REPORT

Quality check in manufacturing Process of ZEDEX

Sourcing of raw materials & trims

Spreading (Inspection done)
Cutting
Sewing(Inspection done)
Washing
Finishing(Inspection done)
Packaging

Sewing Department

200-250 machines
Machine checking is done by maintenance officers in every 3-4 months
There are 2 supervisors in stitching dept for the continuous checking of stitching.
One supervisor checks for front panel of shirt of trouser
And second checks for back panel
They check Proper placement of zippers
Check for size labels
Back teck
Crotch placement
Checking for back
Dart and bone
Stitches

They use different types of machines for different purpose like

5 thread attachment machine for side seam

For belt folder lock specialized machine
Loops machine kausai loop machine
Loop-bartack machine for locking and shaping ,2 thread and 3 thread machine

There is only one quality inspector (Smit Makwan) and no separate quality department

They have one fabric checking machine used for

Identifying defects in fabric

Length checking
They check around 2500 mt fabric in a day
They assign points for each defect
1 mt 4 points

Quality Specifications
o Factory specifications

o Style or garment specifications

Department wise quality system in factory

1) FABRIC STORES

Neatly arrange the fabric rolls received and maintaining the department
cleanliness to avoid spotting and contamination of the fabrics.

Packing the fabrics in plastic sheets can be useful.

Fabric inspection is done on 4 point system.

2) TRIMS STORES

Trims stores have racking system to store the trims in a proper order.

Trims card for each PO/style being processed should be maintained.

3) CUTTING SECTION

Making center to selvedge variation sample for each of the roll to analyze
the shade variation..

Proper pattern checking report.

Proper lay check, marking check, sorting/bundling check report.

4) SEWING SECTION

Effective maintenance for each of the machine.

Proper updated broken needle log (should have needle issuing record
from stores and properly pasted broken needle book).

Effective mockup system on all operational areas.

All scissors and trimmers should be secured properly.

.
Display of trim card at required areas.

Checking garments before wash and after wash for both quality and
measurement.

Random in-line checking at each chain stitch operation like feed of arm
machine.

Each supervisor is advised to check randomly the operation in their own

working limits.

In-line and end-line checking report.

5) FINISHING SECTION

Fabric defect identification by stickering and alteration piece identified by

knotting at place of alters by the checker

Cartoons are properly stacked.

Daily checking report is maintained.

Department wise quality check points

Fabric Store
Trim
accessories
Cutting Room

&

100% fabric inspection

Trims inspection not used
Marker checking
Cut parts checking or audit
Bundle inspection

Sewing

Inline check point (at critical operation)

Department

Roaming checking (Random checking)

End of Line checking (100%)
Audit of checked pieces

Finishing
Department

Initial finishing inspection (after wash) and alterations

Final finishing inspection (After Pressing)
Internal shipment audit

Fabric Store
In the fabric store fabric is being checked before issuing it to cutting department. In
general not all the fabric is checked. 100 % fabric checking is done. Fabrics are
checked in flat table, flat table with light box or on fabric checking machine. 4 point
system for fabric inspection is used to measure the quality level of the incoming
fabric.

Cutting Room
It is said that cutting is the heart of production. If cutting is done well then chances
of occurring defects in the following processes comes down. In cutting room, check
points are I) marker checking, ii) cut part audit and iii) bundle checking.

Sewing Department
Checkpoints in the sewing departments are as following.
Inline inspection
Roaming inspection
End of line inspection or table checking

Finishing Department: Check points in finishing department consists

- Initial finishing inspection

- Final finishing Inspection

Washing: Sometimes, the buyers demand that garments must be given a wash after
stitching.

Button, button hole and rivet attach

Extra Thread trimming: The extra threads which have been left uncut are trimmed. This
can be done manually with thread cutters.

Stain removal: Different types of stains might be formed at the time of garment
handling operations. Different kinds of stains include ball point stains, oil stains, dirt
stains etc.

Thread sucking : this is done to remove the threads stuck to the fabric surface that are
too minute to remove.

End of line inspection: Garments are compared against measurements and tolerances,
defects, loose and misaligned threads and buttons, open seams etc.

Alteration: Any garment found faulty of defects will be sent for alteration.

Ironing: After all these steps, the garments are ironed in a proper manner, folding on
the right creases. Steam ironing is preferred.

DEFECTS IN ZEDEX
PATTERN DEFECTS IN GARMENTS: (CAD)

Some parts of pattern are missing, probably because the marker did not include

the correct number of parts.

Patterns not aligned with respect to the fabric grain.
The pattern may have worn out edges.
SPREADING DEFECTS IN GARMENTS

Not enough plies to cover quantity of garments required.

Incorrect tension of plies, i.e. fabric spread too tight or too loose
Spread distorted by the attraction or repulsion of plies
Plies are not spread accurately one above another for cutting. This results in
mismatching checks.
CUTTING DEFECTS IN GARMENTS

Failure to follow the marker lines resulting in distorted garment parts.

Garment part damaged by careless use of knife, perhaps overrunning cutting

previous piece.
Marker incorrectly positioned on top of spread.

 COLOR DEFECTS IN GARMENTS

Color defects that could occur are difference of the color of final produced
garment to the sample shown, accessories used are of wrong color
combination and mismatching of dye amongst the pieces.

SEWING DEFECTS IN GARMENTS

Broken buttons
Broken stitching
Different shades within the same garment
Dropped stitches
Fabric defects
Holes
Inoperative zipper
Missing stitches
Open seams
Stain
Wrong stitching technique
Usage of different color threads on the garment, creasing of the garment