Quality is a journey, not a destination.

What is Quality?

“Quality is never an accident it is always the result of high intension, sincere effort ,

intelligent direction and skillful execution; it represents the wise choice of many

alternatives”

Prof. Juran

What is Control? Check whether work or not work is being done

properly- is control.

Control is not possible unless objectives and targets are clearly defined.

What is Quality control? “Quality control is a process, a set of activities

designed & regulate the effectiveness of production to achieve quality.”

• Materials

• Information

input

• CONTROLS

• Procedures

• Specification

• Acceptance criteria

• Training

• Objectives

• RESOURCES

• Equipment

• People

Process

• Transformed materials

output

Where needs QA activity?

Desired results are achieved more efficiently when related resources & activities are managed as a process….

Why Measure the Process ?

If you can not measure it You can not manage it

If you can not manage it You can not control it

If you can not control it You can not improve it

Measure is the basis of improvement !

What to Measure in a Process ?

- What is most critical in order to satisfy customer needs ?

E.g. Performance, time, Efficiency & Using optimum resources - Where do we have problems today ? E.g. defects, bottleneck, Complaints, unable to understand needs

of quality & unskilled operators. - Where can problems arise tomorrow ? E.g. operator absent, Benchmarking, etc

What we need to know to measure in process???

Wms manual

General Checking points of Shirts

Specification & Block pattern

Defect classification

Key msmt

Inspection procedure

Defect zone

How to measure

1. How to measure? Please see the video

2. General Checking points of Shirts Please see the video

3. Workmanship manual * Men casual

* Men collection * EDC men * Denim men Please see all attached file

4. Specification & Block pattern Specification : DSS, SWS & MDS

4. Block pattern & Grading philosophy

5. Defect classification Please see attached file

6. Defect Zone

7. Key measurement

7. Key measurement

8. Inspect procedure

8. Inspect procedure

Workshop Group Exercise

• Group Discussion • Choose group leader • Write comments/ideas

1.COMMUNICATION Case Study: Suppose you are asked to make a shirt made with shading fabric. o When and whom do you inform if you find that you can’t

meet the required quality standard? • During fabric inspection? • During production? o What actions do you take to ensure that, style will meet the

standard? • During Fabric inspection? • During bulk production?

When and whom do you inform if you find that you can’t meet the required standard? what action do you take to ensure that style will meet the requirements? During Fabric inspection: - Inform merchant team, production head, cutting & CAD dept. - Inform Fabric supplier if result is fail. - Take measurable step prior to start cutting. During bulk production: - Cutting Marker t/b accurate as per fabric inspection report. - Fabric t/b cut shade/lot wise. - Maintain labeling, numbering properly. - Use shade label in the sewing line. - Send the garments to wash separately by using color binder to identify shade

variation / magnitude.

1.COMMUNICATION- SOLUTION PROPOSAL

2. Defect Classification

on workmanship

Defects Defect Explanation Zone 1 Zone 2 Zone 3

Thread colour incorrect (refering to sample work sheet)

Affecting appearance M M M

Thread thickness incorrect (refering to sample work sheet)

Affecting appearance M M M

Broken seam/ open seam/ needle holes M M M

Holes/damaged fabric due to damaged needles M M M

Size of stitches incorrect

Affecting appearanceM M M

Thread tension not correct M M m

Stretchability of seam or hem incorrect M M M

Untidily joined topstitching M M m

Blind stitching visible on outside M M M

Roping M M m

Puckering

Affecting appearanceM M m

Hanging threads M M m

Uneven/drifting/ wavy stitch line M M m

Unfinished /insecurely finished seams/ not

backtacked

M M M

Bartacks damaged/ incorrect M M M

Feed damage M M M

Stretched curves (e.g. armholes, necklines) M M M

Sewn in pleats M M m

Basting stitch/prestitch exposed M M m

Uneven gatherings M M m

Twisting M M M

Unclean seam M M m

Unbalanced/ uneven components (e.g. pocket height, collar

points)

Affecting appearance

M M m

Lengths (sleeves, seams, overlap/underlap,plackets...)

Affecting appearance M M M

Shapes (neckline, ...)

Affecting appearanceM M M

Distribution (gatherings, ...)

Affecting appearanceM M M

Symmetry

Workmanship

2. Defect classification _ Fabric Defects Defect Explanation Zone 1 Zone 2 Zone 3

Weaving defects: (less than 1cm)

Broken yarn

Slubs

Pills, neps, double pick or mispick

M

M

M

M

M

(m)

M

M

(m)

Flying fibres/ fly-ins: (less than 1cm)

Low contrast

High contrast

M

M

(m)

M

(m)

M

Knots M M m

Pulled threads M M m

Holes M M M

Grainline not correct/ bowing (e.g. slub) M M m

Permanent creases, washer wrinkles M M M

Nap variation/ pile deformation

Affecting appearanceM M M

Finishing/ coating damaged

Affecting appearanceM M M

Print defects:

Bleeding edge, smeared colour

Misregistration

M

M

M

M

M

M

Within garment M M M

From garment to garment

Low contrast

High contrast

m

M

m

M

m

M

Grainline not correct

Affecting appearanceM M M

Nap not correct

Affecting appearanceM M M

Checks/ stripes not matched (refering to sample

work sheet)

M m m

Cutting

Fabric

Colour shading

3. PRODUCTION PROBLEM

Case Study: You are a supplier who often gets complaints regarding collar wms issues: The collar is not symmetrical/hi-low points/ collar point flying. What could be the reason behind? What kind of action do you take in production to avoid it?

Describe in details

3. PRODUCTION PROBLEM- SOLUTION PROPOSAL

What could be the reason? o Cut panel are not accurate. o Neck shape is not symmetrical between Left & right side. o Collarstand notch shape is not ok. o Collarstand button & buttonhole position is not ok. o Collar points length are not ok left & right both side. What kind of action do you take in production to avoid it? o As per block pattern upper & lower collar t/b different. So cutting s/b same. o Collar need to cut by band knife cutting machine. o During sewing of collar, ease of outer collar m/b kept. It should not be cut out while sewing. o During collarstand joining with collar, the NOTCH mark m/b followed. o Collarstand button & buttonhole position t/b correct. o Collar points length both side s/b even. o Front neck shape t/b regular, smooth & symmetrical. o Need to train up operator as well as QC to make them aware about optimum quality

standard.

How expected quality of Esprit can be achieved?

Share your ideas with us!

Thank you