Professional Documents
Culture Documents
QUALITY MANUAL
KUMAR & TYAGI CLOTHING
5 May 2014
[The document contains the Quality Manual for a self assumed company]
Submitted By –
Faculty In-charge –
Neetek Kumar
Mohammad Umar
Prashant Tyagi
DFT
DFT
SEM VI
Madura Garments Exports Ltd – Quality Manual
1. Quality Assurance
2. Continuous improvement
a) Productivity
b) Waste elimination
c) House keeping
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Madura Garments Exports Ltd – Quality Manual
Laying
Style descriptions,
Fabric code, W.O. no,
Design approval, Fabric
one way or two ways?
Re-do NOT OK
OK
Marker placement, Line
balancing, No. of plies?
Re-do
aaa NOT OK
Quality check in between lay
Is W.O .no, size, central line, notches,
straight line, repeat width, Line
balancing, pairing, shade ok, Fabric
defects marked IsCheck Check
for W,OforW.O
W.O.no,Centre no, 3
no,bubbling,Fus
line,Repeat,Balancing,St
weaving
Is Issue ofdefect, Style
W.O.no,size,parts
Quality
line,one ed Quality
passedway
cutokay?
verification, Centre
bundleno,numbering,lay
parts to
Re
Re-Do
Re-Do
-Do
Re-Do notch, thread,Stain,lini
no okay? check
Fabric
line
OK
Cut parts; check the following points
Is W.O. no.,
Re-do Centerline,Repeat,
Balancing,St line,one
NOT OKway,shade OK ?
NOT OK
OK
Quality check during fusing
NOT OK
OK
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Madura Garments Exports Ltd – Quality Manual
Re-Work NOT OK
Check point 1 In- line inspection by
Collar inspection Traffic light System
Collar visual
OK Standard, measurement collar
Re-Work NOT OK
Check point 2
front Left and right front parts.
pairing Visual standard, measurement
Re-Work NOT OK OK
Check point3
trimming Assembled shirt,
& inspection Measurement,
Re-Work NOT OK OK visual Standard.
OK
Release to
finishing
NOT OK
Trolley wise
AQL audit (2.5)
OK
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Madura Garments Exports Ltd – Quality Manual
Folding &
Packing
R OK
E
J AQL NOT OK
C Pre Final Audit/
T Finished Stock Audit
S (10%, 25% and 50%)
Offer for
final
inspection OK
ACCEPT
Release to Warehouse
3. Quality Procedures
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Madura Garments Exports Ltd – Quality Manual
Activity Requirement
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Madura Garments Exports Ltd – Quality Manual
I). Length of the faults is to be measured in the warp or weft direction and the direction in
which the fault is longest is the fault direction. However when the warp and weft length
are same and when the penalty of the shorter direction is heavier, take the fault of the
direction in which the penalty is heavier.
ii). When the fault in the warp direction is over 1yd, the part which is over 1yd is deemed
as fault of the same kind of others.
iii). When two or more faults overlap, apply only the faults which penalty is the heaviest.
iv). When there are two or more faults within the length of 1yd and the penalty points
come over 4 points, the points over 4 points are not added.
v). The inspector needs to be at a distance of 3 feet away from the inspection table and
the linear speed of inspection not to be less than 0.1mtrs per second.
Minimum fault sizes are shown on the Sears Fabric defect scale :-
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Madura Garments Exports Ltd – Quality Manual
Knots Slubs
A – do not count A - do not count
B- Count as 1 point B - do not count
C- Count as 1 point C- Count as 1 point
D- Count as 1 point D- Count as 1 point
E- Count as 3 points E- Count as 1 point
F- Count as 3 points
G- Count as 3 points
Standards for Passing Fabric:-
Average index for inspected rolls not to exceed » 28 points / 100yd².
Maximum index for any roll not to exceed » 40 points / 100yd².
Once the Shade bands are ready, Dye lot or colour segregation has to be done. If
the Shade Band consists of 2-3 different shades, such shades should be segregated
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Madura Garments Exports Ltd – Quality Manual
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Madura Garments Exports Ltd – Quality Manual
All trims been In house should be inspected ( 10% ) & the reports submitted accordingly.
Scope: Interlining, Collar bone, Label, Button, Packing Materials, Swing Ticket, Poly
bag, Product box.
Activity Requirement
A. Interlining
a. Bond strength
1. Take 10” * 4” of fabric strip and lining strip. Note the temperature, pressure and
2.Cut rectangular slit 6”*1” in Tissue paper of speed.
8 ‘* 4”.
3. Sandwich Tissue paper between interlining
and fabric then fuse.
4. Check Pull strength.
Pull strength to be at least 1 kg /
If by varying fusing conditions sufficient sq.cm.
strength is not achieved the lot is rejected.
b. Shrinkage Test.
1. Send two collars to lab every day for
shrinkage test.
c. Visual Inspection
1. Select the roll as per sampling plan. Check for uniformity, micro dots,
uniformity of shade.
Reject the lot is not ok.
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Madura Garments Exports Ltd – Quality Manual
Activity Requirement
B. Labels
a. Visual Examination
1. Check lettering, color, edges as per the No weaving defects.
Master and Specifications. Shade continuity.
Smooth and straight edges.
Centered labels.
Note: Selection Of all trims for the inspection to be as per sampling plan.
Activity Requirement
C. Buttons
1. Check buttons for shade, chip around Uniform in shade, gauge.
the edge. No chip.
2. Get stitched 10 buttons breaks NO breakage
stitched in machine.
3. If any one button breaks, then check No breakage.
for 10 more buttons.
D. Packing Material
1. Check edges, slots and slot spacing. Even edges for all the trims.
Slots and Slot spacing as per the
specifications.
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Madura Garments Exports Ltd – Quality Manual
Activity Requirement
E. Swing ticket
1. Inspect visually the lettering. No stains and misprints.
F. Product Box
1. Check for lettering, hinge, marks and No misprints and spread hues
color.
G. Polycovers
No misprinting and spread hues. Shade
1. Check for lettering, uniformity and continuity to be maintained.
scratches.
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Madura Garments Exports Ltd – Quality Manual
3.4 PP Meeting
A PP meeting should be organized & conducted prior to bulk production including
Buyer’s Representative, Merchandiser, Production Manager & all sectional heads,
Supervisors & Q/C’s involved with the particular style. No Production is to start without
a PP Meeting & all points to be discussed & documented in the PP meeting format
(Annexure 4). The QA Manager or the Technical Manager should write down the
minutes & file the PP meeting comments in the style file “ Technical, Quality, Packing,
Washing, Shipping ETC”.
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Madura Garments Exports Ltd – Quality Manual
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Madura Garments Exports Ltd – Quality Manual
3.10Cutting Department
3.10.1 Laying & Cutting area
Rolls segregated & lay as per shrinkage option or shade band separation in case of
wash & non wash program respectively.
Relaxation of Fabric for Stretch & Knit at least for 12 Hours and fabric relaxation
report maintained.
1. Marker Way
2. All parts – All parts are there in the marker.
3. Ratio – Size ratios as written on the marker.
4. Shrinkage – whether made as per shrinkage option mentioned.
5. Skip – whether any cut line is skipped.
6. Overlap – check for any part overlapped.
7. Grain line – all parts in grain line as per required.
8. Marker length – as per mentioned.
3.10.4 Spreading
1. Table marks – check for the table marks as per the lay length.
2. Bowing – check for bowing in the fabric
3. Narrow goods – check for any narrow goods.
4. Mis-alignment of plies – plies alignment at both ends.
5. Leaning – check at the edges for leaning
6. Ply Tension – check for ply tension
7. Count – whether plies are counted correctly.
8. Nap direction – whether required nap direction is followed.
9. End loss – check for end losses.
While spreading all the defects identified in the fabric inspection stage should be marked
using a contrast color waste fabric stripe. (Annexure 5)
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Madura Garments Exports Ltd – Quality Manual
1. Grain direction
2. Notches
3. Ragged cut
4. Selvedge
5. Bowing
Fusing has to be carried out as per the conditions specified by the interlining supplier,
every four hours one sample of the fused component has to sent for washing and peel
bond strength testing and also the testing of the temp, pressure and time has to be carried
out. In case of failure on any of these all the bundles fused in last 4 hours on that machine
has to be recalled and refused. During fusing the fusing operator has to follow work
instructions as mentioned in the work instructions sheet for fusing (Annexure 6).
Fusing
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Madura Garments Exports Ltd – Quality Manual
Check and record the temperature with the recommended speed and fusing time.
The press will need to be adjusted if variation of more than 5°C below or 10°C above the
recommended fusing temperature is recorded.
Time
Check time with a stopwatch for the actual period for which temperature and pressure is
applied on the fused composite.
Washing
Carry out durability wash test daily on the fused components per fabric per colour.
Peel Bond Strength
Use three strips of fabric, each15x5cms, placed evenly across the belt, position the
interlining to cover the fabric with no overlap
Set the recommended fusing conditions for bulk production and allow it to cool.
Conduct peel bond strength test
Ensure an even bond and acceptable peel bond strength before production.
Fusing – all Interlining fusing has to be ready finished (block cut)
a. Woven interlining – Sewing allowance to be ¼”.
b. Non fusible woven - ----do---------
The entire interlining pattern has to be aligned with shell pattern 1/8" less all
around
For order size more than 2000 pcs for lining cutting die should be used.
The ready to feed bundle should be checked for the following defects
Whether numbers are correct.
Actual quantity as compared to mentioned
Cut parts check against hard pattern.
Shade variation in cut parts with same number.
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Madura Garments Exports Ltd – Quality Manual
Quality control on the product, Packing & stacking should be maintained at the highest
level.
A full functional traffic light system (Annexure 7) should be maintained at all times.
Statistical process controlling ( SPC ) should be implemented for every line to minimize
rejections. No Garment should be passed with inferior quality & rectification to be made
with immediate effect & documented.
This System is a very affective approach in curtailing & discontinuing defected panels &
garments with discrepancies from moving in the Line. There are three colors to identify
the progress of the operator & the quality.
Green, Amber & Red bag with the Instructions of Operation descriptions to be
audited.
* Green – If this color is flagged by the Line Q/C on top of a machine, it indicates
that the Operation is under control & of good standing & could proceed to the next
operation or machine.
* Amber - If this color is flagged, it high lights that the Operation produced by the
Operator is in a tolerance margin & needs close observation from Superiors.
* Red – If the Line Q/C has flagged this color on top of a machine, you should
halt the machine & the operation immediately & rectify same without any delay & ensure
the productivity is not affected. In the same time the Line Q/C must record Instruction
paper what is in color bag & her operation file to follow up & same Q/C will issue a Pink
token to the Supervisor to rectify same & to follow up in three consecutive instance’s in
the same Operation (To Ensure 0 defects are maintained in a particular Operation) &
cross check with the Q/A.
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Madura Garments Exports Ltd – Quality Manual
•The roaming Q/C must continue for each & every machine Incorporating the same
process in the Line (Not more than 32 machines per line), Minimum four times a day.
Each Line Q/A dept should have two “In process Audit stations” for 100% components
check with the defect statistics (In line Inspection report Annexure 8) maintained
which could be analyzed hourly on each Operation to rectify prior to an Assembling
Garments.
•Each end Line should have a QA Audit station performing 100% Inspection of Garments
prior to moving to the next Process & the Defects to be maintained in the “Defect
Analysis Report” (Annexure 9).
No inline & end line checkers should have trimmers.
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Madura Garments Exports Ltd – Quality Manual
3.11.7 Reports
All inspection in Production & finishing should be daily documented by using Inline
reports & a copy of these reports should be submitted to the relevant Merchandiser at
least twice a week without fail.
3.11.8 Samples
The QA Department should submit the following samples, T.O.P – Within 3 days of bulk
input as per buyers required size & Shipment samples as per buyers requirement, one day
before final audit. This should be strictly adhered to.
i) It is mandatory that all Line Quality Supervisors & controllers should patrol their
respective lines on a daily basis
prior to starting bulk production in the morning to ensure that the Line is geared to
Produce high quality Apparels.
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Madura Garments Exports Ltd – Quality Manual
b) Cleanliness of Machines –
1) Well cleaned without any dust.
c) Check for Reject Garments – No Reject garment is to be brought forward from the
previous day without been rectified. All Reject Garments should be rectified on the same
day & not kept separately inside the line.
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