Quality manual formal trouser

Submitted by: Vinay Prajapati M.F.Tech, Sem-I, NIFT, Gandhinagar Submitted to: Ms Nupur Chopra Asst Professor NIFT, Gandhinagar 2010 Quality Manual Formal Trouser National Institute of Fashion Technology, Gandhinagar Contents Page Introduction Objective Cost and Quality Management Responsibility I Purpose II Scope III Organisational Structure and Responsibilities IV Job Description of Responsible Persons For Quality Quality System I Purpose II Scope III Quality System Procedures IV Quality Planning Receiving Inspection I Purpose II Scope III Receiving Inspection IV Accessories V Fabric Inspection VI Fabric Inspection Procedure - Point System VII Rolls Selection Procedures VIII Acceptable Penalty Points IX Acceptable Point Count Level X Rejection Rate XI Running Defects Process Inspection I Purpose II Scope III Process Inspection IV Spreading Inspection V Cutting Inspection VI Sewing Inspection VII Table Inspection VIII Two Hourly Inspection Final Inspection I Purpose II Scope III Activities Garment Inspection ProcedurePage V Defects Classification List (Major) VI Defects Classification List (Minor) Sampling Techniques 10 Pre-Shipment Survey By Acceptance Sampling 11 Control Of Non-Conforming Products I Purpose II Scope III Activities 12 Garment Taken: PETERENGLAND Formal Trouser I Sampling of Formal Trouser II Front View III Back View IV Parts of Formal Trouser 13 Conclusion IV Introduction Page 4 Introduction Page With the increased demand of garments in the world wide, number of garments factories is growing rapidly but Q.A management system cannot be developed in the same speed due to the lack of Q.A management system Quality of product and service along with the efficiency of the work force is the foremost objective to produce products and service of the high standard, which meets all the specifications, including environmental concern and safety Commitments to valued customer: Maintaining the highest achievable quality possible The most competitive pricing in the world market Shortest lead-time with on time delivery The best environment for ethical standard in accordance with world compliance standards Objective Page 6 Objective Page Objectives of these policies are: To understand customer’s perspective of quality To provide better quality of products and service To provide good and safe working environment to the workers, which includes human value, respect, justice, cleanliness, discipline and equality between workers and others To implement quality control system with the aim to achieve zero defect level through efficient management, research, development and continuous improvement Page Cost and Quality 8 Cost and Quality Page 9 Cost and Quality Page 10 QUALITY: Quality is defined as “Totality of characteristics of an entity (product, service etc.) that bears on its ability to satisfy stated and implied needs.” QUALITY CONTROL: Is an effective system for interchanging the quality maintenance and quality improvement efforts of various groups in an organization so as to enable production at the most economical levels which allow full satisfaction for the consumers TOTAL QUALITY MANGEMENT (T.Q.M.): Is described as an all- inclusive fully integrated productivity technique It helps to create new markets, expand existing markets and recapture lost markets by utilizing the optimum capability of man, machine, material, method and produces high and uniform quality of products with reduced costs Total quality control starts from market i.e from purchasing material and machine and ends in the market i.e selling the finished products in the market including after-sale service It includes market analysis, product development, production planning, statistical quality control, preventive maintenance, wastage control, inventory control, cost reduction and after sales service etc The ultimate goal of T.Q.M is to increases the quality/cost ration and continuous improvement It may be done by increasing the quality with same cost, decreasing the cost with same quality and increasing quality and decreasing coast at the same time The basic quality problem is to set correct balance between the cost and quality i.e to find out a suitable quality/cost ration for the product which will satisfy the consumer both for cost and quality 10 Next 268, 454, 013, 201, 017, 194, 361, 452, 419,Page 312 excluding all the numbers, which are out of serial Arranging the numbers in order 013, 017, 194, 201, 268, 312, 361, 419, 452, 454 these are the sample numbers which we want to select randomly 41 PRE-SHIPMENT SURVEY BY ACCEPTANCE SAMPLING ACCEPTANCE SAMPLING Acceptance sampling is the art or science that deals with procedures in which decision to accept or reject lots or process is based on- the examination of samples 100% inspection is generally not justified because of time and cost as well as for the shortage of trained manpower Good sampling inspection, where the items inspected are examined carefully may even provide Better assurance –of product quality than 100% inspection with carelessness The purpose of acceptance sampling is to specify course of action not to control lot quality Acceptance sampling plan merely accepts c, rejects lots Generally we like to ensure that lots of manufactured goods not contain an excessively large portion of defective items This is achieved mainly through the technique of sampling inspection Acceptance sampling has indirect effect on improvement of quality through its encouragement by high rate of acceptance of good quality and through discouragement of bad quality by high rate of rejection It also reduces the risk of rejection of good lots and accepting of bad lots on the basis of sample TERMINOLOGY OF ACCEPTANCE SAMPLING LOTS SIZE: Is the number of units in the lot and is denoted by "N" SAMPLE SIZE: The number of units in the sample and is denoted by "n" LOT INSPECTION: A specific quantity of similar material, or a collection of similar units, offered for inspection and acceptance at one time SAMPLING INSPECTION PLAN: A specific plan which states (a) the sample size (b) The criteria for accepting, rejecting, or taking another sample, to be used in inspecting a lot ACCEPTANCE NUMBER: The large number of defectives (or defects) in the sample or samples under consideration that will permit the acceptance of the inspection lot is called acceptance number, and is denoted by "Ac" REJECTION NUMBER: 41 The smallest number of defectives (or defects) inPage the sample or samples under consideration that will require the rejection of inspection lot is called rejection number, and is denoted by "Re" 42 PRODUCER'S RISK: The probability of rejecting a lot under the sampling inspection plan when the fraction defective in the lot is actually within specified limit is called producer's risk and is denoted by "Pp" CONSUMER'S RISK: The probability of accepting a lot with higher fraction defective than the specified limit under the sampling inspection plan is called consumer's risk and is denoted by "Pc" SINGLE SAMAPLING INSPECTION PLAN: Is the sampling inspection plan in which a decision to accept or to reject a lot is reached after the inspection of a single sample PROCESS AVERAGE QUALITY: Expected quality of products form a given process, usually estimated from first sample inspection results of past lots ACCEPTABLE QUALITY LEVEL: The maximum per cent defective that, for purpose of sampling inspection, can be considered satisfactory as a process average is called acceptable quality level anti is denoted by AQL PROBABILITY OF ACCEPTANCE: Probability that a lot or will be accepted is called probability of acceptance and is denoted by "Pa" OPERATING CHARECTERSTIC CURVE OR O.C CURVE: A curve showing the relation between the probabilities of acceptance, either lot quality or process quality, whichever is applicable is called O.C CURVE The stealer the O.C CURVE, the greater is the protector to the consumer against accepting a bad lot AVERAGE SAMPLE NUMBER: The expected value of the sample size required for coming to a decision, i.e., for acceptance or rejection of a lot, under the sampling inspection plan is called average sample number and is denoted by ASN The curve obtained by plotting ASN against "P" is called ASN curve Lower the ASN curve better is the sampling inspection plan MAJOR DEFECT: A major defect is a defect that is likely to result in failure, or to reduce materially the Liability of the unit of product for its intended purpose 42 Page MINOR DEFECT: 43 A minor defect is a defect that i s not likely to reduce materially the usability of the unit of product for its intended purpose, or a departure from established standards having little bearing on the effective use or operation of the unit Minor defects may be classified into two categories; more important minor defects may be designated as Minor "A" and less important ones, Minor "B" CRITORIA FOR SHIFTING TO TIGHTENED INSPECTION: When normal inspection is on effect, tightened inspection to be instituted when out of consecutive lots or batches have been rejected on original inspection CRITORIA FOR SHIFTING TO NORMAL INSPECTION FROM TIGHTENED INSPECTION: When tightened inspection is in effect, normal inspection shall be instituted when consecutive lots or batches have been considered acceptable on original inspection, criteria for shifter to reduced inspection When normal inspection is on effect, reduced inspection maybe institute when, (a) The preceding 10 lots or batches have been on normal inspection and has been accepted on original inspection (b) The total number of defects in the samples from the preceding 10 lots or batches are equal to or less than the desired level (c) Production is at a steady rate (d) Reduced inspection is considered desirable by the responsible authority CRITERIA FOR SHIFTING TO NORMAL INSPECTION FROM REDUCED INSPECTION: When reduced inspection is on effect, normal inspection must be reinstated whenever a lot or batch is rejected or production becomes in e-regular or delayed or other conditions warrant that normal inspection shall be instituted 43 Page 44 Control of Non-Conforming Products 44 Page 45 Control of Non-Conforming Products Section PURPOSE To prevent the dispatch of non-conforming products to the customer SCOPE This section applies to the products which not conform the require quality ACTIVITIES Non-conforming goods are identified during the checking of receiving section Process inspection or final inspection: • • When a major non-conformance is discovered i.e (one that requires a managerial/executive decision regarding its disposition) it is so identified and segregated," subject to the appropriate management decision, the defective goods are reworked, accepted on concession, re-graded or rejected Where appropriate, the customer is consulted concerning any concession 45 Page 46 Garment Taken PETERENGLAND Formal Trouser 46 Page 47 Sampling of Formal Trouser Parameters No of samples asked for size including counters In Proto Sample 3-5in 32 Size  1-3 sample Buyer  sample counter  1-2 merchandiser counter In fit Sample 3-5 in 32 Size  1-3 sample Buyer  sample counter  1-2 merchandiser counter In Size set 3-5 in 32 Size  1-2 sample Buyer  sample counter  1-2 merchandiser counter In Pre-production 3-5 in 32 Size  1-3 sample Buyer  sample counter  1-2 merchandiser counter In Design sample 3-5 in 32 Size 47    1-3 sample Buyer sample counter 1-2 merchandiser counter Page 48 Fabric Used Cotton (2-ply Superfine Satin) Actual trims like, buttons used -  On waist band  2-on side pocket & one back pocket  Zipper used What actually being checked In Proto Sample  Styling  Pattern  Measurements  Construction In fit Sample  Measurements  Fit  Constructional features  Type of stitching & quality  Position of accessories In size set  Measurements  Fit  Constructional features  Type of stitching & quality  Position of accessories In pre-production Reference sample for the production Comment sent by -mail The process be eliminated altogether, depends upon buyer requirement 48 Page 49 Comment from buyer for different sampling stage till pre-production can be categorized under following heads Style Details Measurement Fit Design comment:   Type and position of trims Shape of critical areas like packet Construction features:    Type of stitches Quality of stitches Quality of seams 49 Page 50 Front View 50 Page 51 51 Back View Page 52 52 Parts of Formal Trouser 53 Page Waist band width Waist band Front raise Fly length Fly width Pocket opening Thai width Leg opening Welt Back raise Back pocket Belt loop Pocket bag Zipper length Size label Brand label Wash care label Total length 1.5” 28” 9” 6” 1.6” 6.8” 21.5” 18” 4.9*0.4 14” 7.2*5” 2.2*0.5” 9.7*6.7” 7” 0.5*0.5” 1.1*0.5” 1.5*1.2” 40” Position from Waist band 0, from side seam 6.2 Position from Waist band 0, from side seam Position from Waist band 2.5, from side seam 1.2 On the right side of the fly below the waist band 1.5” inch below from waist band Right side of the front part inside 53 Conclusion Page 54 54 Conclusion Page 55 Quality has always been a primary requirement and considers being the life of a garment There is no denying the fact that we have been following Quality Control System in the production process since its birth but there might have been differences in those applications in factories Compiling this quality manual is a humble effort to put almost all necessary details of Quality Control System to ensure that all our factories have a written Manual/ Guideline in black and white to follow In the beginning we will not concentrate on the statistical Quality Control System We will follow this after a while when we have enough and required manpower to exercise that Any positive inclusion in this manual which will help the factories in improving quality is always welcome; but has to done with prior approval from the Managing Director We all need to educate and train our work force in line with this Quality Manual to try and streamline our quality system Our united and sincere effort only can help to improve in the sector of quality 55 [...]... Page Quality System 17 17 Quality System Section 2 Page 18 PURPOSE To document and maintain a quality system as a means to ensure that product of all factories to specified requirement SCOPE The quality system operated aims to ensure compliance to specified requirements and is defined and driven by Quality Manual, departmental procedures and work instructions, those are defined in this section QUALITY. .. SYSTEM PROCEDURES The Quality procedure of each factory will be reviewed by the concerned persons of Management of that factory Describing the quality systems of all factories of XYZ, this manual includes a brief description of the functions and mode of operation of the factories management personnel with respect to quality QUALITY PLANNING Documented quality planning is stated by this manual, accompanying... OF RESPONSIBLES PERSONS FOR QUALITY 1 MANAGING DIRECTOR: will ensure the absolute adherence to the quality control system by exercising his authority through his channel of command 2 G.M.Q.A CENTRAL: a) Preparing quality manuals for the group b) Taking approval from the MANAGING DIRECTOR for implementation of the system stated in the manual c) Implementation of statistical quality control system in the... defect level e) Training of QC personals on statistical quality control system and graphical method for achieving target quality level desired by the buyer f) Collections of buyer’s quality guide lines from buyer’s website or manual and convey it to Manager QA central, Manager QA factory and Monitoring for proper implementation to achieve buyer’s quality level g) Maintain liaison with buyers QA team... PLANNING Documented quality planning is stated by this manual, accompanying procedure and instructions and quality, all of which comprise the Quality System Thus, quality planning is, documented and implemented by all Executives and Managers playing a role in the maintenance of product quality and the quality management system To achieve the goal of zero defect level following steps has been taken 1 For... person for right job of QA department 12 Pageof the group the overall quality position of the j) To inform to concern directors and chairman factories by MIS k) Inform the concern director if any factory is unable to perform up to the desired level of quality by corrective action request or verbally l) Study quality related books, journals, manuals and research for continuous improvement 13 3 MANAGER QA... taking care of quality system in their assigned position SCOPE This section covers the organizational structure and responsibilities of all personnel who supervises, perform and verify works at different stages for the improvement and maintenance of quality ORGANIZATIONAL STRUCTURE AND RESPONSIBILITIES The following positions play a managerial role in the maintenance of product quality and the quality control... sampling inspection plan f) Monitor spreading quality control and cutting quality control 14 Page 9 SR Q.I SEWING: Two/Three for each line (Depending on no of machines in line) 15 a) Carry out instructions of Manager QA Factory b) Conduct process capability study of the Line by calculating C.V (Co-Efficient of variation) of hourly defect percentage c) Monitor quality performance of operators for continuous... factors d) In line inspection to see whether the garments quality is as per buyers requirement or not In case of any deviation, take corrective and preventive action e) Briefly describe the buyer requirement and quality control procedure to Manager QA factory for proper monitoring to produce garments as per requirement of buyer f) Report to Manager Quality, all his findings and inspection report for taking... monitoring the quality of production in all factories and subcontract factories 4 MANAGER QA: a) Over All Administration of factories QA dep’t and monitoring the work of Sewing Q.C, Finishing QC, Line QC, QI Cutting and all inspectors as well as evaluation of their performance b) Conduct training and make all his sub ordinates accountable to him for their performance to achieve the target of quality level ... Sample 3-5 in 32 Size  1-3 sample Buyer  sample counter  1-2 merchandiser counter In fit Sample 3-5 in 32 Size  1-3 sample Buyer  sample counter  1-2 merchandiser counter In Size set 3-5 in... Size  1-2 sample Buyer  sample counter  1-2 merchandiser counter In Pre-production 3-5 in 32 Size  1-3 sample Buyer  sample counter  1-2 merchandiser counter In Design sample 3-5 in 32... 10 Pre-Shipment Survey By Acceptance Sampling 11 Control Of Non-Conforming Products I Purpose II Scope III Activities 12 Garment Taken: PETERENGLAND Formal Trouser I Sampling of Formal Trouser