Quality Assurance Department (QAD)

Pride group is more concern about quality. In this factory quality assurance is more
preferred than quality control, but both are in advancement. The Quality Assurance
Department is assigned to maintain consistently uniform quality of the material in
process and various stages of its manufacturing.

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 Objective of Quality Control:
Research.
Selection of raw materials.
Process control.
Process development.
Product testing.
Specification test

Scope of Quality Control, Quality Assurance and Testing:

Testing Lab
Machine auditing system
A good training system.
Excellent analytical backup.
Technical expertise.

Quality Control Procedure:

On line quality control
Off line quality control
Off-Line Tests:
Physical Tests: Chemical Tests:
Threads per inch Fastness to washing
Fabric weight (GSM) Fastness to light
Fabric Width test (Dia) Fastness to heat
Tensile strength Fastness to actual laundering
Tear strength Fastness to sea water
Seam slippage Fastness to Chlorinated water
Abrasion resistance Fastness to water spotting
Pilling resistance Fastness to perspiration
Thermal stability Fastness to light perspiration
Crease resistance Fastness to rubbing
Stretch ability & growth recovery
Smoothness appearance
Bursting Strength

Quality Control Flow Chart:

Quality
QualityControl
Control

On
OnLine
Line Off
Offline
line

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 Yarn Processing
(Yarn test)

Pass Fail

Knitting
Send to spinning mill
Grey fabric inspection

Pass Fail

Grey store
Send to store as reject
Batch making
Fail
Dyeing Shade check
Redyeing

Pass
Finishing

Fabric checking
Physical Lab Inspection Shade

Pass Fail

Delivery Reprocess Reject

Send to store as reject

List of Equipments:
Machineries & equipment used:
Spectrophotometer with Software (Data Color)
Martindale Abrasion Tester
Day Light Box

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 Sample Dyeing Machine (5)
ROBO Lab
Iron
Electric Balance
Crock Meter
Washing Machine (Electrolux Wascator/Siemens)
GSM Cutter
PH Meter
ICI Pilling Box
Martindale Pilling Machine
Bursting Strength Tester
SDL ATLAS Rotawash
Perspirometer
Xenon Test Chamber
Mechanical Shaker Machine

Fabric Inspection:
The inspection of fabric is a procedure by which the defects of fabric are identified
and fabric is classified according to degree or intensity of defects. The fabric
inspection is done for both grey and finished fabric.

Grey Fabric Inspection:

In SKFL grey fabric inspection is performed according to 4 point system.
Four-Point System:
Size of Defect Penalty
0 inches to 3 inches 1 Point
3 inches to 6 inches 2 Point
6 inches to 9 inches 3 Point
More than 9 inches 4 Point

Acceptance Calculation:
o Any Hole 4 Point
o Upto 20P/100m = Class A

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 o Upto 20-30P/100m = Class B
o Upto 30-40P/100m = Class C
o More than 40P/100m = Reject.

Faults found during Grey Fabric Inspection:

Wrong Design:

Causes:
Wrong insertion of yarn during knitting.
Wrong setting of fabric design in knitting machine.
Lycra out:
Causes:
Lycra tears out during running the machine for production.
Barrie Mark/Patta:
Causes:
Yarn package is either hard or soft.
Lot Mixing of yarn.
Improper yarn tension.
Uneven yarn dyeing.

Thick & Thin:

Causes:
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 Diameter of yarn is uneven i.e. yarn irregularity.
Variation of yarn tension in course wise direction.

Sinker Mark:

Causes:
Defective sinker.
Dust in sinker.
Improper servicing time of knitting machine.

Needle Line:
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 Causes:
Needle mixing.
Dust in needle group.
Improper servicing time of knitting machine.

Oil Stain:
Causes:
Dust in cylinder & Dial group.
Dust in needle group.
Improper oil flow.

Pin Hole:
Causes:
Breakage of needle tail.
If needle tail bends.

Loop:
Causes:
Dust in yarn during running the machine for production.
Yarn knot thicker.
Breakage of needle.

Fly Yarn:
Causes:
Fly fiber during knitting.
One colors dirt is knitted with another color during running the machine.

Slub:
Causes:
Excessive ply during yarn production.
Improper machine setting (Blow Room, Carding, Ring Frame).

Uneven Loop
Loose tension/Tight tension
Over looping
Finished Fabric Inspection:
4 point numbering system is followed for finished fabric inspection.

Four-Point System:
Size of Defect Penalty
3 inches or less 1 Point
Over 3, but not over 6 2 Point
Over 6, but not over 9 3 Point
Over 9 inches 4 Point

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Acceptance Calculation (Classification):
< 40 PTS = A
41 60 PTS = B
61 80 PTS = C
80 ABOVE = REJECT.

Faults found during Finished Fabric Inspection:

Chemical Stain:
Causes:
Padder contains dust during silicon finish.
Improper mixing of silicon softener.
Improper PH of softener mixing.
Too much m/c stoppage within short time.
Dirt Stain:
Causes:
Fabric is stored in floor.
Trolley is not properly cleaned.
Finishing m/c is not properly cleaned.
Oil Stain:
Causes:
Dust in cylinder & Dial group.
Dust in needle group.
Improper oil flow.
Dye Stain:
Causes:
Appearance of the darker spots of the same colour caused by incomplete
dissolution of the dye.
Improper dyes quality & dyes dosing.

Insect Spot:
Causes:
Fabric is finished with insect when insect is in surface area of the fabric.
Fabric is stored for long time.
Barrie Mark/Patta:
Causes:
Yarn package is either hard or soft.
Lot Mixing of yarn.
Improper yarn tension.
Uneven yarn dyeing.
Slub:
Causes:
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 Excessive ply during yarn production.
Improper machine setting (Blow Room, Carding, Ring Frame).

Wrong Design:

Causes:
Wrong insertion of yarn during knitting.
Wrong setting of fabric design in knitting machine.
Lycra out:
Causes:
Lycra tears out during running the machine for production.

Thick & Thin:

Causes:
Diameter of yarn is uneven i.e. yarn irregularity.
Variation of yarn tension in course wise direction.

White Specks/ Dead Cotton:

Causes:
If fibre is immature.
Fabric construction contains dead fibre/ damage fibre.

Crease mark:
Causes:
More cycle time.
Faulty plaiting device.
Slack on tight selvedge causes crease at an angle to each selvedge.
Incorrectly set bowed-expander.
Compacting is done when fabric is in folded condition.
Variation of heating and cooling rate.
Improper fabric movement.