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13.0 OBJECTIVES
13.1 INTRODUCTION
13.7 ASSIGNMENTS
13.7.1 CLASS ASSIGNMENTS
13.7.2 HOME ASSIGNMENTS
13.8 SUMMING UP
13.11 REFERENCES
13.13 GLOSSARY
13. TEXTILE TESTING: AN OVERVIEW
To those engaged in the production, distribution and consumption of textiles and
textile products, testing can be a valuable aid as it helps in the selection of raw materials,
process control, process development, product design, etc. This being the first lesson of
the unit on ‘Textile Testing’, it would be appropriate to give first an overview on quality,
quality control, standards etc. In the two subsequent lessons, the actual tests performed on
textile fibres, yarns, fabrics, etc. and the instruments and equipment used fo making these
tests, will be described.
13.0 Objectives
After going through this lesson, you will be able to understand
13.1 Introduction
The common perception in the mind of people that testing is done to assess quality
is still substantially correct though the exact dimensions of quality may not be clearly
understood by them. There is ample evidence that quality has been with us since the dawn
of civilization as archeological sites like Mohenjodaro clearly suggest. However the
concept of quality, as we understand it today, seems to have emerged since about the
Second World War.
Quality considerations are important not only during production but also in the
designing stage. A good example of this is given by Pradip V. Mehta in reference 1 (in
section 13.11) for a garment manufacturing unit. The factors that count for such a unit are
– selection of fabrics, seam and stitch types, proper pattern grading for good fit for the
entire size range, appropriate fabric grain direction, selection of buttons, zipper, etc. One
cannot expect quality garments where buttons cannot withstand laundering, dry cleaning,
pressing, etc. One cannot produce a quality garment if the fabric it is made from shrinks
excessively upon laundering and/or is not colourfast. Chain stitch may be better than lock
stitch where some extensibility of the seam is desired.
Self-check Questions
1. Fill in the blanks
ii) For a quality garment, the fabrics must not __________ and be
________________.
Quality is also defined in terms of “fitness for use” (Reference3 in section 13.11),
a concept which can be applied to garments which must:
• Be free from defects such as stains, material (fabric) defects, open seams,
misaligned buttons etc.
Today this is still the most common type of quality found in the marketplace, by
far also the most uneconomical. Fig.13.1 visualizes such an over-dimensioned quality.
Fig.13.1 Over dimensioned yarn Quality (Taken from Ref. 4)
Fig.13.2 Discrepancy between requirement and quality level (Taken from Reference 4)
The actual quality level i.e. the quality of the yarn under reference, is much above
the required level. This span between the requirement and the measured actual quality
results in considerable costs for the producer and the customer as is evident from Fig.
13.2. This arises because often the exact knowledge of the requirements for the yarn is
missing, frequently as a result of the non-existence of product engineering.
This quality level can also be described as the optimum or the economical quality
i.e. all requirements are fulfilled not more but not less either.
Self-check Questions
2. What are the eight dimensions of quality?
The six benefits of quality that came out of another study are:
In the 1930’s, the idea was mooted that a given result is produced by a set of
conditions or a process not by a specific individual. This led to some drastic change in
thinking and a new approach to quality management.
The need to study the characteristics of a process became clear when the old
techniques of assessing quality were found to be inadequate. The obvious choice was to
use numbers or data, i.e. statistics for this purpose. This gave rise to the concept of
statistical quality control or SQC. When the whole process was studied with the aim of
controlling quality of the product, spectacular reduction in losses was reported by many
companies in the US. A carpet manufacturing company in U.S.A. applied this approach to
its carding department in 1949 and reported a saving of around two million US dollars in
the very first year of the operation of the quality control programme. In spite of the
success of SQC programme, there was a strong feeling that the base for quality
management needed still more widening as other wings of the organization rather than
process alone, also needed to be taken into account. The concept of total quality control
came up as a result
In the 1950’s, the concept of TQC emerged in the U.S.A., According to TQC,
besides the people connected with the actual production, others who are in the
organisation in various capacities, are also responsible for quality. Though the concept
had its origin in the US, the Japanese were the first to implement it with extraordinary
success.
TQM was introduced towards the end of 1970’s and became popular during 1980-
1990’s. It is an extension of TQC and quality management (considered as a Physical
variable) with human variable. It followed the notable success of the Japanese industry
which had prospered following the principle of TQC.
The factors which affect quality include raw materials, process, personnel,
technical knowledge, specifications, standardization and testing etc. All these must work
in tandem.
Self-check Questions
5. How was the base of testing enlarged when moving from craftsman’s approach to
SQC?
The standards may be for product quality or for performance or may be related to
units of measurement, health, safety, etc. The well known ISO 9000 series is a set of five
individual but related international standards on quality management and quality
assurance. ISO 9001 covers design, manufacturing, installation and servicing systems and
it accounts for 20 elements of company operations. ISO 9002 covers production and
installation. ISO 9003 covers only final product inspection and test. ISO 9004 gives
guidelines for quality management and Quality system elements.
Both large and small companies with international business perceive the ISO 9000
series as a route to open markets and improved competitiveness. Being registered for ISO
9001, 9002 and 9003 means having an accredited independent third party conduct an on-
site audit of your company’s operations against the requirement of the appropriate
standard. Upon successful completion of this audit, your company will receive a
registration certificate that identifies your quality system as being in compliance with
these standards.
Activity
2. List some advantages that may accrue to companies that have obtained
ISO certification.
13.7 Assignments
13.7.1 Class assignments
i) Give a clear idea of what is meant by quality and how does standardization help in
quality management.
13.8 Summing Up
Some basic concepts of textile testing like the meaning of quality and its
importance, the approaches for management of quality which include statistical quality
control, total quality control and total quality management and the role of standardization
in terms of ISO 9000 are dealt with in this lesson.
i) Planned, Tested
ii) Shrink, colourfast
5. By moving from the worker, to the production process and people involved with
production.
2. How will you proceed to ensure that a product is as per the required
specifications?
13.11 References
1. Mehta, P. V. 1999. Quality Management: An overview of progress in textiles;
Science and Technology, Vol I, Testing and Quality Management, Edited by
Kothari, V.K. IAFL Publications, New Delhi.
2. Garvin, D. A. 1998, Managing Quality: The strategic and competitive edge, The
free Press, New York.
3. Juran J.M. and Oth. 1988. Quality Control Handbook, 4th Ed. McGraw-Hill, Inc.,
New York.
5. Kothari V.K. 2000. Textile Quality: An overview, in Quality control, 2000, Ed.
V.K. Kothari, Textile Deptt., IIT Delhi.
13.13 Glossary
1. Framework The underlying structure