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QUALITY MANUAL
KUMAR & TYAGI CLOTHING
[The document contains the Quality Manual for a self assumed company]
Faculty In-charge
Submitted By
Mohammad Umar
DFT
Neetek Kumar
Prashant Tyagi
DFT
SEM VI
1. Quality Assurance
1.1 QUALITY POLICY
1.
2.
Continuous improvement
a)
Productivity
b)
Waste elimination
c)
House keeping
3.
4.
5.
2. Quality checkpoints
NOT OK
OK
Issue to Cutting
Laying
Style descriptions,
Fabric code, W.O. no,
Design approval, Fabric
one way or two ways?
Quality
check
at
beginning of the lay
the
Re-do
NOT OK
.
OK
Check for the first ply
Shade, width-wise lay,
Waviness, Bowing?
Re-do
NOT OK
OK
Marker placement, Line
balancing, No. of plies?
Re-do
aaa
NOT OK
Quality check in between lay
Is W.O .no, size, central line, notches,
straight line, repeat width, Line
balancing, pairing, shade ok, Fabric
Check
IsCheck
W.O.no,Centre
defects marked
for W,OforW.O
no,
Re
Re-Do
Re-Do
-Do
Re-Do
no,bubbling,Fus
line,Repeat,Balancing,St
weaving
Style
Is Issue
W.O.no,size,parts
ofdefect,
Quality
ed
Quality
line,one
verification,
Centre
bundleno,numbering,lay
passedway
cutokay?
parts to
thread,Stain,lini
check
notch,
Fabric
no okay?
line
Madura Garments Exports Ltd Quality Manual
NOT OK
straight line, repeat width, Line balancing,
pairing, shade ok, defects marked
Re-do
NOT OK
After laying Check the following points at the
start and end of cutting process.
Is W.O .no, size, parts,
bundle no, numbering, lay,
shade OK?
Re-do
NOT OK
OK
Cut parts; check the following points
Is W.O. no.,
Centerline,Repeat,
Re-do
Balancing,St line,one
NOT OKway,shade OK ?
Re-do
NOT OK
OK
Quality check during fusing
Re-do
NOT OK
OK
Issue of Quality passed cut
parts to sewing
Re-Work
NOT OK
Check point 1
Collar inspection
Re-Work
Re-Work
Re-Work
Collar visual
Standard, measurement collar
OK
NOT OK
NOT OK
Check point 2
front
pairing
OK
NOT OK
Check point3
trimming
& inspection
OK
Assembled shirt,
Measurement,
visual Standard.
OK
Checkpoint 4
Final Inspection
Trolley wise
AQL audit (2.5)
Folding &
Packing
R
E
J
C
T
S
Offer for
final
inspection
OK
AQL
NOT OK
Pre Final Audit/
Finished Stock Audit
(10%, 25% and 50%)
OK
ACCEPT
Release to Warehouse
3. Quality Procedures
Activity
1. Take the roll.
Requirement
Roll to be chosen at random
inches.
Classification
1 point
2 points
3 points
4 points
6 inch.
6 inch.
9 inch.
9 inch.
Minimum fault sizes are shown on the Sears Fabric defect scale :-
Knots
A do not count
B- Count as 1 point
C- Count as 1 point
D- Count as 1 point
E- Count as 3 points
Slubs
A - do not count
B - do not count
C- Count as 1 point
D- Count as 1 point
E- Count as 1 point
F- Count as 3 points
G- Count as 3 points
Standards for Passing Fabric:Average index for inspected rolls not to exceed 28 points / 100yd.
Maximum index for any roll not to exceed
40 points / 100yd.
3.1.2 100% Shade Bands
If the style is a wash garment, Before & after wash Blankets should be submitted ( 3 sets
each ) covering all rolls and it has to attached in the shade continuity card (Annexure 2)
A 100% shade band covering all rolls & all colours pertaining to a certain style /
Consignment should be made & approved prior to cutting of bulk Fabric.
Process.
No sooner the Fabric is in house, The Q/A department must ensure they get the
panels representing all rolls within 6 hours from Stores.
Cut 6 from end of each roll. Over lock & join all panels in correct grain line
direction to be in a Blanket form.
Once the Shade bands are ready, Dye lot or colour segregation has to be done. If
the Shade Band consists of 2-3 different shades, such shades should be segregated
Stores will issue & the cutting / Production will proceed as per the segregated
shades without getting mixed.
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All trims been In house should be inspected ( 10% ) & the reports submitted accordingly.
3.2.1 Trims Inspection
Purpose: To check defects and to decide Acceptance / Rejectance of trims.
Scope: Interlining, Collar bone, Label, Button, Packing Materials, Swing Ticket, Poly
bag, Product box.
Activity
Requirement
A. Interlining
1. meters of lining to be sent to lab.
a. Bond strength
1. Take 10 * 4 of fabric strip and lining strip. Note the temperature, pressure and
2.Cut rectangular slit 6*1 in Tissue paper of speed.
8 * 4.
3. Sandwich Tissue paper between interlining
and fabric then fuse.
4. Check Pull strength.
Pull strength to be at least 1 kg /
If by varying fusing conditions sufficient
sq.cm.
strength is not achieved the lot is rejected.
b. Shrinkage Test.
1. Send two collars to lab every day for
shrinkage test.
c. Visual Inspection
1. Select the roll as per sampling plan.
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Activity
Requirement
B. Labels
a. Visual Examination
1. Check lettering, color, edges as per the
Master and Specifications.
No weaving defects.
Shade continuity.
Smooth and straight edges.
Centered labels.
No color bleeding.
Note: Selection Of all trims for the inspection to be as per sampling plan.
Activity
C. Buttons
1. Check buttons for shade, chip around
the edge.
2. Get stitched 10 buttons breaks
stitched in machine.
3. If any one button breaks, then check
for 10 more buttons.
Requirement
Uniform in shade, gauge.
No chip.
NO breakage
No breakage.
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Activity
E. Swing ticket
1. Inspect visually the lettering.
Requirement
No stains and misprints.
F. Product Box
1. Check for lettering, hinge, marks and
color.
G. Polycovers
1. Check for lettering, uniformity and
scratches.
H. Collarbones
1. Check for edges and points.
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3.4 PP Meeting
A PP meeting should be organized & conducted prior to bulk production including
Buyers Representative, Merchandiser, Production Manager & all sectional heads,
Supervisors & Q/Cs involved with the particular style. No Production is to start without
a PP Meeting & all points to be discussed & documented in the PP meeting format
(Annexure 4). The QA Manager or the Technical Manager should write down the
minutes & file the PP meeting comments in the style file Technical, Quality, Packing,
Washing, Shipping ETC.
3.5 Pilot Run
Once the Production submits the Pilot run, Bulk production should be approved based on
the performance of this cut. If it is not satisfactory, a new pilot run should be made.
3.6 Mock-ups preparation
After the handover meeting of the style to the production floor, the style requirements as
discussed in the meeting should be converted into the visual standards and displayed at
all relevant work stations as guide for the work.
3.7 Test to failure
Purpose
Testing mock up pieces (36) to demonstrate consistency in fabric, threads,
machinery. The test pieces are pulled with a force until they are destroyed establishing
the kilograms at which they are break apart.
Results details- are recorded as = Z factor.
Where there is a consistent result the Z factor will be 4 or above Pass.
Where there is inconsistency the Z factor will be less than 4 Fail.
Importance
These tests and the documentation are our evidence of the control to ensure the product
we make is safe. It also allows us to identify if there is any inconsistency which we need
address to improve the product safety.The TTF results are required to accompany the
master style file and should be discused at the time of hand over meeting.
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15
3.10Cutting Department
3.10.1 Laying & Cutting area
Rolls segregated & lay as per shrinkage option or shade band separation in case of
wash & non wash program respectively.
Relaxation of Fabric for Stretch & Knit at least for 12 Hours and fabric relaxation
report maintained.
Marker Way
All parts All parts are there in the marker.
Ratio Size ratios as written on the marker.
Shrinkage whether made as per shrinkage option mentioned.
Skip whether any cut line is skipped.
Overlap check for any part overlapped.
Grain line all parts in grain line as per required.
Marker length as per mentioned.
3.10.4 Spreading
1.
2.
3.
4.
5.
6.
7.
8.
9.
Table marks check for the table marks as per the lay length.
Bowing check for bowing in the fabric
Narrow goods check for any narrow goods.
Mis-alignment of plies plies alignment at both ends.
Leaning check at the edges for leaning
Ply Tension check for ply tension
Count whether plies are counted correctly.
Nap direction whether required nap direction is followed.
End loss check for end losses.
While spreading all the defects identified in the fabric inspection stage should be marked
using a contrast color waste fabric stripe. (Annexure 5)
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Grain direction
Notches
Ragged cut
Selvedge
Bowing
Fusing
Recall all bundles fused in last 4 hours
Wash testing, temperature testing,
pressure testing, time testing
17
18
19
The roaming Q/C must continue for each & every machine Incorporating the same
process in the Line (Not more than 32 machines per line), Minimum four times a day.
Each Line Q/A dept should have two In process Audit stations for 100% components
check with the defect statistics (In line Inspection report Annexure 8) maintained
which could be analyzed hourly on each Operation to rectify prior to an Assembling
Garments.
Each end Line should have a QA Audit station performing 100% Inspection of Garments
prior to moving to the next Process & the Defects to be maintained in the Defect
Analysis Report (Annexure 9).
No inline & end line checkers should have trimmers.
3.11.2 AQL Audit.
Apart from the 100% Inspection at End Line, the Q/A Dept should Audit the Merchandise
randomly to ensure the Quality standard set by MGEL. Each Auditor should cover 5
Production lines & every hour as per the given AQL (Annexure 10). If the Standard is
acceptable as per the below stipulated table, The Goods can be processed for the next
Operation. However if the Merchandise is not up to the required Criteria, Total Qty
should be returned back to the Production Line for immediate rectification & the same
Auditor should closely Monitor until the rectification is complete. You have to strictly
adhere to maintain an AQL level of 1.5 during Inline Inspections.
3.11.3 Random Measurement Audit.
The QA dept should inspect measurements of Garments randomly covering all styles,
Color & Sizes to ensure the Merchandise is meeting the required Specification before &
after wash. (Annexure11)
3.11.4 Finishing AQL Audit
The QA dept should inspect packed pieces before it is packed into the cartons on the AQL
basis. (Annexure 12)
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b) Cleanliness of Machines
1) Well cleaned without any dust.
2) Oil level & Stains on M/C to be checked.
3) Needles to be checked & should be fluff free & not blunt.
4) Any M/C with Red flags on & if, Mechanic to be questioned.
c) Check for Reject Garments No Reject garment is to be brought forward from the
previous day without been rectified. All Reject Garments should be rectified on the same
day & not kept separately inside the line.
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