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INTRODUCTION
Quality Control
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 in design, styles, colors, suitability of components and fitness of
product for the market.Satisfactory quality can only be ensured through:
3. Faultless construction.
6. suitable packaging
Satisfaction quality can be ensured from the customers point of view by providing:
1. Right product.
2. Right quality.
3. Right time.
4. Undamaged condition.
To ensure the quality level of a garment we need to observe some specific sector
4- All the different parts of the garment should have the perfect size.
Quality section:
2-Q.C Manager
3-Q.C Officer
4- Q.C. In Charge
5- Quality Controller
6- Line Q.C.
2-Q.C Manager
3-Q.C Officer
4- Q.C. In Charge
5- Quality Controller
6- Line Q.C.
7- Process Q.C.
1- Q.C. In Charge
2- Quality Controller
3- Quality Supervisor
4- 2 Hrs Audit
7- Measurement Q.C.
8- Iron Q.C.
Q.M
...
Cutting quality control
Sewing quality controlFinishing quality
Store Q.ITrims and accessories inspection
Line Q.C
1. Fabric inspection.
To fabric which will be used to make the garments, matching with the approved
swatch card.
To inspect fabric and accessories before start the processing
Fabric Test:
The following tests are carried on based on 4 point system. There are used a glass
table. The fabric laid on the table and under the glass a light used to checking
clearly.
Shade matching.
Different types of spot checking.
Side-Centre-Side shade check.
End-End shade check.
Shrinkage Test.
Block check- taking 7 blocks of different size of any one cutting.Bundle check- 100%
check of cutting no, bundle no, and size serial etc.Panel check 100% of cutting
table inspection.
suns burry 403 Purple Pique 42 1260 126 Moonxl S Not found OK OK OK 1 .79%05
suns burry 403 Purple Pique 42 1260 126 Placket XL Not found OK OK OK 2 1.59%06
07 08 09 10 TTL
All defects are rectified and pass.
To check the stitch counting them twice in a day, such as- after starting sewing in
the morning and after lunch break.3.2.6 In- Line Inspection:The garments check in
every line everyday.At least 20 to 30 machine operator works under the quality
inspector. He checks the garments in his line.3.2.7 Table inspection:
This is the
last part of sewing section. The table inspection is done in the final line of every
sewing line. The garments when completed sewing then it goes to the table for
inspection.
Final Inspection:
The garments check 100% at final inspection line before the product deliver.
Fabric inspection:
point system:
The 4-Point System, also called the American Apparel Manufacturers (AAMA) pointgrading system for determining fabric quality, is widely used by producers of
apparel fabrics and is endorsed by the AAMA as well as the ASQC.
The 4-Point System assigns 1, 2, 3 and 4 penalty points according to the size and
significance of the defect. No more than 4 penalty points can be assigned for any
single defect. Defect can be in either length or width direction, the system remains
the same. Only major defects are considered. No penalty points are assigned to
minor defects. In this system, one should inspect at least 10 per cent of the total
rolls in the shipment and make sure to select at least one roll of each color way.
Fabric defects are assigned points based on the following: Total defect points per
100 square yards of fabric are calculated and the acceptance criteria are generally
not more than 40 penalty points. Fabric rolls containing more than 40 points are
considered seconds. Formula:
Points/100 sq yards = Total defect
points/Total length of fabric in yard X 100/1 X 36 inch/Width of fabric in inch.
Finished Fabric Inspection Report:
When the fabric inspect, many types of fault has to check
-Dirt or soil.
-Hole
Cause:
1. High yarn tension.
2. Less strength of yarn which breaks during loop formation.
5.
Solution: 1. For holes problems solution use proper count of yarn.2. Yarn strength is
important.3. It should be free from all kind of foreign particle.4. The gap between
the Cylinder & the Dial should be correctly adjusted as per the knitted loop size.
Pin hole: Very small holes appeared in the fabric.
Cause:
1. Due to break down of latch or bend.
Solution:
Needle broken/laddering:-
These defects occur due to broken needle. The loop does not form in the wale.
Cause:
Stains appear as spots of grease oil or dyes of different color, in a neat & clean
finished fabric surface.
Cause:
1.
2.
Grease & Oil stains from the unguarded moving machine parts like; Gears
Shafts Driving Pulleys & Trolley wheels etc.
4. During transportation.
Solution:
1. To remove the oil mark the machine should be cleaned regularly and lubricants
use carefully.
3. Make sure that the fabric is neatly packed in or covered with Polythene sheets
while transporting or in storage.
Contaminations:
Contaminations appear in the form of foreign matter such as; dyed fibers, husk,
dead fibers etc. in the staple spun yarn or embedded in the knitted fabric structure.
Causes:
1. Presence of dead fibers & other foreign materials, such as; dyed fibers, husk &
synthetic fibers etc.
2. Dyed & other types of fibers flying from the adjacent Knitting machines cling to
the yarn being used for knitting & get embedded in the Grey Fabric.
Solution:
1. Rigid control measures in the Blow Room to prevent the mixing of foreign matters
in the Cotton mixing.
2. Segregate the Spinning & Knitting Machines, with Plastic Curtains or Mosquito
Nets, to prevent the fibers flying from the neighboring machines, from getting
embedded in the yarn / fabric. Fly yarn:
This fault occur when the
flying yarn get mixed with the yarn during knitting.Solution:
The knitting
machine have to clean regularly because the machine when process the yarn to
make fabric lot of fiber drop as wastage and this can be mixed with the fabric
Fabric cutting is the preliminary section in garments industry. The fabric cut into
parts of garments here. This is most important section of garments for inspection
because the fabric spread of 60 to 70 plies on the table for cutting. If there make
any mistake for measurement in cutting it can cause a serious damage for many
garments product. So it required skilled operator and high level of inspection.
1. Fabric spreading: 60 to 70 plies of fabric spread on the cutting table. The fabric
spread is very important. All the fabric measurement is kept same for from one
edge to another edge. Tension of all plies will be same. Marking process:
2. Marking process: This is the second step of cutting section. The pattern parts
place on the fabric plies and draws according to pattern measurement. Marking is
done compactly for possible amount of fabric can save from wastage.
3. Fabric Cutting: After making is done the cutting process begin. High speed
cutting machine cut the fabric plies by the operator. The operator should be skilled
for this process because the fabric has to cut by exact marking measurement.
4. Numbering: When the fabric cut into parts has finished all the parts numbered by
the sticker. This is done for all the parts of a garments can assembled by the same
fabric. So it can minimize the risk of shade variation.
5. Bundling: after numbering the parts has to bundled and sent to the sewing
section
Prepared bundling card according to fabric lay report this card
maintain.
1. Program No
5. Roll No
2. Cutting No
3. Size No
4. Pies
1. Fabric spreading according to correct alignment with marker length and width 2.
Maintain requirements of spreading 3. Lay contains correct number of fabric ply 4.
Correct Ply direction
7. Tension control
1. The dimension of the pattern and the cut piece should be same and accurate 2.
Cut edge should be smooth and clean
3. Avoid blade deflection
4. Maintain cutting angle
5.4. Fault occurs in cutting section and its remedies:
5.4.1. Misalignment of plies: Plies misaligned, resulting in garment parts getting cut
with bits missing in some plies at the edge of the spread.
Cause:
1. Different plies spread too tight or too loose.2. All the plies do not
spread from the edge at same measurements.
Solution:
1. All fabric should spread at same tension.2. Measurement should be equal at all
measurement for the edge.
Less marker efficiency: less marker efficiency cause of increasing wastage and
result a wrong cutting.
Solution:
Check the marker is placed on the spread with the edge parallel to the selvage of
the goods. It must ensure that no plies is creased, damage, or have overlapped
parts. It must be ensured that possible amount of wastage can reduce.
Incorrect tension of plies: Improper tension during spreading can spoil the right
measurements of the cutting parts
Solution: 1. Check the tension during spreading. It is very important for knit fabric.
2. Deflection of blade.
3. Unsharpened blade.
Solution:
The operator has to be alert when he numbered the parts that no
parts cannot be missed from numbering.
Sewing Quality Inspection
Sewing section:
After finishing the cutting process the cutting parts come here for sewing. It is
mainly an assembly section in the garments factory. Different parts of the garments
joined together here and attach other accessories like button, zipper make a
complete product.
6.2. Quality Control in Sewing Section:
1. Input material checking
2. Accessories checking 3. Machine is in well
condition 4. Thread count check 6. Needle size checking 7. Stitching fault should
be checked 8. Garments measurement check 9. Seam fault check
10. Size
mistake check
12. Shade variation within the cloth 13. Wrong placement of
interlining 14. Creased or wrinkle appearance control
Defects occur in sewing section and remedies:
Skipped stitch:
Some place in the stitch line where the stitch does not formed :
Cause:
1. Failure of needle to enter loop at correct time2. Needle deflection or bent
needle3. Thread loop failure due to incorrect needle size for thread size4. Incorrect
sewing tension in the needle5. Thread loop failure due to incorrect setting of thread
control mechanism6. Flagging of fabric due to poor presser foot control
Solution:
1. The sewing tension in the needle should be proper.
Scratch on the sewing product by the needle tip when several stitches are
performed and needle is broken during sewing
Cause:
Solution:
1. The needle has to change immediately. If the scratch on the garments is very big
or deep the product should be rejected.
4. The overhead guide should be directly above cone or the thread package. Also
ensure that thread package shouldnt get tilted during off winding.
Uneven (sleeve, armhole): sleeve or armhole edge fold has a measurement. Uneven
means when the measurement is not same in all place. This occur due to careless
operating by sewing operator
Solution: the uneven place seam has to open and again stitch with right
measurement.
Main level not in centre point:
1. Buyer gives instruction where to place the main level. If it is placing in the wrong
area this is a fault.
Solution: 1. Main level has to attach in the right place.
Oil mark occur from the sewing machine lubricants and spot is appeared on the
garments
Cause:
During the sewing operation oil can accidentally slick out from the
machine and drop on the fabric and spotted.
Solution:
Spot lifter chemical use to remove the oil the mark of the garments. At first the spot
lifting chemical spray on the garments spot then air blown by the machine. The spot
remove.
Side seam are not at the side line. It may come forward or backward.
Cause:
If the front and back part of the garments do not cut by correct
measurement or operator make mistake of sewing the seam formation in the side
come forward or backward from the side formation.
Solution:
Cutting parts must have right measurement and oprator have to
be conscious about that. Some times it can recover by stitching again or it can be
reject.
Seam Pucker:
After sewing when the fabric is puckered in the seam area. It is the wrinkle, or
corrugation of the sewn fabric running across the seam
Cause:
1. Adjust feed timing and fabric control for maximum pulling of the fabric.
2. Check tension level in the thread, Sew with minimum tension possible. Always
adjust bobbin thread tension first then needle thread tension.
3. Check if the coefficient of friction of the thread with metal is high.
Shade problem:
It is the problem appeared when the two parts shade looks different in the garments
Causes:
It is also may be a problem in cutting section where this parts made numbering
mistake.
For the lack of experience or concentration of worker and if different parts are mixed
by worker.
Solution:
Shade problem parts are separate and actual parts are attached
Kacha problem:
If unexpected parts are shown by the garments from sewing area then this problem
is occurred
Causes:
For lack of experience or concentration of worker.Solution:
The unexpected part is cut out precisely.
Solution:
Cause:
If garments color and sewing thread does not match with color
Solution:
The sewing thread must have the same color with the garments.
To ensure that before sewing the thread must check with the garments.
Washing Quality Inspection
Washing section:
Washing process of garment is done to create wash look appearance. After washing
the garments create a new looks which seems the new touch of fashion.
-Washing technique create new fashion such as tagging, grinding, destroy, Blasting,
whiskering, permanent wrinkle, deep dye, tie dye, p.p spray, hand crapping, p.p
spoon zing etc. Which is also seems the best touch of garments.
-The main and important function of washing is to reduce size materials as a result
the garment become size free and become soft hand feel.
-When these soft garments are touched then it seems to best touch of garments.
-To attraction the customers/Buyer by different types of Fashionable washing and
market developments.
-Due to washing, shrinkage occurs in the garments. There is no possibility of further
shrinkage of wash garments.
-Any dirt, spot or germ if added in the garments during manufacturing is also
removed due to washing
7.2 Quality control in washing section:
2. Uneven check.
Finishing section:
This is the final section of the garments industry. Various types of fault check here.
This is the important section where finally the product has to inspect and solve the
defect of the garments.
Quality Control in Finishing Section:
5. Wrong fold
8. Collar closing
Fault occur in finishing section and its remedies: Ironing problem: Some ironing
problem occurred are giving bellow most 8.3.1 Shoulder up down: During ironing if
the shoulder side is not placed correctly Causes: It is also the mistake of the
worker.Remedies: Shoulder placed correctly and ironing again.
Bottom up down:
Puckering:
Crease if brought in the fabric and ironing. Causes: For the lack of concentration of
worker if he ironing the garment on the crease area.Remedies: Remove the crease
from the fabric and ironing again.
Poor folding resulting poor appearance: Due to poor folding the garments
Appearance looks odd or not appreciating.
Solution:
Incorrect packing: The packing should do by following instruction from the buyer.
Size mistake:
Different size sign are used in garment and lock pin label
Causes:
Place the lock pin which size are shown in the product
Barcode problem:
If the main label and hang tag barcode are not similar.
Causes: Its a mistake of worker.Solution: Same barcode of main label and hang tag
are placed.
CONCLUSION
Quality control plays a vital role in knit garments production. Nowadays buyer
requires specific quality in all major parts of the finished products. What special in
this report is that the information data and description very much objective &
practical. We have tried to complete this project work as much we can. It will help
us to maintain the quality of the garments in garments production.