Garments production process & quality assurance

1

GARMENT PRODUCTION PROCESS AND QUALITY ASSURANCE

MASTER TEXTILE MILLS LTD.GARMENTS DIVISION M-6

Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.

MASTER TEXTILE MILLS LTD. (GARMENTS DIVISION)

MASTER TEXTILE MILLS LTD. (GARMENTS DIVISION)

2Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.

Garment Production is a process where fabric is being converted into Garments.

Garment manufacturing includes number of processes from order receiving to dispatching shipment of the finished garments.

Process flow charts will help us to understand how raw materials are moved from one process to another process, until fabric and accessories are transformed into the Garments.

In presentation “Working of Quality Assurance” in garment production process is shown with snaps. Numbering is given to QA working and their snaps are also given.

GARMENT PRODUCTION PROCESS


DEFINITION:

Quality assurance is an organization's guarantee that the product or service it offers meets the accepted quality standards.

OBJECTIVES:

1. Achieve the Right Final Product on Time.

2. Plan and Monitor the Overall Systems of Functioning of Quality System.

3. Customer’s Satisfaction.

4. Focus on Gradual and Continuous Improvement.

QUALITY ASSURANCE


GARMENT PRODUCTION PROCESS FLOW CHART

Note: Numbered Boxes are Quality Check Points.

SAMPLING

- FIT SAMPLE - SIZE SET SAMPLE

PP SAMPLE APPROVALFABRIC AND TRIMS

IN-HOUSE

MATERIAL SOURSING

PPC (PLANNING ) - MAIN POWER - MATERIAL - MACHINES

MATERIAL INSPECTION

MARKETING ORDER RECEIVING

CUTTING

PP MEETING

1

TRIAL RUN (PP SIZE SETS) - APPROVED SAMPLE’S CUSTOMER COMMENTS VARIFY

FAILFAIL

PASSPASS

STITCHING

WASHINGFINISHING

PACKING

SHIPMENT DISPATCH

SHIPMENT AUDITS

2


In Garment Production Process First Role of Quality Assurance is: 1. Inspection of Fabric

2. Inspection and Testing of Garment Accessories.

1. For fabric Inspection we have Fabric Inspection Department (FID):

FABRIC INSPECTION DEPARTMENT (FID): FABRIC INSPECTION: HEADERS COLLECTION

AND PREPARATION:

2. FABRIC SHADING

1. FABRIC INSPECTION

3. FABRIC SHRINKAGE

4. FABRIC WIDTH

5. FABRIC LCR VARIATION

MATERIAL INSPECTION

1


FID FINALINSPECTIONREPORT:

DECLARATIONAFTER ALL TESTS AND PROVIDES INFORMATIONOF SHRINKAGES.

MATERIAL INSPECTION

FABIC SHADING

FABRIC SHRINKAGE 1


2. Inspection and Testing of Garment Accessories. For this we have QA Lab. QUALITY ASSURANCE LAB.: This performs three types of tests:

Tests performed are given as under:

…………………………………………………………………………………………………………………………………………………..

23. FLAME RETARDANT

25. AZO DYES

24. FORMALDEHYDES

FROM OUT SOURCE

22. LEAD & CADMIIUM

26. PATHALATES

8. SKEW TEST

3. STRETCH AND RECOVERY

6. FABRIC COUNT

4. ABRASION.

9. PH OF FABRIC

10. GSM

7. PILLING

1. DIMENTIONAL STABILITY TO WASHING

11. CMC

2. SEAM SLIPPAGE AND STRENGTH

5. FABRIC COMPOSITION

MATERIAL INSPECTION

3. ACCESSORIES TESTS

1. FABRIC & GARMENT TESTS

2. CHEMICALS TESTS

19. DRY CLEANING

COLOUR FASTNESS TESTS

20. WATER

16. PERSPIRATION

17. WASHING

18. CROCKING

13. TENSILE STRENGTH

12. TEAR ING STRENGTH

FABRIC STRENGTH TESTS

15. STRETCH STRENGTH

21. LIGHT

1


MATERIAL INSPECTION

1


FINAL LAB. TEST REPORT:

MATERIAL INSPECTION

ZIPPER STRENGTH

ELASTIC STRETCHABILIYPULL TEST

NICKEL TEST

FERROUS TEST

THREAD STRENGTH

Q.A LAB. ACCESSORIES TESTS:REV: 00

Date

Art#

Yarn Count Shade

Construction End Use

Ref

METHOD # REQUIRED Results

ASTM D 3776

ISO 3071

Out Seam

ISO 12945-1

ISO 12947-2

Approved by:

Tear StrengthWarp

ISO 13937-1Weft

ISO-13935-1

Front Rise

Back Rise

Out Seam

Seam SlippageWarp

Seam Strength

In Seam

Loops

ISO 105 E04

Back Rise

ISO 105 EO1

ISO 13934 -2

ISO 6330 @ 40 °C

Weft

Abrision

Stretch PropertiesStretch

UnrecoverablaDu Pont 10

Prepared by : Checked by :

Remarks ;

ISO 13936-1

Final Result

Pilling (ICI)

Staining

MASTER TEXTILE MILLS ( GARMENTS DI VISION M- 6 )

Customer

Order#

Seat Width

Front Rise

Process

Waist

Color fastness to Water

Dimensional Stability to Washing

Color fastness to Rubbing Dry

Wet

Shade Change

Weave

Composition

pH Value

Staining cotton/poly

Warp

ISO 6330 @ 40 °C

ISO 105 X12

GSM

Apperance After Washing

Shade Change

Tensile Strength ( Grab )

TEST

Laboratory Final Test Report QR/LABG/03

Sample Descriptions

Selvedge Type

ISO 105 E04

Color Fastness to Perspiration (Acidic)Shade Change


Weft

Appreance

Color Fastness to Perspiration (Alkaline)

Shade Change


1


Before Bulk Cutting PPC Department arranges a meeting with merchandiser, customer’s auditor, QA, IE and Production Department. In this meeting all Customer Comments are discussed on a size set of pre-

production garments or on a trail run.

This meeting is called “PP-Meeting”.

QA Cutting Master Verifies Comments and Pattern After Amendment.

PP MEETING WITH CUSTOMER

PRE-PRODUCTION MEETINGS

2


CUTTING DEPATMENT PROCESS FLOW CHART

PATTERN VERIFICATION

EMBROIDERY CHECK

FUSING

EMROIDERY

NUMBERING

SHADE MARKING

CUTTING

STITCHING

PATTERN VRIFICATION

SPREADING

SORTING & BUNDELING

3

BUNDELINGCHECK8

SPREADING

CHECK

5

CHK SHADE MARKING

6

CAD / CAM

NUMBERINGCHECK

PASSPASS

FAILFAIL

PASSPASS

FAILFAIL

9

MEASUREMENTSVRIFICATION

4

73



QUALITY ASSURANCE CUTTING AND EMBROIDERY

EMBROIDERY

SHADE MARKING INSPECTION AND PATTERN CHECK

SPREADING INSPECTION

BUNDLES INSPECTION NUMBERING CHECK7

5 6

8 9

MEASUREMENTS VERIFICATION4


STITCHING DEPATMENT PROCESS FLOW CHART

INSPECTIONINLINE

INSPECTIONTABLE

FRONT SECTION

ASSEMBLY 2

STITCHING

INSPECTIONTABLE

ASSEMBLY 1

INSPECTIONINLINE

FRONT AND BACK SECTION

11

SMALL PARTS

BACK SECTION

STITCHING LINES

WIP STACKING FINAL BATCHAUDIT

20MEASUREMENT

CHECK

12

FINALINSPECTION

18

WASHING

PPS COMMENTS VERIFY

INSPECTIONINLINE

15

INSPECTIONINLINE

15

INSPECTIONINLINE

15

PPS COMMENTS VERIFY

PPS COMMENTS VERIFY

PPS COMMENTS VERIFY

PPS COMMENTS VERIFY

INSPECTIONTABLE

16

INSPECTIONTABLE

17

10

10

10

10

10

19

13 14



QUALITY ASSURANCE STITCHING

STITCHING INLINE INSPECTION IN ALL FRONT BACK AND ASSEMBLY SECTIOINS

SMALL PARTS BACK SECTION FINAL

SMALL PARTS FRONT SECTION INSP. SMALL PARTS FRONT SECTION INLINE CUSTOMER COMMENTS VERIFICATION

SMALL PARTS BACK SECTION INLINE

10 11 12

13 14 15


QUALITY ASSURANCE STITCHING

FINAL INSPECTION TABLE

ASSEMBLY 1 INSPECTION TABLE

MEASUREMENT CHECK

FINAL BATCH AUDIT

FRONT AND BACK SECTION INSPECTION TABLE

16

19

17

18 20


1ST BATCH MMT

WASHING

RUBBIING

SCRAPPING INSPECTIONINLINE

SHADING

SPRAYING

WASHING

HYDRO AND DRY

FINISHING

22

PASS

SHADE BOOTHS

SHADING AT SHADE BOOTHS

1ST BATCH MEASUREMENT AND INLINE INSPECTIONS

PROCESS FLOW CHART WASHING DEPARTMEN & QA WASHING

23

21

21,22

23



PROCESS FLOW CHART FINISHING DEPATMENT

TRIMMING INSPECTION TABLES

A/W ACCESSORIES INLINE INSPECTIOON

25

24

FINAL BATCHAUDIT

FINISHING

TRIMMING

INSPECTION TABLES

24

MEASUREMENT

FINAL CHECKING

PACKING

PRESSING

LEATHER PATCH & LABELS ATTATCH

INLINEINSPECT.

25

BUTTONING

MMT + INLINEINSPEC.

26

MEASUREMENTTABLES

27

SUPER CHECKTABLES

28 30FINAL INSPECT.

TABLES

29

B-2SECTION

31

FAILFAIL

PASSPASS

FAILFAIL

PASSPASSNote: Numbered Boxes are Quality Check Points.


QUALITY ASSURANCE FINISHING

MEASUREMENT CHECK TABLES PRESSING MMT & INLINE INSPEC.

FINAL CHECK TABLES FINAL BATCH AUDIT

SUPER CHECK TABLES

B-2 RECONCILIATION

26 27 28

29 30 31


PACKING DEPARTMENT, QA PACKING AND FINAL AUDITS

After final audits packed cartons will transferred to finish goods store. Finish Goods Store will receive packing lists, will check weight of each carton and will ship on the time of delivery.

PACKING

PACKING

DISPATCH

INLINEINSPECTION

SHADING

32

CARDING

INTERNALAUDITS

33

PACKING INLINE

32

INTERNAL INLINE INSPECTIONS AND FINAL AUDITS

33


THANKS

THANK YOU


Garments production process & quality assurance

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