Essentials of Quality Control Programme in Textiles

Quality is defined as the level of acceptance of a good or service. It is an essential requirement for any kind of product. Every product should maintain the standard quality level. In this 21st century of globalization, the market is becoming more and more complex, that’s why every industry is facing a high level of competition for their business. So the product must fulfill the customer requirement. For this reason, every product should maintain the quality level.

For the textile industry and apparel industry, product quality is calculated in terms of quality standard of fiber, yarn. Fabric construction, colorfastness, design, and the final finished garment. Nowadays buyers are very much quality conscious. If it is possible to maintain a high-quality system of inspection policy, the buyers shall be motivated and more quality products can be made.

Measurement Leadership

Experience has proven that the key to effective quality control is measurement’s leadership in the program. If top measurement wants good quality and displays leadership in quality concerns, measurement and production supervisors will follow through. Without leadership from the top, there is often little or no improvement in quality no matter what system is used.

These days’ suppliers are serious about improving quality control. The measurement of such suppliers has learned to identify the correct common problem areas such as the following:

• No piece goods inspection, not even measuring yardage to see that company gets what it paid in total yards.
• No cutting inspection other than by a cutting supervisor.
• A ratio of only one sewing supervisor every 100-200 operators.
• A lack of quality inspectors or a ratio only one inspector to 100-200 operators or inspectors who are primarily bundling movers.
• Final 100 percent inspectors who are on piece rate pay and are performing operational functions such as trim, turn, button, zipper close, fold and package.
• Little or no training program for any type of inspector.
• Inspector’s salary rates lower than the rate for any other job in the plan, pay at the minimum allowed.
• No checking for size other than measuring a few pilot lot garments.
• No lab testing or lab equipment, not even a washing machine.
• No inspection or checking of contracted merchandise beyond possibly sending someone to the contract shop once a week or once every two weeks, primarily to check delivery status.
• Acceptance and shipment of import merchandise without checking it of quality or size

These conditions suggest areas to think about as one gets training. After the training one is able to evaluate the system in terms of recommendations for an efficient quality control program.

Final Statistical Auditing

The most crucial part of any quality control process is the final inspection. Statistical Auditing methods suggest the following quality control production:

• Evaluate your piece goods suppliers, identify bad shipments and take corrective actions.
• Evaluate your operations in all areas of production(cutting, sewing, Finishing) and take corrective actions as necessary.
• Evaluate the terms and conditions specified in the letter/letter of credit/contract. Identify bad production and take corrective actions.

Guidelines for Quality Management

Measurement plays a critical role in quality control. The following guidelines for measurement reflect recommendations for initiating an effective quality control program.

Measurement is responsible for determining who will have the final decision regarding quality control problems. The chain of responsibility may vary depending upon the3 size and staff of the manufacturer.

Example:

Jacket quality inspection method

Final Audit for Shipment

• Open poly-bag, check poly-bag sticker and marketing label.
• Remove garment
• Lay flat on table Face up the collar on top sleeves extended flat
• Give the front of garment an overall visual examination check for fabric defects, shading, and soil.
• Check hang tags

For unlined jackets

• Open and check front closure completely-Unfold the front edges, take out inside packing and put aside.
• Give inside of garment an overall visual examination
• Check inside of collar and hood – check style details, label, hood
• Check right linear shoulder seam.
• Check inside right armhole seam, top to bottom and 3” inside armhole.

For reversible jackets

• Check inside right side seam, bottom to top
• Check inside right front closure edge.
• Check closure seam, embellishments, inside pockets and logos.
• Check inside/outside bottom hem, right to left.
• Return to a flat position.
• Check inside right side seam, bottom to top.
• Check inside left armhole seam, top to bottom and 3” inside armhole
• Check left liner shoulder seam.
• Check inside a left front closure, top to bottom.
• Return front edges to center.
• Close garment closure hardware completely.

For an unlined jacket with front snaps, buttons, and velcro

• Open top three buttons, snaps, Velcro
• Check inside collar to left inside shoulder seam and armhole for styling details.
• Move to right inside shoulder seam and armhole for styling details.
• Close buttons, snaps, Velcro.
• Check inside, outside bottom hem, right to left.
• Fold front and back hem up to 4”.
• Check back hem.
• Return to a flat position.
• Check outside front chest embellishments, seams, logos, styling details.
• Check front closure, pockets, inset hands.
• Check collar, hood for seams and embellishments.
• Measure neck seam.
• Check outside collar/hood for styling details and shading.
• Fold top of garment forward at the shoulder.
• Check outside back collar/neck seam.
• Check right shoulder seam and sleeve crease for styling details.
• Measure sleeve length.
• Check right front armhole seam.
• Fold sleeve across the front of the garment.
• Check back armhole and panel shading.
• Check inside, outside right sleeve hem, a cuff for styling details, lining, closure.
• Turn cuff inside out 3” and inspect seams.
• Check right underarm seam.
• Return sleeves to an extended flat position.
• Check right side seam.
• Check left side seam.
• Check left an underarm seam.
• Check left sleeve hem, a cuff for styling details, lining and closures- turn off cuff inside out 3” and inspects seams.
• Check left front armhole seam.
• Fold left sleeve across the front of the garment.
• Check left back armhole seam and shading.
• Return sleeve to an extended flat position.
• Check on left shoulder and sleeve crease.
• Turn garment over to back, collar to your left.
• Measure body length.
• Measure body width.
• Check back embellishments, seams, and logos.
• Give the back and overall visual examination.
• Check for fabric defects, shading, and soil.
• Check back vent.

No Defects

• Replace all original internal packaging materials.
• RE-fold garment to an original state.
• Replace into poly-bag.
• Reseal poly-bag.
• Remove from work surface to storage.

Defective Garments

• Mark Defect.
• Fold garment neatly defect mark up.
• Remove from work surface to defect storage.
• Repeat Process for all garments in sample lot.