PRESENTATION ON
TEXTILE TESTING AND
QUALITY CONTROL CODE: TEX2205
Made by:
MD. Sabbir Islam Khan [Link] Hassan
ID : 192-019-811 ID: 192-030-811
INTRODUCTION
How do They Maintain Quality Factors
They have documented a quality manual that states the quality of that particular product
Management establishes plan to maintain that quality.
They have to follow that specific plan and follow a sequence of activities relevant to that particular product.
Quality Assurance Department
Quality assurance (QA) is a way of preventing mistakes and defects in
manufactured products and avoiding problems when delivering products or
services to customers; which ISO 9000 defines as "part of quality management
focused on providing confidence that quality requirements will be fulfilled"
Quality assurance of this industry builds quality into each step of the
manufacturing process including fabric selection designing, production, and
beyond.
all the products assessed for quality in the preproduction phase, during
production, and with a final inspection after the product has been completed.
Main Objective of Quality Assurance Department:-
The main objective of the quality assurance departments is to ensure the quality of
finished products according to the customer or standard fixed by the management
Role of Quality Assurance
Main role of this department is to is to check the quality of finished products. For
this, quality audit is conducted.
they checks finished garments according to customers P.O.
Fabric Quality, Color, Sizes, Accessories, Embroidery, Stitching Quality everything is
checked by Quality Assurance Department.
If everything is OK then the shipment gets approval otherwise it is rejected.
Role of Quality Assurance
Quality policy of this industry is to satisfy customer at every cost. While
auditing finished goods Q.A Officer also checks the measurements of
the garments and match them with standard for the respective sizes.
In final inspection the officer have a standard fault form. He checks the
garment and find faults. If the fault ratio is more than 2.5% he rejected the
piece.
In that form description of faults are mentioned.
Q.A department ensures that 100 % quality is maintained.
Beside Quality Assurance department evaluate the performance for the In-
line inspectors and final inspectors.
Quality Assurance Department:
Quality Assurance Manager
Deputy Manager Quality Assurance
Assistant Manager Quality Assurance
Quality Assurance Officer
Quality Assurance Auditors
Management Trainee
Preventive Action takers (Q.A) :
a) Fabric Audit
b) Cutting Audit
c) Inline Audit
d) Measurement Audit
e) Finishing Audit
f) Final Good Audit
Corrective Actions:
a) Warnings
b) Demotions
Quality control Department
Quality Control :
Quality is a standard achieved by following some processes and system so that
industry could produce a defect free product to the customer.
Quality control is a system implemented to make these processes successful.
Different quality control systems are as follow.
Objects of quality control:
• Research.
• Selection of raw materials.
• Process control.
• Process development.
• Product testing.
• Specification test
Quality management system in this industry:
0n-Line
Off-Lin,
Online Quality control:
There are two types of online quality control.
These are as follows: -
• Raw material control: Raw material control . means control the quality of
raw materials (e.g.- Quality of Grey fabric, Dyes, Chemicals and Auxiliary)
• Process control: Process control means the selection a right process and
controlling of some parameters. Such as ph, Water hardness, water volume,
Temperature, Reel Speed, Pump pressure, etc .
Online Tests:
Dyed fabric.
Shade check.
Wash fastness.
Water fastness.
Crocking fastness .
Off-Line Tests:
Off-Line tests for finished fabrics are divided into two groups.
These are as follows:
Chemical tests
Physical tests
Chemical Tests:
•Color fastness to washing.
•Color Fastness to light.
•color Fastness to heat.
•color Fastness to actual laundering
•Color Fastness to Chlorinated water.
• Color Fastness to water spotting.
•Color Fastness to perspiration.
•Color Fastness to Seawater.
•Flammability test.
•Fiber analysis.
•Ph test.
•Spray test (water repellency).
•Phenolic yellowing
Physical tests:
•GSM of Fabric.
•Abrasion resistance / Pilling.
•Dimensional stability test.
•Spirality test.
•Color fastness to rubbing .t (Dry / Wet).
•Bursting strength test (For Knitted fabric).
Tensile Strength test (For Woven fabric
Laboratory: Laboratory is the heart of dyeing Industry. An efficient laboratory can
increase the efficiency of dyeing. So, laboratory in-charge. is sometimes called
pilot. Before bulk production a sample is sent to buyer for approval. Laboratory
supplies the recipe to the floor.
Purpose o f Laboratory:
•Get color approval from buyer.
•Recipe supply to the floor.
•Shade correction.
•Minimize the deviation between bulk and laboratory
Laboratory line:
•Standard sample :At first recipe % of standard sample is measured by CCM
(computer color matching) system.
•Laboratory Trial: Then by taking those recipe, laboratory officers produce
laboratory trial and match with standard according to buyer requirement.
•Approved Sample: Then sample swatch, which is matched with the standard, is
send to buyer for approval.
Libratory machine with its specification
Test Name : Colourfastness to Washing, Dry cleaning.
Name of the m/c : Rota Wash
Origin : U.K
[Link] m/c : 02
Test Method IS0105,06, IS0105-D02
Test Name : Dimensional Stability, Spirality, Appearance after washing
Name of the m/c : Electrolux wascator.
Origin : U.K
[Link] m/c : 01
Test Method : ISO 6330, ISO 26330
Libratory machine with its specification
Test Name : Shrinkage Test.
Name of the m/c: Electrolux
Origin : U.K
[Link] m/c : 01
Test Method :
Libratory machine with its specification
Test Name : Colour Fastness to Wash Test.
Name of the m/c : Gyro wash
Origin : U.K
[Link] m/c : 02
Test Method : ISO. 105,06
Libratory machine with its specification
Lab Dip m/c:
[Link] m/c: 02
M/C NO- 01
Brand name : Ahiba Nuance Lab Dip
Dyeing m/c
Origin : U.S.A
M/C NO- 02
Brand name : Ahiba Nuance Lab Dip
Dyeing m/c
Origin : U.S.A
Libratory machine with its specification
No. of Light Box: 02
Light Box no: 01
Brand : Speetralight-111
Origin : U.S.A
Light Source:
• Day Light (D-65)
• Cool White
• Horizon
• UV
• TL-84
• A (F11-10 degree)
Light Box no: 02
Brand : Verivide
Origin :U.K
Light Source:
• Day Light (D-65)
• UV
• TL-84
• A (F11-10 degree)
Feeding inspection
Fabrics are feeded in to automatic fabric inspection system .
automatic inspection system locates the defects in the fabric, marks them, records,
stores, and analyses or classifies the information about the defects. The evaluation
unit of the machine is based on the application of neural networks. Uster Fabriscan
is used for this
Viewing Glass– 72 x 21 inches
Max Fabric Width – 65 inches
Machine Speed – Variable up to 15 (meters/min)
Gears Motor– 1HP
Supply Voltage – 220V/50HZ/Single Phase
Dimensions (L x B x H) – 2000x1950x1750 (in
mm)
Approximate machine weight – 450 Kgs
7.0 system
7.0 system is one of the inline garment inspection systems followed by this industry. 7.0 system is similar to
the traffic light inspection system used by garment manufacturers.
In the 7.0 quality inspection system, the roving quality checker visits each operator working in a production
line. The quality checker picks 7 garments from the work done by the operator and checks all the pieces. If
the quality checker finds a single defective garment in 7 checked pieces, he marks RED on the operator
quality performance sheet (Or put a Red Flag on the workstation). This means the operator needs to improve
her stitching quality.
When a line has an operator with a red flag (in quality performance), the quality checker or the line
supervisor needs to attend the operator and explain to the operator what is wrong in her stitching. How to
correct the defects while stitching.
The operator may understand the quality requirement, but due to poor skill on machine/material handling,
defects may be generated. In such cases, the line supervisor or the trainer provides training to the operator.
Traffic control system
In-line Auditor starts the day work with “Patrol Inspection” of which he/she checks 3
components/pieces from each and every operation. In-line Auditor turns the Traffic Light Cards
(TL Cards ) into respective colors according to the Inspection.
Zero defects - Green
One defect - Yellow
Two or more defects – Red
Action on Traffic Light : Auditor turns the Traffic Light Cards ( TL Cards ) into respective colors
according to the result of the Inspection.
Green-Appreciate & ask to continue the Operation
Yellow- Inform to operator & Production Supervisor to increase the attention & the level
Red -Stop the operation. Inform to Operator, Production Supervisor to identify the problem &
solve it with the help of Mechanic & Technician.
A single sheet will keep record for the whole month for an operator. Inline Quality
checker, on the first day of the month have to fill details such as Operator name,
Line number and name of the Month.. At the end of month, performance of
operator can be easily noted form color filled columns.
Corrective and Preventive Actions
The corrective and preventive actions are very strong in this industry. Strong
preventive actions are designed to ensure the quality and avoid any kind of fault.
But if anything goes wrong then relevant person immediately take corrective
action
Preventive measures taken to make defect free product responsibilities of quality
assurance:
There are three responsibilities of quality assurance.
(1) Monitoring the system
(2) Evaluating staff involved
(3) Assuring quality of product
Preventive Action takers (Q.A) :
a) Fabric Audit
b) Cutting Audit
c) Inline Audit
d) Measurement Audit
e) Finishing Audit
f) Final Good Audit
Corrective Actions:
a) Warnings
b) Demotions