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7.2 Tolerances
Tolerance limits
7.3 The threshold of faults
Training quality standards and faults
analysis
7.4 Sampling techniques
Checking levels of faults and seconds
8. QUALITY COMMUNICATIONS
Control of quality in garment assembly
Example of quality feedback - marks and
stains
Action checklist to improve garment
cleanliness
economics of cleanliness
Fault cost assessment record
Quality Control Requirements - Order of
Priorities
Quality Assurance
"The establishment and maintenance of ALL
activities and functions concerned with the
attainment of requisite quality"
Quality Control
"The systems required for programming and
co-ordinating the efforts of the various
Sewing defects
Open seams, wrong stitching techniques, nonmatching threads, missing stitches, improper
creasing of the garment, improper thread
tension etc. are some of the sewing defects
which can affect the garment quality adversely.
Colour defects
Variation of colour between the sample and the
final garment, wrong colour combinations and
mismatching dyes should always be avoided.
Sizing defects
Wrong gradation of sizes, difference in
measurement of various parts of a garment like
sleeves of XL size for body of L size garment
can deteriorate the garments beyond repair.
Garment defects
Broken or defective buttons, snaps, stitches,
different shades within the same garment,
dropped stitches, exposed notches, fabric
defects, holes, faulty zippers, loose or hanging
sewing threads, misaligned buttons and holes,
missing buttons, needle cuts, pulled or loose
yarn,
Inspection:
Inspection may be defined as the
visual examination in relation to some standards.
Objective:
The main objectives of inspection are
i. Detection of defects.
ii. Correcting the defects or defective
garments.
Detection of defects
Inform defects to
appropriate personnel
Determination of
causes of defects
Fig: Inspection Loop.
Raw Materials
B) Sew ability:
The sewing ability of a thread is
called sew ability. During sew ability test
the following quality of thread should be
tested
i. Imperfection
ii. Finish
iii. Package density
iv. Winding
v. Yardage
In-process Inspection
Sewing Checks
Final Inspection
Recovery Inspection
Product Tests
AQL (II)
# Three types of sampling plans
-single, double and multiple.
# Each sampling plan can be
performed in three levelnormal, tightened and reduced,
depending on quality of products.
Example
Single Sampling Plan-Normal Inspection
Assume AQL is 2.5% and lot size is 600
garments, find out the following :
The total number of samples need to
inspect
The acceptable number of the samples
The rejection number of the samples
Answer
Single Sampling Plan
First, from Table 1 find out the code letter for
lot size of 600 and inspection level II is J
From Table 2 (single sampling plan), the letter
J corresponds to sample sizes of 80.
So, 80 samples are needed to inspect out of
600
At AQL 2.5%, if defective garments are less
than or equal to 5, whole lots will be accepted,
if it is found to be 6 or more, whole lots will be
rejected.
Example II
Double Sampling Plan
Assume AQL is 4% and lot size is 2000
garments, find out from double sampling
plan on the following:
The total sample sizes need to inspect
What is the first acceptable number
What is the second acceptable number
Answer
Double Sampling Plan
First, Table 1 of 2000 lots at inspection level
II is letter K
Table 3, double sampling plan shows the
sample size of letter K is 80.
First inspection, at AQL 4%, the acceptable
number is 5, rejection number is 9
If any number between 5 to 9, second
inspection is needed
Answer
Double sampling Plan (II)
For second inspection, the sample sizes
again is 80
At AQL 4%, the cumulated acceptable
number is 12 and rejection number is 13.
Conclusion
If the number of defective garments found
in the first sample is 6, and in second
sample is 5, making a total of 11, then the
whole lot of 2,000 pieces will be accepted.
References
Garments and Technology
Prof. M. A. Kashem
Jimmy K.C. Lam
The Hong Kong Polytechnic University
Introduction to garments manufacturing
Harold Carr
Fashion dictionary
Engr. Mohammad Faizur Rahman (Rashed),
Assistant Professor (Garments Technology),
Department of Textile Technology, AUST
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