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ASSIGNMENT ON GARMENT MANUFACTURING - QUALITY

CONTROL.PDF

Page 5 of 48
Quality is a multi-dimensional
aspect. There are many aspects
of quality based
on which the garment exporters
are supposed to work.
- Quality of the production.
- Quality of the design of the
garment.
- Purchasing functions' quality
should also be maintained.
- Quality of final inspection
should be superior.
- Quality of the sales has to be
also maintained.
- Quality of marketing of the
final product is also important
as the
quality of the garment itself.
See to it that......
There are certain quality related
problems in garment
manufacturing that
should not be overlooked:
Sewing defects - Like open
seams, wrong stitching
techniques used, same color
garment, but usage of different
color threads on the garment,
miss out of
stitches in between, creasing of
the garment, thread tension and
raw edges
are some sewing defects that
could occur so should be taken
care of.
Color effects - Color defects
that could occur are - difference
of the color of
final produced garment to the
sample shown, accessories used
are of wrong
color combination and
mismatching of dye amongst
the pieces.
Sizing defects - Wrong
gradation of sizes, difference in
measurement of a
garment part from other, for
example- sleeves of 'XL' size
but body of 'L'
size. Such defects do not occur
has to be seen too.
Garment defects - During
manufacturing process defects
could occur like -
faulty zippers, irregular
hemming, loose buttons, raw
edges, improper button
holes, uneven parts,
inappropriate trimming, and
difference in fabric colors.
Conclusion
Quality is ultimately a question
of customer satisfaction. Good
Quality
increases the value of a product
or service, establishes brand
name, and builds
up good reputation for the
garment exporter, which in turn
results into
Page 6 of 48
consumer satisfaction, high
sales and foreign exchange for
the country. The
perceived quality of a garment
is the result of a number of
aspects, which
together help achieve the
desired level of satisfaction for
the customer.
Therefore quality control in
terms of garment, pre-sales
service, posts sales
service, delivery; pricing, etc
are essentials for any garment
exporter.
Necessity Of Quality
Control On Garment
There are main three factors for
our garment sector. They are as
follows:
I) Price
II) Lead-time
III) Quality
From those we cannot control
price and lead time. But we can
control one
thing “Quality”. If we make
high quality product then we
may have a chance
to increase the price, and
expend the lead-time from
buyer. Quality is the
key to survive in this high
competitive world market. That
is why Quality is
important.
Quality Control
QC refers to the measures that
must be included during each
assay run to
verify that the test is working
properly.
Quality Assurance
QA is defined as the overall
program that ensures that the
final results
reported by the laboratory are
correct.
“The aim of quality control is
simply to ensure that the results
generated by
the test are correct. However,
quality assurance is concerned
with much
more: that the right test is
carried out on the right
specimen, and that the
right result and right
interpretation is delivered to the
right person at the
right time”
Total Quality Management
(TQM)
An integrated effort designed to
improve quality performance at
every level
of the organization. Quality in
each and every section of an
organization both in
product and service is called Total
Quality Management.
Page 7 of 48
Factory Detail
Name of the factory : Interfab
Shirt Manufacturing Ltd.
 A Sister Concern of
Viyellatex Group of Industries.
Location : Borobari, Gazipur.
Establishment : 1998
Basic products : Shirt & Blouse
Product Category : Men’s dress,
casual shirt, ladies blouse, school
wear
& Fashion wear.
Building Structure : Six (6)
storied
Working areas : 250,000 sqf.
Production : 600,000 Pecs per
month.
- Supposed by their washing,
printing, and embroidery section.
- One stop service for all trims and
accessories except cartooning.
Interfab Shirt manufacturing Ltd.
is an export oriented oven shirts
garments
factory. Now it has 30 production
lines. It supplies to the world’s
famous brand
retailers like Marks & Spencer,
PVH, Tesco, TU, Adams, and
H&M etc.
This factory has fully automated
cutting section supported by
Gerber with multi
work station Computer Aided
Design (CAD), multi spreader and
leaser guided cutter.
Around 1000 oil-free stitch
programmable Japanese sewing
machines with various
type fusing machines and auxiliary
facilities are installed there for the
purpose of full
non- iron shirt production.
Conveyor system with 24 Vacuum
Tables and 26
automatic Folding Tables are also
installed there

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Assignment on Garment Manufacturing - Quality Control.pdf

TRANSCRIPT OF ASSIGNMENT ON GARMENT MANUFACTURING - QUALITY CONTROL.PDF
Table of Contains Name of Topic Page No Quality Control Aspects Of Garment ExportsQuality is

ultimately a question of customer satisfaction. Good Quality increases the value of a product or

service, establishes brand name, and builds up good reputation for the garment exporter, which in

turn results into consumer satisfaction, high sales and foreign exchange for the country. The

perceived quality of a garment is the result of a number of aspects, which together help achieve the

desired level of satisfaction for the customer. Therefore quality control in terms of garment, pre-sales

service, posts -sales service, delivery, pricing, etc are essentials for any garment exporter. For every

industry or business, to get increased sales and better name amongst consumers and fellow

companies it is important to maintain a level of quality. Especially for the businesses engaged in

export business has to sustain a high level of quality to ensure better business globally. Generally

quality control standards for export are set strictly, as this business is also holds the prestige of the

country, whose company is doing the export. Export houses earn foreign exchange for the country,

so it becomes mandatory to have good quality control of their products. In the garment industry

quality control is practiced right from the initial stage of sourcing raw materials to the stage of final

finished garment. For textile and apparel industry product quality is calculated in terms of quality and

standard of fibres, yarns, fabric construction, color fastness, surface designs and the final finished

garment products. However quality expectations for export are related to the type of customer

segments and the retail outlets. There are a number of factors on which quality fitness of garment

industry is based such as - performance, reliability, durability, visual and perceived quality of the

garment. Quality needs to be defined in terms of a particular framework of cost. The national

regulatory quality certification and international quality programmers like ISO 9000 series lay down

the broad quality parameters based on which companies maintain the export quality in the garment

and apparel industry. Here some of main fabric properties that are taken into consideration for

garment manufacturing for export basis: Overall look of the garment.Page 2 of 48 - Right formation

of the garment. Feel and fall of the garment. Physical properties. Color fastness of the garment.

Finishing properties Presentation of the final produced garment. Sourcing of Fabrics There are

certain problems that could be faced by garment manufacturers when sourcing for certain fabrics, so

precautions should be taken for it beforehand to minimize the problems. The garment exporters
source cotton fabrics mainly from handloom sectors, power looms and mills. Each of these sectors

presents their own unique set of problems to the garment exporters. Sourcing cotton from handloom

sectors might present some set of problems like color variation, missing ends and picks, irregular

weaves and unreliable supplies. However, the handloom sector is significant source of heavier

cotton. Common problems faced in power loom cotton sourcing are broken ends and reed marks,

thick and thin places, difference in width and massive variation in costing. The major problem in mill-

made fabric sourcing is to meet huge demands from the mills. Fabrics have to be ordered well in

advance in mills and the long time taken for producing the fabric is a matter of concern for garment

exporters. Mills generally hesitate to take small orders which pose a problem for small scale

exporters. It is not that sourcing problem which only confined to cotton fabrics, but also to other

fabrics as well. In silk garment industry there are some sorts of problems faced by silk garment

exporters. Some of the problems that could be faced by silk garment exporters are as follows: .

Shortage of imported silk yarns in the quantities required, as a result delivery is delayed. . Silk

material is very vulnerable to stains during manufacturing process as well as stocking, staining

results in rejection so a lot of care has to taken during these procedures. . Roll length of the silk yarn

is often insufficient. Page 3 of 48 . Color fastness of dyed silk material is sometimes not

satisfactory. . There are also chances of warp breakage. Basic Thumb Rules for Garment Exporters

For a garment exporter there are many strategies and rules that are required to be followed to

achieve good business. The fabric quality, product quality, delivery, price, packaging and

presentation are some of the many aspects that need to be taken care of in garment export

business. Some rules that are advisable for garment exporters are listed below: Quality has to be

taken care by the exporter, excuses are not entertained in international market for negligence for low

quality garments, new or existing exporters for both it is mandatory to use design, technology and

quality as major up gradation tools. Apart from superior quality of the garment, its pricing, packaging,

delivery, etc has to be also taken care of. The garment shown in the catalogue should match with

the final garment delivered. It is important to perform according to the promises given to the buyer,

or else it creates very bad impression and results in loss of business and reputation. In international

market, quality reassurance is required at every point. Proper documentation and high standard
labels on the garment are also important aspects as these things also create good impression.

Timely delivery of garments is as important as its quality. If your competitor has the better quality of

garment in same pricing, it is better to also enhance your garment quality. Before entering into

international market, garment exporters have to carefully frame out the quality standards, or else if

anything goes wrong it could harm the organization. And after that strictly follow it. The garment

quality should match the samples shown during taking the orders. The garment exporters should

know to negotiate a premium price after quality assurance is done. Page 4 of 48 Quality is a multi-

dimensional aspect. There are many aspects of quality based on which the garment exporters are

supposed to work. Quality of the production. Quality of the design of the garment. Purchasing

functions' quality should also be maintained. Quality of final inspection should be superior. Quality of

the sales has to be also maintained. Quality of marketing of the final product is also important as the

quality of the garment itself. See to it that...... There are certain quality related problems in garment

manufacturing that should not be overlooked: Sewing defects - Like open seams, wrong stitching

techniques used, same color garment, but usage of different color threads on the garment, miss out

of stitches in between, creasing of the garment, thread tension and raw edges are some sewing

defects that could occur so should be taken care of. Color effects - Color defects that could occur

are - difference of the color of final produced garment to the sample shown, accessories used are of

wrong color combination and mismatching of dye amongst the pieces. Sizing defects - Wrong

gradation of sizes, difference in measurement of a garment part from other, for example- sleeves of

'XL' size but body of 'L' size. Such defects do not occur has to be seen too. Garment defects -

During manufacturing process defects could occur like faulty zippers, irregular hemming, loose

buttons, raw edges, improper button holes, uneven parts, inappropriate trimming, and difference in

fabric colors. Conclusion Quality is ultimately a question of customer satisfaction. Good Quality

increases the value of a product or service, establishes brand name, and builds up good reputation

for the garment exporter, which in turn results intoPage 5 of 48 consumer satisfaction, high sales

and foreign exchange for the country. The perceived quality of a garment is the result of a number of

aspects, which together help achieve the desired level of satisfaction for the customer. Therefore

quality control in terms of garment, pre-sales service, posts sales service, delivery; pricing, etc are
essentials for any garment exporter. Necessity Of Quality Control On GarmentThere are main three

factors for our garment sector. They are as follows: I) II) III) Price Lead-time Quality From those we

cannot control price and lead time. But we can control one thing Quality. If we make high quality

product then we may have a chance to increase the price, and expend the lead-time from buyer.

Quality is the key to survive in this high competitive world market. That is why Quality is important.

Quality ControlQC refers to the measures that must be included during each assay run to verify that

the test is working properly. Quality AssuranceQA is defined as the overall program that ensures that

the final results reported by the laboratory are correct. The aim of quality control is simply to ensure

that the results generated by the test are correct. However, quality assurance is concerned with

much more: that the right test is carried out on the right specimen, and that the right result and right

interpretation is delivered to the right person at the right time Total Quality Management (TQM)An

integrated effort designed to improve quality performance at every level of the organization. Quality

in each and every section of an organization both inproduct and service is called Total Quality

Management. Page 6 of 48 Factory DetailName of the factory : Interfab Shirt Manufacturing Ltd. A

Sister Concern of Viyellatex Group of Industries. Location Establishment Basic products Product

Category : : : : Borobari, Gazipur. 1998 Shirt & Blouse Mens dress, casual shirt, ladies blouse,

school wear & Fashion wear. Building Structure Working areas Production : : : Six (6) storied

250,000 sqf. 600,000 Pecs per month. - Supposed by their washing, printing, and embroidery

section. One stop service for all trims and accessories except cartooning. Interfab Shirt

manufacturing Ltd. is an export oriented oven shirts garments factory. Now it has 30 production

lines. It supplies to the worlds famous brand retailers like Marks & Spencer, PVH, Tesco, TU,

Adams, and H&M etc. This factory has fully automated cutting section supported by Gerber with

multi work station Computer Aided Design (CAD), multi spreader and leaser guided cutter. Around

1000 oil-free stitch programmable Japanese sewing machines with various type fusing machines

and auxiliary facilities are installed there for the purpose of full non- iron shirt production. Conveyor

system with 24 Vacuum Tables and 26 automatic Folding Tables are also installed there Page 7 of

48 Present working StatusManagement Staff : 58 280 2412 2750 Non-Management Staff : Workers

Total Manpower : : Yearly Turn over2000-2001 2001-2002 2002-2003 2003-2004 2004-2005 2005-
2006 2006-2007 2007-2008 2008-2009 : : : : : : : : : 3.2 million 4.05 million 5.75 million 7.00 million

8.93 million 9.11 million 14.00 million 17.5 million 20.7 million 24.00 million 2009-2010 (Projected) :

Page 8 of 48 Overview of Factory- Designed as a State of art Readymade Garments factory. Ensure

productive under ethical, legal and humane condition. High professional and experienced work force.

Having very strong sourcing capabilities both local and external. Values of the factoryTheir dreams

inspire them. Their plans drive them. Their customers make them thrive. Their team is buyer. Their

innovation energizes them. Their standards keep rising. Strength of the factoryThey are compliance

with GSP, ETI, BSCI & local law. On time delivery on quality garments. Low rate of migration. Happy

working environment. Technological InitiativesTheir entire business is being arranged by worlds

renowned ERP solution SAP. - They are using Fast React software for their production planning.

They are using GSD for workout the SMV of all articles. Page 9 of 48 Organogram of Quality Control

of Factory Major Fateh-UL-Islam, Psc(Retd.) Chief Operating Officer Interfab Shirt Manufacturing Ltd

QC Manager Quality Controller Quality Controller Quality Controller Quality Controller Quality

Inspector Quality Inspector Quality Inspector Quality Inspector Store & Sample Pattern, Marker &

Cutting Sewing Finishing In-Line Quality Inspector End-Line Inspector They have 30 sewing line

every line have in-line quality inspector and end-line inspector. Page 10 of 48 Buyers of Interfab

Shirt Manufacturing LtdByuer Name Marks & Spencer Logo S. Oliver PVH G-STAR PUMA E-SPRIT

ITO YOKADO Page 11 of 48 Section wise quality control of Interfab Shirt Manufacturing LtdTo

insure quality of the product, quality control personal check each and every different section of the

factory. 1. Store:Every material comes in the store first. It makes store very important in quality

control. In store the factory quality people check inventory, fabric quality, the correct fabric is

imported or not, the color, other material, trims and accessories. The inspection team can perform a

visual inspection of products as available at the beginning of the production cycle against a client's

instructions and Purchase Order specifications. The "Initial Production Check" when combined with

a "Final Random Inspection" and any other on-line production checks, helps in taking corrective

actions at an early stage of production cycle. The inspection team will send out intermediary reports

to Page 12 of 48 the client and keep them informed about the production progress relative to the

delivery terms. Product development and approval We ask factories to develop each fabric, each
garment and each item before starting a bulk production run to make sure that the supplier masters

all aspects of the production for a specific item. All quality aspects have to be approved: shrinkage,

gsm, M/m defaults, measures, look, pH, colorfastness, pilling, Approving all accessories ensures

that the whole consignment will not be delayed because of failure to supply one accessory -> sewing

thread, labels, buttons, zip, boxes, shipping notice, polybags, sealing tape, Yarn Yarn is checked

upon delivery. We check the report about the quality of the raw material delivered with the yarn. This

report tell us mainly the staple length of the raw material fibres, the micronaire (diameter of fibres),

shape of fibres,...the count of the yarn, its contamination-free performance, evenness of the yarn

(thick & thin places, neps), roughness, elongation performance. Weaving At the knitting and weaving

stage, we can already obtain a fair idea about finished fabric: gsm, fabric appearance, fabric

composition, density (number of ctheirse per cm or inch) even if we know that the dyeing process

will have a strong impact on all these parameters. Other tests consist of removing any knitting

defects. Page 13 of 48 Dyeing Fabric is washed, bleached, dyed, put through a calendering machine

and a bath of softener or other kind of bath to give specific characteristics to the fabric (ignifuge,

bacteria free, ) compacted and dried. This process has a strong impact on the shrinkage of the

fabric, its softness, resistance and its pH (important for the skin). Before sending the fabric for

cutting, we check and approve the most important aspects at this stage: constant color matching

based on their standard but also with previous productions. For this we use light boxes and the

SPM. Other crucial aspects to be checked are pilling and colorfastness. CMT At that making stage

we start the garment production as such. Here, after 24 htheirs of fabric relaxation (to reduce the risk

of shrinkage, twist or skewage), we cut, stitch, trim, iron, fold and pack the garments. Each of these

steps has an influence on various quality aspects such as shrinkage, spots, measurements, general

aspect of the garment. At the end of sewing lines, each garment is individually checked. Main quality

aspects here are: measurements, the design, cut and look of the whole garment (we also check the

patterns used by the workers to cut the fabric parts) Major/minor defaults (holes, spots, threads,..),

garment accessories (button, zip, eyelet, stoppers, cords, stud,) have been checked upon delivery

and is now checked again once on the garment. Page 14 of 48 Accessories The difference can be

located in terms of certain details. The look, the design, the technical performance of the
accessories that we use for their garments are of utmost importance. The resistance of a zip, the

practical nature of a button and luminosity of high-visibility strips this is what makes their garments

really theirs. Sewing threads Specification no: date: Needle thread for o/lock, cover seams and L/S

tabbing and finishing Fiber Structure Designation Shade Other requirements Color fastness Bobbin

thread for lockstitch Same as the needle thread Tapes Specification Location Width Structure Shade

Color fastness Zips Specification noPage 15 of 48 Location Length Tapes Shade Color fastness

Stability Other requirement They do the shade variation of the fabric in here. They have lots of space

in store. They have fixed a rack for a buyer. They never put the fabric of buyer to others rack.

Materials are tested from the store before using. In here different materials are gone through

different tests. Like the tearing test of fabric, breaking test of button etc. Process specification

example fabric References spec no Fabric description Product specification nos. relating

Specification no date Machine gauge dam feeders Speed Width roll length finished: Page 16 of 48

Min. useable roll weight finished: Doffing revs: Doffing time Technical manufacturing requirements

Stitch length ground Composition fabric ground (Off m/c) inlay Width (off m/c) Finishing requirements

Processes Finished fabric parameters C/3cm W/3cm wt/sq.m Width overall Process specification -

example Make-up order References spec no Make-up order for Specification no Product

specification no. relating: Manufacturing requirement Page 17 of 48 Operation Seam Spec. Ref.

Extras/seam finish Process specification - example Seam specification References spec no

Specification for Specification ref. no: date Make-up order nos.: Sewing threads Manufacturing

requirements Stitch Bight s/5cm Run-in Needle Tension Fabric Examination Specification For

examination to be a success it is vital that the examiner has an examination specification. This

should include items along the lines of the following:Length Width WeightPage 18 of 48 Incorrect

colors Incorrect pattern Bow and Skew Number of parts Fault rate Dye listing or tilt Stains and marks

They are fully equipped Testing Lab accredited by M&S and PUMA. They use 4 Point system for

inspecting fabric. Inspection of fabricFabric Defect Askewed or Bias : condition where filling yarns

are not square with warp yarns on woven fabrics or where ctheirses are not square with wale lines

on knits. Back Fabric Seam Impression : backing fabric is often used to cushion fabric being printed.

If there is a joining seam in the backing fabric, an impression will result on printed fabric. Barre :
occurs in circular knit. Caused by mixing yarn on feed into machine. Fabric will appear to have

horizontal streaks. Birdseye : caused by unintentional tucking from malfunctioning needle. Usually

two small distorted stitches, side by side. This term should not be confused with birdseye fabric

which is in fact created intentionally. Bowing : Usually caused by finishing. Woven filling yarns lien in

an arc across fabric width: in knits the ctheirse lines lie in an arc across width of goods. Critical on

stripes or patterns and not as critical on solid color fabrics.Page 19 of 48 Broken Color Pattern :

Usually caused by colored yarn out of place on frame. Color Out : the result of color running low in

reservoir on printing machine. Color Smear : The result of color being smeared during printing.

Crease Mark : differs from crease streak in that streak will probably appear for an entire roll. Crease

mark appears where creases are caused by fabric folds in the finishing process. On napped fabric,

final pressing may not be able to restore fabric or original condition. Often discoloration is a problem.

Crease Streak : Occurs in tubular knits. Results from creased fabric passing through squeeze rollers

in the dyeing process. Drop Stitches : results from malfunctioning needle or jack. Will appear as

holes or missing stitches. Dye Streak In Printing : Results from a damaged doctor blade or a blade

not cleaned properly. Usually a long streak until the operator notices the problem. End Out : Occurs

in Warp knit. Results from knitting machine continuing to run with missing end. Hole : caused by

broken needle. Jerk-in : caused by an extra piece of filling yarn being jerked part way into the fabric

by the shuttle. The defect will appear at the selvage. Knots : caused by tying spools of yarn together.

Missing Yarn : Occurs in warp knit. Reuslts from wrong fiber yarn (or wrong size yarn) placed on

warp. Fabric could appear as thick end or different color if fibers have different affinity for dye. Mixed

End (yarn) : Yarn of a different fiber blend used on the warp frame, resulting in a streak in the

fabric.Page 20 of 48 Mottled : Color applied unevenly during printing. Needle Line : Caused by bent

needle forming distorted stitches. Usually a vertical line. Open Reed : results from a bent reed wire

causing warp ends to be held apart, exposing the filling yarn. Will be conspicuous on fabrics that use

different colored yarns on warp and shuttle. Pin Holes : Holes along selvage caused by pins holding

fabric while it processes through tenter frame. Press-Off : results when all or some of the needles on

circular knitting fail to function and fabric either falls off the machine or design is completely

disrupted or destroyed. Many knitting needles are broken and have to be replaced when bad press-
off occurs. Bad press-offs usually start a new roll of fabric. Printing Machine Stop : Dye or ink

smudged along width of fabric as a result of the printing machine stopping. Print Out of Repair :

Caused by print rollers not being synchronized properly. This results in various colors of the design

not being printed in the proper position. Puckered Selvage : Usually caused by selvage being

stretched in finishing or by uneven wetting out in sanforization process. Runner : caused by broken

needle. The runner will appear as vertical line. Most machines have a stopping device to stop the

machine when a needle breaks. Sanforize Pucker : Results from uneven wetting out on sanforize;

usually caused by defective spray heads. Fabric will appear wavy or puckering when Page 21 of 48

spread on cutting table. Difficult to detect while inspecting on inspection machine with fabric under

roller tension. Scrimp : the result of fabric being folded or creased when passing through tenter

frames. Slub (woven fabric) : usually caused by an extra piece of yarn that is woven into fabric. It

can also be caused by thick places in the yarn. caused by fly waste being spun in yarn in the

spinning process. Slub (Knit fabric) : Usually caused by a thick or heavy place in yarn, or by ling

getting onto yarn feeds. Smash : caused by a number of ruptured warp ends that have been

repaired. Soiled Filling or End : Dirty, oily looking spots on the warp or filling yarns, or on packaged-

dyed yarn. Stop Mark : when the loom is stopped, the yarn elongates under tension; when the loom

starts again, the slack is woven into the fabric. Straying End : Warp Knit. Caused when an end of

yarn breaks and the loose end strays and is knit irregularly into another area. Thin Place: often

caused by the filling yarn breaking and the loom continuing to run until the operator notices the

problem. Water Spots : Usually caused by wet fabric being allowed to remain too long before drying:

color migrates leaving blotchy spots. If anyone want to produce high quality garments, you need high

quality piece goods. When a sewing factory receives fabric from the mill, it is difficult to conduct a full

100% inspection of the fabric. Apparel Search recommends a minimum 10% inspection of all piece

goods prior to spreading the fabric. Many factories attempt to inspect the fabric during the spreading,

but this is probably unrealistic to depend on the spreader to control thePage 22 of 48 Often is fabric

quality evaluation. The fabric should be inspected prior to the fabric reaching the cutting tables.

Inspection system of fabric The defect classification works as follows. Size of Defect: 3 inches or

less = 1 point penalty Over 3 inches but not over 6 inches = 2 point penalty Over 6 inches but not
over 9 inches = 3 point penalty Over 9 inches = 4 point penalty Note: a maximum of 4 points should

be charged to one linear yard. Also, note that only "major" defects are charged. The acceptable

score varies. Many companies use 40 points per 100 yards as acceptable defect rate. However,

others may find this not acceptable. Here is some math to show you an example. Total Yardage

received: 5400 Acceptance Point-count: 40 per 100 yards Total Yards Inspected : 540 Total penalty

points found in the sample inspection: 150 points 150 divided by 540 times 100 = 27.77 points per

100 yards (because the allowance is 40 points per 100 yards, this shipment would be acceptable).

Page 23 of 48 Above are only a few examples of fabric testing procedures? In fact, above is only a

short summary of the processes. If you are responsible for inspecting fabric, you really will need to

do more research on this subject Page 24 of 48 They are fully equipped Testing Lab accredited by

M&S and PUMA Marks & Spencer PUMA 10% of all materials comes to the store are inspected

randomly. To issue anything from store they use software named SEP. 2. Sample making:Sample is

the reflection of any factory to the buyer. It is the sample who represents the factory in front of

buyers. Unlike any other factory Interfab is very much careful about their quality of sample. The

points they consider to check a sample are; whether the samples is as per buyers specification or

not, style description, sketch, measurement sheet etc. They have a Product development section

along with the sample section. Page 25 of 48 They create different types of new design here and

give presentation to buyer. 3. Cutting section:Pattern & Marker: At first the patterns are made

according to the size set sample approved by the buyer. Then the sample is checked. The

measurement curved spaces like; arm hole, seam allowances, notch or cut mark, drill mark,

gradation, allowances, pattern part missing, mixed parts, direction of the pattern in marker,

overlapping, etc are carefully checked here. Then the marker goes to marker. The people in marker

section set pattern in different ways to get the maximum efficiency. This factory has a CAD section.

All the markers are done here by CDA. So they get butter, efficient maker in lowest possible time.

The efficiency of their shirts is 88 to 90% varies on styling. Spreading: During spreading they check;

fabric relaxation, incorrect tension of plies, wrong direction of piles, mismatching of checking of

checks and stripes, narrow fabric, shaded fabric. Over all they check if there are any faults on the

fabric. Here spreading is done in two ways: Page 26 of 48 I) II) Auto spreader Manual spreading
Auto spreader is more accurate, efficient and time consuming than manual. Effective inspection

requires random examination of cutting operations. The inspector should not develop a set routine.

You do not want the workers to be in the habit of knowing when and how you will conduct their

inspection. You should make every effort to get a fair representation of the cutting production by

making random checks on the cutting room floor. When checking spreaders, make certain to check

for marker placement, shading, table marks, etc. Here are a few issues to check. Marker Placement:

check that the marker is placed on the spread with the edge parallel to the selvage of the piece

goods. Verify that all cut pieces will be complete. Shading: unless all parts are ply marked, it is

essential to have a system to control shading. Table marks: check the table marks as they table is

marked. tolerance for the splices. Markers: ensure that no markers are creased, damaged, or have

overlapped parts. Splices: after completion of the spread, check splice laps to see that both piles

extend past the marked splice by no less than 1/2 inch and no more than 1 inch. Narrow Goods:

after completion of the spread, check the far edge of the spread to see that all plies extend beyond

the marker line. Tension: check tension during spreading. This is very important on knit fabrics.Page

27 of 48 Allow no minus Count: check the count after completion of spreading, and before cutting.

Count all plies at both ends. There should be no tolerance. Leaning: check carefully to ensure that

one edge of the fabric is square to table top. Visually inspect the alignment of the edge with the table

top. Record the spreading defects by the quantity of defects found for each checkpoint. Any

defective work discovered by the inspector should be immediately corrected. Do not only record the

problem. Make sure to fix the problem immediately. One of the keys to producing good quality

merchandise is an in-process quality control program. Although it is possible to control their outgoing

quality with only a good final audit, it is NOT recommended to simply rely on that approach. Unless

you install an effective in-process quality control program, their cost of excessive seconds and

repairs may be high. It is far more effective to correct the problem at the operator level, then after the

garment is completely assembled, pressed, packages and prepared for shipping. Being able to

deliver their merchandise on time is important to their customers. Good in-process controls help

assure that the final audit runs smoothly and allows for timely delivery. You certainly do not want to

learn in their final audit about problems that could have easily been fixed if detected earlier. The
primary purpose of the in-process auditing is to identify problems as early as possible. A problem

may be caused by the operator, the machine, or other factors. The inline audits will help you find

specific problems in production. The only way to fix a problem is to find the problem. It is important to

find errors as quickly as possible so that they can be corrected as fast as possible. Cutting Cutting

could be done in two different ways:Page 28 of 48 I) II) With marker. Without marker. When cutting

is done manually, there has to be a marker. But cutting is done by auto spreader and auto cutter, no

marker is needed there. But to insure the perfection of cutting a marker is put on the fabric. Interfab

can cut more than 30,000 Pecs of garment in a day. Bundling, Numbering, Cut panel checking After

cutting the cut parts are bundled together. It is done to prevent missing parts, shave variation etc.

Every part of a lair is given a unic number. Numbering is done to make a garment from a lay.

Numbering is done by sticker, pen and machine, depends on the fabric. On every bundle the cut

piece of marker is put on. 8 to 10% of the bundles are checked called cut panel checking. Fusing

SectionAs we know that, we can have maximum quality if the fusing section is under the cutting

section. In this industry fusing, printing, embroidery is controlled by cutting. 4. Sewing Section:There

are some systems are practice in the sewing floor. Interfab takes Traffic Light System. Page 29 of 48

Seam Control checksThese checks should be made on a regular basis usually by the quality control

staff; to ensure that the seams being produced are meeting the technical specification laid down. An

example for a Seam control check card is given below: Fabric strength Needle thread strength Bight

Seam stitches per unit lengthPage 30 of 48 Affect strength across seam Fabric stiffness Needle

thread extensibility Needle thread tension Seam stitches per unit length Affect seam grinning and

gaping Seam stitches per unit length Needle thread extensibility Fabric extensibility Combined

thickness of fabric plies Cover thread thickness Needle thread tension DIAGRAM Presser foot

pressure Affect seam extensibility Stitches per inch There is a minimum below which a seam will not

hold without gaping and grinning, and the stitches will ride prominently on the fabric surfaces. There

is a maximum above which the seam jams with sewing thread, the base fabric is damaged, and the

seam puckers and is thick and rigid. Page 31 of 48 Fault analysis card FAULT APPEARANCE Split

Stitch on Linking Half stitch or part Of stitch CAUSE EFFECT Failure to place whole stitch on point

Weak part in seam which under pressure will break away RESPONSIBILITY ACTION Operative
Remove fabric from points and run on PREVENTION Check each stitch is on a constructive point

when fabric is run on There are some systems are practice in the sewing floor. Interfab takes Traffic

Light System. General faults are, for example, those resulting from machine or operative defects,

which may be common to any garment in the workroom. They may include such as: 1. Skip stitches

2. Unbalanced seams 3. Careless handling faults 4. Seam breakaway 5. Incorrect tensions Job

faults are those which are specific to a given garment e.g. 1. Bad pattern match 2. Wrong

measurement 'Fault Analysis' is the name of a well tried technique in which all facets of each fault

are recorded under appropriate headings. Together with an examplePage 32 of 48 or examples of

each fault the analysis provides an invaluable teaching aid. The headings are indicated below with

an explanation of each Sewing Checksa. Stitches per cm. and thread run-in ratio checked to be

within tolerance of specification. b. Evenness, balance and correct bight, no stitching missed c.

Extensibility and security correct (i.e. no cracking or laddering). d. Absence of skip stitching. e.

Accountability of machinist. In-Process Quality Check (IPQC)The in-process quality check is

designed to provide early warning of quality or other problems arising during production and which

may delay shipment. In other words, it is intended to provide a snapshot of the status of production

at a factory. During production, semi-finished parts must be inspected based on AQL or percentage

according to the company policy and inspection plan. There are perfections charts in the sewing line

and end line. Checks carried out include stocks of raw materials, production rates, estimated

production completion date, production bottlenecks, etc. Page 33 of 48 End line Quality CheckAfter

sewing an end line inspector check 8 to 10% of the finished product. At the end of the line there is a

counting board. It counts the production of every hour. It helps to fulfill the target production. If the

fabric is light colored or white they use a protective cap on collar top. Any spot or dirt on these

sensitive parts, it is very difficult to remove. Control of quality in garment assembly 1. Components of

an Effective System The requirements of an effective system are: i. Specification - i.e. that parts of

the total specification which is required by the making-up supervisor. Page 34 of 48 ii. Monitoring of

a. the product to ensure conformity with the specification b. The machinists to determine where non-

compliance with the specification arises. i. ii. Collection of data - from supervisor's sample checks.

Analysis of data. Corrective action a. short term- fault correction b. long term - fault prevention
Garment check by Supervisor The sample of garments checked by the Supervisor must be

representative of the total production. Sample size is a function of the fault rate and the degree of

confidence required. Typically, at a confidence level of 95% and a fault rate of around 5% the

sample size would be 54 dozen or 648 garments. In the case of a complex garment this would

almost certainly absorb a disproportionate amount of the supervisor's time - bearing in mind her

other duties. The solution is firstly to concentrate the check on the less dependable and skilled

machinists, checking the others mainly at a major change, such as a change of style. Secondly, by

checking those critical faults which are currently at an unacceptable level or are showing an upward

trend. By this procedure a sample of meaningful size can be take in the critical areas. Page 35 of 48

i. Where it is not possible to take the optimum sample, bear in mind the square-law, i.e. that a their

garment, sample is 4x4=16 times better than 1 garment, and eight garment sample is 8x8=64 times

better than a single garment and so on. ii. The sample should be truly random i.e. of a number of

garments, which have passed through a given operation each one, should have an equal chance of

being selected. Checking a given machinist at precisely the same times each day will not produce a

meaningful sample. 1. Data Service for action by Supervisor Data arising from final examination is

invaluable to the sewing room supervisor. Typically findings are recorded on a chart as shown below

and the rate for each fault calculated. 5. Finishing section:Finishing section is the final section to

make the product to sellable condition. Page 36 of 48 They control the finishing section to achieve

the maximum quality possible. Wash garments are 100% checked here. Pressing, folding, tagging,

packing are main operations of finishing. Those operations are checked carefully. Sequence of final

inspection of garments: To perform a reasonable inspection we have to maintain sequences of

different steps of the inspection are as follows: 1. Packing list verify/ compare with P.O. sheet:

Before starting inspection we have to check the final status of the lot with p.o. sheet & packing list.

Checkpoints are as follows: a) Quantity b) Color c) Size d) Packing 2. Inspection preparation: To get

the accrete result we must have well preparation for final inspection are as follows: a) required

facilities are: 1 Sufficient space a. Shade correct and not varying from one part of garment to

another. b. Cut is correct - e.g. neck, collar and sleeves balanced, pockets correct. c. Measurements

within tolerance of specification, weight correct. d. Appearance correct, patterns matching. Page 37
of 48 e. Seams finished correctly, absence of miss stitching, cracking and laddering. f. Accessories

correctly applied and working. g. Absence of fabric faults and stains. h. Correct labeling. i.

Accountability of making-up (volume of work unsatisfactory; break-down under various fault

categories.) Recovery Inspection a. Check whether remedial works satisfactory. b. Check on volume

of work successfully recovered. c. Avoidance of work recycling. Yarn Checks 1. Count Tests on

Staple Fiber Yarns: Check on count variability, within cones and between deliveries: to be within

tolerance of specification. If coarse, yarn utilization impaired. Check on running average. 2. Bulking

Tests on Continuous Filament Textured Yarns: Check on consistency, and on filamentation 3.

Condition Checks: Check on incorrect condition 4. Yarn wrapping: Levelness of yarn (also User

levelness). Further Yarn Checks (2nd order priority) Page 38 of 48 1. Fiber analysis: As specified for

correct labeling 2. Fiber quality: As required 3. Yarn twist: On new deliveries and on demand for fault

diagnosis. To be within specified tolerance 4. Co-efficient of friction: Test and compare to

specification 5. Oil content: When records of finishing loss, yarn utilization, count, grey weights, or

finished weights abnormal, oil content checked; and also if yarn running abnormally. Content figure

to be within tolerance of specification. 6. Accessories Checks: Shade and size checked to be correct

(e.g. buttons) Stability (e.g. linings and trims and zip tapes) within tolerance of specification.

Extensibility and modulus (e.g. binding and elastic) within tolerance of specification. Items work

properly (e.g. zips) Sewing threads, correct shade, ticket number and sews normally 7. Boxed Stock

Audits Goods in warehouse - sample checked for quality and faults. Goods rejected - check to see if

correctly rejected. Page 39 of 48 8. Machine Efficiency Ratio of knitting time or goods produced

compared with basis if no downtime. Provides measure of machine performance - analyzed against

knitter, machinist, fabric quality, garment style and yarn. 9. Yarn Utilization 10. Fabric Utilization As

with machine efficiency, checks on process performance. Analyzed against operation section, style,

fabric or yarn. During Production Check (DUPRO) The DUPRO provides the on-line inspection, DQC

qualified inspectors will check that the corrections and improvements suggested during the IPC were

implemented, examine the existing productions, advised the manufacturers of any further corrections

or improvements to be made. The DUPRO should be carried out when 30-50% of the merchandise

has been produced (minimum 50 pieces) in this services, inspector will on-line check the production
materials, process, semi-finished and finished products. During Production Inspection (DUPRO) is

used for to guarantee uniformity of the actual production and specification. Audit:Audit can be

performed in the sewing floor as well as in the finishing section or whatever required. Mini QC:Every

day the products made by Interfab are checked. Each and every shirt is inspected here. Pre-final

Inspection: Page 40 of 48 In Interfab before final inspection they perform three per-final inspections.

They are as follows: I) II) III) After 25% garment produced are made and pecked. After 50% garment

produced are made and pecked. After 75% garment produced are made and pecked. Factory

AuditThe Factory assessment is performed by our Auditor following a general framework designed

after SA 8000 standard and completed, when requested, with the client's specific requirements. The

audit takes at least one full day and begins with a request for documentation. The factory

management is assembled. One of the documents reviewed is the Quality Certification. The grantor

of the certificate is scrutinized as are the periodic reviews. The factory is required to submit

documents for a part similar to the part being considered for production. Documents requested

include: Process Flow Chart Control Plan Dimensional Layout Capability Study Production Failure

Effects Mode Analysis The auditor inspects the factory beginning with raw material storage and

inspection. Tooling workshops are inspected. The auditor then "walks" the Control Plan through

every manufacturing process. The last steps of the factory inspection are final test, packaging, and

laboratory areas. By the end of the auditing day, the auditor knows if the quality systems claimed by

the factory are in practice and if the management is committed to constant improvement. Page 41 of

48 Quality control recordsThe above data, immediately on being generated, is automatically entered

on records as continuity charts, either in tabular, graphical or computerized form. This action takes

very little time, and enables the current data to be compared with previous data and with other

related Q. C. data. The visual impact of the presentation is immediate and creates rapid feed-back of

vital information to production and other interested management personnel. The essential features of

the standard are contained in the following basic requirements:1. Quality System 2. Organization 3.

Review of Quality System 4. Documentation/Records 5. Equipment 6. Purchased Materials and

Services 7. Manufacturing Control 8. Work Instructions/Workmanship 9. Corrective Action 10.

Completed Item and Inspection and Test 11. Sampling Procedures 12. Control on Non-conforming
Material 13. Alternative Inspection Procedures and EquipmentPage 42 of 48 14. Indication of

Inspection Status 15. Protection and Preservation of Product Handling, Storage and Delivery 16.

Training. Pre shipment Inspection (PSI) or Final inspection:To select sample Interfab Shirt

Manufacturing Ltd follows some certain rule. The rules are given as below:Special Inspection Levels

Lot or batch size S-1 A A A A B B B B C C C C D D D S-2 A A A B B B C C C D D D E E E S-3 A A

B B C C D D E E F F G G H S-4 A A B C C D E E F G G H J J K General Inspection Levels I A A B

C C D E F G H J K L M N II A B C D E F G H J K L M N P Q III B C D E F G H J K L M N P Q R 2 ~

8 9 ~ 15 16 ~ 25 26 ~ 50 51 ~ 90 91 ~ 150 151 ~ 280 281 ~ 500 501 ~ 1200 1201 ~ 3200 3201 ~

10000 10001 ~ 35000 35001 ~ 150000 150001 ~ 500000 500001 and over TABLE II SINGLE

SAMPLING PLANS FOR NORMAL INSPECTION: Page 43 of 48 Acceptable Quality Levels(normal

inspection) Sample size code letter 0.25 0.40 0.65 1.0 1.5 Ac Re Ac Re Ac Re 2.5 Ac Re 4.0 Ac Re

6.5 Ac Re 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 1 2 1 2 2 3 1 2 2 3 3 4 1 2 2 3 3 4 5 6 1 2 1 2 2 3 2 3 3 4 1 2

2 3 3 4 5 6 1 2 2 3 3 4 5 6 1 2 2 3 3 4 5 6 7 8 10 Ac Re Sample size Ac Re 2 3 5 8 13 20 32 50 80

125 200 315 500 800 Ac Re A B CD E F G H J K L M N P 7 8 10 11 7 8 10 11 14 15 21 22 2 3 3 4 5

6 7 8 10 11 14 15 3 4 5 6 7 8 10 11 14 15 5 6 7 8 10 14 15 21 11 22 21 22 21 22 3 4 5 6 5 6 7 8 10

11 14 15 21 7 8 10 11 14 Page 44 of 48 Q 1250 7 8 10 11 14 15 15 21 22 22 R 2000 10 11 14 15 21

22 Usually the AQL of this factory is 2.5. The Interfab team performs a final random inspection

comprising of a detailed visual inspection of goods before shipment. It is generally conducted on the

premises of the manufacturer, on samples selected according to defined sampling procedures. The

inspection criteria covering quality, quantity, marking and packing are based on the client's

specifications and reference samples, as provided. Upon completion of the final random inspection a

detailed inspection report is sent to the client and the inspection certificate issued to the supplier if all

findings are positive.The top management of Interfab performs the final inspection. They have so

good relation to its entire buyer that the buyer don not need to send their representatives or third

party inspection team. Interfab does not take any charge for the final inspection. Some of the various

inspection options available to you are listed below. Buyer can choose which options you would like

to have completed or not. 1. Quantity 2. Master Carton Markings 3. Master Carton Weight &

Dimension 4. Master Carton Content Verification 5. Product Packaging Comparison 6. Packaged

Product Weight 7. Packaging Dimension 8. Product Packaging/ Remailer Description 9. Sample/

Product ComparisonPage 45 of 48 10. Workmanship 11. Product Functional Verification 12. Master

Carton Transportation Drop Test 13. Packaged Product Transportation Drop Test 14. Instruction

Sheet/ Booklet Quality AssuranceInterfab Inspection provides product shipment inspection services

for buyers purchasing item. Their qualified inspection personnel will take any available samples

and/or product related requirements, and inspect shipments thoroughly before they depart

Bangladesh. They offer product testing and quality verification and report their findings so that buyer

can make the decision to have the shipment sent or returned to the manufacturer. They know how

stressful it can be to worry whether the items buyer purchased will be of the quality and design you

want them to be. Their inspection personnel have years of experience and can give buyer a quality

inspection of the products buyer have purchased before they leave Bangladesh. In the factory they

have every floor palned. It is a sign of TQM. Page 46 of 48 Interfab has world class machines, skilled

work force, all over that they are intended to achieve the maximum possible quality. That makes

them one of the leading Garment manufacturing factories in our country. After all of that it is clear

that Interfab Shirt Manufacturing Limited is a Page 47 of 48 Model Total Quality Management

factory. It is a kind of factory that is working forward to enhance business among the developing

nations and making us proud of it. If three shirts are sold in UK one of them is made by Interfab Shirt

Manufacturing Limited. At last we want to thank our Honorable teacher, Kazi Shamsur Rahman for

giving us a chance to see such a nice factory like it. THE ENDPage 48 of 48

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e,convincing customers to everyday the store in hunt

of what’s

new and to buy

now…

since it will be vanished tomorrow. appreciation to the twofold weekly delivery ofrefill stock as well as
new items, clientele constantly return to stores to look through newitems. Zara's worldwide average of
17 visits per customer per year is significantly higherthan the three visits to its competitors As the eyes
and ears of the company, empowerretail manager offer word-of-mouth in series on client wants and
preferenceThis is fairly at chances with relying exclusively on automatically composed data, anapproach
used by competitors. Therefore lines that are not advertising well are rapidlydetached and trendy items
quickly replenished. A swift turn around on stock helpsproduce cash, reduce inventory and eliminates
the need for major debt.

Zara’s business model can be

busted down into three basic apparatus: concept,

capabilities, and value drivers. Zara’s

primary concept is to uphold design, creation, and

ZARA is a Spanish brand owned by

INDITEX. It was established in
1975 and it has over than
2100 stores located in leading cities
across 87 countries with almost 120
000 employees. ZARA
is the main development driver
for INDITEX and plays a major
role in increasing its share of
sales in particular via ZARA’s
international activities [9].
In order to be reactive to the
consumer demand during the season,
ZARA began to invest in the
production logistics, information
technology, implementing Just in
Time system, acquisition of a
130 000 m² warehouse near the
headquarters in Arteixo and an
advanced communication system
to connect the headquarters to the
buying center, production factories
and stores [10].
International Journal of Managing Value
and Supply Chains (IJMVSC) Vol. 7,
No. 4, December 2016
19
The development of IT solutions
(logistics, retailing, finance,
merchandising…) continued during
the 1990s and has been developed
internally. This in-house software
development is required by
ZARA’s specific needs [11].
Consequently, the business system
that had resulted was particularly
distinctive. ZARA manufactured its
most fashion-sensitive products
internally [9]. Unlike its
rivals, more than 50% of ZARA’s
production is based in Europe [12].
In addition, ZARA success is
explained by its agile supply chain
efficiency [13][14]. ZARA’s
supply chain can be divided into
four elements [9]: product design,
sourcing and production,
distribution & retailing (Figure 2)

Figure 2.ZARA’s business system [9]

2.1. Product Design:
The main task of the design team is
not limited to product innovation,
but also in reorganizing
existing products elements and
transforming them into new
products [15]. In other words,
ZARA’s design team works not only
on design of the upcoming season
but also on the update of
the current season designs. The
design team comprises designers,
market specialists and buyers
who design almost 40 000 items
per year from which 10 000 items
are selected for production
[16]. Designs are inspired from
different sources: exhibitions, fairs,
podiums, magazines [13].
2.2. Sourcing and Manufacturing:
ZARA purchases the fabric and other
raw materials from external
suppliers with the help of its
buying centers (in Barcelona &
Hong Kong) and the buying team
at the headquarters [9]. Key
criteria for the buying decision are:
required level of reactivity and
expertise, effectiveness in
terms of costs and the possession
of sufficient production capacity
[16]. COMDITEL,
INDITEX’s subsidiary, is in charge
of the major part of fabric sourcing,
dealing with more than
200 external suppliers.
ZARA produces half of its
production in its own 22 Spanish
small companies and uses
subcontractors for sewing operations
[13] [16]. The other half of
production is made by external
suppliers, 70% of them are based in
Europe (in particular Spain & north
of Portugal). From Asia,
ZARA procures basic items because
of costs advantages.
2.3. Distribution:
ZARA’s system consists of an
approximately 400 000 m² facility
located in Arteixo and much
smaller satellite centers in
Argentina, Brazil, and Mexico that
consolidated shipments from
Arteixo [9]. The finished clothes,
after being packed and inspected
in quality, are sent to
distribution center through
underground conveying belt [16].
International Journal of Managing Value
and Supply Chains (IJMVSC) Vol. 7,
No. 4, December 2016
20
Operating hours follow the weekly
rhythm of the orders. In a normal
week, the warehouse
functions around the clock for four
days but runs for only one or two
shifts on the remaining three
days. Ordinarily, 1200 people fill
the orders, each within eight hours.
But during peak seasons,
the company adds as many as 400
temporary workers to maintain lead
times [16]. Shipments
from the warehouse are made twice
a week to each store via third-party
(3PL) delivery services,
with shipments two days a week to
one part of the store network and two
days a week to the other
[9].
Distributions are carried out
according to orders from each store;
goods are ready for delivery 8
hours upon receipt of orders [15].
Shipments reach most European
stores in 24 hours, U.S. stores
in 48 hours, and Japanese shops in 72
hours [9].
2.4. Retailing:
ZARA tries to localize its stores in
the most refined, prestigious and
overcrowded places [16]. It
runs three independent product lines:
women, men, and children. Each
product line is managed
by a separate team of regional
managers, commercials and
designers. Also, the three product
lines
are managed by three independent
section managers at each store.
Each section manager has a
team of sales people and cashiers; the
women’s section manager is also the
overall store manager
[10].
The stores varies greatly in size and
layout but an average store is 1
200 m² in size and carries
about 40,000 units of inventory [8].
ZARA put a lot of emphasis on
creating attractive interior
designs that conveys freedom and
quiet comfort to the customer but
also on ensuring that shelves
and store windows are similarly
presented in all ZARA stores [10].
Sales data are sent from ZARA’s
stores to the head office on a daily
basis and replenishment
orders are made twice a week in
accordance with the available
inventory and sales situation [15].