Introduction to

Quality

What is Quality Practical

Life

What is Quality
The best money can buy
Meeting a specification or
conformance to specifications.
Product with no defect found
Meeting or exceeding customer
expectation

Soya Bean Oil

Plastic Bucket

A Pair of Shoes

A Can of Cola

Popular Brands in
Bangladesh

Quality in Our Factory

What is Quality - Definition

Quality is conformance to
specifications
In manufacturing, a measure of
excellence or a state of being free
from
defects,
deficiencies
and
significant variations.

Quality Fitness for Use

It must be free from defects such as stain,
material (fabric) defects, open seams,
loose hanging broken stitches, Skip/Slip
stitches
It must fit properly for the label size.
It must look attractive.
It must perform satisfactorily in normal
use that a garment must be able to
withstand normal laundering/dry
cleaning/pressing cycles. Without loss of
color or shrinkage; seams must not come
apart; fabric must not tear

Production Process
Input

Process

Product

Inspection

Accept

Rework

Reject

Alter / Defect / Rejects

Aspects of Quality
Quality Inspection

What is Quality Control

Quality control is the process of
examining your output for minimum
levels of quality in some dimension.
The quality control team does not
actually improve the quality, they just
stop production when the measured
quality drops below a given limit.
QC is product oriented.

Quality Control

Approved Sample

Ye

Specification

What is Quality Assurance

QA is a set of activities for ensuring
quality in the processes
The difference is that QA is process
oriented and QC is product oriented.

Quality Assurance

Quality Inspection
Raw Material

Fabric
Inspection
Accessorie
s
Inspection

Cut Panels
Un Finished
Parts (Front /
Back)
End Line

After
Ironing
Pre Final /
Final
Inspection

Why need Quality

Inspections

Quality inspection are measures aimed at checking,

measuring, or testing

Why need Quality

Inspections

Quality inspection serves three main

purposes:

Types of Quality Inspections

1

 Pre-Production Inspection

should specify clearly what the

inspector must pay attention to

 During Production
Inspection (DuPro)

The few products that were already manufactured

can (hopefully) be re-worked without inducing a
delay

The same issues can be avoided on the rest of

production.

 Final Random Inspection

(also called pre-shipment
inspection)
Conformityto specs:
(As per Approved Sample)

Number of visual defects:

(Based on AQL)

Role of Quality Inspector

Why We need to Reduce

Rework

How Can Reduce Rework

Doing Things Right

Doing Things Right means doing

them right the first time.

What we are doing now

In
Process

End Line
(Table)

Finishin
g

Hourly
Output +
Alter
Recheck

Hourly
Output +
Alter
Recheck

Hourly
Output +
Alter
Recheck

120+ 40

80+ 25

100+ 50

In
Proce
ss

Final
Inspecti
on

How Doing Things Right

Check Garment in a proper way
Identify Defects Correctly (Minor /
Major / Critical)
Get information how to do it
After completing a step of your work,
check the results achieved so far
(Check next step findings)

How Doing Things Right

Contd
If you encounter an error, do not only
fix it. Check for the root cause and
address it
Do not try to be perfect. Sometimes
you just have to accept minor errors
because otherwise, you would never
finish a job

Quality is not an act, it is

ahabit
Habit

Behavi
or

Satisfied Employees

Culture

Satisfied Customer

Good Quality
Product to
Customer
More Orders to Company

More Benefits to Employees

Quality it always stands out

Defects
AMinor defect is a discrepancy
from the standards, but one that is
not likely to affect the usability
AMajor defect is one that is likely
to create failure of the unit for its
intended purpose.
ACritical defect is one that is
deemed to be hazardous or unsafe.

Examples of potential minor defects:

Poor sewing:
Untrimmed and uncut Threads
Color differences:
It is quite common for products to be made in
slightly different colors than ordered.

Examples of possible Major defects:

Holes and scratches
Size/Weight Discrepancies
Also common is for measurements to be
off, sometimes by millimeters, other times
even by inches

 Example of a critical defect

Critical defects are also defined as a
defect that is likely to result in
hazardous or unsafe conditions for an
individual in using the product and
that does not meet the mandatory
regulations.
A critical defect in clothes may cause
accident to the wearer and may
malfunction
when
wearer
out
wearing a garment with critical

Example of some critical

defects:
Loose
components:
Trims
and
fasteners those are used in the
garment but not secure properly. For
example, buttons, snaps, stones etc.
Sharp edges: During the processing
of the garment it come in contact
with various sharp metals such as
needles, staples. Broken needles,
damaged or broken snap buttons,
rivets, wire and pins.

Example of some critical

defects:
Drawstrings at head or neck for baby
or kids products. Draw string must be
avoided in kids clothes.
Thread or trims which are extensively
long or loose

Defects per hundred

units (DHU)
Number of total defects in 100
checked garments. The formula for
calculating DHU is
DHU = Total no. of defects found X
100 / Total pieces checked
Total pcs Checked 200
Defective pcs - 15
Defects found in that 15pcs 60
DHU = (60*100/200) = 30

Percent Defective (%)

Total number of defective pieces in
100 checked garments.
Percentage defective = Total no.
of defective pieces X 100 / Total
pieces checked
Total pcs Checked 200
Defective pcs 15
Defect % = (15*100/200) = 7.5%

June Month Finishing

Defects

June Month Line Defects