monitoring and maintaining of the quality

of products and services.

Basic Categories of Statistical Quality Control(S.Q.C):

All the tools of SQC are helpful in evaluating the quality

of services. SQC uses different tools to analyze quality

problem.

1) Descriptive Statistics

2) Statistical Process Control (SPC)3) Acceptance Sampling

1. Descriptive Statistics:

Descriptive Statistics involves describing quality

characteristics and relationships.

2. Statistical process control (SPC):The application of statistical techniques to determine

whether a process is functioning as desired

3. Acceptance Sampling:


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The application of statistical techniques to determine

whether a population of items should be accepted or

rejected based on inspection of a sample of those items.

Variations of Statistical Quality Control(S.Q.C):

1. Allowable or cause variation

2. Assignable or preventable variation

Function of Statistical Quality Control(S.Q.C):

1. Evaluation of quality standards of incomeing material,product process and finished goods.

2. Judging the conformity of the process to establish

standards taking suitable action , when deviation are

noted.

3. Evaluation of optimum quality, obtainable under given

condition.4. Improvement of quality and productivity by process

control and experimentation.

Main purpose of Statistical Quality Control(S.Q.C):

The main purpose of Statistical Quality Control(S.Q.C) is

to divide statistical method for separating allowablevariation from preventable variation.


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The Significance of Statistical Quality Control(S.Q.C) in

the Textile Industry:

1. The expected quality of product can be produced andhence customers satisfaction can be achieved which

brings higher profit.

2. It is very easy to separate allowable variation from the

preventable variation by this.

3. It ensures an early detection of faults in process and

hence minimum wastage.

4. With its help one can easily defect the impact of chance

in production process in the change in quality.

5. It ensures overall co-ordination.

6. It can be use in the interpretation control chart.

Some test for quality control textile finishing:

Test For Quality Control:1. Shrinkage Test

2. GSM Test

3. Tensile Test

4. Tearing Test

5. Color Fastness Test

6. Rubbing fastness Test

7. PH Test8. Shade Matching Test

9. Fabric Width Test


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Conclusion:There are many quality parameters in different types of fabric. And

there are also many different faults in different types of fabric, which are

effect in quality of fabric. If we control those faults and effects ,we canget the good quality of fabric. So quality control is very important for all

types of fabric and textiles.

Documents

Assignment on Quality and Quality Control Final