Quality Control Procedure (Part 05)

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CLASSIFICATION OF MAJOR AND MINOR DEFECTS

MATERIALS (FABRICS)

DEFECTS	MAJOR	MINOR
Any holes, obvious weakness or flaw that could develop into a hole.	Yes
Any cuts, tears or surface repairs made during production, packaging or transit.	Yes
Any pulled threads or snags between buttons or button holes, seams or visible part.	Yes
Any Slub 1cm or more in length or 2 threads wide in any conspicuous or focal points of garments. Other hidden or obscure areas. Any Slub 1cm or below.	Yes	Yes Yes
Any barre fabric, dye spots, misprints, smudges or faulty registration of prints that are obviously noticeable	Yes
Any miss-matching or stripes, checks, plaids, on fronts, backs or seams. (Not agreed on sealed sample).	Yes
Any bowing of the fabric. If it seriously affects the appearance or performance of the garment. a.    1.2cm or more b.    Less than 1cm	Yes	Yes
Any shading of parts within the garment. Shade variations within or between garments. (Not agreed on sealed sample).	Yes
Any pilling or surface fuzzing of fabrics.	Yes
Any yellowing of fabric trims and shoulder pads due to nitrogen dioxide and packaging.	Yes
Any high immature cotton or foreign fiber content.	Yes
Any monofilament sowing yarns.	Yes
Any variation on in handle or finish (Not agreed on sealed sample).	Yes

Regards

Bipul

Quality Control Procedure (Part 04)

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DUTIES OF A BUYING HOUSE QUALITY INSPECTOR’S 

1. On completion of dyeing / finishing, check the following points prior to cutting:

a. Main fabric, collars, cuffs and neck rib - all dye lot’s are correct shade to the approved swatch

b. Fabric appearance.

c. Collars, culls and neck rib - weight and knitting tensions are consistent.

d. Submit one meter of fabric for testing across all color ways stated on contract.

e. If all die above checks are satisfactory, release to cutting department. Ensure fabric is cut on the grain


The following checks should be made at the start of production:

a. Spot check lines for major / minor defects as identified in classification. Ensure make up meets the standards of the sealed sample and that any customer comments are adhered to.

b. Check for shading in garments.

c. Check measurement's are within size chart tolerance

d. Check pressing standards are maintained.

e. Check sew in labels are inserted as per the information on the contract.

f. Check that supervisors and quality inspectors are working to given procedures.

g. Submit production samples and complete quality report sheet.

h. Communicate by mobile and fax any problems encountered in the factory at production stage.


Stock quality audit role check as listed below :

a. Stock to be checked in accordance with the major / minor defects classification using the attached sampling plan guide. Always check stock against the seal sample and comments made.

b. Sew in labels / kimballs.

c. Packaging - i.e. correct size poly bag, and correct pack ratio. d. Cartons - i.e. quality, dimensions, description detail on outside of carton.

Regards

Bipul

Quality Control Procedure (Part 03)

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8. Table inspector

a. Measure garments are correct for size.

b. Check collar has been attached evenly, and there is no puckering at the front neck opening.

c. Remove lot number stickers. Mb if lot numbers do not all correspond, reject the garment and report to the supervisor.

d. Check for fabric flaws.

e. Check for stains.

f. Check top stitching, buttons and button holes.

g. Check labels

h. Check for neck stretch

i. Check for needle damage


9. Pressing

a. Press garments flat, do not press the front panel and then turn the sleeves over onto it and press, as this leaves sleeve impression marks on the body panels

b. Lightly steam the placket.

c. Fold as demonstrated



10. Final examination

a. Check for stains.

b. Ensure that sleeves / collars / cuffs match the body panel. If there is a variation in shade, then reject-garments. Do not send for packing.

c. Check that the label is central, and that the correct size has been inserted.

d. Check the panels for fabric flaws and holes.

e. Check the top stitching for slipped stitches.

f. Check buttons / button holes.

g. Scan side scams for breaking out.

h. Check placket is straight.

i. Fold as demonstrated



11. Packing

a. Ensure collars are attached evenly - reject garments with puckering

b. In the ease of twin packs, ensure both garments are the same shade.

c. Cheek Kimball and hanging tag for correct size and sew in label.

d. Pack according to customer requirement,'.

12. Quality Inspectors (on each line)

a. Ensure helper’s are correctly instructed to identify make up faults.

b. Machinists should be checked morning and afternoon.

c. Table inspectors should be checked four times daily.

d. Ensure neck stretch is achievable on t-shirts.

e. Check tensions, scam bite, stitches per 2.5cm, and cracking on seams.

f. Check for needle damage.

g. Make sure that the over lockers have taken off the correct seam allowance

h. Check pressing i packing.

i. Check final examination.


13. Supervisors (on each line)

Supervisors are responsible for ensuring that all quality procedures are adhered to, and that quality standards arc maintained throughout the production process. This should reduce the number of garments returned from the final examination area.


14. Single Jersey / Polyester / Cotton Fabric 

Always use number 7 needles, not size number 9 with these fabrics in order to prevent needle damage.

Regards

Bipul

Quality Control Procedure (Part 02)

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Factory Quality procedure


Make Up / Examination / Pressing & Packing


1. Continuity

Before fabric is issued to the cutting department, a swatch is to be taken off each dye batch of fabric, plus collars and cuffs, and mounted onto a continuity card for checking against approved swatch. If a batch is received which does not match the approved swatch, then the fabric is to be rejected. Collars and cuffs should be tested and treated in the same way.


2. Collars/cuffs

Ensure that the correct lot numbers are attached to the main fabric


3. Cutting table

Whew laying out fabric only lay out one lot number at a tune. Check for dye evenness, knitting faults and hand feel.


4. Numbering
a. Each sleeve, front and back panels, and placket should be numbered. In addition, the back neck tape should be given a matching lot number.

b. Stall should be organized so as to have one person sticking numbers, and another bundling.


5. Sewing

a. When bundles of work arc loaded onto the line, the line supervisor should check that collars, culls, plackets and body panels have the same lot number before stitching begins

b. When cutting down the ccntie of the placket, make sure that the cut is slightly to the left hand side as worn. This should ensure that the placket docs not break out on the* right hand bottom corner

c. Check labels.


6. Thread trimmings

Ensure all thread ends are cleanly cut.



7. Initial Examination to be done by helpers on line

The following should be checked

a. All scams for cracking, missed stitching, tensions etc.

b. All top stitching.

c. Buttons and button holes.

d. Placket for breaking out at bottom corner,

e. All seams for needle damage

f. Shoulder tape twisted.

g. Twin needle stitching around neck / armholes is not cracking

h. Twin needle hemming to ensure no raw edges arc visible.

i. Sew in labels arc positioned at the centre of die back neck.

j. Collars are marked to the correct measurement.

k. Tensions.

l. Shoulder tape secure.

m. Neck stretch is achievable and not cracking.

To be continue...................

Quality Control Procedure (Part 01)

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1) Fabrication:

A) Yarn quality and yarn count check.          

B) Lab dip approval

C) Grey fabric check at the knitting stage,

D) Fabrics, collar cuff, rib etc check with approval

E) Fabrics feel in-house test report check each batch.

F) Shrinkage, gsm, color fastness double check in own office.

G) " CMC" report " DEL" "E" value check hatch batches'

H) Shade continuity card all dye lot and keep record.

I) Bulk fabrics approval color wise (if necessary style and order wise also)

*** "CMC" and "DEL" "E"  - Click here

2) Pre production:

Pre production sample approval with all accessories (actual)

3) Cutting:

A) Pattern check with approval sample and spec

B) Test cutting should cover all the sizes and color.

C) Check measurement details.

D) Bulk cutting approval and fabrics lay as per buyer requirement.

4) Sewing:

A) Check accessories, trim with approval

B) Check machineries fitness

C) Check stitch count per inch all sewing operation as per buyer requirement.

D) Machine feet "pressure mark" all swe1ng operation (i.e. placket, placket box, collar, rib and armhole) must be control. Machine feet pressure- mark for darker color not acceptable.

E) Machine tension (O/l, P/m, F/L) operation wise check.

F) For ale the trousers make sure that back & forth stitching on the crouch.

  

5) Finishing:

A) Press garments flat, do not press front placket, collar, front panel armhole and all seam area.

B) All over lock raw edges (i.e. Armhole side seam) laying under the garments same direction

C) For darker color iron show must be used before ironing.

D) Folding and card board marks is not show when garments is flat.

E) Any accessories mark (it. Label, hang tag, tag pin, safety pin, button) are not acceptable.

6) Packing:

A) After folding garments should be neat and clean both side than put in to poly bag and sealed

B) Presentation and get up check before carton.

C) No pressures when closed the carton.

D) Top, bottom, card board and divider must be need before closing the carton’s

Regards

Bipul