National Institute Fashion Technology, Chennai

APPAREL QUALITY MANAGEMENT

ASSIGNMENT – 1.b

Submitted to : Submitted by :
Mr. D Praveen Nagarajan Himanshu
BFT/18/743
Semester: 5
 INTRODUCTION TO QUALITY CONTROL

Quality control (QC) is a process through which a business seeks to ensure

that product quality is maintained or improved. Quality control requires the
business to create an environment in which both management and employees
strive for perfection. This is done by training personnel,
creating benchmarks for product quality and testing products to check
for statistically significant variations.
 7 QUALITY CONTROL TOOLS

A team researched and developed these seven new quality control tools, often
called the seven management and planning tools, or simply the seven
management tools:

Stratification (Divide and Conquer)

Histogram
Check Sheet (Tally Sheet)
Cause-and-effect diagram (“fishbone” or Ishikawa diagram)
Pareto chart (80/20 Rule)
Scatter diagram
Control chart
 7 QUALITY CONTROL TOOLS

These Seven Basic Tools of Quality (also known as 7 QC Tools) originated in

Japan when the country was undergoing major quality revolution and had
become a mandatory topic as part of Japanese’s industrial training program.
These tools which comprised of simple graphical and statistical techniques
were helpful in solving critical quality related issues. These tools were often
referred as Seven Basics Tools of Quality because these tools could be
implemented by any person with very basic training in statistics and were
simple to apply to solve quality-related complex issues.7 QC tools can be
applied across any industry starting from product development phase till
delivery.
 STRATIFICATION (DIVIDE AND CONQUER)

Stratification is a method of dividing data into sub–categories and classify

data based on group, division, class or levels that helps in deriving meaningful
information to understand an existing problem.
The very purpose of Stratification is to divide the data and conquer the
meaning full Information to solve a problem.
 EXAMPLE:

An employee is absent in a factory on following dates)

(09- Sept, 15- Sept,19- Sept, 23- Sept, 27- Sept,29- Sept,30- Sept)
Stratified data: (Same data classified by day of the week )

DAY Mon Tue Wed Thu Fri sat

Frequency of Absent 0 3 3 0 0 1
Days

Frequency of absent days

 HISTOGRAM

Histogram introduced by Karl Pearson is a bar graph representing the

frequency distribution on each bars.
The very purpose of Histogram is to study the density of data in any given
distribution and understand the factors or data that repeat more often.
Histogram helps in prioritizing factors and identify which are the areas that
needs utmost attention immediately.
 CHECK SHEET (TALLY SHEET)

A check sheet can be metrics, structured table or form for collecting data and
analysing them. When the information collected is quantitative in nature, the
check sheet can also be called as tally sheet.
The very purpose of checklist is to list down the important checkpoints or
events in a tabular/metrics format and keep on updating or marking the status
on their occurrence which helps in understanding the progress, defect patterns
and even causes for defects.
CAUSE-AND-EFFECT DIAGRAM. (“FISHBONE” OR ISHIKAWA DIAGRAM)

The very purpose of this diagram is to identify all root causes behind a
problem.
Once a quality related problem is defined, the factors leading to the causal of
the problem are identified.
In manufacturing industry, to identify the source of variation the causes are
usually grouped into below major categories:
People
Methods
Machines
Material
Measurements
Environment
 PARETO CHART (80 – 20 RULE)

The very purpose of Pareto Chart is to highlight the most important factors
that is the reason for major cause of problem or failure.
Pareto chart is having bars graphs and line graphs where individual factors are
represented by a bar graph in descending order of their impact and the
cumulative total is shown by a line graph.
Pareto charts help experts in following ways:
Distinguish between vital few and trivial many.
Displays relative importance of causes of a problem.
Helps to focus on causes that will have the greatest impact when solved.
 SCATTER DIAGRAM

Very purpose of scatter Diagram is to establish a relationship between

problem (overall effect) and causes that are affecting.
The relationship can be linear, curvilinear, exponential, logarithmic, quadratic,
polynomial etc.
Stronger the correlation, stronger the relationship will hold true.
Example: A production of an apparel industry depend upon the raw material and
man power so according to the scatter diagram raw material should on X-axis as
the independent variable and the production is on Y-axis as it is a dependent
variable so if the X increases Y is also increases so scatter diagram form in that
case is diagram(a) if the thing happens opposite to it results in the diagram (b).
 CONTROL CHART

The very purpose of control chart is to determine if the process is stable and
capable with in current conditions.
Control chart is basically a statistical chart which helps in determining if an
industrial process is within control and capable to meet the customer defined
specification limits.
Control chart helps in predicting process performance, understand the various
production patterns and study how a process changes or shifts from normally
specified control limits over a period of time.
 7 OLD QC TOOLS

These 7 old Tools of Quality are used before the new or basic qc have introduced
in the market. Old QC tools are implemented by the peoples with very basic
training in statistics and were a bit complex as compare to new Qc tools to apply
and solve quality-related issues.7 old QC tools are applied across many industry in
early 1970s starting from product development phase till delivery.

7 Old QC tools are:

1. Affinity diagram
2. Interrelationship diagram
3. Tree diagram
4. Matrix diagram
5. Prioritize Matrix
6. Arrow diagram
7. Process Decision Program Chart(PDPC)
 AFFINITY DIAGRAM

Organizes a large number of ideas into their natural relationships.

When to Use an Affinity Diagram

When you are confronted with many facts or ideas in apparent chaos
When issues seem too large and complex to grasp
When group consensus is necessary

Typical situations are:

After a brainstorming exercise
When analysing verbal data, such as survey results
When collecting and organizing large data sets
When developing relationships or themes among ideas
When reducing attributes to categories that can be addressed at a higher level
 EXAMPLE

If a apparel industry is facing an issue related their quality or delay in orders

its may have some defects in their administration system.

Operators / staff Distribution Quality Capacity

Lack of Not enough Variable raw Working hours are

staff/operator transport facility material quality less
training
Difficulties in Transportation is Packaging is not Efficiency is low
recruiting expensive good

High overtime Product damaged Quality control MM is not there

in transit system is not good
 INTERRELATIONSHIP DIAGRAM

Shows cause-and-effect relationships and helps analyse the natural links

between different aspects of a company.
When to Use an Interrelationship Diagram:
When trying to understand links between ideas or cause-and-effect
relationships, such as when trying to identify an area of greatest impact for
improvement
When a complex issue is being analysed for causes
When a complex solution is being implemented
After generating an affinity diagram, fishbone diagram, or tree diagram to
more completely explore the relations of ideas
 EXAMPLE

A production unit has a order of 15000 shirt before but has ow changed the
order to trousers. Now has to produce 10000 trousers so there is the change in the
PP layout which results in the delay of the order at the end. So I have make the
possibilities and circumstances in which the order has been delay.
 TREE DIAGRAM

Breaks down broad categories into finer and

finer levels of detail, helping to move step-by-
step thinking from generalities to specifics.

Example: A garment industry has these

processes during their garment finishing
process.
 MATRIX DIAGRAM

Shows the relationship between two, three, or four groups of information and
can give information about the relationship, such as its strength, the roles
played by various individuals, or measurements.

Example: A client has given an order to a

garment manufacturing unit. So they have
stablished the relation between the
company and this diagram has shown how
each and every department has worked to
maintain the relationship between a
company and the client.
 PRIORITIZE MATRIX

A complex mathematical technique for analysing matrices, often replaced by

the similar prioritization matrix. A prioritization matrix is an L-shaped
matrix that uses pairwise comparisons of a list of options to a set of criteria
in order to choose the best options.

Symbol Represents

Done on daily basis

Done on weekly basis

Done on monthly basis

Done on yearly basis

 EXAMPLE

Machine Maintenance of a Garment Industry

Machine name Oiling Parts check lubrication Parts replacement

DNLS

SNLS

OVERLOCK

FLAT LOCK
 ARROW DIAGRAM

Shows the required order of tasks in a

project or process, the best schedule for
the entire project, and potential scheduling
and resource problems and their solutions.

Example: Arrow diagram showing the

process flow of quality check
procedure for the top garments.
 PROCESS DECISION PROGRAM CHART

Systematically identifies what might

go wrong in a plan under
development.

Example: PDPC diagram of

process flow of the process from
pattern making to the sewing.
THANK YOU