Areas Covered

1. Introduction, QA, QC, SQC, TQM, EMS, and Standards

2. Quality Control in Yarn Manufacturing (Yarn test in knit composite)
3. Quality Control in Grey Fabric (Knit and Woven) Manufacturing
4. Quality Control in Wet Processing and AOP
5. Quality Control in Garment Manufacturing
 Fabric Inspection in Store
 Sample Section
 Cutting Section
 Printing and Embroidery Section
 Accessories
 Sewing Section
 Washing
 Finishing Section
 Final Inspection of Garments
Textile Testing and Quality Control III

Basic Concept
of
Quality & Quality Control

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 Quality?
 The totality of features and characteristics of a product or service that
bear on its ability to satisfy stated or implied needs.

 The degree of excellence that a product posses.

 Quality refers to the characteristics of a product or service that defines

its ability to consistently meet or exceed the customer demand.

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 Aspects of quality

 Performance: This refers to appropriate functionality of the product or whether

the product performs satisfactory as desired or expected by the customer. (Will
the product/service do the intended job?)

 Conformance: Conformance means as per specification. It refers to how well or

accurately a product or service correspond to design.)

 Reliability: It refers to the ability of an item to perform a required function

under stated conditions for a period of time. (How often does the product/service
fail?)

 Durability: This refers to useful technical life or longevity of performance of the

product or service. (How long does the product/service last?) 4
 Aspects of quality
 Innovative features: Innovative features refers to extra useful characteristics
of the product, more than the desired primary ones

 Service after sale: For many years, Service after sale had been considered as
an extra business. But, now-a-days, because of increased focus on customer
satisfaction, service after sale is considered as part of the product. (How easy
to repair the product / to solve the problems in service?)

 Maintainability/serviceability: Maintenance and servicing of engineering

products are of importance now-a-days to a large cross-section of customers.

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 Aspects of quality
 Ease of use: One of the recent trends of customers quality requirement is
ease of use of product. Customer never like a product which is complex to use.
Thus, ease of use has become one of the major aspect of quality.

 Aesthetics: Aesthetic of product, especially in case of customer goods, is a

utmost importance to customers. Thus, aesthetic is also an important aspect
of quality. (What does the product/service look/smell/sound/feel like?)

 Others: Now-a-days, many other aspect, such as safety, health issues etc. are
considered as part and parcel of quality.

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 Factors affecting quality

 Customer: They are the ultimate users or beneficiaries of quality. As such,

any quality management drive should focus on this element while preparing
a quality plan.

 Processes: This element is responsible for transforming the inputs to

quality outputs. Traditionally, people used to think that the process is only
factor which needs to be controlled for ensuring quality. Modern quality
management views that employees and materials should be responsible for
quality.

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 Factors affecting quality

 Employee: Now-a-days, role of employee in delivering quality product is

valued highly. Employees are considered as internal customers, who need to
be kept satisfied in order to deliver quality product. Thus, they should be
trained regularly with high degree of motivation and skill.

 Materials (Suppliers): Role of suppliers in delivering quality goods is now

well recognized. A good manufacturing process does not have much to
contribute to quality if supplied materials are not of enough good quality.

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Consequences of Poor Quality

 Lower Productivity - due to Rework, rejection

 Loss of Material - due to Rework, rejection
 Loss of business - Organization image
 Liability - Warranty, replacement, repair
 Quality Control

 Quality control can be defined as the checking, verification and regulation of

degree of excellence of an attribute or property of something.

 The operational techniques and activities that are used to fulfill requirements of
quality.

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 Quality Assurance

 Quality Assurance is known as QA and focuses on preventing

defect. Quality Assurance ensures that the approaches,
techniques, methods and processes are designed for the projects
are implemented correctly.

 Quality Assurance is a proactive process and is Preventive in

nature. Quality Assurance has to complete before Quality Control.

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 QC vs QA
QA QC

Definition QA is a set of activities for ensuring QC is a set of activities for

quality in the processes by which ensuring quality in products. The
products are developed. activities focus on identifying
defects in the actual products
produced.

Focus on QA aim is to prevent the defect. A QC aim is to identify and

improve the defects.
Goal The goal of QA is to improve The goal of QC is to identify
development and test processes so defects after a product is
that defects do not arise when the developed and before it's
product is being developed. released.

Establish a good quality Finding & eliminating sources of

management system and the quality problems through tools &
How assessment of its adequacy. equipment so that customer's
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Periodic conformance audits of the requirements are continually
operations of the system. met.
Question for you
If Yes – Why?
If No –Why?

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 Statistical Quality Control

Statistical quality control (SQC): Statistical quality control or SQC

can be defined as the method of QC where a series of results are
analyzed with the help of statistical tools and techniques and
decision is made about controlling the process.
The purpose of SQC is to generate authenticity and significance
about a series of test result.

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 Type of quality control

Mainly 2 types of quality control:

i) Process control
ii) Product control

i) Process control: Controlling of process sequence or steps to produce

desired quality product is called process control.

ii) Product control: The control which is used to decrease defective items
within different lots of produced good is known as product control.
It is applied after production process
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 Types of quality control

Process control is two types:

a) Online quality control
b) Offline quality control

a) Online quality control: This type of quality control is performed in process

stage i.e. without stopping the production process, during the production
running time, the machine automatically tests the variation and takes
immediate step to rectify the variation.
Checking and rectification of variation/fault in processing stage is known as
online quality control.

Example: #Roving tension control device in simplex machine.

#Sliver hank is controlled by auto leveller in carding & draw frame.
# Garment inspection during sewing 16
 Type of quality control

b) Offline quality control: This type of quality control consists of laboratory

tests or inspection which are done by stopping the production process or end of the
production.

Here necessary steps are taken according to test result.

Example: # Checking of count and TPI variation

# Strength testing
# Evenness testing
# Final Inspection of garment (AQL)
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 Textile testing?

 Laboratory experiment to determine textile data of fibre, yarn, fabric and

end use product (garment, home textile etc.)

 Textile testing is the application of engineering knowledge and science for

the measurement of properties and characteristics of textile materials
(Fibre, yarn, fabric, garment, etc.)

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 Importance of textile testing

 To determine the properties and characteristics of fibre, yarn, fabric and end
product.

 To compare the qualities of textile raw materials, intermediate products and finished
products.

 To maintain the standard established by different organization. Example: ISO,

AATCC, BSTI, BS, DIN, etc.

 To meet market and consumer demand standard.

 To improve and control processing techniques by research and developments.

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 Factors affecting test result

 The sampling

 Atmospheric condition for testing

 Method of testing

 Instrument used

 Efficiency of the technicians, etc.

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 Total Quality Management (TQM)

 TOTAL = Total involves everyone & all activities in the company.

 QUALITY= Conformance to requirements (meeting customer requirements).
 MANAGEMENT= Quality must & can be managed.
 TQM= A process for managing quality, it must be a continuous way of life, a philosophy of
perpetual improvement in everything.

TQM is one of the most widely accepted quality control system. According to the TQM concept
an organization involves all the resources like raw materials, suppliers, almost all persons
working in the company, the whole seller, retailer and consumers to undertake decisions to
achieve a target quality.

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 Standards
 Something that is established by authority, custom or general
consent as a model or example to be followed.

 Something established for use as a rule or basis of comparison in

measuring or judging capacity, quantity, content, extent, value,
quality etc.

 The type, model or example commonly or generally accepted

adhered to; criterion set for usage or practice.

 According to ISO, standards are documented agreements

containing technical specifications or other precise criteria to be
used consistently as rules, guidelines or definitions of
characteristics to ensure that materials, products, processes and
services are fit for their purpose.
 Standards: Benefits
 Standards facilitate communication and prevent misunderstanding

 Standards make parts interchangeability possible and as a result

mass production is possible

 Standards can be used in marketing strategy to promote purchase

of products that meet nationally recognized requirements,
especially, when conformance is backed by a certain program.

 Standards reduce cost and save money.

 Standards

 Sources of Standards:
 Standards
 Sources of Standards:
 Standards: ISO
 ISO is an independent, non-governmental international organization with
a membership of 164 national standards bodies.
 Established in 1947 to promote development of standardization of
related activities in the world.

 Mission is to facilitate the international exchange of goods and services

and to develop cooperation in the sphere of intellectual, scientific,
technological and economic activity

 ISO publishes various international agreements as international standards.

 ISO sets standards for many diversified field like information, textile,
packaging, distribution of goods, energy production and utilization.
Management System: Standards of ISO

 ISO 9000: Quality Management System

 ISO 14000: Environmental management systems
 ISO 26000: Guidance on social responsibility
 ISO 31000: Risk Management Principles and Guidelines
Standards: ISO 9000 Series - Quality Management

ISO 9000: It is the first standard in the series and is entitled

“Quality Management and Quality Assurance Standards-
Guidelines for Selection and Use”.
They are generic, not specific to any particular products.
They can be used by manufacturing and service industries.
Standards: ISO14000 - International Environmental Standards

 The ISO 14000 series, currently being developed by the

International Organizational for Standardization (ISO), is a
collection of voluntary standards that assists organizations
to achieve environmental and financial gains through the
implementation of effective environmental management.
 The standards provide both a model for reorganization
environmental management and guidelines to ensure
environmental issues are considered within decision
making practices.
Standards: Environmental Management System (EMS)

An environmental Management System is a tool for managing the impacts of

an Organization’s activities on the environment. It provides a structured
approach to planning and implementing environment protection measures.

An EMS can be a powerful tool for organizations to improve their

environmental performance and enhance their business efficiency. An EMS is
not prescriptive; rather it requires organizations to take an active role in
examining their practices, and then determining how their impacts should be
managed. This approach encourages creative and relevant solutions from
organization itself.
Standards: Environmental Management
System (EMS)
Benefits of an EMS

An EMS can assist a company in the following ways:

 Minimize environmental liabilities

 Maximize the efficient use of resources
 Reduce waste
 Demonstrate a good corporate image
 Build awareness of environmental concern among employees
 Gain a better understanding of the environmental impacts of business activities
 Increase profit, improving environmental performance through more efficient
operations.
 Standards: Steps towards ISO certification

Step-1. Management commitment

Step-2. Quality system requirement and quality policy manual

Step-3. Planning

Step-4. Training, Education and quality awareness.

Step-5. Implementation

Step-6. Auditing and Corrective action

Step-7. Certification.
ISO: seven Quality Management Principles (QMPs)
ISO 9000, ISO 9001 and related ISO quality management
standards are based on seven QMPs
The seven quality management principles are :
QMP 1 – Customer focus
QMP 2 – Leadership
QMP 3 – Engagement of people
QMP 4 – Process approach
QMP 5 – Improvement
QMP 6 – Evidence-based decision making
QMP 7 – Relationship management
Statements on quality management principles:
QMP 1 – Customer focus
Statements on quality management principles
QMP 2 – Leadership
Statements on quality management principles
QMP 3 – Engagement of people
Statements on quality management principles
QMP 4 – Process approach
Statements on quality management principles
QMP 5 – Improvement
Statements on quality management principles
QMP 6 – Evidence-based decision making
Statements on quality management principles
QMP 7 – Relationship management