Tuesday, August 1, 2017

Function of Quality Control Department in Garment Manufacturing

Quality control department:
Quality means customer needs is to be satisfied but maintaining an adequate standard of quality also costs effort. 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. As producers of apparel there must be a constant endeavor to produce work of good quality.
Quality inspector checking garments
Figure 1- Quality inspector checking garments
Process flow chart of quality section:
Working flow chart of quality department
Figure 2- Working flow chart of quality department
Working procedure of quality control department in apparel industry:

Fabric Inspection and QC Procedures: Incoming fabrics are inspected at JC Penney’s recommended 4 Point system. 100% fabric is inspected by fabric QC’s. Each fault is given points keeping in view the nature and intensity of the faults. 40 Points are allowed in 100 inspected yards. If number of faults/points exceeded than 40 per 100 yard, the fabric roll is rejected. Lab test reports are also taken from fabric suppliers and verified through internal and third party labs randomly.

Accessories Inspection: Accessories at the time of receipt in store are randomly inspected by QC’s/concerned persons at least up to 10% of the received quantity.

Cut Parts Inspection: 100% cut parts are inspected before input to sewing. The rejected components are replaced from remnants or removed. Cut parts are also inspected 100% before sending and after receipt from printing and/or embroidery.

Sewing Inline Inspection: During stitching operations, the inspections are done on JC Penney’s recommended 7-0 System. Inline QC inspects 7 pieces randomly for each machine operator twice a day. If he finds any fault among these 7 inspected pcs, the Sewing operator has to inspect the whole bundle himself and offer inspection again to Inline QC. If the inspection is fault free, then this sewing operator will undergo follow up inspection of 03 Consecutive bundles. If 03 Follow up Inspections are ok, the Inline QC moves to next machine operator. Follow up inspection, the Inline QC finds any fault, then the said sewing operator has to go under 2nd follow up inspection. If the 2nd follow up fails then operator has to stop the work for two decisions to be made depending on the nature of the faults (either machine to go under maintenance or sewing operator to go for training or replacement).

Sewing End Line Inspection: 100 % garments are checked on sewing related faults after sewing completion. Both in and out sides of the garments are inspected.

Use of Auto Trimmer & Thread Sucking Machines: We are using Auto Trimmers for clipping to avoid un-necessary clipping cuts during this process. We are also using thread sucker machines to ensure that packed garments are free from loose threads.

Final QC Inspection: Garments are checked 100% on quality after pressing for fabrication, finishing, appearance, sewing, shading, labeling etc. to make sure that quality garments are packed into cartons.

Measurement Specs Control: Before packing, garments are 100% checked on measurements for key measuring points.

Internal Q.C Lab & Third Party Testing: Fabrics and garments are randomly tested at internal QC lab on fabrics’ basic performance features like fabric weight, shrinkage, torqueing, color fastness, PH Value etc. In addition to this, garments are sent to third party labs (SGS, ITS, BV) for independent testing to make sure that the outgoing goods are meeting customer’s required quality standards.
 
About Author:
Mohammad Sajjadul Karim Bhuiyan
BGMEA University of Fashion and Technology
Email: sajjadulkarim7@gmail.com

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