Assignment on an Overview of Quality

and Quality Control in Textile Industry.

Introduction:
Quality means customer needs is to be satisfied. Failure to maintain an adequate quality standard can
therefore be unsuccessful. But maintaining an adequate standard of quality also costs effort. From the
first investigation to find out what the potential customer for a new product really wants, through the
processes of design, specification, controlled manufacture and sale. There are a number of factors on
which quality fitness of garment industry is based such as - performance, reliability, durability, visual
and perceived quality of the garment. Quality needs to be defined in terms of a particular framework of
cost.

Figure: Garment quality check

Quality Control:
Quality is of prime importance in any aspect of business. Customers demand and expect value for
money. As producers of apparel there must be a constant endeavor to produce work of good quality.
"The systems required for programming and coordinating the efforts of the various groups in an
organization to maintain the requisite quality". As such Quality Control is seen as the agent of Quality
Assurance or Total Quality Control.
In the garment industry quality control is practiced right from the initial stage of sourcing raw materials
to the stage of final finished garment. For textile and apparel industry product quality is calculated in
terms of quality and standard of fibres, yarns, fabric construction, colour fastness, surface designs and
the final finished garment products. However quality expectations for export are related to the type of
customer segments and the retail outlets.Quality control and standards are one of the most important
aspects of the content of any job and therefore a major factor in training.
Total Quality Control:
"To ensure that the requisite quality of product is achieved". This ensures customer satisfaction, but it
leaves quality control as a necessary but expensive evil.
To ensure, at minimum practicable cost, that the requisite quality of product is being achieved at every
stage of manufacture from raw materials to boxed stock.
Objectives:
 To maximize the production of goods within the specified tolerances correctly the first
time.
 To achieve a satisfactory design of the fabric or garment in relation to the level of
choice in design, styles, colours, suitability of components and fitness of product for
the market.

Textile Quality Control Experts:

Quality Control: AQM performs quality control and inspection services for different customers from all
over the world. Using international standards such as ISO 2859, our Quality Controllers (QC) method
consists to check different control points.

Conformity: The QC checks the conformity of the product (design, colors, raw material…) with the Pre-
Production Sample (PPS) and other technical files.

Quality: Our QC checks for defects (fabric defects, colors defects, accessories and label defects,
manufacturing defects) and classifies them accordingly.

Measurement: Following the measurement chart, our QC checks the measures for each size of the
product.

Packaging: Our QC checks the quantity of cartons, size of cartons, their weight, shipping marks, etc.

Concept of Quality:
Simply, quality refers to one or more desirable characteristics that a product should possess. Quality is
inversely proportional to (unwanted) variability.

Figure: Quality curve

Quality Characteristics:
Every product possesses a number of properties that jointly describe what the user or consumer thinks
of as quality. These properties are known as quality characteristics. For example, fiber length is known
to be one of the important quality characteristics of a fiber.

Quality Cost:
Preventing, detecting and dealing with defects cause costs that are called quality costs or costs of
quality. Quality costs can be broken down into four broad groups.

(1). Prevention Costs:

 Product/process design.
 Process control.
 Burn-in.
 Training.
 Quality data acquisition and analysis

(2). Appraisal Costs:

 Inspection and test of incoming material.
 Product inspection and test.
 Material and services consumed.
 Maintaining accuracy of test equipment.
(3). Internal failure Costs:
 Scrap
 Rework
 Retest
 Failure analysis
 Downtime
 Yield losses
 Downgrading/ off-spacing
(4). External failure costs:
 Complaint adjustment
 Returned product/material
 Liability costs
 External costs

Quality control in Garment Manufacturing Process:

Quality is a relative term. It means customer needs is to be satisfied. Quality is of prime importance in
any aspect of business. Customers demand and expect value for money. As producers of apparel there
must be a constant endeavor to produce work of good quality. In previous article, I discuss about
quality control system in garment industry. Now I will give a short description of Quality Control in
Garment Manufacturing Process.

Quality inspection and control in RMG industry:

The various Steps of Garments manufacturing where in-process inspection and quality control are done
are mentioned below-
 1. In Sample making section
2. In- Marker making section
3. Inspection in fabric spreading section
4. Inspection in fabric cutting section
5. Inspection in fabric sewn section
6. Inspection in pressing & Finishing section

Quality Control in Sample Section:

 Maintaining buyer Specification standard
 Checking the sample and its different issues
 Measurements checking
 Fabric color, gsm, Fastness etc properties required checking
 Spi and other parameter checking
Quality Control in Marker Making:
 To check notch or drill mark
 Fabric width must be higher than marker width
 Fabric length must be higher than marker length
 Matching of green line
 Check pattern size and dimension
 Matching of check and stripe taking into consideration
 Considering garments production plan
 Cutting table length consideration
 Pattern direction consideration
Quality Control in Fabric Spreading:
 Fabric spreading according to correct alignment with marker length and width
 Maintain requirements of spreading
 Matching of check and stripe
 Lay contains correct number of fabric ply
 Correct Ply direction
 To control the fabric splicing
 Tension control
Quality Control in Fabric Cutting:
 The dimension of the pattern and the cut piece should be same and accurate
 Cut edge should be smooth and clean
 Notch should be cut finely
 Drill hole should made at proper place
 No yarn fraying should occur at cut edge
 Avoid blade deflection
 Maintain cutting angle
 More skilled operator using
Quality Control in Sewing Section:
 Input material checking
 Cut panel and accessories checking
 Machine is in well condition
  Thread count check
 Special work like embroidery, printing panel check
 Needle size checking
 Stitching fault should be checked
 Garments measurement check
 Seam fault check
 Size mistake check
 Mismatching matching of trimming
 Shade variation within the cloth
 Wrong placement of interlining
 Creased or wrinkle appearance control
Quality Control in Finishing Section:
 Proper inspection of the garments including measurement, spot, dirt, impurities
 Water spot
 Shading variation check
 Smooth and unfold in pocket
 In secured or broken chain or button
 Wrong fold
 Proper shape in garments
 Properly dried in after pressing
 Wanted wrinkle or fold in lining
 Get up checking
 Collar closing
 Side seam
 Sleeve placket attach
 Cuff attach
 Bottom hem
 Back yoke
 Every parts of a body
Quality Control of Sewing Thread:
A slender, strong strand or cord, especially one designed for sewing or other needlework. Most threads
are made by plying and twisting yarns. A wide variety of thread types are in use today, e.g., spun cotton
and spun polyester, core-spun cotton with a polyester filament core, polyester or nylon filaments
(often bonded), and mono filament threads.

Following Features of Sewing Thread are Considered:

1. Thread Construction/Ticket number
 Thread count
 Thread Ply
 Number of twist
 Thread balance
 Thread Tenacity
 Thread Elongation
2. Sew ability
3. Imperfection
4. Thread finish
5. Thread color
6. Package Density
7. Winding
8. Yardage
Quality Control System:
1. On- line quality control system
2. Off line quality control system

On Line Quality Control System:

This type of quality control is carried out without stopping the production process. During the running
of production process a set up is automatically performs and detect the fault and also takes corrective
action. Online quality control comprises with the raw material quality control and the process control.
Raw Material Control :
As the quality product depends on the raw material quality so we must be provided with the best
quality raw material with an economical consideration. The fabric must be without fault, with proper
absorbency, whiteness as per requirement of the subsequent process. The Grey inspection report gives
the condition of the raw fabric.
Process Control :
The method chosen for the process must be provided with the necessary accurate parameters. Here
the specific gravity, water level, residual hydrogen per oxide etc. at each stage is checked.
Laboratory :
Lab is the head of the textile industries. Higher precision lab can aid easily to achieve the goal of the
organization. Before bulk production a sample for the approval from industry is sent to the buyer. As
per the requirement of the buyer the shade is prepared in a lab considering the economical aspects.
Lab Line:
 Standard sample: The buyer to the industry gives the standard sample. The sample is
measured by the CCM to get the recipe.
 Lab trial: Getting the recipe the lab officer produce lab trial and match with standard according
to buyer requirement. Lab trial is made by the AHIBA dyeing machine.There are some
programs for dyeing.
Off Line Quality Control System:
Performed in the laboratory and other production area by stopping the production process consisting
of fabric inspection and laboratory and other test. Correction steps are taken according to the test
result.
Off-Line Tests:
All the Off-Line tests for finished fabrics can be grouped as follows:
A. Physical tests
B. Chemical tests

A. Physical Tests:
 GSM test
 Shrinkage test
 Spirality test
 Tensile strength
 Abrasion resistance
 Pilling resistance
 Button Strength Testing
 Crease resistance
 Dimentional stability
 Brusting strength test
B. Chemical Tests:
 Color Fastness to washing.
 Color Fastness to lighting.
 Color Fastness to heat.
 Color Fastness to Chlorinated water.
 Color Fastness to water spotting.
 Color Fastness to perspiration.
 Color Fastness to Seawater.
 Fibre analysis.
 PH test.
 Repellency.

Quality of Fabric:
Quality is very important for all types of fabric and textiles. There are some important topics given
blow about quality of fabric.
Quality Parameters of Woven, Knitted and Non-woven Fabrics:
Generally to test the quality parameters of woven,knitted and non-woven fabric, the fabric must be
conditioning at 24 hours in the standard testing atmosphere. It is very important for all types of fabric.
Quality Parameters of Woven Fabrics:
There are some quality parameters of woven fabric.
1. Dimensional characteristics:
 Length
 Width
 Thickness.
2. Weight of fabric:
  Weight per unit area.
 Weight per unit length.
3. Fabric strength and extensibility:
 Tensile strength.
 Tearing strength.
4. Threads per inch of fabric:
 Ends per inch.
 Picks per inch.
5. Yarn count:
 Warp count
 Weft count.
6. Crimp:
 Warp crimp
 Weft crimp.
7. Handle:.
 Stiffness
 Drape.
8. Crease resistance and crease recovery.
9. Air permeability.
10. Abrasion resistance.
11. Water resistance.
12. Shrinkages.
13.Different fastness properties:
 Fastness to light.
 Fastness to wash.
 Fastness to perspiration.
 Fastness to Rubbing.
Quality Parameters of Knitted Fabrics:
There are some quality parameters of knitted fabric:
 Strength and extensibility.
 Course density.
 Wales density.
 Lop length.
 Elasticity.
 Deformation.
 Grams per square meter (G.S.M)
 Yarn count.
 Design.
Quality Parameters of Non-woven Fabrics:
There are some quality parameters of non-woven fabric:
 Strength and extensibility of fabric.
 Weight.
 Thickness.
 Air permeability.
  Crease resistance.
 Stability of washing.
 Stability of dry cleaning.
 Dimensional stability.
 Elasticity.

Some test for quality control textile finishing:

 Shrinkage Test
 GSM Test
 Tensile Test
 Tearing Test
 Color Fastness Test
 Rubbing fastness Test
 PH Test
 Shade Matching Test
 Fabric Width Test

Statistical Quality Control (S.Q.C) :

It is the application of statistical tools in the manufacturing process for the purpose of quality control.
In SQC technique attempt is made to seek out systematic causes of variation as soon as they occur so
that the actual variation may be supposed to be due to the guranted random causes.
Statistical quality control refers to the use of statistical methods in the monitoring and maintaining of
the quality of products and services.
Main Purpose of Statistical Quality Control (S.Q.C):
The main purpose of Statistical Quality Control(S.Q.C) is to divide statistical method for separating
allowable variation from preventable variation.

The Significance of Statistical Quality Control (S.Q.C) in the Textile Industry:

1. The expected quality of product can be produced and hence customers satisfaction can be
achieved which brings higher profit.
2. It is very easy to separate allowable variation from the preventable variation by this.
3. It ensures an early detection of faults in process and hence minimum wastage.
4. With its help one can easily defect the impact of chance in production process in the change in
quality.
5. It ensures overall co-ordination.
6. It can be use in the interpretation control chart.

Conclusion:
There are many quality parameters in different types of fabric. And there are also many different faults
in different types of fabric, which are effect in quality of fabric. If we control those faults and effects
,we can get the good quality of fabric. So quality control is very important for all types of fabric and
textiles.