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An Overview of Quality and Quality Control in Textile Industry
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Akter Hossain
Department of Textile Engineering
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Introduction:
Quality means customer needs is to be satisfied. Failure to maintain an adequate quality standard can
therefore be unsuccessful. But maintaining an adequate standard of quality also costs effort. From the
first investigation to find out what the potential customer for a new product really wants, through the
processes of design, specification, controlled manufacture and sale.
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.
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Assurance or Total Quality Control.
To ensure, at minimum practicable cost, that the requisite quality of product is being achieved at every
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stage of manufacture from raw materials to boxed stock
To achieve a satisfactory design of the fabric or garment in relation to the level of choice in design, QA Software Testing
styles, colours, suitability of components and fitness of product for the market.
Conformity: The QC checks the conformity of the product (design, colors, raw material…) with the Pre- Bleaching Bra Calculation
Production Sample (PPS) and other technical files.
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Quality: Our QC checks for defects (fabric defects, colors defects, accessories and label defects, Career
manufacturing defects) and classifies them accordingly. Circular Knitting Clothing Color
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(1). Prevention Costs:
Needle Nonwoven Pattern Pigment
Product/process design.
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Process control.
Pretreatment Printing
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Complaint adjustment
Undergarment Uster M/C Vat Dye
Returned product/material
Warp Knitting
Liability costs
Warping Washing Wastage Water
External costs
Weaving
Quality inspection
Measurements checking
Fabric spreading according to correct alignment with marker length and width
The dimension of the pattern and the cut piece should be same and accurate
Water spot
Wrong fold
Get up checking
Collar closing
Side seam
Cuff attach
Bottom hem
Back yoke
Thread count
Thread Ply
Number of twist
Thread balance
Thread Tenacity
Thread Elongation
2. Sew ability
3. Imperfection
4. Thread finish
5. Thread color
6. Package Density
7. Winding
8. Yardage
Zipper
Process Control :
The method chosen for the process must be provided with the necessary accurate parameters. Here
the specific gravity, water level, residual hydrogen per oxide etc. at each stage is checked.
Laboratory :
Lab is the head of the textile industries. Higher precision lab can aid easily to achieve the goal of the
organization. Before bulk production a sample for the approval from industry is sent to the buyer. As per
the requirement of the buyer the shade is prepared in a lab considering the economical aspects.
Lab Line:
1. Standard sample: The buyer to the industry gives the standard sample. The sample is measured
by the CCM to get the recipe.
2. Lab trial: Getting the recipe the lab officer produce lab trial and match with standard according to
buyer requirement. Lab trial is made by the AHIBA dyeing machine.There are some programs for
dyeing.
Off-Line Tests: All the Off-Line tests for finished fabrics can be grouped as follows:
A. Physical tests
B. Chemical tests
A. Physical Tests:
1. GSM test
2. Shrinkage test
3. Spirality test
4. Tensile strength
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5. Abrasion resistance
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B. Chemical Tests:
1. Dimensional characteristics:
Length
Width
Thickness.
2. Weight of fabric:
Tensile strength.
Tearing strength.
5. Yarn count:
Warp count
Weft count.
6. Crimp:
Warp crimp
Weft crimp.
7. Handle:.
Stiffness
Drape.
Fastness to light.
Fastness to wash.
Fastness to perspiration.
Fastness to Rubbing.
1. Quality of production
2. Quality of design of the garment
3. Purchasing functions – quality should be maintained
4. Quality of final inspection should be superior
5. Quality of the sales also has to be maintained
6. Quality of marketing of the final product is also important as the
7. Quality of the garment itself
To ensure quality:
In this context, customer is the entity receiving a service or product from our work. For example, we can
take a short production line.
Quality problem in cutting may lead to problems in sewing,inspecting and finishing. It’s like “garbage in
garbage out”. In other words, one needs to have good quality materials to produce good quality goods.
So this has to be applied to every process in the system to have a total quality control.
Measurements are a vital part of any quality improvement program. Anything that is not measured does
not improve. We need to establish these standard measures and measure the progress periodically.
Team work is also an essential element for the success of the program. Remember “ONE of us is NOT
better than an All of US”. The whole effort needs to have a direction that a team leader will provide.
4. Comment on both good and bad quality. We all have a tendency to be silent during good times and
vocal during the bad.
1. Marker is checked for all parts and for any variation against pattern.
2. Spreading has to be inspected
3. During cutting:
4. The marker line had to be followed
5. All notches should be located correctly with even depth say 1/8 in. (± 1/16). When cutting, care
should be taken not to shift the stack of parts to a side or cut with the blade at an angle.
6. In bundling and shade marking, care should be taken to ensure that the numbering is correct. For
the final audit process, the quality inspector will determine how many bundles to check from every
size depending on the sample size.
Quality Training:
The purpose of the training program is to train operators to attain high speed and production together
with good quality work. Good quality comes from the consistent use of correct methods
1. Initial instruction
Point out the key points of method and quality to the trainee and be sure that she understands them.
2. Trainee practice
When the trainee first practices an exercise, the instructor should watch her methods very closely and
correct any incorrect methods immediately. The trainee should not be timed or be permitted to start
timing until she is doing the exercise correctly. Even after starting her timing, the instructor should keep
a close watch on her methods and quality.
3. Quality checking
Whenever the instructor finds any faulty work, or whenever defects are found by other inspectors or
operators, the instructor should:
Look at the faulty work or record to determine what mistakes the trainee is making.
Tell the trainee not just what she is doing wrong, but what she must do to perform the work correctly.
4. Methods checking
The best way for an instructor to ensure good quality is by watching the trainee while he is working, by
inspecting some of his work and by correcting any faults immediately. It is much easier and more
effective to correct a fault when it happens, than to try to change the method after he has turned out a
quantity of bad work. In order to become skilled at this part of training, the instructor should take every
opportunity to stand and watch each trainee at work, in order to detect and stop any defects in method,
immediately.
Statistical quality control refers to the use of statistical methods in the monitoring and maintaining of the
quality of products and services.
1. Descriptive Statistics
2. Statistical Process Control (SPC)
3. Acceptance Sampling
1. Descriptive Statistics:
Descriptive Statistics involves describing quality characteristics and relationships.
1. Evaluation of quality standards of incomeing material, product process and finished goods.
2. Judging the conformity of the process to establish standards taking suitable action , when
deviation are noted.
1. The expected quality of product can be produced and hence customers satisfaction can be
achieved which brings higher profit.
2. It is very easy to separate allowable variation from the preventable variation by this.
3. It ensures an early detection of faults in process and hence minimum wastage.
4. With its help one can easily defect the impact of chance in production process in the change in
quality.
1. Shrinkage Test
2. GSM Test
3. Tensile Test
4. Tearing Test
5. Color Fastness Test
6. Rubbing fastness Test
7. PH Test
8. Shade Matching Test
9. Fabric Width Test
Conclusion:
There are many quality parameters in different types of fabric. And there are also many different faults
in different types of fabric, which are effect in quality of fabric. If we control those faults and effects ,we
can get the good quality of fabric. So quality control is very important for all types of fabric and textiles.
Published by:
S. M. Hossen Uzzal
B.Sc. in Textile Technology
Monno Fabrics Ltd. Manikgonj
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