QUALITY CONTROL MEASURES IN

QUALITY CONTROL IN TEXTILES (TE-305) ASSIGNMENT

12/7/2023

NED UNIVERSITY OF ENGINEERING AND TECHNLOGY

TEXTILE DEPARTMENT
ABSTRACT:
Quality control plays a crucial role in ensuring the production of high-quality product in the
manufacturing process. It involves a series of activities and techniques aimed at monitoring and
maintaining the desired quality standards.

In the yarn manufacturing process, quality control begins with the selection of raw materials,
such as fibers, to ensure their suitability for producing the desired yarn characteristics. It involves
conducting inspections and tests at different stages, likewise at,blending, carding, drawing, and
spinning, to identify any deviations from the quality standards.

Various parameters are monitored during the manufacturing process to ensure consistent quality.
These parameters may include yarn count, strength, evenness, twist,color fastness etc. Quality
control techniques, such as visual inspections, physical tests, and statistical analysis, are
employed to identify any defects or variations and take corrective actions promptly.

Additionally, quality control in yarn manufacturing involves implementing quality assurance

measures, such as regular maintenance of machinery, calibration of instruments, and adherence
to standard operating procedures. This helps in preventing potential issues and maintaining the
overall quality of the yarn.

By implementing effective quality control practices, yarn manufacturers can ensure that the
produced yarn meets the required specifications and customer expectations. This, in turn,
contributes to the production of high-quality textile products and customer satisfaction.

INTRODUCTION:
What Is Quality Control (QC)?
Quality control (QC) is a process through which a business seeks to ensure that product quality is
maintained or improved. Quality control requires the company to create an environment where
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.
A significant aspect of quality control is the establishment of well-defined controls. These
controls help standardize both production and reactions to quality issues. Limiting room for error
by specifying which production activities are to be completed by which personnel reduces the
chance that employees will be involved in tasks for which they do not have adequate training.

WHAT IS QUALITY CONTROL IN TEXTILES(QCT)?

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Principles of quality control in textile industry refer to the various concepts that make up a textile
factory’s quality assurance program. Quality assurance programs provide managers and staff
with the philosophy, structure and strategies necessary to improve service and product delivery.
Many businesses follow established concepts as outlined by quality organizations, Total Quality
Management or International Organization for Standardization.
Quality could be termed as customers’ satisfaction; a good quality product means that it will
fulfill all the purposes for which it has been produced. Quality control is a continuous and
regular control of the parameters which affect the quality of the final product. It comprises of
planning, raw data compilation, its investigation and implementation. Quality control in textile
industry is the most important thing. So maintaining quality control in textile is a supreme
priority task for textile engineers.
What is the definition of quality for the concerned process and how quality is maintained in
the process? Discuss the structure and scope of the quality control functions in the
respective process.

QUALITY:
The term Quality has been defined in different ways by various authors.
The author GARVIN divided quality into 5 categories: Transcendent, product-based, user-
based, manufacturing-based, and value- based. He further described the eight dimensions of
quality which are: performance, features, reliability, conformance, durability, serviceability,
aesthetics and perceived quality.
Another author CROSBY further described quality as " Quality is conformance to requirements
or specifications."
A more general definition proposed by JURAN which is " Quality is fitness for use."

MAINTENANCE OF QUALITY IN A PROCESS:

Quality has to be something that's considered from the very beginning and built into everything a
business or organization does. Planning carefully, monitoring your work, and constant
reevaluation and adjustment are all extremely important. You don't ensure quality by catching
mistakes before they reach the customer; you ensure it by setting up a system in which you don't
make the mistakes to begin with. Everyone in the organization must understand and adopt this
point of view if the organization is truly going to have quality performance.

QUALITY PARAMETERS:
Quality Control (QC):

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Definition: Quality control involves activities and techniques used to monitor and control the
characteristics of a product or process to meet specified requirements.

Functions:
Inspection: Examining products or processes to ensure they meet predefined standards.
Testing: Performing tests to verify that products meet specified performance criteria.
Statistical Process Control (SPC): Using statistical methods to monitor and control a process to
ensure it operates within specified limits.
Sampling: Selecting a representative sample from a batch for inspection or testing.

Structure:
In-process Inspection: Checking products at various stages of production to identify and correct
defects early.
Final Inspection: Examining finished products to ensure they meet all quality standards before
they are released to customers.
Documentation and Record Keeping: Maintaining detailed records of inspections, tests, and
quality control activities.

Scope:
Manufacturing: Ensuring that products meet quality standards during the manufacturing
process.
Service Industry: Monitoring and improving the quality of service delivery.
Software Development: Verifying that software meets specified requirements and functions
without errors.

Quality Assurance (QA):

Definition: Quality assurance is a set of planned and systematic activities implemented within
the quality system to provide confidence that a product or service will meet specified
requirements.

Functions:
Process Audits: Evaluating processes to ensure they comply with established standards.
Training: Providing education and training to employees to ensure they understand and adhere
to quality standards.
Documentation and Standard Operating Procedures (SOPs): Developing and maintaining
documentation that defines quality standards and procedures.

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Continuous Improvement: Implementing processes for ongoing improvement to prevent
defects and enhance overall quality.

Structure:
Quality Management System (QMS): Establishing a framework for managing and improving
an organization's quality processes.
Quality Policy and Objectives: Defining the organization's commitment to quality and setting
measurable objectives.
Risk Management: Identifying and mitigating risks that could impact quality.

Scope:
Product Development: Ensuring that products are designed and developed with quality in mind.
Process Improvement: Implementing methodologies such as Six Sigma or Lean to optimize
processes.
Regulatory Compliance: Ensuring compliance with industry standards and regulatory
requirements. [1]

Important quality characteristic of the textile products which are manufactured in the
process. How these characteristics are maintained?

The important quality characteristics of textile products can be broadly categorized into two
main groups:
 Utility characteristics
 Durability characteristics.

UTILITY CHARACTERSTICS:
STRENGTH: The ability of the textile product to resist deformation or breaking under stress.
This is measured using the tensile strength test.
ABRASION RESISTANCE: The ability of the textile product to withstand wear and tear. This
is measured using the Martindale abrasion test.
MOISTURE RESISTANCE: The ability of the textile product to repel water or other liquids.
This is measured using the water resistance test.
BREATHABILITY: The ability of the textile product to allow air and moisture to pass through
it. This is measured using the air permeability test.

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THERMAL CONDUCTIVITY: The ability of the textile product to conduct heat. This is
measured using the thermal conductivity test.
COLOR FASTNESS: The ability of the textile product to retain its color when exposed to light,
washing, or other chemicals. This is measured using the colorfastness test.
DIMENSIONAL STABILITY: The ability of the textile product to maintain its shape and size
when exposed to moisture, heat, or other conditions. This is measured using the dimensional
stability test

DURABILITY CHARACTERSTICS:
SHRINKAGE RESISTANCE: The ability of the textile product to resist shrinking when
washed or dried. This is measured using the shrinkage test.
WRINKLE RESISTANCE: The ability of the textile product to resist wrinkling. This is
measured using the wrinkle recovery test.
MOTH RESISTANCE: The ability of the textile product to resist damage from moths. This is
measured using the moth resistance test.
PILLING RESISTANCE: The ability of the textile product to resist the formation of pills or
fuzz. This is measured using the pilling test.

MAINTENANCE OF QUALITY CHARACTERSTICS:

FIBER SELECTION: The choice of fibers used to make the textile product will have a
significant impact on its quality characteristics. For example, cotton is known for its strength,
breathability, and absorbency, while wool is known for its warmth, resilience, and wrinkle
resistance.
YARN PREPARATION: The process of preparing the yarn for weaving or knitting can also
affect the quality of the textile product. For example, proper yarn spinning can help to ensure that
the yarn is strong and even, while proper yarn dyeing can help to ensure that the color is fast.
FABRIC CONSTRUCTION: The way that the fabric is woven or knitted can also affect its
quality characteristics. For example, a tightly woven fabric will be more durable than a loosely
woven fabric.
FINISHING: Finishing processes, such as dyeing, bleaching, and printing, can be used to
enhance the appearance and durability of the textile product.
CARE: The way that the textile product is cared for can also affect its quality. For example,
washing the textile product in cold water and using a gentle detergent can help to protect its color
and shape. [2]

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What are specific online quality control activities and offline quality control activities?

ON-LINE QAULITY CONTROL CHARACTERSTICS:

This type of quality control is carried out without stopping the production process. During the
running of production process, a setup is automatically performs and detect the fault and also
takes corrective action. Online quality control comprises with the raw material quality control
and the process control.

RAW MATERIAL CONTROL:

As the quality product depends on the raw material quality so we must be provided with the best
quality raw material with an economical consideration. The fabric must be without fault, with
proper absorbency, whiteness as per requirement of the subsequent process. The Grey inspection
report gives the condition of the raw fabric.

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:
Standard Sample: The buyer to the industry gives the standard sample. The sample is measured
by the CCM to get the recipe.
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.

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OFF-LINE QUALITY CONTROL ACTIVITIES:
Performed in the laboratory and other production area by stopping the production process
consisting of fabric inspection and laboratory and other test. Correction steps are taken according
to the test result.
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:
 GSM test
 Shrinkage test
 Spirality test
 Tensile strength
 Abrasion resistance
 Pilling resistance
 Button Strength Testing
 Crease resistance
 Dimensional stability
 Bursting strength test

B. Chemical Tests:
 Color Fastness to washing.
 Color Fastness to lighting.
 Color Fastness to heat.
 Color Fastness to Chlorinated water.
 Color Fastness to water spotting.
 Color Fastness to perspiration.
 Color Fastness to Seawater.
 Fiber analysis.
 pH test.
 Repellency.

The resources, infrastructure, and standards for inspection and testing activities, as well as the
sampling and grading of products, can vary depending on the industry and specific product being
evaluated. However, some general principles apply across all industries. [3]

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Resources/Infrastructure for the inspection and testing activities (equipment and facilities
and standards followed). How sampling is performed and products are graded?

RESOURCES AND INFRASTRUCTURE:

The resources and infrastructure needed for inspection and testing activities can be broadly
categorized into three areas:

EQUIPMENT: This includes specialized tools, instruments, and apparatus used to measure,
analyze, and assess the quality of products. Examples include measuring devices, testing
machines, chemical analyzers, and microscopes.

FACILITIES: This includes dedicated spaces for conducting inspections and tests. These
facilities should be designed to provide a controlled environment that minimizes interference and
ensures the accuracy of test results. Examples include laboratories, testing chambers, and
inspection booths.

PERSONNEL: Qualified and trained personnel are essential for carrying out inspection and
testing activities. This includes inspectors, testers, technicians, and laboratory scientists. They
should have the necessary expertise and experience to perform the required tasks and interpret
the results.

STANDARDS:

Inspection and testing activities should be conducted in accordance with established standards
and guidelines. These standards provide a framework for ensuring that products meet the
required quality specifications and safety standards. Examples of relevant standards include ISO
9001 for quality management systems, ASTM International standards for materials testing, and
IEC standards for electrical and electronic equipment.

SAMPLING:

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Sampling is a critical part of inspection and testing activities, as it allows for the evaluation of a
representative sample of a larger product population. The specific sampling method used will
depend on the type of product, the desired level of confidence, and the cost constraints. Common
sampling methods include:

RANDOM SAMPLING: This involves selecting samples from the product population in a
random and unbiased manner.

STRATIFIED SAMPLING: This involves dividing the product population into subgroups or
strata and then selecting samples from each stratum.

SYSTEMATIC SAMPLING: This involves selecting samples at regular intervals from the
product population.

GRADING:

Product grading involves assigning a quality score or classification based on the inspection and
testing results. The grading system will vary depending on the industry and product, but it
typically involves assigning a numerical or alphabetical grade that corresponds to the product's
quality level. For example, a product might be graded as A, B, C, or D, with A representing the
highest quality and D representing the lowest quality.

In summary, the resources, infrastructure, and standards for inspection and testing activities, as
well as the sampling and grading of products, play a crucial role in ensuring product quality and
safety. By following established guidelines and employing appropriate methods, manufacturers
and regulatory bodies can effectively assess and ensure the quality of products across a wide
range of industries. [4]

What type of variations exist in the process and which ones are important to consider?
What are the most occurring special causes? Discuss common causes in each process for
main quality characteristics.

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Every piece of data which is measured will show some degree of variation, no matter how much
we try, we could never attain identical results for two different situations - each result will be
different, even if the difference is slight. Variation may be defined as,
“The numerical value used to indicate how widely individuals in a group vary.”

TYPES OF VARIATION:
Change is inevitable, even in statistics. You’ll need to know what kind of variation affects your
process because the course of action you take will depend on the type of variance. There are two
types of variance:
1. Common Cause Variation
2. Special Cause Variation.

COMMON CAUSE VARIATION:

Common Cause Variation, also referred to as “Natural Problems”, are the usual quantifiable and
historical variations in a system that are natural. They are inherent to the system and are always
present. Their impact on output may be uniform relative to that of special causes.
EXAMPLE:
Some examples of common causes of variation are as follows:
poor product design, poor process design, unfit operation, unsuitable machine, untrained
operators, inherent variability in incoming materials from vendor, lack of adequate supervision
skills, poor lighting, poor temperature and humidity, etc.

SPECIAL CAUSE VARIATION:

Special Cause Variation, on the other hand, refers to unexpected glitches that affect a process. It
is also known as an “Assignable Cause.” These causes are those for which an identifiable reasons
can be determined, that forces the system to go out of control.
EXAMPLES:
tool wear, operator fatigue, poor raw material, if machine malfunctions, computer crashes, there
is a power cut, etc.

COMMON CAUSES FOR EACH PROCESS IN YARN MANUFACTURING

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In yarn manufacturing, various processes contribute to the final quality characteristics of the
product. Here are common causes affecting main quality characteristics in key manufacturing
processes:

SPINNING:

Fiber Selection: Improper fiber selection can lead towards quality degradation.
Drafting Issues: Improper drafting can result in irregular yarn diameter and reduced tensile
strength.
Spinning Tension: Inadequate or excessive tension during spinning can impact yarn strength and
twist uniformity.

TWISTING:

Twist Level: Inconsistent twist application can lead to variations in yarn strength, appearance,
and evenness.
Twisting Speed: Incorrect twisting speeds may cause yarn breakage and affect the overall
quality.
Twisting Direction: Inconsistent twisting direction can impact yarn stability and appearance.

WINDING:

Winding Tension: Uneven winding tension can cause snarls, knots, and affect package density.
Yarn Traverse: Irregular yarn traverse during winding can lead to uneven packages and affect
downstream processes.
Clearing Process: Inadequate clearing of defects during winding can result in lower yarn quality.

DYEING:

Dye Penetration: Incomplete penetration of dye can result in color variations and impact the
appearance of the yarn.

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Temperature Control: Poor temperature control during dyeing may affect yarn strength and
colorfastness.
Chemical Application: Improper application of dye or other chemicals can lead to variations in
yarn characteristics.

FINISHING:

Heat Setting: Inconsistent heat setting can affect yarn stability and cause dimensional changes.
Moisture Content: Improper moisture levels during finishing can impact yarn weight and
appearance.
Tension Control: Inadequate tension control during finishing processes can lead to variations in
yarn properties.

Addressing these factors through careful monitoring, process optimization, and quality control
measures can significantly enhance the overall quality of yarn in manufacturing. [5]

What actions follow in case of non-conformance of the product in various stages of the
process?

1. POLICY, PLANNING, ORGANIZATION AND ADMINISTRATION:

A quality policy is essential for developing consistency in the company's goals. Once a plan is
developed, an organization must be established to aid in the achievement of the plan. Quality
manuals are often created for this purpose. Furthermore, procedures for administering the plans
in practice should be detailed, and costs should be identified.

2. PRODUCT DESIGN ASSURANCE, SPECIFICATION DEVELOPMENT

AND CONTROL:
With the customers' requirements in mind, a product design is formulated. Through prototype
development and testing this design will undergo modifications until it satisfactorily meets all
requirements. Tolerances on the products characteristics will be developed based on careful
consideration of the manufacturing capabilities. During the production phase procedures should
be defined to check and control the product characteristic to conform to the standards of design.

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3. CONTROL OF PURCHASED MATERIAL AND PARTS:
The production of a quality product is very much influenced by the quality of the raw materials
and components used. Investigate the cause of the non-conformance to understand why it
occurred. This could involve examining raw materials, equipment, Procedures etc. must be
developed to evaluate the capability and performance of the vendors. Some companies require
vendors to demonstrate an adequate use of statistical quality control methods before they can be
considered as candidates for selection Specifications should be set for incoming items and then
explained to the vendors. It incoming inspection is to be performed, then the vendors must be
notified Quality. cost, and ability to meet due dates should be considered in choosing vendors. A
company should attempt to develop harmonious long-term relationships with its vendors
Corrective actions for controlling purchased materials should be developed if nonconformance
occurs and if the materials are to be inspected.
In yarn manufacturing if our raw material is not upto the mark or requirement we can not
produce yarn with required characteristics.

4. PRODUCTION QUALITY CONTROL:

This is a critical aspect of the whole framework for quality. It involves determining process
specifications selecting equipment, training per sonnel designing forms and charts, selecting
inspection points, and collecting and analyzing process data to determine whether it is under
control. It is also important to determine process capability, to conduct experiments on
improving the process and to perform final inspection. It should be emphasized that preventive
maintenance and feed-forward structures, in addition to feedback control are useful in production
and process control. Minimizing in-process inventory and using the just-in-time concept, where
items are received just when they are needed, can also improve productivity Proper application
of the just-in-time principle is dependent.

5. USER CONTROL AND FIELD PERFORMANCE:

A system must exist to collect information from the consumer and to determine the level of
performance of the product or service Poor field performance may necessitate changes in design.
How will the information be collected from consumers? Design of the data forms, the frequency
with which data is collected, the types of analyses to use, appropriate advertising and promotion
schemes, and installation plans and procedures are some of the items to be considered.
Feedback on product also plays a very important role, Careful thought should begiven to
designing a system that will collect, analyze and act on consumer feedback.

6. CORRECTIVE ACTION:

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 Timely corrective action is the key to creating and maintaining a quality system, Problems
therefore need to be detected, categorized, and systematically documented Effective remedial
actions also need to be documented so that results are consistently successful Furthermore,
structure whose task is to detect problems and take corrective actions need to be created.
Corrective actions may be required with such different entities as the incoming material and
component, the vendors, the process and equipment, the operators and the product.
Specific procedures for each of these categories as well as appropriate follow-up must be
determined.

7. EMPLOYEE SELECTION, TRAINING AND MODIFICATION:

The employee is the cornerstone the success of a total quality system. This means every
employee from the temps to the operators to the CEO. People in staff roles contribute
significantly too. Errors in administrative paperwork, which delay orders for raw materials and
components as critical as adjustments made on the assembly line. Guidelines should be
established to select people for particular jobs, a task that may involve job analyses and
identification of skills of the available pool of personnel. Job manuals should be developed to
train people. In every situation, there must be a clear demonstration by management of their
commitment to help select train and motivate employees to produce a better quality product.

8. LEGAL REQUIREMENTS, PRODUCT LIABILITY AND USER SAFETY:

The failure of products within the warranty period and the hazardous effects of malfunction are
of grave concern to manufacturers Liability suits can be an enormous expense and companies
have to budget for warranty costs. Consumer tolerances also change with time. Minor blemishes
or cosmetic defects that were once acceptable may not be so because of more stringent demands
imposed by the consumer Furthermore, the US. judicial system enforces the rule of strict
liability, which creates the need to plan for field failures and their possible legal implications.
Strict liability refers to the presumption of liability when a given event occurs. All advertising
statements must be supportable by certified data. Therefore, product durability, safety, and
environ mental concerns must be integrated in the quality system

9. SAMPLING AND OTHER STATISTICAL TECHNIQUES:

This segment of the total quality system is composed of the analytical tools and techniques.
sampling is done from bigger lots by selecting few products randomly from the whole lot
produced. sampling is done at 2 stages that is, incoming stage and outgoing stage.
Incoming inspection is done after arriving of raw material to check whether the material in
according to the requirement or not.

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In case of yarn production we can check strength, length, e.t.c (different properties of fiber), in
contrast, outgoing inspection is done after the production process and before delivering the
product to customer, example: count of the yarn, etc.

In yarn manufacturing processes we require machine parameters like machine speed etc. that is
to be adjusted by the employee if these parameters are incorrect the produced yarn might result
in non-conformity. Raw materials properties like fiber length, strength, elongation plays a vital
role in output Results. Environment conditions like, temperature and humidity should be up to
the mark otherwise we cannot produce the yard with specific qualities and characteristics that are
required by the customers and may result in nonconformity. Therefore, to avoid non-
conformities we should follow the above mention quality system. [6]

CONCLUSION:
In conclusion, achieving and maintaining quality in a manufacturing process involves a
comprehensive approach encompassing various dimensions. The definition of quality, as
presented by different authors, highlights its multi-faceted nature. Quality control functions, such
as inspection, testing, statistical process control, and sampling, play crucial roles in ensuring
products meet specified requirements.

In the context of textile product quality, utility and durability characteristics are paramount.
Strength, abrasion resistance, moisture resistance, and other factors contribute to the overall
quality of textile products. Maintaining these characteristics involves careful consideration of
fiber selection, yarn preparation, fabric construction, finishing, and proper care.

Online and offline quality control activities further enhance the quality assurance process. Online
control, including raw material control and process control, ensures real-time monitoring and
correction during production. Offline tests in the laboratory cover physical and chemical aspects,
guaranteeing a comprehensive evaluation of finished fabrics.

The resources, infrastructure, and standards for inspection and testing are critical components of
quality control. Equipped with proper equipment, facilities, and personnel, adherence to
established standards ensures consistency and reliability. Sampling methods and grading systems
contribute to effective quality assessment across diverse industries.

Understanding and addressing variations in the manufacturing process is essential. Common

cause variations and special cause variations necessitate different approaches for improvement.

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Identifying common causes in yarn manufacturing processes, such as spinning, twisting,
winding, dyeing, and finishing, allows for targeted corrective actions and process optimization.

In cases of non-conformance, a systematic approach is vital. From policy development to

corrective actions, each stage requires careful planning, organization, and documentation.
Employee selection, training, and modification, as well as legal considerations and user safety,
contribute to a holistic quality system. Sampling and statistical techniques provide analytical
tools for effective quality control.

Ultimately, a well-established total quality system ensures that products not only meet but
consistently exceed customer expectations. By addressing every aspect from design to
production, feedback, corrective actions, and continuous improvement, organizations can build a
culture of quality that is fundamental to sustained success.

REFERENCES:
1. https://textilelearner.net/principles-of-textile-quality-control/
2. https://ctb.ku.edu/en/table-of-contents/maintain/maintain-quality-performance/
overview/main#:~:text=Planning%20carefully%2C%20monitoring%20your%20work,the
%20mistakes%20to%20begin%20with
3. https://law.resource.org/pub/in/bis/S12/is.sp.15.1.1989.pdf
4. ISO 9001:2015 - Quality management systems - Requirements
5. https://www.simplilearn.com/common-vs-special-cause-of-variance-article
6. Fundamentals of quality control and improvement, by Amitava mitra (2nd edition)

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