Management Procedure Allow trainees to gain an insight into the varie practiced by major organizations, and Contents: + Conceot of Qulty + Undestanding cost of poor qulty(COPO) Quality ‘deat Cor Product Qu 's Conformance To Requirements, salve Based Quality i The Degree Of Excellence At An Acceptable Pie as Degree To Which A Set Of herent Characterstis Fulfil Scanned with CamScannerEffects of poor Quality * Low customer satisfaction + Low productivity, sales & profit * Low morale of workforce + More re-work, material & labor costs *+ High inspection costs + Delay in shipping + High repair costs * Higher inventory costs + Greater waste of material anpeopet AQA eeview wo 3/22/20: Concept of TQM Whatis TaM? Total quality management (TQM) is dened as botn 2’management phiosopny and set of guiding prineples to iwove all a ambers of en organization in he process and responsible fr producing duaity products and services, Total - everyone should be involved to achieve ‘Quality ~the degree of excellence of @ product or sevice provides ‘anner of handling, controlling, directing, eC Management = act, art oF mi iaations process to achieve the TOM is the art of managing the whole organ rere oi renceed the customer expectations ‘excellence of product or service that meet nw of Quality Ee - vom | a [ee as «| tevomnae een eer 7 | rans = 9 | marae | rina cat ace Scanned with CamScannertle growin ans nae ven everyone can succaus Seek business excellence ond competitive leadership to satisfy our omer’ expectations = ‘Dotne righ things ight the fst time, every time.” $$$ Cost Components of Quality 22? Cost of Quality Cost of Quality peetion and quali Scanned with CamScannerSupplier Relationship Principles of Customer-Supplier relationship Partnering Sou 1B Supplier Selection ‘Supplier Certification Principles of Customer-Sup relationship ler Or. Kaoru Ishikawa has suggested 10 principles to ensure quality products and services and eliminate unsatisfactory conditions between the customer and the supplier: = Both customers and the supp! for the control of quality. = Both the customer and supplier should be independent of each other and respect each other’s independence. —The customer is responsible for providing the supplier with clear sufficient requirements so that supplier can know precisely what to produce. ~ Both the customer and the supplier should enter into 2 non adversarial contract with respect to quality, quantity, price, delivery method, and terms payments. rs are ful responsible Principles of Customer-Supplier relationship = The supper is responsible for providing the quay that customer ane Submating ncesary ata upon caso’ request. = Born he custome andthe supplier shoud decide the method to evalate the uly ofthe product or serie tote satisfaction af bath partes = Both the customer and the supplier should establish in the contract the trethod by whch they ean reach an arable seement of any dapute that maya = both the ust sometimes using sericea = Both te customer and the supplier should perform bu fpocutement, peducton and invertory planing, ceria work, and systems sett an amiable and sstctryratonshp 8 anand. = When deting with business transactions, both the customer and supplier Should always hve the best interest ofthe end user in ig satisty the + and the supplier should continually exchange information, functional teams, in order to improve the product of ess activities such a5 Scanned with CamScannerSupplier Relationship + PARTNERING Went between two or mo 118 organizations forthe purpate of 4 # oa! and objectives by masimiing the atlectiveness of each Dartkipant’s resources. Thee hey elements of partnering * Long Term Commitment + Teast + snared vision + source + Sole + Mul + Single ee eee ir tee eee) Supplier Selection Supplier Selection Based On- eQuality philosophy of the customer Stable management High technical standards with future tiRaw materials & parts meet quality std. BiDelivery as per schedule Effective quality system Record of customer satisfaction credit dust ty in Supplier Rating On Time delivery BService Binternal Structure Customer Satisfaction Review Reports Supplier Relationship Relationship Development Inspection + 100% inspection Training —Team Approach — Recognition & Reward Scanned with CamScannerDefect Taxonomy al, Major andl Mi Categories Defect Taxonomy Need to create a Taxonomy of Defects Across the Factory??? weliens* wit 36 @fySE 47 (Defect VS Defective) f& 435 36 (DHU) CAPS GOP eI VE cera ara y ait >) @IB FIT (Defect) 448 2) BB 4e steFTA FeaHt (Defective) ) Gras Sa AIH HG ae EB YT S Fa CW! FAG BA Scanned with CamScannerment): Sa cote wo wy covert wate cre atodecivecamen ee wera ACA, ey > SUI eS eB ere wr ea cores OATS > GB coms areal OB ats oma, aft oe BAF CIPI... : aia, oK am GD compare eet 216 ° re cats arf coe oo il “ob eo Seana Fore tb AB ear: Of FEARGRT (OHU-Defect per hundred Unit}??? HU FATS AS 00 FIR CMT COS Sate US Ge THB (Defect) MON WA AS HVT CS FST fur fE.g8525 (HU) Ata Sat wA27? DHU facta aeata ert - ; 1 CB BS Fry TBH CHE Ta AAG HE FR; HRT BATS BH, SA " 1 GB BA MBA 6 CUB TOE CHB MOM CT HR ALT AMG ATS TA Scanned with CamScannerDefect per Hundred Unit (DHU) eros aching Scanned with CamScanner31221202 Hoe aR Fe Gp} or ~ even Quality Tools: LU | Scanned with CamScannerTime Checklist Defects 10t0 11] 11012 201 [Bottom hem puckering Drop Stitch He i Ineedle cut fi fi Labe! up down fi Sleeve up. down boot ay > ie) a sam ton! Pareto Charts a7 feet: tenc tices rune sgron No of Roll Histograms Fabric GSM frequency | ul GSM Range Scatter Diagrams Scanned with CamScannerContro} charts Understanding of Quality Standard Operating Procedure * The Steps: Shem a nites be 3/22/2021 Understanding of Quality Standard Operating Procedure + soot simans omg ee Se Satori «awn dc cen ‘The objectveethavig Sta ‘he beciectRavng Stancic Operating Process (SOPs "9 provide nstuctons having the tere ota drecne To Mandavize tose fetes Rogen {Sater of eperatons mat re dfnte to enable ‘To improve me commun process varaion . neatonbeteeen employees ney reducing the Steps in Implementing Quality Procedure Style Start-up Operating Procedure Fabric inspection Operating Procedure Cutting Room Inspection Operating Procedure = Sewing section Inspection Operating Procedure . Finishing section Inspection Operating Procedure Scanned with CamScannerStyle Start-up Procedure = aa l =E Style Start-up Quality Standard Operating Procedure Style Start-up Quality Standard Operating} Procedure + The Style Start-up Procedures includes following points: ES eee Style Start-up Quality Standard Operating Procedure Key Inspection Points: + The Key Inspection Points are prepared by the QAM / QA for the benefit of al ‘This is a list of quality parameters as desired by the buyer, at most noticeable locations in the garment, This also includes information derived from the comments of the buyer + These are also instructed to the operator trainers so that they can ensure knowledge of these points down to the individual operator level Scanned with CamScanner3/22/2021 Style Start-up Quality Standard Operating} Procedure ‘Quality Specification Sheet lon sheets are prepared by the QAE/ QAM, for tion inthe operation bulletin, sheet for each operation is discussed with in case of taining the respective operator ‘Then, QASIOCs (or the operator trainer permanently puts up these ‘sheets at respective workstations) for future reference ofthe operator. Style Start-up Quality Standard Operating sm BAGLAUTE Style Start-up Quality Standard Operating] Procedure ‘The sve startup check at Before te procucton begins + Tie shes x generated by he QAHIOA and requ ne presence of ne IE, nen cage, GAGAM,Mechane ‘Te team moves to each station enecing whee al he necessary requremen for Staring an operation are mel or not 1s tat need 19 Be proper order on me sewing oor “+The mactine nas proper setings, quads, ead tension, stn mation ete. This it done long wine mechan ‘Te woriglace haste guides, attachments, lrs ec. and hat cae has been taken forhouseheepig + Tne maneds aeserbing me posioning of the pars, pick up, sewing rmoverests, espe ec ae propery descrbedto te QA. an he operator Scanned with CamScanner1. Fabric Inspection 2. Shade Analysis 3. 100 % roll GSM Measurement 4, 100 % roll shrinkage test 5. AQL based Accessories inspection Fabric Inspection Done through Fabric Inspection machine. vary important for every industries sin fabreimspecton, here checks several tings Vn fabre are tere any Je F not Wn Fabre, fare defects ve. off shade oF shade vaaton, hol in fab, sped eft ele. can be visual ater entering into cetect ava the sore room For those defects it willbe problematic for making garments making infarc inspecton, ao check fabric srengtn, col, quantity To evaluate the result there are different system ic. 4 point system 10 point system ete, 3/22/2021 Scanned with CamScanner3/22/2021 4 Point System ‘oa points costo ats inspected x38 100 Pon00 9. meter inspaia x Cae wah nes) Fomiwa ( Tota pots courts or at ts inpaces x GSH X Pont 9. SSK 19 “oa Fabric We gin Kg 1000 “PONT FABRIC MSPECTION REPORT Scanned with CamScannera ee Marker inspection 2 meen wo ay ea following points isted below. 7. Marker Inspection is s ‘Marking is not permissibie direc effect to poor cutting and pane! Size variavons between the layers “Marker width snould not exceed the fabric wid “Grain ines shouts be psratiol tome fabric savages Ce ‘The QA aucitor should ensure auditing the spreaders during the ‘ctual operation. The frequency of te audit shoul be based on the materal being process, ing. Spreader should use a base paper laid directly ‘ensure, tat fabric fmily held in place ‘Check the tension regulary during spreading ‘Need to be watchful about he shading during spreading. “The laying should do smoothly without puling the fabric. ding should respect al the standards provided by the ancisers, Cutting Inspection Following parameters should be consigered durng operation — “Types of fabric. “Types of machine used for cuting Machine speed, recision of cuting, Visual defects. Cut Panel inspection + The inspector must eneck ll te pans of each eu ‘randomly by picking the ples from i. ‘+The top miasle and botom ples shoul be checked in each bundle against the onigna patern '+ The cut pane needs 10 be lat onthe table and place the patter on the ‘panel and check. Ithebps 1 avoid unnecessary pulng ofthe eut part to ‘match toe pate ‘+ The maximum alowed tolerance is + or~ 1/8 of an inch only and make sure the tolerances been gen bythe buyer should not used atthe cutng stage Scanned with CamScanner3/22/2021 we | ees | Daly MIS mary Scanned with CamScannernecked for sual detects. The key objecoves are to screen 00% at the end cf tne and capture folowing data Scanned with CamScanner3/22/2021 40 ser ltoning oecives one, ane ae 180 nspechon: cncantatgatenton Scanned with CamScanner1 of quality 'ecepled by that sampling plan. "steal measurement of the maximum number of detective S00d8 considered acceptable in @ particular sample size for te Purpose of sampting inspection, nS Most frequently used by the mibtary standard @ based on the AQL system, MASTER TABLE FOR NORMAL INSPECTION Lk elolfelolalel fe AQL Santen AGL swten Inspection le reduced inspection when @ TEHTERED z} -[al-lelel--le ol el zl-[e{lzJol-le| Scanned with CamScannerFINAL INSPECTION 3/22/2021 FINAL INSPECTION PROCEDURE FINAL INSPECTION PROCEDURE AUDITING TOOLS: PROCEDURE QUAL MANUAL pees Scanned with CamScannerFINAL INSPECTION PROCEDURE ADDITIONAL REQUIREMENTS: Following additional requirements should be followed; * Pre- final pass report * Packing list * Deviation Chart + QRS (Qu ied reference sample) / Color wise QRS eee PACKING LIST VERIFICATION DEVIATION CHART CARTON QUANTITY AND CARTON LABELS Scanned with CamScannerPACKING INSPECTION & REPORTING PROCEDURE ings are recorded in inspection report form. * (C, production merchandiser and vende cntative signs inspection report WA fragt aroha - fafa a ag = QO » pesgeavio Basen 1 3. wtda ke, Ta WY, PB Scanned with CamScanner9, Brae OF BEI FS 9. SRI GA SRG ra 10, are iG spHfeTS 11. Bo are iB “Anyone who stops improving has stopped being good” Scanned with CamScanner