PROJECT OF QA

SUBMITTED TO: MR. RAN RANATUNGA

SR. GLOBAL DIRECTOR (QA)

YOUNGONE (CEPZ) LTD.

E-MAIL:- ranranatunga@youngonectg.com

SUBMITTED BY: MD ISMAIL HOSSAIN CHY (RASEL)

MANAGEMENT TRAINEE (QA)

ID NO: 20358825

YCL – 2, SECTOR # 2

E-mail:- ismail.chy@youngonectg.com

SUBMISSION DATE : 2nd SEPTEMBER, 2015

Quality Management System – Policy and Procedure

Q.A Procedure in Sewing Floor

In-Line Inspection Traffic light system

Shell Inspection

End of Line/ Final table inspection

Seam sealing and Inspection ProcedureBasic jacket layout

Basic pant layout

Process of down

Layout of down jacket

Special machines and process of special machines

Process of fabric inspection

Process of MCD department

Process of pattern department

Process of sample department

Process of cut panel inspection

Youngone perform following in line inspection process please explain in details, For In-line inspection, an AQL 1.5, Level III (normal) inspection is required for both visual and measurements at the end of each major operation. For Pre-Final Inspection, an AQL 1.0, Level III (normal) inspection is required.. For Final inspection, an AQL 2.5, Level III (normal) inspection is required. See Table II.Process of Youngone testing laboratory

What are the job roll and job responsibilities of Management Trainee?

What do you want to be once you completed the training?

CONTENT

Quality means customer needs to be satisfied. There are a number of factors on which quality fitness of garment industry is based such as performance, reliability, durability, visual & perceived quality of the garment. Quality needs to be defined in terms of a particular framework of cost.

QMS is basically a collection of business processes focused on manufacturing proper quality clothing, footwear or fashion accessories. The objective of a quality management system is to maintain a quality policy & maintain the quality objectives to meet internal or customer requirements. In the garment com. the process takes on many aspects. Most of the leading companies develop compliance manuals (vendor manuals) that detail their quality management’s procedures in a very specific manner. Although equally concerned with maintain good quality.

Fabric received at the fabric Warehouse undergoes testing (Shrinkage,

color wash etc.) prior to issue.

Trims and accessories also undergo 10% checking for quality and quality prior to issue.

Size set and pilot run (if required) approvals are done before bulk cutting / production.

In the cutting Department, Markers, cut panels, patterns etc. are checked 100% and verified.

A dedicated Inspector is engaged to conduct random Inspections In-line (traffic light system), mid-line and end-line for spec and quality.

100% Garment checking with measurement is done mid and end-line.

Cut-control system is in place to control non-wash and washed (before wash & after wash) garments.

Washed garments are checked 100% for washing defects, spec etc. before the trimming and checking.

In finishing, pre-final checking, ironing, final checking with spec.

QMS POLICY & PROCEDURE

Q.A: WHAT IS QUALITY MANAGEMENT SYSTEM

WHAT IS QUALITY MANAGEMENT SYSTEM

A dedicated Inspector is engaged to conduct random Inspections in the finishing area with regard to trimming, checking, ironing, packing etc. 100% checking for tags, ratio, shade etc. is conducted.

On the basis of the Inspection there is a color card system to analyze the quality output of individual operator in every section.

With regards to the rating they get, they are given training /awareness on improving / maintaining the same quality standards further on.

Packed quantities are inspected on a regular basis. Internal / Pre-final /Final Inspections are conducted regularly before shipment.

STRATEGY:

We work to have full understanding of our clients and their consumers‟ requirements, then measure, Monitor and deliver to their complete expectations. Youngone is committed to be a reliable supplier of choice by always understanding our clients and their consumers‟ requirements then reliably delivering to their expectations at an excellent value.We are committed to continuous improvement to enhance our quality reputation and production efficiency.

TACTICS:

DEPARTMENTAL QUALITY STATEMENTSSales will collaborate with Quality Assurance to:

Understand and document client quality requirements Ensure that all materials are specified for physical properties and

performance Ensure that all products are tested and passed prior to production Ensure that all processes are reviewed and optimized for smooth

production flow prior to Production.

MCD‟s will ensure that only shipments that have been inspected and passed are issued for use. And that full identification and control of materials and finished goods is maintained at all times.

Development, Technical Services and Engineering will ensure that the client’s designs can be efficiently and cost effectively produced within Youngone minimum quality standards and client quality standards prior to acceptance of order.

YOUNGONE QUALITY PROCEDURE:

Production through the QC function will ensure that: all testing and verification of materials and preproduction samples is completed well in advance to avoid production interruption; that all specifications, materials and processes are well controlled and documented and will not begin bulk production until all are tested and approved. All Youngone production units, owned or contracted, will use written measures and controls on applicable aspects of quality as required by the buyer and corporate QA.

Corporate QA will maintain fully independent measurement and reporting of quality levels, issuesand achievements and will perform QA audits sufficient to provide statistically valid evidence of thisControl.

Quality inspectors are allocated here as 3 persons per production line, 2 persons for In-Line and 1 person for End-Line. While input any style of any buyer, concerned persons of sales, Production Manager of concerned floor, Technician, Pattern maker, MCD and QA of concerned floor sit together about specific style and ensure color card, Buyer’s Comments, Approved sample, Worksheet etc. In following area, quality inspectors do their jobs:

In-Line Inspection:

Inspectors/ Supervisors are checking each process randomly along with trims.

Shell/ Mid Line Inspection:

Before attaching shell with lining, inspectors are checking individual shell or lining 100% here for construction, appearance and measurement.

End of Line/ Final table inspection:

Inspectors are checking here 100% as construction, Stitch density, measurement and appearance, color way with trim card, worksheet, and comparing approved sample with first piece garment. If they find any type of reject, they put sticker on defect and give to concerned sewing supervisor for repairing with signature on report. If any garments found with not repairable defect, inspectors are keeping those a side and informing to supervisor for decision. If supervisor became unable to decide, then they go to top as per general organogram. Later if all concerned of quality and production can reach in a decision for making those defected garments as B-Grade.

Q.A: Procedure in Sewing Floor

Pre – Production/ Inspection Preparation:

1. MOCK – UP PROCEDURE:A. Collect Fabric Swatch as Color WiseB. Collect Heat Transfer Print Film/ PaperC. BOM (Work Sheet)D. Machine SetupE. Team [Q.A/Maintenance/Operator]F. Logo Instruction from Supplier

2. MOCK – UP ANALYSIS:

A. If there is any information from supplier related Time/Temperature/Pressure, it has to be followedat initial stage.

B. If there is no related information from supplier, and then it needs to set uptime/temperature/pressure based on fabric type as trial and error methodC. Record time temperature and pressure.D. If mock looks ok in terms of visual and hand feel, than send to lab for washing and storage test.E. Collect Lab Test Report If result is passing, proceed for production in bulk. If fail, it needs toresubmit mock up to Lab by readjusting the time/temp/pressure.

3. BULK PRODUCTION

A. To set up the machine separately as per passed mock up.B. 100% inspection all the panel.C. To check placement fabric color and logo randomly.D. To keep the record and make daily inspection and weekly summary report.E. Daily lab submits.Caution:A. If any failure is being observed, it needs to find out the reason and production needs to stop untilget solution.B. To avoid shining mark:1. Daily clean the machine2. Use rubber as per logo size.

3. Try to set one type of Logo for one separate machine.

First 10pcs of garments should review and make sure all the machines are set for correct tension and SPI. If there are any problems, mechanic should get corrective actions immediately to correct the machine settings

In – Line Quality System – Traffic light should be functioned for each works station.(Please Refer detail process for In Line quality)

Continuous Capacity check and rebalancing should be done till line reach the plan targets

First 10pcs should be measured and corrective actions should be taken by the technician for improvements

Measurements Inspections should be established after every critical step such as grading, shrinkage test, before wash, after wash, before press, and after press (if applicable). Any discrepancies of measurements should be informed to the technical Departments for corrective actions or method Changes

Q.A: Sewing Process

During the course of the day, the In line inspector (TLSA- Traffic Light System Auditor) will randomly check the operator’s work as 7 pcs out of bundle and the minimum round of daily checks per operator will be 4 per day.

1st Visit – (Regular Visit) Traffic Light System Auditor (TLSA) has to cover all machines and evaluate the process in terms of Constructional issues as well as other visual defects. During the inspection time, when 1 pc of garment is to be defective or substandard, the Green Light Card should be replaced by a Yellow light card During the next inspection time, if NO any defect found, the card remain in Green light.

2nd Visit – (Follow Up) TLSA has to cover all Critical to Quality (CTQ – which needs approve mocks on process), Yellow and Red labeled process. During follow up visit, while there is no defect found, Yellow color can be changed to Green, if more than one defect, it should be Changed to Red.

3rd Visit – (Follow Up) same as 2nd visit.

4th Visit – (Regular Visit) TLSA has to cover all process again and judge each process in terms of overall quality view.

When the garments successfully pass in consecutive inspections for 2 times and the result is zero defects, the red light card can be replaced by a yellow light card. In case of continuous red light, process should be stopped and find the solution to rectify immediately. Floor management has to be involved.

Q.A: IN-LINE INSPECTION OF TRAFFIC LIGHT SYSTEM

Inspection Procedure in Cutting Section

Layer Inspection:After completing random inspection in Material Control Department, Cutting section receivesspecific fabric of specific invoice and style for laying. Q.A teams are checking following thingsbefore spreading and cutting fabric:

1. Ticket Information2. Specific Shade, comparison with Shade card (done by MCD Quality Team)3. Fabric Inspection Report (Which done by MCD QA team)4. Shading within panel like side to side shading/ Side-Center-Side shading visually5. Fabric defects.If they see any unusual things while checking layer, they will hold or request concerned cuttingpeople to keep a side certain fabric lots/ rolls.After completion of inspection, all records are documented properly.

Cut Panel Inspection:After cutting fabric, all cut panels specially major parts must be checked here 100% to ensure Zero defect Garments. Following things are highlighted while cut panel inspection:1. Any types of defects on panels2. Cut panel accuracy with pattern3. Rejected panels sorting out and making record in Log book with panel serial number.4. Handed over defected panels to concerned responsible person of cutting section for ensuringreplacement with good panel.5. Making inspection reports

Cutting Section Inspection comprises of four areas of inspection

Spreading inspection Marker inspection Cutting inspection Bundling inspection

Q.A: INSPECTION PROCESS OF CUT PANEL

Marker Inspection

o The marker inspection is carried out either before spreading or after spreading is finished.

o The Cutting Section Quality Assurance Supervisor checks to ensures that the marker is not creased or damaged, and if the Style number, size and lot number is correct and clearly print each part of the marker.

o The fabric cut table width should be the same width as the marker width.

o The table should be marked to the length of the marker and marker is placed on layers with the edge is parallel to the salvage of the piece goods. Verify that all cut pieces are completed.

o After completion of the spreading, check if all plies extent beyond the marker start/end line.

o Check the total parts of the marker to ensure that the marker physically contains the exact number of pieces required for the garment.

o Any findings recorded on the “Cutting Section Inspection Report”, and respective Cutting Supervisor is informed to carry out necessary action. The corrective action also must be recorded on the “Cutting Section Inspection Report”.

Spreading Inspection

The meaning of following mentioned fabric is including shell fabric and interlining.

The spreading inspection is carried out while spreading process is going on.

The Quality Assurance Supervisor inspects and makes sure that the correct fabric has been spread with reference to the “Technical Package” and “Fabric Swatch Card”. Fabric direction should be in accordance with the “Tech Pack” specification such as non-directional, directional, one – way, face side etc.

During spreading, fabric should spread tension free, excessive wrinkles on the fabric or along salvage should not be allowed. The Quality Assurance Supervisor also inspects randomly for major fabric defects. For the stripe or check fabric, the layer ensures that pins have been placed onto correct center stripe and correct place so that the pinhole will not cause any fabric damage after the garments is finished.

The inspector also checks for side to side and end to end shading. If the shading is found within one ply, the defect should be immediately reported to respective QA Executive and Cutting In charge through the QA Supervisor. The findings should be recorded on the “Cutting Section Inspection Report” For shade band order, the Inspector randomly checks that the fabric rolls number and the respective shade lots (A, B, C etc.) with the Shade Band Report from Fabric Inspection Section. In addition, the Quality Supervisor randomly checks that the shade lots for a style with a combination of different Invoices are correctly assigned by the Cutting Personal or not.

Seam sealing

Hydrostatic Standardswe have to follow individual customer manual per performance standard, which could be variousfrom customer to customer. Otherwise the most common used hydrostatic standard applying to thetape-sealed seam is exposure to 3 psi for 2 minutes before and after washed (3 cycles wash & dry).ProceduresAll seam tape and its relevant products must be sourced from a reliable seam tape supplier. It isand critical element to ensure the garment performance.SECTOR QA development team will send fabric to the nominated supplier, which will base on theHydrostatic Standard requirement to identify the compatible tape and recommend the applicationcondition during development stage.Upon receipt of bulk fabric prior to production started, factory must send bulk fabric toSECTOR QA for further testing to ensure the compatibility of the selected tape since there have beenmany cases of unintentional changes in the chemistry of the coating formula during bulk fabricproduction compared with the sample fabric yardage or even changes of fabric supplier.Common Wash method for testing tape-seal seam:40°C water , 5X wash cycle with 1 tumble dry low, 1 washing cycle = 45mins.

Remarks:Some customers require the water-proof standard is in the unit of “mm of H2O”, however, thehydrostatic water resistant testers, in our existing factories in Chittagong, Dhaka, China, Vietnam andKorea, cannot be tested and read in mm of H2O, mostly read in post or kg/cm2 . Even checking withH & H Asia Ltd which is specialized in thermoplastic technology, the market currently does not haveand cannot modify existing tester to read mm of H2O directly.Thus factories are allowed to use their existing in-house testers but to convert the units (e.g. psi orkg/cm2) to meet the standard in “mm of H2O” using the below convert data.Units convert data:1 psi = 703.7 mm0.1 kg/cm2 = 1,000 mm of H2O0.01 MPa = 1,020 mm of H2OConsidering of the common standard, 3 psi for 2 minutes, is sufficient for all intended uses virtuallyand the higher resistant force applied to the product may damage the appearance or performance ofthe waterproof fabric itself; it is recommended to strictly follow customer’s standards (with higherrequirement) on samples or mock up samples when doing hydrostatic tests, but to follow commonstandard (3 psi for 2 minutes) on daily bulk unit testing randomly.

For high performance or 100% Water-proof technical garment, foundation requirements are needed as following:

Fabric utilizes a range of laminates and coating to achieve a standard of waterproof andbreathability.

Various accessories apply on different places of garment and presenting differencefunctions, proper making way for attaching the trims are required.

Proper construction is the major concern. Special construction or its application may beneeded to fulfill the styling or technology innovation.

Hydrostatic test and spraying test is the ordinary testing methods in the market, 3 rd partylaboratories have been conducting both the methods as a standard for waterproof.Garment factories have to perform and record hydrostatic testing during the productionperiod.Type of adhesive tape

Adhesive film bonding

A thermo glue film to adhere materials together, to prevent water leakingbetween assembles materials, trims and stitches, to achieve waterproof function.

Using heat press machine.

Seam Seal Taping

A thermo plastic adhesive tape taped on stitched seam to prevent water leakingthrough stitches between the assemble materials.

Using hot air sealer.

Categories:

Fully seam seal (100% Waterproof Garment)

For professional technical purpose;

Very high standard required on both hydrostatic and spraying tests; No water is allowed to penetrate to the wearer’s body from any tiny jointed seam, design or decorative part of the garment. It will have a comparative high price concern. Half way seam seal For decorative or casual purpose; Comparative lower standard required on both hydrostatic and spraying tests; Selectively applying seam seal tape or any technique on the garment to meeting the targeted price and consumer.

Half way seam seal standard (HSS)A reference guideline to specific the carious seam seal standard for half way seam sealcategories:From HSS5 (higher requirement) to HSS1 (lower requirement) HSS5: All seams are taped, e.g. hood seam, neck hole seam, shoulder seam, armhole seam, under sleeve seam + side seam, all partition seams, pocket seams…..etc.. All taped seams should be waterproof and passed hydrostatic test; in case, some pocket opening or some tiny holes with slightly water penetration would be acceptable. HSS4: All critical seams are taped, e.g. hood seam, neck hole seam, shoulder seam, armhole seam, front + back yoke seam, under sleeve seam + side seam, upper stitch seam of pocket. All taped seams should be waterproof and passed hydrostatic test; in case some front edge, side vent opening, pocket opening or tiny holes would be performing minor water penetration. HSS3: All major seams are taped, e.g. hood seam, neck hole seam, shoulder seam,armhole seam, under sleeve seam + side seam, upper stitch seam of pocket. Alltaped seams should be waterproof and passed hydrostatic test; garment would beperforming water penetration.

HSS2: Some major seams are taped, e.g. hood seam, neck hole seam, shoulder seam,armhole seam. All taped seams should be waterproof but not necessary toperform hydrostatic test depended on customer requirement; garment would beperforming large surface of water penetration. HSS1: A few stitched seams are taped, e.g. hood seam, shoulder seam, armhole seam.Taped seams are needless to perform hydrostatic test; garment would becompletely water penetrated.

1. After received the fabric by cutting section QA personnel collect all types of reports from MCD QA department. At first shade group compare with fabric, received roll and lab test pass report. If both report are OK than proceed to layer inspection.

2. Layer inspection: At first cutting personnel confirm style/ Fabric / Fabric surface / Hand feel & compare with the Trim card. Check side centre side shading/ running shading & compare with MCD shading report. Confirm roll-to-roll shade variation & check marker positions are correctly to base on Fabric nature. Smoothly check all spreading layer & defects area indicate by paper & compare with MCD individual fabric inspection report. Maintain layer inspection report & log book.

3. Any fleece fabric & Padding item Q.A personnel send to the fabric for GSM (Grams Square Miter) Lab. Test & collect the Lab. Result.

4. After cutting the layer Q.A personnel ensure cut panel accuracy with pattern although check any cutting discrepancies in component & make cut panel Accuracy Report.

5. Table Inspections: Received the bundle issue at first table Q.A personnel check bundle ticket/ confirm the style & fabric surface. Cutting Q.A personnel check only paper indicates cut panel. If get any information from layer (Yellow tag & others) check 100% cut panel before pass to issue in production line & findings defect panel take out from bundle for replacement & maintain Cut panel inspection report/ Summery report & log book.

IN BRIEFLY

6. After check the Cut panel Cutting Q.A indicate Embroidery panel to send the Embroidery room.

7. Heat Transfer Label: At first Q.A personnel check the Machine adjustment Time/ Temperature & Pressure as per Heat Transfer Logo. After attached mockup panel Q.A people submit for Lab. Test Peels off (3/5 cycle wash) & Storage test (72 hour). If lab result pass than run the logo attachment same Time/ Temperature & Pressure. Cutting Q.A 100% check the panel before pass to production line & make Heat Transfer Label inspection report & log book. Every week Q.A ¾ time submit to panel (Color wise) for Lab. Result.

8. Fusing part: First adjust the machine Speed / Temperature 7 make mockup to send for lab Test. If Lab. Result is OK than run the machine for fusing attaches Speed / Temperature.

9. Q.A related all inspection report dispatching to related section Cutting & Sales.

Procedure for Material Control Department:

Q.A. Procedure for Material Control Department

Materials Receiving Status

Lab Test – Fabric/ Trims

Washing Garments:

Light BoxFabric /Trims

inspection AQL-2.5

Fabric Inspection 4 (four) point

System

Fabric Visual Inspection

and Results

Check Color

Shading

Results Status

Youngone QA includes this procedure to assist the manufacturing process: Material Receiving StatusUpon arrival of all types of fabric/ Trims as per invoice from supplier, MCD (Material Control Department) personnel submit Receiving Status to QA in order to make Inspection Plan and log in Fabric/Trims receiving Book. If there are no specific priority, QA will finish primary inspection within 5 working days after arrival of fabric.Lab Test – Fabric/TrimsMCD personnel send Fabric/Trims swatches from specific consignment to YO Lab for various types of tests based on Fabric/ Trims criteria by using YO Lab submitting Format soon as receiving fabrics.

Shade SeparationInitially QA segregate shade variation in fabric roll to avoid any chance of mixing shade in same P.O. by following below points:a) At first Sales will provide buyer prescribed color standard (if any), Shipping swatches from fabric vendor against each dye lot.

b) QA cut swatches in around A4 or some size from middle of each roll in each consignment for comparing shade variation.c) Authorized QA persons compare physical swatches with color standard and shipping swatches as well as make a group according to shade in light box in dark room under light source D65 (if there is no special requirement from buyer for specific light source) and attach all roll’s swatches in shade continuity card along with separate card with (3x4)” size swatches from each group like A,B,C with shade continuity report and the shade summary report . QA distribute shade summary card with report to concerned person for Cutting, Sales, MCD and Packing section. Sending severe shade variation YO Lab (if required) for spectrophotometer reading. YO standard is DE# (0 to 1) for roll to toll and DE# (0 to 0.6) within roll.

d) QA rejects any specific shade if they find any off shade or server deferent shade and provide sales to inform supplier as well as buyer for confirmation /replacement. To claim to fabric supplier, QA will provide spectrophotometer reading, comparing with color standard/supplier’s shipping swatch (if available) or comparing with shade A

e) Sales will make plan for cutting various shade as PO/Country/ Carton wise after getting Shade card with QA advise as well as provide information to QA management by mail/written prior to issuing to cutting section.

Washing Garments: At first swatches (6”x6”) size 3pcs from middle of each roll in each consignment to make blanket (6x6) =36 pieces = 1 blanket in same color, usually QA make 3 blanket, 2pcs send to washing plant for washing as per buyer requirement. From that washed blanket, authorized QA persons make group according to shade and attach all rolls‟ swatches in shade continuity card along with separate card with (3x4)” size swatches from each group like A, B, C with shade continuity report and the Shade summary report. Sending severe shade variation to YO lab (if required) for spectrophotometer reading.

Light Box: International light box equipped with D 65 – North Sky DaylightTL 84 – 4100KUV Light (optional)

Light box must be kept in dark room with well curtained and ensure no outside light interference can be occurred.

Fabric / Trims inspection AQLBy referring to receiving status QA select fabric roll/ Trims randomly for fabric/ Trims inspection as per the MIL – STD 105D inspection level 2, AQL – 2.5 charts if there is no other requirement from buyer. If any fabric/ Trim receiving status less than 8 rolls/ trims 100pcs, then full qty to total yards/pieces to be inspected.

Fabric Visual Inspection and ResultsVisual inspection on machine is being recorded in an individual fabric roll inspection report, which is very easy to determine the position of defect, and how severe the defect is resulted. MCD QA is analyzing the report and taking decision for appropriate results.

How to Check Color Shading: To check side – center – side shading from every inspected roll, needto cut about 12 Inches full width by folding side to center to side will be sewn.To check running shading every inspected rolls must be laying over the table by folding every 2/3 yards distance & compare visually & doing lab test (within roll/ within Garments, Youngone Standard DE# 0 to 0.6). For color shading checking QA evaluate roll wise grading like A (for use), B (for use on condition), C (not for use) & C grade is treated as fail with red tag.

Result Status:a) Pass: If there is no buyer specific requirement, 0-25 Points per 100 Linear Yards is being considered as pass to cutting section with approval from MCD-QA concern.b) Yellow Tag: Over 25 points per 100 Linear Yards but can be possible to use with short replacement, any individual roll should be yellow tagged with specific comments of defects.Individual fabric roll inspection sheet also should be attached with Tag to see the pattern of defects for identification. It should be hold until the decision from authorized person of QA, Sales to use.Yellow tagged rolls can’t be kept in MCD area by mixing with passed or non-inspected fabric lots.

c) Red Tag: Enroll of the consignment can be non-usable by the visual evaluation or Lab – reading is being treated as fail with a red tag. All red tagged rolls should be kept in MCD in isolated area with clear identification mark and maintaining Log Book.

To use red tag, it must be approved along with sufficient supporting documents (Buyer confirmation /related email communication/higher management approval) to be recorded in a log book for future reference All individual Fabric roll inspection results to be summarized in Fabric Inspection Summary report.

Fabric inspection Summary:

All individual Fabric roll inspection results to be summarized in Fabric inspection Summary report.

Final disposition of Consignment and dispatch reports:Results of full consignment are given by QA in Fabric inspection summary report. Decision for making Yes/No on the shipment is being taken with the help of AQL Chart (2.5). In case of fail shipment, QA continue inspection up to 60% of the specific consignment. To continue 100% inspection, QA are claiming to supplier through Sales for charge of inspection cost in a specific format – Claim Worksheet. YO claim charge is 3.25 Us dollar per hour inspection cost. After completion of inspection summary report, QA dispatch that to concerned persons of sales, cutting & MCD section.

Trims Inspection & results:Visual inspection is being recorded in a trims inspection report.

Results Status:After completion of random inspection based on Mill-Std 105D, AQL-2.5 only Passed Lots can be preceded for production and if the findings are not acceptable, total consignment to be hold and continue inspection for another 20% for clarification. Items became failure in inspection should be kept in isolated area with red tag based on severity. To use red tagged trims, it must be approved along with sufficient supporting documents to be recorded in a log book for future reference.

Q.A: End- Line Inspection:

Measurement

Approved Tech Pack

Approved Swatch

Approved Buyer Sample

Approved Shade Band

Approved Wash Standard

Clockwise Garments Check

Update Report

Maintain QA file

End of Line/ Final table inspection

Inspectors are checking here 100% as construction, Stitch density, measurement, and appearance, color way with trim card, worksheet, and comparing approved sample with first piece garment. If they find any type of reject, they put sticker on defect and give to concerned sewing supervisor for repairing with signature on report. If any garments found with not repairable defect, inspectors are keeping those aside and informing to supervisor for decision. If supervisor became unable to decide, then they go to top as per general organogram. Later if all concerned of quality and production

can reach in a decision for making those defected garments as B-Grade.

Q.A

For fabrics, initial inspections are conducted for 10% of the quantity. If it doesn’t satisfy the 4 – point standard levels (as mentioned below), a further quantity of 10% is inspected. Still if the 4 – point standard level is not achieved, the supplier is informed and the buyer is consulted depending on whether the defects are within the tolerance levels of the buyer’s requirements, the fabric is accepted or rejected.

4 – Point Standard Levels 0 – 3 defects – 1 points 3 – 6 defects – 2 points 6 – 9 defects – 3 points Over 9 defects – 4 points

The goods are inspected for shade differences, holes, line marks and other manufacturing defects. For styles which require washing, blankets are made out of the fabric from each roll from washing tests. Further to the receipt of the washing reports, the fabric is segregated shade wise and lot wise. For customer orders, 100% inspection is carried out and for other buyers; 10% - 25% inspection is done. On receipt of request for Fabric from the Factory, the said quantity is issued from the warehouse lot wise and shade wise foe each style.

Subsequent to the issue of Fabric to the Factory if any problem is found in the Fabric, the issue of further quantity is stalled, on the advice of the technical personnel till further confirmation.Rejected Fabric is stacked in designated areas till further confirmation and marked so that they don’t mix with the good Fabric.

Process of fabric inspection

Fabric should be inspected at least 10% to cover all the colors and die lotsWhatever the defect, it should be counted as a demerit point and number of demerit points will be varied from the size of the defect as given in the below size table Defect Demerit PointLength of defect Demerit Points

3 inches or less 1

Over 3 inches but not over 6 inches 2

Over 6 inches but not over 9 inches 3

Over 9 inches 4

Defects appearing within one inch of either edge shall be disregarded. Any hole other than pin holes should be considered as major defects assigned 4 demerit points. Linear Yard Basis:Acceptable tolerance = 20 points per 100 linear yard. Square Yard Basis:Points/100 sq. yd = Total Points scored in the bulk X 100 X 36 Width of the roll (inch) X total yards inspected.

Acceptable tolerance =

28 points per 100 square yard for each individual roll 20 points per 100 square yard for average of rolls inspected. 1st Quality: Penalty points not exceed the acceptable tolerance. 2nd Quality: Penalty points exceed the acceptable tolerance.

FABRIC INSPECTION FLOW CHART

Q.A: Process of pattern department: A Pattern is the actual copy of different parts of a garment that is made by cutting board paper after sketching on it. According to this pattern cloth is cut and then garment is made .For industrial Production different Patterns are made for different size and a marker is made with these different patterns for a large –scale production. Then many cloths are cut at a time and finally garments are made by large number of workers in garments industry.

In first functions of pattern department started to get buyer speck sheet/measurement and BOM. Sales or merchandiser are the responsible person who collects the speck sheet and BOM from buyer. Pattern department follow this document and make pattern for different size as per buyer requirement. In youngone pattern department we see, they are follow step by step spec measurement. Give a example in bellow:

For a jacket pattern:

Neck Chest Armhole Waist Bottom hem Sleeve elbow sleeve opening hood height etc

For a pant pattern waist band hip front rise back rise thigh knee bottom

They follow actual measurement which is given in spec sheet and they maintain proper construction or design.

After complete the pattern to make a marker for large scale production. Marker is created by CAD (computer added design). Marker generally two types i) normal marker ii) shading marker.

i) Normal marker is used for A grade fabric. Where no shading are found.

ii) Shading marker is used for B or C grade fabric.

Finally to save time and money to make fast and cheaper production.

Q.A: Shell Inspection

Procedure

Before attaching shell with lining, inspectors are checking individuals shell or lining 100% here for construction, appearance and measurement.

In shell table inspector maintain two documents:

1) Measurement

2) Daily Inspection report (shell)

3) Hourly Chart

ProcessAt first the inspector receives the garments from line then inspects the garment clockwise and takes measurement critical point of the garment. If the garment is ok then he passes it for next operation. If not then he mark the point with sticker and pass back for repairing.

Q.A: Process of Sample Department:1. Initial Sample

2. Proto Sample3. Sales Sample4. Fit Sample5. Pre-Production Sample6. Size Set Sample New styles are informed by merchandising through schedule and concerned original pattern, technical specs & trim sheet is provided to sample room. Pattern makers make sure the 0 pattern is correct by checking & measuring before giving to Gerber for digitizing. All fabric needs to perform shrinkage test (wash garment/spandex fabric) and result are obtained. Shrinkage result should forward to Gerber and shrinkage added pattern is given back to the pattern marker to confirm the shrinkage pattern is okay to specs. Then can cut the sample. When pattern & cutting process are done for the concerned style, trims are made ready. When cutting sample decision has to be made weather. Need to do a one piece garment or not straightway do the required sample. Cut sample is sewn as per the requirements in the technical specs. Sample should be measured after sewn. (If wash garment) should send to washing and after washing again measurements has to be taken. The necessary trims are attached and sample is checked & pressed.

Sample Room ProcessSample Requirements Upon receiving approval comments, pattern adjustments are made if required and pattern is checked and then have to see whether a bulk fabric is available & shrinkage has to be tested and results given to Gerber and pattern is graded and nest pattern is given to the pattern marker to confirm the grading & pattern copies are taken for the necessary sizes and samples are cut. Upon PP Sample is approved, as per comments pattern adjustments are made and according to bulk shrinkage pattern is made again and checked and confirmed by the pattern marker to go ahead with the pilot runs or size set. As per pilot or size set run results patterns are confirmed for bulk cutting. For each & every fit sample / size set, pilot run and every shrinkage groups finished patterns are made by pattern helper and during bulk production lines finish patter board requirement is met by the pattern section.

The above said is the process of sample room involved in making sample.

We need to check some useful points which are given below:

For fit sample substitute thread & trims can be used. For PP sample or Size set all fabric and trims should be in bulk trims andfabric. When sending samples to Customer following must accompany.1. Sample measurement sheet.2. Sample made pattern.3. Correctly filled hang tag.

Process of sample department

New styles are informed by merchandising through schedule and concerned original pattern, technical specs & trim sheet is provided to sample room.

Pattern makers make sure the pattern is correct by checking & measuring before giving to Gerber for digitizing.

All fabric needs to perform shrinkage test (wash garment/spandex fabric) and result are obtained.

Shrinkage result should forward to Gerber and shrinkage added pattern is given back to the pattern marker to confirm the shrinkage pattern is okay to specs. Then can cut the sample.

When pattern & cutting process being done for the concerned style, trims are made ready.

]When cutting sample decision has to be made whether: Need to do a one pc garment or not Straightway do the required sample.

Cut sample is sewn as per the requirements in the technical specs.

Sample should be measured after sewn. (If wash garment) should send to washing and after washing again measurements has to be taken.

The necessary trims are attached and sample is checked & pressed.

Upon receiving approval comments, pattern adjustments are made if required and pattern is checked and then have to see whether a bulk fabric is available & shrinkage has to be tested and results given to Gerber and pattern is graded and nest pattern is given to the pattern marker to confirm the grading & pattern copies are taken for the necessary sizes and samples are cut.

Upon PP Sample is approved as per comments pattern adjustments are made and according to bulk shrinkage pattern is made again and checked and confirmed by the pattern marker to go ahead with the pilot runs or size set.

As per pilot or size set run results patterns are confirmed for bulk cutting.For each & every fit sample / size set, pilot run and every shrinkage groups finished patterns are made by pattern helper and during bulk production lines finish patter board requirement is met by the pattern section.

The above said is the process of sample room involved in making sample.We need to check some useful points which are given below:

For fit sample substitute thread & trims can be used.For PP sample or Size set all fabric and trims should be in bulk trims and fabric. When sending samples to Customer following must accompany.

Sample measurement sheet. Sample made pattern. Correctly filled hang tag.

Q.A: Process of down:Process of down are as follows:

1.Receiving Down In MCD

2. Making Pilo.

3. Lab testing.

4. Down send to the Floor for Production.

5. Metal Inspection.

6. Distribution of down according to quilting Requirement. 7. Joinint in line According to process.

8. Checked Finished Garments in Metal Machine.

In the process of down First of all MCD departments received down from supplier. Then in the immediate next step involve in this process is making pillow after making the pillow down are send to the youngone laboratory for test , after passing all the test the down are send to the floor with a view to producing garment. After receiving the down in the floor the next step is metal inspection. After metal inspection the next step is distributing down according to quilting requirement and joint the process and at the last step checked finished garments in the metal machine.

Q.A: PROCESS OF YOUNGONE TESTING LABORATORY:

Received Sample From MCD in Receiving & Delivery center.

Data entry with the name of tests & Receiving & delivery Date.

. 3. Differentiate according to sample & Buyer Requirement.

o 4. Conducting Tests.

Fabric Color Fastness Test

Mockups wash Test & Storage Test.

Garment all test.

Fabric All Test:( color fastness, Breaking Strength Test, Tearing Strength Test, Water Resistance Test, rain Test, water Repellency Test, Pilling Test, Shading Test, Air Permeability.

Makes Report of all Test.

Collecting Report from Receiving & delivery Center.

Lab Activities and Function

Lab Testing Name and method

Q.A: THE PROCESS OF SPECIAL MACHINES

SL. Special machine

Picture Special process

1 Top centre /Multi chain stitch

Attaching button, cuffs, placket and waist band

2 Flat lock

Inseam, out seam stitch of

shirt, jacket and pant.

3 Six thread

flat lock

Any two parts joining.

4 Eyelet hole

On flap pocket ,waist

band of pant ,blazer and coat is attached

5 Cuffs Rolling

On the attaching cuffs

Q.A: Basic Jacket Layout:

Operator Operation Description

Process Pictures

1 Loop 2 Needle Stitch

2 Lining Hood inter lock

3 Pocket Making

4 Sleeve Part Attach

5 Side Seam sewing

6 Collar Sewing

7 Collar attach with Shoulder

8 Sleeve Attach With Shoulder

9 Loop Attach

10 Tap Attach

Lining Part

11 Over lock & Pocket Attach

12 Bar tack

13 Snap Attach

Operator Operation Description Process Pictures

14 Hood sewing

15 Hood 1/16’’ Stitch

16 Hood Seam sealing

17 Hood Marking

18 Hood shell Lining Sewing

19 Hood Ruling stitch

Hood Part

20 Velcro Attach

Operator Operation Description

Process Pictures

21 Complete Chest pocket

22 Complete lower pocket making

23 Collar Making

24 Collar Flap Attach

25 Chest & lower Pocket Flep Stitch

26 Side Facing Attach

27 Chest part, Lower Part, Yoke Part Sewing

28 Chest part, Lower Part, Yoke Part Stitch

29 Both Sleeve part Sewing

30 Back Yoke & Side Part Sewing

31 Sleeve & Back part Stitch

32 Back, Front, & Sleeve Sewing

33 Armhole & Placket Stitch

34 Placket Sewing & Stitch

35 Placket & Collar Attach

36 Center Front zipper attach

37 Pocket And Hood Zipper bar tack

38 Seem sealing

39 Cuff Elastic Attach & Rulling

40 Eye let hole

41 Shell & lining attach

42 Cuff shell Lining Sewing

43 Collar & zipper Stitch

44 Bottom Ruling

Q.A: Basic Pant Layout

Operator Operation Description Process Pictures

1 Lining , Quilting & Tack

2 Lining Over Lock, Getter Lining Over lock, Lining Lower Part Over lock

3 Lining lower part over lock & all Front , Back Length, Rise sewing, level Attach

4 Side seam & Inseam lining

5 Leg Getters Making

6 Leg Getter Attach, All Pocket Facing, Sewing, Stitch

7 Pocket Flap Making & Stitch

8 Hand Pocket Tack, Zipper Stitch & Sewing

9 Hand Pocket Tack Pocket Flap Attach

10 Fly Making & Attach

11 Knee BAT,Front Back upper Part Sewing

12 Back pocket Making

13 All Pocket Tack, Closed & Over lock

14 Back Pocket Sewing & Flap Attach.

15 Thigh Vent Zipper Making

16 Back Upper & Lower sewing

17 T. Vent Zipper Mash, Sewing And Stitch

18 Side Seam, Inseam, Lower Side Sewing

19 Loop Making Attach

20 All Bar tack

21 Seam Tape

22 Seam Tape Strummer

23 Shell Lining

24 Shell Thigh Bend Zipper

25 Waistband Making

26 Waistband Sewing

27 Waistband Stitch & Fly Stitch

28 Bottom Ruling & Waistband loop tack

29 Loop Barrack & Cutting

Q.A: WHAT IS AQL?

In the distant past goods were produced by hand or using simple machinery that guaranteed a slow but steady introduction of products into the marketplace. These products were generally finished by individual workmen and closely inspected prior to sale, guaranteeing that each product attained the level of quality that was required by their customer.

Acceptable Quality Level is the quality level, which, for purposes of sampling inspection, is the limitation of satisfactory manufacturing process. All buyers will have a formal quality system – both In-line Inspections and Final Inspections.

With the advent of mass production many products ceased to be hand finished and were instead machined and passed into the marketplace faster than any team of inspectors could possibly check them. This created a dilemma; how do you ensure that your customers receive the quality of product that they expect without inspecting each and every finished Item? For some-time no answer was apparent and industry continued to churn out millions of products without any agreed and systematic way of checking their quality.

A. Main Line (Sports)

1. For In-line inspection, an AQL 1.5, Level II (normal) inspection is required for both visual and measurements at the end of each major operation. See Table I.

2. For Final Inspection, an AQL 2.5, Level II (normal) inspection is required. See Table I.

Q.A: The process of seam sealing Seam sealing means Sewing line and joint parts sealing by seam tape to ensure water resistance and to protect the human from water and weather.

There are two types of seam sealing:

Gore

Non gore

Gore

Gore and non gore have two types of seam tape:1. 2-layer2. 3- layer

The working procedure of seam sealing:

After receiving seam tape style fabric MCD QA done coating delimitation test and water resistance test. Seam sealing QA make sure mock up by actual seam tape and fabric for each color as per buyer requirement. Mock up result pass then we precede production.

There are some reject at sealing garments:Tape missing Pleat

Bias Puckering

Off center Open seam tape

Burn Air bubble

Coating damage Wrinkle

Tape folded Tape peels off

Inspection procedure:

Seam tape machine check system

Check temperature Nozzle air Roller pressure

Nozzle setting Nozzle speed Roller speed

Maintenance machine set up Seam tape actual or not.

Stop mark machine check system:

Check temperature Timing press ness Machine maintenance

Machine alarm okay or not

Stop mark machine

Suter test & procedure:

Suter tester seam pressure testing device portable water penetration tester. Qualities offer extensive range of advanced textile testing equipment.

Each gmts randomly check 4 or 5 cross points & report at suter test format.Suter standard

(a) Gore seam tape (2L/3L)- 3PSI 2 min

(b)Non Gore Seam tape (2L)-3PSI 2 min

(C)None Gore Seam Tape (3L)- 3PSI 2min

Q.A: Job rolls and job responsibilities of Management Trainee following:

Help the manager & concern person to set policies.

Evaluate work output.

Attend lectures, watch guest speakers, and create projects, and take tests.

Monitoring & Controlling Qualities issues.

Find out root cause of Problem, analysis & prevent at the source.

Work for how to decrease the defect rate.

Educate the supervisors & sewing operators for better production.

Work together to ensure the good QUALITY GARMENT.

Work with other managers to plan and direct the work of the organization.

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