QUALITY

Flowchart
Order Confirmation

Preproduction meeting

Documentation check

Fabric arrival

Accessories arrival

Dimensions test

Quantity/Quality Check

Performance test

Performance test

Test cutting

Cutting

Ironing

Assortment

Audit on finished garments

Cut piece inspection

Finishing

Sewing

Final Audit

In line inspection

Visual inspection

General Procedures 1. Factory quality assurance program consists of 3 levels, technical team, production team and audit team. The technical team to do the following a) follow up work before actual production b) Fabric testing and trims testing c) Pattern and marker approval d) Sewing and testing of production samples e) Fabric inspection f) Check the work of cutter, layer, bundler and identify workers with bad quality work g) Check and replace defective cut piece h) Check on embroidery, printing, washing, cutting sewing and finishing sub contractor 2. Production team to do the following work during production to prevent unacceptable garments in production a) Check the work of sewer and identify sewer with bad quality work b) Ensure preventive measures are taken to avoid producing unacceptable garments c) Check on the quality of the garment produced and send rejected garment back to sewer for immediate repair 3. Audit team to do the following work after production to ensure shipped goods are within buyer acceptable level a) Final checking of finished garments, defective garments are sent back for rework b) Do in house audit as per buyer quality requirements c) Ensure preventive measures are taken to reduce the percentage of rejected garments d) To do final audit on packed garments to know factory outgoing quality level e) Check on packing trims f) Check packing assortment 1. 2. 3. 4. 5. 6. 7. Fabric inspection procedure Performance test Composition / color fastness / shrinkage / strength / and other performance are to be tested by quality assurance to buyers requirements. Inspection quantity a) Random sampling of more than 10% of the total number of rolls, minimum of 1 roll for every dye lot Width a) Fabric width is to be measure in 3 parts, 5 yards from beginning of fabric, in the center and at 5 yards from the end of the roll and recorded on fabric inspection report Length a) The length of the roll is to be recorded on fabric inspection report Defects a) See defects list Report a) Inspection report is to be filled up using the 4 point system

Fabric acceptance guidelines 1. Invoice difference due to a) Invoice weight in gross weight instead of net weight b) Shortage of quantity from packing list

c) Shortage of qty from roll d) Purchase order difference e) Density heavier than contracted in purchase order f) Width of fabric difference more than 1 inches g) Fabric trim not proportional to main body fabric 2. Quality of fabric 3. Fabric pinhole width more that 1.50 inches 4. Front and back end of each roll without clean finish 5. Color matching 6. Yarn count 7. Handfeel 8. Shrinkage 9. Color fastness 10.Color shading between 11.Approved shade and dyelots 12.Approved shade by buyer is compared with the dyelots that is given by the fabric mills. Ensure that fabric is cut and separated by dyelots. 13.Dyelots 14.Different dyelots are to be separated and not to be allowed to be mixed 15.Rolls 16.Different rolls must be separated when laying by separator ties,

1. 2. 3. 4. 5. 6. 7. 8. 9.

Paper pattern and marker approval Marker technician with the help of labtest QC cut out fabric test sample yardage to do steaming and washing / dyeing test. At the same time cut sample fabric for making preproduction samples Upon receiving the results of shrinkage, marker technician to advise head office where new adjusted pattern will be received Upon receiving the pattern to check patter and marker for Correct size and ratio Same direction of fabric grain within a garment Stripes are matching within a garment Marker width is according to received fabric width Wastage on the drawn marker In the event of urgent marker is required. Pattern maker technician to do his own pattern and marker.

Cut piece inspection 1. Cut piece inspection is done by the sewing department in the assortment operators. 2. Cut piece is to be compared with paper pattern and determined if suitable for sewing. 1. 2. 3. 4. Fabric and accessories arrival Production officer is to update fabric report and notify of any shortage in terms of density, weight, fabric width of the fabric received. Production officer is to update Accessories report as well as ensure that the accessories received are enough for cut quantity that is calculated in the fabric report Upon arrival of bulk fabric, Store coordinator is to

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a) Remove fabric sticker from fabric for production officer to fax / email back to head office b) Weigh each roll of fabric and update fabric stock card. c) Cut sample yardage total 3 yards. Measure 5 yards from beginning of the roll before cutting sample. d) Get advice from sample coordinator on the quantity required to cut for sample marking. All the fabric is given to sample coordinator to do preproduction sample e) Store fabric by dye lot f) From the 3 yards of sample to g) Cut sample yardage to check on density in terms of grams per yard and fabric width of fabric marking with dye lots and roll number on sample yardage h) Assist production officer to update accessories chart with fabric and accessories swatches i) Assist production officer to update accessories chart with fabric and accessories received quantity and dates j) Balance fabric to pass to Quality assurance k) prepare Fabric stock card according to purchase order check the following a) Weigh each roll of fabric to see if there is weight discrepancy with fabric packing list or fabric invoice b) if there is difference in density from fabric purchase order c) if there is difference in width from fabric purchase order d) the needle hole edge is not to be more than 1 inch e) the front and back end of fabric are clean finished f) the weight stated in packing list or fabric invoice is gross instead of net weight g) body fabric and trims fabric are proportional in weight Upon arrival of accessories, Store coordinator to a) weigh and count all accessories b) check quality of accessories corresponds with production chart c) check against supplier packing list / delivery order for discrepancy d) display all accessories received e) accessories are not allowed to be kept in cartons f) record all the actual quantities received in accessories stock cards. g) make sure that there is no issue of any accessories without approval. h) make sure that accessories are to be issued by input quantity corresponding to sample consumption Production officer to update production fabric and accessories chart and pass to production manager for approval Production officer is to pass a copy to each of the following departments a) Accessories store b) Sewing department c) Packing department d) Self keeping e) 4 copies to cc to head office f) Submit to production manager for immediate approval Sample coordinator to a) Collect fabric and accessories from Store coordinator. b) To sew up samples for production manager approval and comments. c) Once sample is approved to pass to production officer to pass to buyer QC for comments. d) calculate accessories consumption and pass to production officer and production manager for approval

Inline quality check 1. Inline QC will patrol the sewing line doing the following a) filling the measurement chart. b) checking on workmanship c) cheking on sewing method d) informing the sewing line supervisor on any defective workmanship e) assist sewing line supervisor in overcoming workmanship and measurement issues Visual inspection 1. Visual inspection or table QC is done at the end of sewing a) 100% of output is to be visually inspected for the following critical and major defects table QC form is to be filled in and comments to be added. Monitor drop in workmanship and measurement defects b) Table QC form is to be given to QA at the end of the day to be counter signed by management. 2. If table QC finds same issues repeatedly, sewing line supervisor should be informed and problem have to be corrected before operator is allowed to continue. Internal Audit 1. Upon completion of a po of an order, QA should do an internal audit. Internal final or audit is usually done before final buyer QC for internal purposes. a) Famous Textile uses the MIL-STD-105E. b) We usually do internal final audit based on AQL 4.0General inspection level II. c) On page 13 of MIL-STD-105E is the lot or batch size. d) On page 14, will tell us the correct sampling qty and accept and reject qty. 2. Internal audit report will determine if order is ready for buyer qc final, 3. Should internal audit be of a failed status, cartons should be opened and issues rectified before buyer qcs arrival.

Fabric defects list Yarn Slubs Barre Uneven yarn Yarn contamination Dead cotton Other Construction Missing line Holes Streaks Stop mark Knots Other Dyeing Dye spots / streaks Color tone Shading Other Finishing Bowing/ skewing Pin holes Width Other Cleanliness Stains Oil spots Dirt soil Other