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Shanto-Mariam University of Creative Technology

Module Name: - Apparel Quality Managent

Module Code: - AMM-2205.

AMM assignment

Submitted To:
[Link] Hossain.
Lecturer
Dept. of Fashion Design & Technology.

Submitted by:
Sayed Mashrur Rafid
ID: 232051059
Group: E
Batch :48th
Semester: 4th

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Part - A
1. Sampling Plan for 8000 T-shirts

For a shipment of 8000 T-shirts, we follow ISO 2859-1 or ANSI/ASQ Z1.4 for
sampling. Under General Inspection Level II, the lot size of 8000 corresponds
to code letter "L". The sample size for code L is 200. Based on AQL 2.5% for
major defects and 4.0% for minor, the acceptance/rejection thresholds are:

- Major: Accept ≤ 10, Reject ≥ 11

- Minor: Accept ≤ 14, Reject ≥ 15
If inspectors find 11 major defects and 8 minor defects:

- Major defects = 11 → Exceeds acceptance number → Reject

- Minor defects = 8 → Within acceptable limit → Accept

Final decision: Since major defects exceed acceptable level, the shipment is
rejected. This process ensures quality control without inspecting all items,
balancing efficiency and product quality. Corrective actions must be taken
before reshipment. AQL-based sampling helps maintain customer trust and
minimize returns.

2. Re-engineering a Cotton Nightgown

To meet sleepwear flammability regulations (like CFR 1615/1616 in the US),

the loose cotton nightgown must be modified.
1. Fabric: Use modacrylic or fire-retardant treated cotton (e.g., Proban-
treated).
2. Finish: Apply flame-resistant finish like Pyrovatex or Proban on 100%
cotton.
3. Weave: Use a tighter weave to resist flame spread while preserving drape.
4. Weight: Use medium-weight fabric (130–150 GSM) to keep flowy feel.
5. Pattern Adjustment: Slightly reduce flare width and hemline length to

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reduce ignition risk.

6. Lining: Add fire-resistant soft inner lining for better protection.
7. Trims: Avoid synthetic lace or plastic trims that melt easily.
8. Design: Maintain gathered sleeves and flare, but reduce excessive fabric in
high-risk zones.
The re-engineered gown meets fire safety while retaining the aesthetic appeal.
Always test under standardized burn testing (e.g., vertical flame test).
Certification labeling is mandatory for compliance.

3. Risk Matrix for Neck Cords

Decorative neck cords pose serious choking/strangulation hazards for

toddlers. To assess the risk, we create a Risk Matrix:

Hazard | Likelihood | Severity | Risk Level

---------------------------------------------------------------------------
Choking | Likely | Severe | High
Strangulation | Moderate | Fatal | Critical
Tangling | Likely | Moderate | High

This matrix clearly shows High to Critical Risk, making cords unacceptable per
CPSC and EN 14682 standards. Instead of cords, propose alternatives:
- Faux drawstrings: stitched down ends to mimic look
- Printed cords: use fabric print designs that simulate cords
- Elastic loops: non-functional stretch loops secured inside seam
- Embroidered plackets or contrast stitching
These options meet branding demands and ensure compliance. Emphasize
legal liabilities and consumer safety to convince the buyer. Final
recommendation: remove functional cords entirely in toddler wear.

4. Meetings to Start a Quality Circle

To launch a sewing-line Quality Circle, hold the following four meetings:

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1. Introductory Meeting
- Agenda: Define QC concept, goals, benefits
- Tools: Presentation, posters
- Output: Volunteer sign-ups

2. Problem Identification Meeting

- Agenda: Discuss common defects/delays
- Tools: Brainstorming, checklists
- Output: List of top 3 problems

3. Root Cause Analysis Meeting

- Agenda: Analyze cause of one main issue
- Tools: Fishbone diagram (Ishikawa), 5 Whys
- Output: Clear root cause

4. Solution Planning Meeting

- Agenda: Develop improvement plan
- Tools: Gantt chart, PDCA model
- Output: Implementable action steps

These meetings ensure participation, team spirit, and practical solutions.

Management support is vital to maintain momentum and reward outcomes.

5. Traffic Light System and TQM

The Traffic Light System (TLS) is a visual performance tool that aligns well
with TQM principles. TLS assigns colors to quality levels:
- Green: Acceptable
- Yellow: Caution – needs attention
- Red: Unacceptable

Integration with TQM:

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1. Continuous Improvement: Red zones trigger immediate corrective action.

2. Employee Involvement: Operators track quality visually and react fast.
3. Customer Focus: Reductions in defect rates increase customer satisfaction.
4. Fact-based Decision Making: Weekly reports enable data-driven discussions.

Weekly Defect Reports help by:

- Highlighting persistent defect types
- Pinpointing failing lines/machines
- Supporting training decisions
- Guiding quality improvement projects

In summary, TLS simplifies quality tracking and aligns daily operations with
long-term TQM goals.

6. Benefits of Quality Circles

Quality Circles ( QCs ) are small voluntary groups from the same work area
who meet regularly to solve work-related problems. Benefits include:

1. Employee Motivation
- Employees feel valued and heard
- Participatory environment enhances job satisfaction
- Recognition boosts morale

2. Teamwork Development
- Encourages open communication
- Builds trust and collaboration
- Promotes cross-functional understanding

3. Factory Productivity
- Identifies root causes of issues like rework, delay
- Suggests low-cost improvements
- Reduces downtime and waste

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- Enhances quality and efficiency

QCs also improve safety awareness, foster innovation, and help create a
culture of continuous improvement. Long-term, they lead to higher retention
and stronger management-worker relationships.

7. Impact of WRAP Certification

WRAP (Worldwide Responsible Accredited Production) is a globally

recognized certification ensuring ethical manufacturing. Its impact includes:

1. Workplace Conditions
- Ensures no forced or child labor
- Maintains safe, healthy environments
- Mandates fair working hours and wages
- Reduces harassment and abuse cases

2. Brand Reputation
- Enhances image as an ethical company
- Attracts socially conscious customers
- Strengthens competitive advantage in global markets

3. Buyer Trust
- Builds credibility with international buyers
- Meets compliance for CSR audits
- Reduces risk of supply chain scandals
- Encourages long-term contracts

Overall, WRAP bridges ethical gaps in the RMG sector and aligns Bangladeshi
factories with global human rights standards.

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Part - B

1. Define AQL in one sentence.

Answer: AQL (Acceptable Quality Limit) is the maximum number of
defective items considered acceptable in a sample during quality
inspections.

2. List the three general inspection levels.

Answer: The three general inspection levels are: Level I, Level II, and Level
III.

3. State two sun-protection fabric variables for kids wear.

Answer: Two sun-protection fabric variables are: UPF rating and fabric
density or tightness of the weave.

4. What does a yellow card signify in the traffic-light system?

Answer: A yellow card indicates caution, suggesting that defects are
present but not severe enough for rejection.

5. Name any two tools commonly used by a Quality Circle.

Answer: Two tools used by a Quality Circle are: Fishbone Diagram and
Brainstorming.

6. Give one benefit of ISO standards to consumers.

Answer: ISO standards ensure consistent quality and safety of products,
increasing consumer confidence.

7. Which WRAP principal addresses forced labor?

Answer: WRAP Principle 1 addresses the prohibition of forced labor.

8. Distinguish internal vs external failure cost with one example each.

Answer: Internal failure cost: Costs due to defects found before delivery
(e.g., rework). External failure cost: Costs after delivery (e.g., returns from

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customers).

9. What is the key purpose of a quality audit under ISO 9001?

Answer: To ensure the quality management system is effectively
implemented and maintained.

10. Expand the acronym ASTM.

Answer: ASTM stands for American Society for Testing and Materials.

Part - C

1. AQL stands for Actual Quality Limit. — False

2. Level II inspection is the most commonly used in SQC. — True

3. Drawstrings in kids’ garments are acceptable if stitched firmly. — False

4. Fire-resistant fabrics are necessary for kids' sleepwear. — True

5. ISO 9002 is applicable only for garment dyeing units. — False

6. WRAP promotes sustainable manufacturing practices. — True

7. In Traffic Light Chart, yellow indicates perfect production. — False

8. Accessories like buttons and sequins can cause choking hazards. — True

9. Quality Circle members must be from the same department. — True

10. ISO 18001 is for environmental management only. — False

11. Quality audit is a one-time activity. — False

12. Quality Cost includes inspection cost and rework cost. — True

13. Green card in traffic light system shows rework needed. — False

14. ASTM is a European standards organization. — False

15. Student Quality Circles started in Nepal. — True

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Thank You