How to Manage Quality in the Apparel Industry

8/6/2019 How to Manage Quality in the Apparel Industry

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How to Manage Quality in the Apparel Industry

Quality management is abusiness function where owners and managers review a sample of productsto determine if they meet internal company standards. This ensures that products leaving thecompany will meet consumer expectations. The apparel industry is a common user of quality control

because they produce items in mass quantities using both machines and manual labor. Companieswill often set up an entire quality control program to review products continuously to ensure thehighest product quality possible.

Instructions

o 1Create a check sheet of common quality issues. Business owners and managers may outline errorssuch as broken buttons or stitching, fabric defects or color variations, missing buttons or buttonholes,seam issues and other similar problems.

o 2Develop a sampling process and schedule. While it is impossible to test every garment a companyproduces, managers will typically create a schedule for testing certain product lines and determinehow many garments will make a good sample for quality testing.

o 3Separate quality control by process. Business owners and managers should ensure that they testgarments at each production stage. This selection process ensures that companies do not wastemoney by fully producing poor quality garments.

o 4Implement corrective actions. Quality control is useless if a company cannot correct issues quicklyand in a timely fashion. Company management should have a process available that is easy toimplement so corrective actions are immediate and solve the issue accordingly.


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Introduction to quality control

For every industry or business, to get increased sales and better name amongst consumers

and fellow companies it is important to maintain a level of quality. Especially for the

businesses engaged in export business has to sustain a high level of quality to ensure better

business globally. Generally quality control standards for export are set strictly, as this

business is also holds the prestige of the country, whose company is doing the export.

Export houses earn foreign exchange for the country, so it becomes mandatory to have

good quality control of their products. 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 fibers, yarns, fabric construction, color 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.

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. The national regulatory

quality certification and international quality programmes like ISO 9000 series lay down the

broad quality parameters based on which companies maintain the export quality in the

garment and apparel industry. Here some of main fabric properties that are taken into

consideration for garment manufacturing for export basis:

. Overall look of the garment.

. Right formation of the garment.

. Feel and fall of the garment.

. Physical properties.

. Colour fastness of the garment.

. Finishing properties

. Presentation of the final produced garment.

Sourcing of Fabrics

There are certain problems that could be faced by garment manufacturers when sourcing

for certain fabrics, so precautions should be taken for it beforehand to minimize the

problems. The garment exporters source cotton fabrics mainly from handloom sectors,


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powerlooms and mills. Each of these sectors presents their own unique set of problems to

the garment exporters. Sourcing cotton from handloom sectors might present some set of

problems like colour variation, missing ends and picks, irregular weaves and unreliable

supplies. However, the handloom sector is significant source of heavier cotton. Common

problems faced in powerloom cotton sourcing are broken ends and reed marks, thick and

thin places, difference in width and massive variation in costing. The major problem in mill-made fabric sourcing is to meet huge demands from the mills. Fabrics have to be ordered

well in advance in mills and the long time taken for producing the fabric is a matter of

concern for garment exporters. Mills generally hesitate to take small orders which pose a

problem for small scale exporters.

It is not that sourcing problems which only confined to cotton fabrics, but also to other

fabrics as well. In silk garment industry there are some sorts of problems faced by silk

garment exporters. Some of the problems that could be faced by silk garment exporters are

as follows:

. Shortage of imported silk yarns in the quantities required, as a result delivery is delayed.

. Silk material is very vulnerable to stains during manufacturing process as well as stocking,

staining results in rejection so a lot of care has to taken during these procedures.

. Roll length of the silk yarn is often insufficient.

. Colour fastness of dyed silk material is sometimes not satisfactory.

. There are also chances of warp breakage.

Basic Thumb Rules for Garment Exporters

For a garment exporter there are many strategies and rules that are required to be followed

to achieve good business. The fabric quality, product quality, delivery, price, packaging and

presentation are some of the many aspects that need to be taken care of in garment export

business. Some rules that are advisable for garment exporters are listed below:

. Quality has to be taken care by the exporter, excuses are not entertained in international

market for negligence for low quality garments, new or existing exporters for both it is

mandatory to use design, technology and quality as major upgradation tools.

. Apart from superior quality of the garment, its pricing, packaging, delivery, etc has to be

also taken care of.

. The garment shown in the catalogue should match with the final garment delivered.


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. It is important to perform according to the promises given to the buyer, or else it creates

very bad impression and results in loss of business and reputation.

. In international market, quality reassurance is required at every point.

. Proper documentation and high standard labels on the garment are also important aspectsas these things also create good impression.

. Timely delivery of garments is as important as its quality.

. If your competitor has the better quality of garment in same pricing, it is better to also

enhance your garment quality.

. Before entering into international market, garment exporters have to carefully frame out

the quality standards, or else if anything goes wrong it could harm the organization. And

after that strictly follow it.

. The garment quality should match the samples shown during taking the orders.

. The garment exporters should know to negotiate a premium price after quality assurance

is done.

Quality is a multi-dimensional aspect. There are many aspects of quality based on which the

garment exporters are supposed to work.

. Quality of the production.

. Quality of the design of the garment.

. Purchasing functions' quality should also be maintained.

. Quality of final inspection should be superior.

. Quality of the sales has to be also maintained.

. Quality of marketing of the final product is also important as the quality of the garment

itself.

See to it that......

There are certain quality related problems in garment manufacturing that should not be

overlooked:

Sewing defects - Like open seams, wrong stitching techniques used, same colour garment,

but usage of different colour threads on the garment, miss out of stitches in between,


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creasing of the garment, erroneous thread tension and raw edges are some sewing defects

that could occur so should be taken care of.

Colour effects - Colour defects that could occur are - difference of the colour of final

produced garment to the sample shown, accessories used are of wrong colour combination

and mismatching of dye amongst the pieces.

Sizing defects - Wrong gradation of sizes, difference in measurement of a garment part

from other, for example- sleeves of 'XL' size but body of 'L' size. Such defects do not occur

has to be seen too.

Garment defects - During manufacturing process defects could occur like - faulty zippers,

irregular hemming, loose buttons, raw edges, improper button holes, uneven parts,

inappropriate trimming, and difference in fabric colours.

Conclusion

Quality is ultimately a question of customer satisfaction. Good Quality increases the value of

a product or service, establishes brand name, and builds up good reputation for the

garment exporter, which in turn results into consumer satisfaction, high sales and foreign

exchange for the country. The perceived quality of a garment is the result of a number of

aspects, which together help achieve the desired level of satisfaction for the customer.

Therefore quality control in terms of garment, pre-sales service, posts -sales service,

delivery, pricing, etc are essentials for any garment exporter.

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Cutting Tools Used in the Garment Industries

The old adage when it comes to sewing is "measure twice, cut once." When it comes to professionalgarment making, the cutting part doesn't always mean grabbing a generic pair of scissors.Depending on the job, there are many tools used by seamstresses, tailors and other garmentindustry workers when making clothes. There is a different tool for each kind of cutting task.

1.Scissors and Shears

o A sharp pair of scissors or shears is integral to cutting fabric. The difference between scissors andshears is in the handle: the two handles on a pair of scissors are identical, whereas one handle islarger than the other on a pair of shears. Scissors and shears can be used for most basic cuttingtasks.

Knife Cutting Machines

o Cutting machines are commonly used for the mass commercial production of clothing. The straightknife cutting machine is the most commonly used machine. Other cutting machines include bandknife machines and round knife machines. Both computerized and manual versions of thesemachines are available.

RotaryCutters

o These small hand-held devices with a circular blade that slices through fabric. They are similar to theround blade machines used in commercial garment making, but smaller and not motorized. They areusually used with a self-healing mat to avoid damaging work surfaces.

Pinking Shears

o Pinking shears are specialty scissors with scalloped blades. They are used to finish seams byproviding an edge that does not unravel.

straight knife

The Working Principle of Straight Knife of Garment Manufacturing which is used on Cutting

Section are as below-

1. Firstly, switch on this cutting machine.

2. Then, place the cutting machine at any corner of the table.

3. Then switch on the blade


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4. Then the operator moves the machine by hand through the stationaryfabric layers and

cut along marker lines until finish the marker.

Disadvantages of Straight Knife as Cutting Machine:

1. Blade deflection occurs so quality may be hampered.

2. Skill hand required.

The Knife Band | Features of Band Knife MachinesThe features of the Band knife which is used in cutting section of Garment manufacturing

are described below:

Features of Band Knife Machine:

1. This machine worked as saw mill technique.

2. Not possible to cut fabric directly from lay.

3. Block pieces of fabric required in bundle form to cut by this machine.

4. Blade moving vertically through a flat working table.

5. Machine remains stationary and fabric is moveable.

6. Specially used to cut small parts more accurately.

Disadvantages of Band Knife Machine:

1. Fabric wastage is high.

2. Work load high.

3. Push cutting needles in better vision but is more dangerous.


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Garment Industry Machine

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We manufacture and export quality garment industry machines. The machine has variable heat

selections that suits to all kinds of fabrics. Our range of garment industry machines includes steam

presses, cloth drill machines, straight knife cutting machines, round blade cutting machines, manual

fusing machines and snap attaching machines.

Steam Press

With pressing surface seven times the size of the regular

irons it almost cuts ironing time in half . The machine has

variable heat selections for all kinds of fabrics.

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Cloth Drill Machine


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This machine can drill holes through numerous layers of

fabric, indicating button holes, pockets, darts and other

attachment points. It is useful for marking on the fabric

without leaving a burn mark.

Send Enquiry

Straight Knife Cutting Machine

This machine is available for cutting materials like cotton,

woollen hemp, silk, chemical fibre, sponge leather etc. This

machine has 8 inches straight knife. Powerful motor can be

started by centrifugal switch. It is equipped with automatic

knife grinding device and lubrication system. It has features

of stable run, convenient operations and powerful cuttingability.

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Round Blade Cutting Machine


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This machine is available for cutting materials like cotton,

woollen hemp, silk, chemical fibre, sponge leather etc. This

machine is a round knife cutting machine. It has 100/110

mm cutting blade & can cut up to 1inch layer of fabric It is

equipped with automatic knife grinding device. It has

features of stable run, convenient operations and powerfulcutting ability.

Send Enquiry

Manual Fusing Machine

Ideal machine to fuse collars, cuffs and front placket. It is a

manually operated system and require no extra

attachments like compressors etc. It is best machine for

start ups, small and medium manufactures. It has High

performance and less maintenance.

Send Enquiry

Snap Attaching Machine


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Also know as Button binding machine. it is suitable for

binding all kinds of metal snap fasteners, craft b uttons,

jeans buttons, rivets, springs, snappers, shoes rivets, etc. on

all kinds of clothese, knitting slopwork, down coats, jeans,

shoes, hats, leathers, plastics and sailcloth. The machine can

change the mould easily as per customer's requirement.


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Flat Bed Press

{ margin-bottom: 0.21cm; }Whirler make Flat Bed Press

y Designed for fine pressing of flat linen like Table covers, Pillow covers, Napkins, Kitchen linen

uniforms.

y The suction feature, quality padding and Teflon lining on hot head Guarantee fine finishing / pressin

y Machine is fully auto model with auto time, auto stop and stand of arm on pre-set time with motor,

panel, blower, FRL unit.

y uto programmable with reset feature , Auto temperature control , Pneumatically operated

y Size of the head / bed: 750mm x 1500mm

y Steam / Electric heated model.

Head & Bed size : 1500 x 750 mm

Suction Blower : hp

Steam Consumption : 40 kg / hr

Steam Inlet size : 0.5 inches BSP

Air Connection : 100 lt / min

Dimensions with open head : 1600 x 1580 x 1900 mm

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Flatwork Ironer for Laundry


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p { margin-bottom: 0.21cm; }

Whirler make Flat work Ironer Electric Chest Hea

y Front feed back return ironer, after drying processing type.

y Safeties devices like finger protection, temperature control, forward & reverse control etc are standar

y Variable frequency drive for various operating speed,

y Technical details :

Roller length : 1600 mm

RollerDia : 280 mm

Electrical heater : 6 kw

Motor capacity : 1 hpOver all Dimensions (l x b x h ) : 2260 x 1346 x2133 mm


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SHIRTFINISHING MACHINES

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Customizing our range of shirt finishing machines, we make sure that we cater to the requirements of

our clients spread across the globe. These shirt finishing machines are customized as per thespecifications of our clients and are in compliance with various industrial standards.

Our range of shirt finishing machines includes shirt body press machines, shirt finishing machines and

shirt collar & cuff press machines.

Shirt Body Press Machine

We are offering a highly functional rangeof Shirt Body Press Machine which is

customized as per the specifications of our

clients. These are offered at industry

leading price and are known for high

performance.

Specifications:

y Innovative automatic unit for a

quality pressing of shirts body, yoke

and shoulders, 288.00 presses theshirt with no limits

Features:

y Two dummies with vacuum, with

movable upper part, extensible

device on the sides by pneumatic

Finishing Machine

We are serving the ever-increasingdemands of garments by manufacturing a

precision engineered range of finishing

machines.

These are customized as per the

specifications of our clients and are in

compliance with various industrial

standards. We make use of high grade raw

material to fabricate a range that stands

high on the features of quality,

performance, service life and otherfeatures.

This Electropneumatic dummy is used for

simultaneous pressing of body, shoulders

and sleeves of shirts and is equipped with:

y Blowing and vacuum unisex dummy


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inflatable bags, retractable sleeves

supports and pneumatic collar

clamp

y Electrically heated plates

y Electronic temperature control with

independent adjustment betweenfront and back plates

y Adjustable separate pressing

pressures for body, shoulders and

inflatable bags

y Manual water spraying gun

y Built-in vacuum unit of 4 HP, with

silenced exhaust stack

y Electronic safety guard device

y Sequential control pedal

programming by PLC

(Programmable Logic Controller)

Options:

y Automatic water spraying unit

y Self-Contained unit of water-

feeding for spraying system

y Automatic front unloader.

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with automatic adjustment of the

shoulder width

y Electrical heated front shape for

shirt front strap locking and

pressing

y Pneumatic devices for sideadjustment, front and rear locking

of shirt tail and complete traction

clear front shape to facilitate the

loading and unloading operations

y Adjustable sleeve tensioning clamp

with automatic closure of cuffs and

sleeve tensioning

y Blowing by means of built-in

electric fan

y Built-in vacuum fan

y Steam overheatery Adjustable pressing pressure for

front shape and for side

y Adjustment devices and shirt

traction

y Programmer (10 programs, 4

functions) with possibility to select

the pressing cycles with ventilation

of hot air and cold air

y Adaption for connection to the

central steam, and compressed air

planty Steam consumption 40/50 Kg/h

y Installed power: Kw 3,2

y Voltage: 3~50Hz 230 V - 3+N~50Hz

400 V

Send Enquiry

How to Manage Quality in the Apparel Industry

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