Dhaka, Bangladesh Assignment On Production Process flow chart & quality check points of garments manufacturing

Submitted By: Abdullah Ali Akbar Reja FMP-1, 3rd Sem. Id- 2010-4-219

Submitted To: Md. Tamim Jahan Faculty, PFI

Submission Date: 01 July, 2010

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Table of Content

No 01 02 03 04 05 06 07 08

Subject Introduction Quality & quality inspection Process flowchart for mans full sleeve shirt manufacturing

Page 02 03-07 08

Quality check point in process flowchart 09 SEWING SECTION (Operation breakdown OF MANS FULL 10-12 SLEEVE SHIRT) Quality check point in sewing section according to operation breakdown References & bibliography 13 14 15

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Introduction

A product must satisfy the consumer in terms of beauty, attractiveness, taste, shape, design and longevity of depending on the type of product. A product devoid of quality has no demand among consumers and as such has no salability. So it is very necessary for every company to establish quality check or quality assurance department in the industry. This assignment helps me to understand inspection methodology for sewing, finishing, and packing, help me to evaluate various production processes. It also helps me to source information and to collate, evaluate and manage it, communicate clearly and succinctly in both oral and written form.

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Quality & Quality Inspection
Quality: Quality is an ideal, a condition of excellence. Product quality is based on a product attribute. User-based quality is fitness for use, manufacturing based quality is conformance to requirements, value based quality is the degree of excellence at an acceptable price. ISO 9000:2000 Define it is “degree to which a set of inherent characteristics fulfill requirement.” Quality inspection in apparel industries: Quality inspection is done to control quality of garments. Checking of fabric, sewing thread, button, stitch, zipper, garments size etc according to required standard or specification is known as inspection. Quality inspection is important for every section of apparel industries. There are three steeps in apparel industries to control quality, i.e. 1. Raw Material Inspection; 2. In Process Inspection; 3. Final Inspection; Raw Material Inspection: Fabric, sewing thread, button, trims, interlining, labels, tags quality check is done in raw material inspection steep. 1. Fabric Inspection: Normally fabric inspection is done through Fabric Inspection machine. It is very important for every industries check fabric before cutting. In fabric inspection their checks several things i.e. in fabric are there any defect available or not. In fabric, fabric defects viz. off shad or shade variation, hole in fabric, barre effect etc. can be visual after entering into the store room. For those defects it will be problem able for making garments making. In fabric inspection there also check fabric strength, color, quantity, bayous. To check fabric there are different system i.e. 4 point system, 10 point system etc.
2. Sewing Thread Inspection:

During stitching fabric frequently brakeage of sewing thread is one of the great problems for garments manufacturing. So that it is necessary to check thread construction, sew ability, color, imperfection, finish, package density, winding, yardage of sewing thread.
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In thread construction thread number, thread ply, thread balance, thread tenacity, thread elongation, number of twist is necessary to check. 3. Trims & Accessories check: Button, interlining, label & tags are also need to check so that quality can be maintain according to required quality. For button, button strength, button color, quantity etc are check. In Process Inspection Inspectioning different parts of garments before sewing are called in process inspection. It starts from marker making, than fabric spreading, fabric cutting, fabric sewing, pressing or finishing checking is done in process. Marker Making: For some marker fault quality of garments can be lower, i.e.

It is necessary to check all the parts of garments pattern are in marker. In marker labeling or coding of pattern should be check Pattern direction should be check. The entire pattern are sated correctly should be check. Pattern grain line is very important thing which must be considered during marker making. During marker making every pattern pieces dimension should be accurate. During marker making fabric length and width should be consider.

• • •

Fabric Spreading: For those fault which effect garments quality occurs during fabric spreading and should be consider is given bellow; •

During fabric spreading it should be spread according to marker length and width and fabric alignment should be correct in both sides. Fabric should not be spread so tight or loose. During fabric spreading because of uneven tension in fabric bias or bowing can be create. Fabric must be spread in proper way so that fabric wastage can reduce.
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• •

• •

It should be consider are there any static electricity problem is available or not. Fabric ply must be spread correctly

Fabric Cutting: For high quality garments high quality cutting is necessary. To control fabric cutting quality good there must be consider some things; • • • • • Pattern dimension and cutting parts dimension is same or not. Cutting parts edge how much smooth and clear. Are there any parts add with other parts because of fusion problem. Notch mark cutting is done accurately. Drill mark is placed correct position & size or not.

Shorting/ Bundling: It is necessary to check numbering, shorting, and bundling is done accurately. Fabric Sewing: In garments industries most large & important section is sewing section. In this section it is necessary to check all the machine operators’ work. In this section some common faults and problems must be considered, these are; 1. Sewing defects: Needle damage; Skipped stitch; Thread breaks; Seam pucker; Wrong stitch density; Uneven stitch; Staggered stitch; Improperly formed stitch; Oil spot or stain.
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2. Seaming defects: Uneven width; Fault stitch line; Back stitch must be given properly; Twisting; Check or strip matching; Seam matching; Wrong stitch face side or back side; Thread color shade variation. 3. Assembly defects: If finished component does not accurate size. Garments do not accurate in size. If any design skip to join. Component is not joining in right place. If lining is tight or loose. If parts direction is wrong. 4. Pressing or Finishing: Fabric burn or burn spot attach with body. Any types of water spot. Color shading occurs because of hot ironing. Button is insecure or broken. Garments are folding accurately. Pocket is pressed smoothly and except fold. Garments shape is accurate. Those things are plays important role that have to be check during in process.
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Final Inspection In final inspection generally inspect fully complete garments. Before final inspection there has no chance to check complete garments. It is important from the buyer to finally check. In final inspection normally garments size, form fitting, fabric faults are check. Size: For size, it is check according to what size is written in size label. Shirt inspection check list
No 01 02 03 04 05 06 07 08 09 Location Collar Size Button & button hole Pocket Hem Yoke & shoulder Side seam Cuffs Finished appearance Inspect for Both points are same or not, strip or check is match accurately, stitch, collar flat or not. Size label is in correct place, and every parts size is correct or not. Placed in right place or not, evenness of gap between one button to other, stitch is done correctly, are there any broken button or not. Pocket upper edge horizontal or not, pocket position, size, stitch, stripe or check is match, flat or not. Stitch, are there any puckering occur or not, edge free from stitch. Stitch, puckering problem, skipped stitch. Pattern matching, stitch, free from raw edge Strips or check matching, top stitch, flat or not. Threads edge comes out or not, are there any oil spot or not, fabric fault, color matching, strip matching.

Packing: Before packing it is necessary to check fabric is free from broken needle. It is also need to check packing raw material is free from making any problem in garments and after packing it is packed accurately.

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Process flowchart for mans full sleeve shirt manufacturing
Side Operation Operation Design/ Sketch Pattern Design Sample Making Costing Production Pattern Grading Raw Materials in Into Store Marker Making/ Lay Planning Fabric Spreading Fabric Cutting Shorting/ Bundling Fusing Sewing/ Assembling Manual Manual Method Manual

Basic Block

Manual

Manual

Manual

Iron Press
Lock Stitch, Over Lock, Button Holing, Button Attaching M/C

Final Pressing/ Finishing

Ironing

Final Inspection

Manual Manual

Packing Deliver to Buyer

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Quality check point in process flowchart
Side Operation & Quality Check Operation Raw Materials in Into Store Quality checking of Fabric, Button, Sewing thread, fusing paper, trims, label & tags etc Marker Making/ Lay Planning Fabric Spreading Manual Method

Quality Check

Marker Inspection Quality Check/ Fabric Inspection

Manual

Quality Check/ Fabric Inspection Fusing Quality Check

Fabric Cutting

Manual

Shorting/ Bundling

Iron Press
Lock Stitch, Over Lock, Button Holing, Button Attaching M/C

Sewing/ Assembling

Final Pressing/ Finishing

Ironing

Final Inspection Inspection

Manual

Packing Deliver to Buyer

Manual

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SEWING SECTION (Operation breakdown OF MANS FULL SLEEVE SHIRT)
Operation Breakdown Style No: Buyer: MENS F/SLV SHIRT WHITE & STYPE FABRIC(COLLAR,BAND, BOX Description: PLKT) NONE FUSED,BOX PLKT KANSAI, DOUBLE BACK YOKE,PKT W/SML PKT,FRONT SIDE PANAL,FRONT LOOP S/N Operation M/C Attachment COLLAR 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 MATCH & MARK COLLAR PARTS MAKE LOWER COLLAR W/LINING TRIM / TURN LOWER COLLAR PRESS LOWER COLLAR TS LOWER COLLAR-1/16 TS LOWER COLLAR-1/4 MAKE UPPER COLLAR W/LINING TRIM / TURN UPPER COLLAR PRESS UPPER COLLAR TS UPPER COLLAR-1/16 TS UPPER COLLAR-1/4 HEM COLLAR BAND W/LINING ATT.COLLAR BAND TO COLLAR TURN & TS COLLAR BAND B/H COLLAR BAND-1 ATT. BTN ON BAND-1 TRIM BOTTOM OF C/BAND POCKET 18 19 20 21 22 23 MAKE PLIT ON SMALL POCKET X 2 TACK PLIT TWOSIDE 2 X 2 PRESS HEMOF SMALL POCKET-2 PRESS SMALL POCKET-2 SMALL POCKET POSITION MARK AT MAIN POCKET SMALL POCKET JOIN WEITH MAIN LS1 LS1 LS1 IRON MAN LS1 MAN LS1 MAN MAN LS1 LS1 LS1 MAN MAN LS1 LS1 LS1 LS1 LS1 BH BS MAN TABLE NG-1/4''
CLR TURNING

CLR PRESS CR 1/4'' NG-1/4''
CLR TURNING

CLR PRESS CR 1/4'' CR-5/16" NG-3/16" CR-1/16" LBH-781 LK-1903 MO-1950

CL-1/16" TABLE TABLE CR-1/16"
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24 25 26 27 28

POCKET T/S SMALL POCKET MAKE PLIT ON MAIN POCKET X 2 TACK PLIT TWOSIDE 2 X 2 PRESS HEMOF MAIN POCKET-2 PRESS MAIN POCKET-2 FRONT LOOP AT SHOULDER

LS1 LS1 LS1 LS1 IRON

CR-1/4"

CL-1/16" TABLE

29 30

LOOP ROLLIN LOOP MAKE BACK PART

LS1 LS1

31 32 33

ATC MAIN LABEL W/ INSERT SIZE LBL TO BK YOKE LS1 ATC BK YOKE TO BK LS1 TOPSTITCH BK YOKE LS1 FRONT

REG FOOT

34 35 36 37 38 39 40 41 42

HEM T/S BOX PLACKET KANSAI HEM TS BTN PLKT LS1 1/16" EDGE STITCH BTN PLKT LS1 TACK CARE LABEL TO FRONT LS1 ATTACH MAIN POCKET LS1 T/S MAIN POCKET LS1 MATCH & MARK FRONT LOOP AT SHOULDER MAN ATT SHOULDER WITH FRONT LOOP T/S STITCH SHOULDER SLEEVE LS1 LS1

FT 1/4"-1"1/4" FOLDER CR-1/16" REG FOOT CR-1/16" CR-1/4" TABLE 1/4' FOA FOLDER

43 44 45 46 47

SLEEVE GAMBLE SLEEVE GAMBLE TUCK SLEEVE PLACKET ATTACH CUFF INTERLINING CUFF ROLLING

LS1 LS1 LS1 MAN LS1

IRON
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48 49 50

CUFF MAKE CUFF TS CUFF JOIN FINAL ASSEMBLY

LS1 LS1 LS1

51 52 53 54 55 56 57

ATT./TS SLEEVE ARM- HOLE ATTACH COLLAR TO BODY ATT. TWIL TAPE TO CLR CLOSE COLLAR

CS2 LS1 LS1 LS1

1/4" FOLDER T- GUIDE GUIDE CR-1/16" T guide

BOTTOM HEM LS1 SEW BUTTON HOLE AT BODY X 6 & LOOP BH ATT. BTN TO BTN PLKT & LOOP BS

CL-3/8

Sketch

Front side

Back side

Fig: Men’s Full sleeve shirt

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Quality check point in sewing section according to operation breakdown
1
BH POC KET STA RT

TBL

7

LS1

LS1 3 8 LS1

SLEEVE

MAN LS1

MAN

15

1 4 1 7 1 8

LS1

LS1 LS1

MAN

CLR END & Q/C

LS1 LS1 LS1

2 7 LS1 2 6

LS1

2 5 2 4

PK T EN D

LS1

IRON

2 8

3 2

LS1

1 3

LS1

3 1 3 0 2 9

Q/ C F/ LO OP

Q/C – Quality checking point. Directio n

LS1

B K P R T

5 5

1 2

LS1

3 3

LS1

LS1

Q/ C

5 4

1 1

LS1

KANSAI

3 4

LS1

T A B L E

5 3

3 5

LS1

1 0

LS1

LS1

5 2

9

3 6

CS2

5 1

8

3 7

IRON

6

3 9

46

LS1

LS1

4 0

MAN/TABLE

LS1

LS1

LS1

2 3

2 2

1 9

2 0

4

3

BS

2 1

IR O N

1 6

MAN

MAN

TBL

CO LL ER ST AR T

START 2 LS1 Q/A LS1 4 2 LS1 5 LS1 4 1

LS1 43 Q / C 44

LS1 45

LS1 47 57 BS

LS1 48 56 BH BH

LS1

LS1 50

LS1 49

Q / C

F I N A L A S S E M B L Y

Q / C

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Conclusion
This is a great opportunities for me doing this assignment on quality check. To complete this project I do my best. I have gathered much experience doing this assignment. I learn how to check quality for manufacturing Men’s shirt, process flowchart for garments manufacturing and quality check point. I understood inspection methodology for sewing finishing and packing.

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References & Bibliography
1. Cooklin, G. (1991) Introduction to Clothing Manufacture. Oxford: Blackwell

Publishing Company.
2. Kashem, M. A. (1993) Garments & Technology. Dhaka: Grantho Nir Publishers.

Sketch:
3. Reja, A. A. A (2010) Men’s Full sleeve shirt. [Sketch]

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