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Flowchart
Order Confirmation
Preproduction
meeting
Documentation
Fabric arrival Accessories arrival
check
Quantity/Quality
Dimensions test
Check
Test cutting
Ironing
Cutting
Audit on finished
Assortment garments
Final Audit
Sewing
In line inspection
Visual inspection
General Procedures
1. Factory quality assurance program consists of 3 levels, technical team, production team and
audit team. The technical team to do the following
a) follow up work before actual production
b) Fabric testing and trims testing
c) Pattern and marker approval
d) Sewing and testing of production samples
e) Fabric inspection
f) Check the work of cutter, layer, bundler and identify workers with bad quality work
g) Check and replace defective cut piece
h) Check on embroidery, printing, washing, cutting sewing and finishing sub contractor
2. Production team to do the following work during production to prevent unacceptable garments
in production
a) Check the work of sewer and identify sewer with bad quality work
b) Ensure preventive measures are taken to avoid producing unacceptable garments
c) Check on the quality of the garment produced and send rejected garment back to sewer for
immediate repair
3. Audit team to do the following work after production to ensure shipped goods are within buyer
acceptable level
a) Final checking of finished garments, defective garments are sent back for rework
b) Do in house audit as per buyer quality requirements
c) Ensure preventive measures are taken to reduce the percentage of rejected garments
d) To do final audit on packed garments to know factory outgoing quality level
e) Check on packing trims
f) Check packing assortment
Visual inspection
1. Visual inspection or table QC is done at the end of sewing
a) 100% of output is to be visually inspected for the following
• critical and major defects
• table QC form is to be filled in and comments to be added.
• Monitor drop in workmanship and measurement defects
b) Table QC form is to be given to QA at the end of the day to be counter signed by
management.
2. If table QC finds same issues repeatedly, sewing line supervisor should be informed and
problem have to be corrected before operator is allowed to continue.
Internal Audit
1. Upon completion of a po of an order, QA should do an internal audit. Internal final or audit is
usually done before final buyer QC for internal purposes.
a) Famous Textile uses the MIL-STD-105E.
b) We usually do internal final audit based on AQL 4.0General inspection level II.
c) On page 13 of MIL-STD-105E is the lot or batch size.
d) On page 14, will tell us the correct sampling qty and accept and reject qty.
2. Internal audit report will determine if order is ready for buyer qc final,
3. Should internal audit be of a failed status, cartons should be opened and issues rectified before
buyer qcs arrival.
Fabric defects list
• Yarn
• Slubs
• Barre
• Uneven yarn
• Yarn contamination
• Dead cotton
• Other
• Construction
• Missing line
• Holes
• Streaks
• Stop mark
• Knots
• Other
• Dyeing
• Dye spots / streaks
• Color tone
• Shading
• Other
• Finishing
• Bowing/ skewing
• Pin holes
• Width
• Other
• Cleanliness
• Stains
• Oil spots
• Dirt soil
• Other