Quality Control Management

 PIECE GOODS INSPECTION SYSTEMS

During piece goods inspection – we follow some systems

• We inspect- at least 10% of the total rolls in the shipment
• We select – at least one of the roll each color or more than one roll per color
• We indicate as a major defect – i.e. slabs, mixed yarn, hole , needle mark , missing yarn, 
  crease mark, foreign yarn, Shading, oil mark, dirty, dye spot, color out, broken pattern, grain line etc..

 CUTTING DEPARTMENT QUALITY CONTROL

• Fabric Relaxation – we open fabric rolls before 24 hours start fabric spreading, rolls selection with same width & shade dye lot.
• We follow – during spreading — marking placement, running shading, fabric ply tension,
  layer counting, fabric edge controlling. Fabric plies counting. Over lapping & pilling
  direction.
• We follow – after cutting – narrow goods, cut pieces checked by original pattern, notches, miss-cut, ragged cutting, Matching plies.

  IN PROCESS  QUALITY  CONTROL

Our main motto is to producing good quality merchandises. So we control quality in
process as one of the key.

IN PROCESS AUDITING SYSTEM

• To ensure good quality – we provide two nos. inspector for 30-40 machines
• To maintain record data – we provide a format against each machine
• We make sampling plan with allowable defects
• We have written quality standards
• We take measurement in critical process
• We use arrow sticker to identify defects
• We inspect 07 pcs. from per bundle i.e.> 24.pcs
• We follow – AQL- 2.5 in process
• About reject bundle- the inspector enters the operators name on the four tickets, places these tickets with the rejected bundle & takes the bundle to the sewing supervisor for review. The sewing supervisor explains the problem to the operator, shows the operator how to repair or correct the problem. & instructs the operator to 100% inspect the entire bundle, making all necessary repairs before starting to work another bundle.

RECORD  KEEPING  IN- PROCEES  AUDITING

We maintain a record or report from for each individual process as below:

• Date, operator name & time – clock number
• Operation number
• Sewing supervisor & line number
• Daily in process audits showing units inspected & units found defect
• We maintain a weekly summary to show total units inspected, total defects found &
  Percent defective

TABLE  INSPECTION

To maintaining good quality – we make a inspection report from ”sewing line finish garment”;

• Date/hourly production quantity, inspected quantity, rejected quantity & pass quantity
• Identify defective & rectified quantity

ACCEPTABLE  QUALITY  LABEL (AQL)

Before start finishing work – we follow AQL system through a format;

• Buyer, item, style, Purchase Order, order quantity, audit time, lot quantity, sample quantity, 
  measurement, defect allowed, total defects Percent of defects. Pass/fail
• Pass >> allowed for start the finishing work
• Fail >> full lot – 100% re-inspection

PRE- FINAL  INSPECTION

We make a pre final to avoid as bellows;

• Incorrect quantity.
• Incorrect price ticket/bar code, hang tag/OTC tag, hanger &sizer cap, garment sticker/poly bag sticker.
• Carton – shipping mark printing problem/carton sticker.
• Carton not as specified.
• Crushed or damaged cartons.
• Incorrect pre-pack 1] assortments 2] Amounts 3] Pre- pack stickers