NATIONAL COMPETENCY STANDARDS - nvq.gov.lk

NATIONAL COMPETENCY STANDARDS

for

QUALITY CONTROLLER (APPAREL PRODUCTION)

(Competency Standards Code: D18S005)

National Apprentice & Industrial Training Authority971, Sri Jayawardenapura Mawatha,

Welikada,Rajagiriya.

Endorsed byTertiary & Vocational Education Commission354/2, Nipunatha Piyasa, Elwitigala Mawatha,

Narahenpita.

Ministry of Youth Affairs and Skills Development

Competency StandardCode No: D18S005

Endoresement Date:20th November 2007

Revision No.: 00 Revision Date:20th November 2010

Page I

COPY RIGHT

The National Competency Standard is a written specification of competencies required in a particularoccupation. The principal agencies involved in the development and endorsement of the NationalCompetency Standards are the National Apprentice and Industrial Training Authority (NAITA) and theTertiary and Vocational Education Commission (TVEC).

Identification of trades and occupations for Competency Standard development are done by theTVEC based on the Labour Market Information. It is the sole responsibility of NAlTA to identify TradeSpecialists from the industry to develop the Competency Standards. The draft standards developedare technically validated by National Industrial Training Advisory Committee (NITAC). TVEC endorsesthe Competency Standards based on the recommendation of NITAC.

The National Competency Standards could be used as a referral document for the development of acurriculum to be used by training agencies. Also it serves as the base document for providing trainingconsistent with National Vocational Qualifications.

All rights reserved. Reproduction in any manner in whole or in part, in English or other languages isprohibited.

© TVEC publication - code D18S005 - 20th November 2007

This Document was developed with the co-operation and expertise of

Joint Apparel Association Forum

Sponsored by

United States Agency for International Development(USAID)




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PREFACE

National Competency Standards are an essential elements for the implementation of a unified Technicaland Vocational Education & Training System for Sri Lanka and forms the basis for the National VocationalQualification Framework of Sri Lanka, which provide for award of nationally recognized qualifications.The National Skill Standards are developed in consultation with the industry and are designed using anationally agreed specific format to maintain uniformity and consistency of standards amongst occupations.

The National Competency Standards specify the standards of performance of a competent worker andthe various context in which work may take place. National Competency Standards also describe theknowledge, skills and attitudes required in a particular occupation. National Competency Standardsprovide explicit advice to assessors and employers regarding the knowledge, skill and attitudes to bedemonstrated by the candidates seeking formal recognition for the competencies acquired either followingtraining or through work experience.

National Competency Standards focus on what is expected of a worker in the work place rather than onthe learning process.

National Competency Standards stress upon the ability to transfer and apply knowledge andskills to new situations and environments.

In National Competency standards the emphasis is upon outcomes and upon the application ofknowledge and skills, not just the specification of knowledge and skills.

National Competency Standards are concerned with what people are able to do and the abilityto do a task in a range of contexts.

National Competency Standards include all aspects of work place performance and not onlynarrow task skills.

National Competency Standards can serve a number of purposes including:

Providing advice to curriculum developers about the knowledge, skills and attitude to be includedin the curriculum.

Providing specifications to Competency Based Assessors about the knowledge, skills and attitudesto be demonstrated by candidates.

Providing advice to industry about job functions, which in turn can be used for the developmentof job descriptions, performance appraisal systems and work flow analysis.

The lead organization for the development of National Competency Standards is the National Apprentice& Industrial Training Authority. The standards so developed are endorsed by the Tertiary & VocationalEducation Commission as National Documents.

Amal Senalankadhikara Dr.T.A.PiyasiriChairman Director GeneralNational Apprentice & Industrial Tertiary & VocationalTraining Authority Education Commission




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ACKNOWLEDGEMENT

Overall Direction

Mr. Amal Senalankadhikara Chairman, National Apprentice & Industrial Training Authority

Dr. T.A. Piyasiri Director General, Tertiary and Vocational Education Commission

Mr. Ronald Saunders Manager Vocational Education, CH2MHILL/USAID

Dr.T.A.G.Gunasekara Vocational Education Expert, CH2MHILL/USAID

Mr. K.W.J.de.R. Perera Director, National Apprentice & Industrial Training Authority

Technical Support Mr. K.S.Roshan Jayawardana - Junior Manager Quality, Star Garment (Pvt ) Ltd

Mrs. A.T.Padmini Silva - Technical Training Officer, CITI

Mr. W.M.S.K.Wijebahu - Technical Training Assistant, CITI

Mrs. Malani Korale - Asst.Manager, Quality Assurance, Comfortwear (Pvt) Ltd

Mr. Madusanka Ranatunga - Quality Controller ,Crystal Martin (Pvt ) Ltd

Ms. Priyadarshani Ranasinghe - Quality Controller Supervisor, Hameedia

Group

Mr. Rohana Kumara Soundrarajan - Roving Quality Controller, Crystal Martin

(Pvt) Ltd

Mr. D.Hemachandra - Director/General, Manager ,Samson (Export) Ltd - NITAC

Mr. P. Lalith Somaratne - Manager Technical Training, Stretchline (Pvt) Ltd -

NITAC

Mr. Athula Mendis - Assistant Factory Manager , Texvel Jursy Ltd (Velona

Group) – NITAC

Mr. Nihal Wanigathunga - Senior Lecturer, Department of Textile and Clothing

Technology, University of Moratuwa - NITAC

Mr. J.D.Percival Perera - Director/Secretary,Institute of Management Service

(UK)Sri Lanka Branch -NITAC

Mrs. Devika Rodrigo - Director(Standards & Accreditation) Tertiary and

Vocational Education Commission - NITAC

Mrs. K.G.N.P.Rajapaksha - Management Academic Assistant, NITESL - NITAC

Mr. M.A. Darmadasa - Deputy Director, Ministry of Public Administration - NITAC

Mr. Lalith Atukorala - Manager Training, Bodyline (Pvt ) Ltd - NITAC

Mr. B.N.de Silva - Managing Director/Proprietor, Linton’s Academy of Tailoring -

NITAC

Mr. Lakshman Ranasuriya - Co-ordinator, CH2MHILL/USAID

Mrs. Kanthi de Silva - Co-ordinator, CH2MHILL/USAID

Administrative Support Mrs. Nilufer Chitty - Administrative Officer, CH2MHILL/USAID

Facilitator Mrs. D.C. Wahalatantri, Assistant Director, Curriculum DevelopmentSection, NAITA

Co-ordinator (NAITA) Mr.M.M.I.Samaranayaka - Curriculum Development Section, NAITA

Editing Review Mrs.D.C.Wahalatantri - Assistant Director, Curriculum Development

Section, NAITA




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NATIONAL COMPETENCY STANDARD FORQUALITY CONTROLLER (Apparel Production)

(CODE NO. D18S005)

NATIONAL CERTIFICATE AT NVQ LEVEL 4 IN THE OCCUPATION OFQUALITY CONTROLLER (Apparel Production)

1. Endorsement date: 20th November 2007 2. Date for review: 20th November 2010

3. Qualification code: D18 S005Q1 L4

4. Development Group andNational Industrial TrainingAdvisory Committee:

Development Group• Mr. P. Lalith Somaratne - Manager Technical Training

Stretchline (Pvt) Ltd• Mr. Lalith Atukorala - Training Manager, Bodyline (Pvt ) Ltd• Mr. K.S.Roshan Jayawardana - Junior Manager Quality Star

Garment (Pvt) Ltd• Mrs. Malani Korale - Asst.Manager - Quality Assurance,

Comfortwear ( Pvt ) Ltd• Mr. Rohana Kumara Soundrarajan - Roving Quality

Controller, Crystal - Martin ( Pvt ) Ltd• Mr. Madusanka Ranatunga - Quality Controller, Crystal -

Martin (Pvt ) Ltd• Mrs. A.T. Padmiini Silva - Technical Training Officer, CITI.• Mr. W.M.S.K.Wijebahu - Technical Training Assistant, CITI.• Ms. Priyadarshani Ranasinghe - Quality Controller

Supervisor, Hameedia Group

NITAC• Mr.D.Hemachandra - Director/ General Manager, Samson

(Export) Ltd• Mr.Jamshid J. Sourjah - General Manager, Hameedia Group• Mr.P.Lalith Somaratna - Manager-Technical Training,

Stretchline (Pvt) Ltd• Mr.Athula Mendis - Assistant Factory Manager, Texvel Jursy

Ltd, (Velona Group)• Mr.Ramitha Dissanayake – Manager Workstudy , Star

Garment (Pvt) Ltd• Mr.Nihal Wanigatunga - Senior Lecturer, Department of

Textile and Clothing Technology, University of Moratuwa• Mrs.Chandrika Trimawithana - Lecturer- Clothing Industry

Training Institute• Mr.J.D.Percival Perera- Director / Secretary, Institute of

Management Services (UK), Sri Lanka Branch• Mr.Ranjan Perera - Merchandising Manager, Daya Apparel

(Pvt) Ltd




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• Mr.Lalith Atukorala – Manager Training , Bodyline (Pvt) Ltd• Mr.B.N.De Silva- Managing Director / Proprietor –Linton’s

Academy of Tailoring• Mrs. Devika Rodrigo - Director (Standards & Accreditation)

Tertiary and Vocational Education Commission• Mrs.K.G.N.P.Rajapaksha - Management Academic Assistant,

NITESL• Mr. M.A.Dharmadasa - Deputy Director, Ministry of Public

Administration• Mrs.G.H.R.S.E Silva - Factory Inspecting Engineer,

Department of Labour• Mrs.D.C.Wahalatantri - Assistant Director (C/D), NAITA• Mrs.M.P.Teja Malkanthi - Inspector (C/D) NAITA

5. Purpose of thequalification

6. Regulations for thequalification

7. Schedule of Units

8. Accreditation requirements

9. Certification

10.Assessment consistencyrequirements

11.Transition arrangements

12.Contact for comments

13.Prerequisite diagram

To certify that the holder of this qualification has acquired thecompetencies contained in the units listed in section 7 below.

The holder should have been assessed by a LicensedAssessor and found competent in the units listed in section 7and certified by the TVEC.

Unit no TitleD18S005U01 Ensure quality standard to feed the lineD18S005U02 Inspect production process

The qualification shall be offered in compliance with theaccreditation requirement of the TVEC as stipulated in theNational Vocational Qualifications framework of Sri Lanka

TVEC shall certify the qualifications in terms of the regulation atsection 6 above

TVEC unit responsible for consistency of assessments shalltake appropriate steps to ensure consistency of assessments

Competency based assessments shall be undertaken bytrained assessors until TVEC arranges to issue license to theassessors

Chairman, National Apprentice and Industrial TrainingAuthority,971,Sri Jayawardenapura Mawatha,Welikada,Rajagiriya

No Prerequisites




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NATIONAL COMPETENCY STANDARD

for

QUALITY CONTROLLER (APPAREL PRODUCTION)(Competency Standard Code : D18S005)

List of units Code No. Level Page

1. Ensure quality standard to feed line D18S005U01 4 3

2. Inspect production process D18S005U02 4 6

Packaging for National Vocational Qualifications (NVQ)

National Certificate at NVQ Level 04 in the occupation of Quality Controller will be awarded tothose who are competent in units 1+2 – D18 S005Q1L4




Page 2

This page is intentionally left blank.




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UNIT TITLE Ensure quality standard to feed line

DESCRIPTOR This unit covers the competencies required to assist the supervisor to stitch sample,identify problems, review sample, attend production meeting, discuss issues andfind solutions in production process to achieve buyer’s requirements ensuring safety

CODE D18S005U 01

ELEMENTS OFCOMPETENCE

PERFORMANCE CRITERIA

1. Study approvedsample andspecification

2. Review trialsample

3. Attend to preproductionmeeting

4. Ensure qualityparameters tofeed line

1.1 Sample and specifications obtained from sample room as perstandard operating procedure

1.2 Approved samples compared with technical package forspecification

2.1 Garment is sewn by the supervisor as per the technical package/ operational sequence / buyer’s requirement ensured bysupervising process

2.2 Trail sample checked with the approved sample visually forworkmanship

2.3 Any changes attended discussing with relevant authority

3.1 Different types of issues in constructing trial sample and achievingbuyer’s standard discussed with relevant personnel and solutionsmade

3.2 Information required for a quality production gathered bydiscussing with relevant personnel

4.1 Inputs ensured for quality parameters against buyers requirement

4.2 Mock - ups satisfying with quality standards approved foroperations

4.3 Pilot run outcome with reports submitted to authorized personsfor approval for bulk production as per standard operatingprocedure




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RANGE STATEMENT

Work connected to this unit may take place in a garment manufacturing factory.

The following equipment and material may be used for this:

• Standard measuring tape. • Pull tester • Magnifying glass • Table • Vernier calliper • Newton gauge

The following documents may be used in this unit

• pen • arrow sticker • card • pencil • eraser • file • paper • highlighter • card board • ruler • invisible pen • original sample • Colour continuity card


• Style file • Organizational formats

The performance of this unit is expected to be carried out to the following standards

• Buyer’s standards• Standard operating procedure• International organization for standardization• Worldwide regulation for apparel production (WRAP)

ASSESSMENT GUIDE

Forms of assessment

Continuous / holistic assessment is suitable to assess the competencies in the occupation of QualityController with regard to this unit.

Assessment context

This unit may be assessed on the job, demonstrated by an individual working alone or as a member of ateam.

Critical aspects

• Maintain accuracy of measurements • Accuracy of processing data • Analytical tracing of defects • Free of colour blindness

Special note –

• Use accepted work aids




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Assessment conditions

The candidate will be provided with all tools, equipments, materials and documentation required as outlinedwithin this unit.

The candidate will be permitted to refer the following documents- Relevant workplace procedures- Relevant product manufacturer’s instructions- Relevant manuals, standards and reference material

The candidate will be required to :-

- Answer questions asked by the assessor orally or by other methods ofcommunication

- Identify superiors who can be approached for the collection of competencyevidence where appropriate

- Present evidence of credit for an off – job training related to this unit

Assessor must be satisfied that the candidate can competently and consistently perform all elements ofthe unit as specified by the criteria and that he / she possesses the required underpinning knowledge.

Special notes

During the assessment the candidate will :-

- Demonstrate safe work practices at all times- Communicate information about processes , events or tasks being undertaken to

ensure safe and efficient working environment- Take responsibility for the quality of his / her own work- Plan tasks and review task requirement as appropriate- Relate to all stake holders according to accepted company conventions- Perform all tasks in accordance with standard operating procedures- Use accepted techniques, practices and processes in line with work place

procedures

Tasks involved will be completed within reasonable time frames related to typical work place activities

Resources required for assessment

These include material, tools, equipments and machines listed within this unit

UNDERPINNING KNOWLEDGE UNDERPINNING SKILLS

• Sewing defects & operational procedure• Acceptable quality levels (A.Q.L.)• Basic statistics• Fabric types & behavior• Properties of fabric.• Stitches & seam types• Sewing threads needles, trims and accessories• Knowledge of sewing• Garment defects & remedial action• Quality standards• Garment inspection procedure

• Follow standard operating procedure• Inspect garments• Identify and analyze sewing defects• Identify stitch seam types• Identify trims• Data collecting• Analytical & presentation skill• Effective communication• Team work• Technical skill• Read & understand style file• Demonstration skill.• Handle tool• Measuring skill• Maintain report




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UNIT TITLE Inspect production process

DESCRIPTOR This unit covers competencies required, to select samples from production process,inspect for defects and take necessary action to meet quality standards.

CODE D18S005U02

ELEMENTS OFCOMPETENCE

PERFORMANCE CRITERIA

1. Select sample

2. Record data

3. Take necessaryaction

1.1 Previous days issues and solutions discussed with relevantpersonnel before starting work

1.2 Samples selected for inspection as per the standard operatingprocedures

1.3 Selected sample inspected against specifications and mock-ups approved for operations

2.1 Defects inspected and relevant data recorded in in-processinspection record sheet

2.2 Data processed in case of critical operations if necessary as perstandard operating procedure

3.1 Result of inspection informed to each operator and communicatedto relevant personnel as per standard operating procedures

3.2 Corrective and preventive action taken as appropriate

3.3 Quality standards maintained as per buyers standards followingup corrective / preventive actions

3.4 Finished garments inspected and measured against approvedsample & technical specification sheet as per standard operatingprocedure

3.5 Comments from auditors obtained and corrective & preventiveactions taken as appropriate

RANGE STATEMENT

This unit may include sewing process of any type of garment.

The following tools and equipment may be used for this unit.

• Standard measuring tape• Pull tester• Dummy• Vernier calliper

• Magnifying glass• Table• Newton gauge




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The following material may be used for this unit.

• pen • arrow sticker• pencil • paper• highlighter • original sample• ruler • approved sample• card • eraser• file • invisible pen• card board • mock - up• symbol card (colour - red, yellow, green)


• Style file• Organizational format

The performance of this unit is expected to be carried out to the following standards

• Buyer’s standard• Standard operating procedure• International organization for standardization• Worldwide Regulation for Apparel Production (WRAP)• Factories ordinance

ASSESSMENT GUIDE

Forms of Assessment

Holistic / continuous assessment is suitable to assess the competencies in the occupation of QualityController with regard to this unit.

Assessment Context

This unit may be assessed on the job demonstrated by an individual working alone or as a member of ateam.

Critical Aspects

• Maintain accuracy of measurements and appearance against buyer’s standards • Knowledge of care labels • Free of colour blindness

Assessment conditions

The candidate will be provided with all tools, equipment, material and documentation required asoutlined within this unit.

The candidate will be permitted to refer the following documents- Relevant workplace procedures- Relevant product manufacturer’s instructions- Relevant manuals , standards and reference material




Page 8

The candidate will be required to

- Answer questions asked by the assessor, orally or by other methods ofcommunication.

- Identify superiors who can be approached for the collection of competencyevidence where appropriate

- Present evidence of credit for an off – job training related to this unit

Assessor must be satisfied that the candidate can competently and consistently perform all elements ofthe unit as specified by the criteria and that he / she possesses the required underpinning knowledge.

During the assessment the candidate will

- Demonstrate safe work practices at all times- Communicate information about processes, events or tasks being undertaken to

ensure safe and efficient working environment- Take responsibility for the quality of his / her own work- Plan tasks and review task requirement as appropriate- Relate to all stake holders according to accepted company conventions- Perform all tasks in accordance with standard operating procedures- Use accepted techniques, practices and processes in line with work place

procedures

Tasks involved will be completed within reasonable time frames related to typical work place activities.

Resource required for the assessment

These include material, tools, equipment and machines listed within this unit

UNDERPINNING KNOWLEDGE UNDERPINNING SKILLS

• Read & understand style file• Sewing defects & operational procedure• Acceptable quality levels (A.Q.L.)• Basic statistic• Fabric types & behavior• Stitches & seam types• Sewing threads needles, trims, accessories• Knowledge of sewing• Company quality policies• Quality standards• Garment inspection procedure• Garment defects and remedial action

• Inspect garment• Follow standards operating procedure• Identify and analyze sewing defects• Identify stitch seam types• Identify trims• Data collecting• Analytical & presentation skill• Effective communication• Team work• Technical skill• Demonstration skill• Handle tools• Measuring skills• Maintain reports• Maintain buyer’s standards

Ministry of Vocational & Technical Training

QUALITY CONTROLLER

CURRICULUM OUTLINE Validated by National Industrial Training Advisory Committee on 28th March 2008

Developed by

National Institute of Technical Education of Sri Lanka

No: 100, Kandawala Road, Ratmalana

Sponsored by

United States Agency for International Development (USAID)

April 2008

Quality Controller - Curriculum Outline

CONTENTS

Page No. 01. Introduction 2 02. Contribution for the development of this Curriculum 3 03. Occupational Outlook 6 04 Competency Profile 7 05. Programme Structure 8 06. Module Numbers and Modules

M-01 Introduction to Apparel Industry 9 M-02 Communication skills and Ethics 10 M-03 Leadership 11 M-04 General practices in the shop floor 12 M-05 Basic tools of quality controlling 13 M-06 Quality standard for raw materials and

cutting room process 14

M-07 Ensure quality standards to feed line 15

M-08 Inspect sewing production process 20 M-09 Finishing and packing 23

Curriculum Development Division – NITESL


INTRODUCTION This is the steering curriculum document prepared for conducting competency based training. This document takes someone through a quick walk over the contents of the training programme. The complete curriculum package of the competency based training programme consists of two other documents, namely the “Trainer’s Guide” and the “Learner’s Guide” A page or two has been set off in this document to provide details of each module constituting the programme. Following details in respect of each module are included here. • Tasks included in the module. • Standards to be achieved in performing the same. • Related knowledge required to perform these tasks. • Tools, machinery equipment and learning and teaching aids required to

complete the module. • Target time for completion of the module. Further, this document would provide an idea as to the number of training modules prepared for this trade and whether it would be possible to conduct a CBT programme in any given center.

Curriculum Development Division - NITESL 2


CONTRIBUTIONS FOR THE DEVELOPMENT OF THIS CURRICULUM

Resource persons who provided occupational information at the DACUM Workshop and the Task Analysis Workshops

Mr. Lalith Somaratne Manager-Training , Stretchline Holdngs Ltd.

Ms. Ruchira Fernando Senior Quality Controller, Noyon Lanka (Pvt) Ltd.

Dr. Nirmali de Silva Course Director-Fashion Design Degree, Department of Textile & Clothing Technology, University of Motratuwa

Ms. Subadra Dissanayake Head of Textile Training MMT, MAS Institute of Management Technology

Ms. Erandhi Amarapala Quality Executive, Body line Holdings Ltd.

Ms. Manoja Badrani Technical Training Officer, Clothing Industry Training Institute

Ms. A.T. Padmini Silva Technical Training Officer, Clothing Industry Training Institute

Ms. Ramani Silva Technical Training Officer, Clothing Industry Training Institute

Mr. K.S. Roshan Jayawardana Quality controlling Manager, Star Garments (Pvt) Ltd.

Mr. D.M.S.B. Dassanayake Assistant Manager, Quality Assurance, Prym Intimates Lanka

Ms. K.G.N. Pushpa Rajapaksa Assistant Lecturer, Management, National Institute of Technical Education

Mr. Sisira Palihawadana Continental Fashions (Pvt) Ltd.

Ms. Malani Korale Assistant Manager, Quality Assurance Comfortwear (Pvt) Ltd.

Mr. Chaminda Imaduwa Comfortwear (Pvt) Ltd.



DACUM Workshop

1. Workshop Facilitator

Mrs. C. Premarathna Lecturer, Trainer Training & Training Research Section , National Apprentice and Industrial Training Authority

2. Workshop Coordinator

Mr. M.M.I. Samaranayaka Inspector, Curriculum Development Section, National Apprentice and Industrial Training Authority

Task Analysis Workshops

1. Workshop Facilitators

Mr. D.D. Wijesinghe Director, National Institute of Technical Education of Sri Lanka

Mr. D.D.D. Suraweera Deputy Director, National Institute of Technical Education of Sri Lanka / Director, Learning Resources Development Centre

Mr. Vipula Kulathunga Assistant Lecturer, National Institute of Technical Education -Sri Lanka

2. Workshop Coordinator

Ms. K.G.N.P. Rajapaksha Assistant Lecturer, National Institute of Technical Education of Sri Lanka

3. Workshop Recorder

Mr. Jayalal Wettasinghe Assistant Lecturer, National Institute of Technical Education of Sri Lanka

Ms. T.R. Vidanapathirane Assistant Lecturer, National Institute of Technical Education of Sri Lanka

3. Curriculum Writer

Ms. K.G.N.P. Rajapaksha Assistant Lecturer, National Institute of Technical Education of Sri Lanka

4. Administrative Coordinators

Mr. L.H.L.L. Ranasuriya Curriculum Development and Procurement Officer, United States Agency for International Development

Mrs. Nilufer Chitty Procurement Administrator, United States Agency for International Development



5. Consultancy and direction for Curriculum Development

Mr. D.D. Wijesinghe Director, National Institute of Technical Education of Sri Lanka

Mr. D.D.D. Suraweera Deputy Director, National Institute of Technical Education of Sri Lanka / Director, Learning Resources Development Centre

6. Overall supervision for Curriculum Development

Mr. K.A.H. Kalugampitiya Director General, National Institute of Technical Education of Sri Lanka

Dr. T.A.G. Gunasekara Vocational Education Expert, CH2MHILL / United States Agency for International Development

Validated by National Industrial and Training Advisory Committee

Members Mr. Ramitha Dissanayake Manager, Work-study, Star Garment (Pvt)

Ltd

Mr. Lalith Somaratne Manager-Training ,Stretchline Holdngs Ltd.

Mr. Athula Mendis Assistant Factory Manager Texvel Jurcy Ltd. (Velona Group)

Mrs. Devika Rodrigo Director (Standards & Accreditation) Tertiary and Vocational Education Commission

Mrs. Chandrika Trimawithana Lecturer, Clothing Industry Training Institute

Mrs. A. T. Padmini Silva Lecturer, Clothing Industry Training Institute

Mr. Nihal Wanigathunga Senior Lecturer, Department of Textile and Clothing Technology , University of Moratuwa

Mr. N. L. D. Senarathna Samson Groups (Pvt) Ltd. Ms. K. G. N. P. Rajapaksha Assistant Lecturer,

National Institute of Technical Education of Sri Lanka

Facilitator Mrs. D. C. Wahalathanthri Assistant Director,

Curriculum Development, National Apprentice and Industrial Training Authority

Coordinator Mrs. I. L. V. L. R. Ibulana

Inspector, Curriculum Development Section, Apprentice and Industrial Training Authority




Quality controller can develop his/her career as quality assurance executive, quality controllers in buying office, field quality assurance inspector, assistant manager and quality managers at various levels.

A quality controller should be necessarily a good team player. Also he/she should be a person with patience, positive thinking, managing time, cleanliness and concerned about environmental conditions. He/She should show efficiency and accuracy of the work as a quality controller and be able to deal with quality issues in a professional manner.

The main responsibility of the quality controller is to monitor the quality of product of in line process and he /she should be able to monitor the quality issues of both pre and post phases of production.

To become a successful quality controller he/she should have a sound knowledge of production processes, quality systems (checking measurements and other quality parameters related to garments during the-process & final inspection), machinery and materials used in the Apparel Industry and the ability of the proper inspection of garments.

In a highly dynamic and competitive business environment, the role of quality controller is very important. Quality controllers aim to ensure that the requisite quality of product is achieved as per buyer’s requirements and the standards.

Textile and Apparel industry is the major foreign exchange generating industry in Sri Lanka. In spite of the high competition among the garment manufacturing countries, the Sri Lankan garment products have been able to take the lead, mainly due to the high quality of products maintained by the manufactures.

OCCUPATIONAL OUTLOOK


COMPETENCY PROFILE

COMPETENCY AREA COMPETENCIES

A

A1. Study approved sample and specification

A2. Assist to saw trial sample

A3. Review Trial sample

A4. Participate in pre-production meeting

A5. Approve production mock-ups

A6. Review pilot production

A7. Participate in pilot appraisal meeting

B

B1. Inspect sewing operations

B2. Review completed garments

B3. Fit on garments

B4. Attend for auditors comment

Inspect sewing production process

Ensure quality standards to feed line.




PROGRAMME STRUCTURE

TIME (HOURS) COMPETENCY AREA

MODULE NO.

MODULE TITLE COMPETENCIES Institutional Industrial

Basic module M-01

Introduction to Apparel Industry.

30

(one day field visit)

--

Basic module M-02 Communication skills and Ethics. 30 --

Basic module M-03 Leadership.

12 --

Basic module M-04 General practices in the shop floor. 30 --

Basic module M-05 Basic tools of quality controlling. 60 --

Basic module M-06 Quality standard for raw materials and cutting room process.

90

(2 Days field visit )

--

A Ensure quality standards to feed line M-07

Ensure quality standards to feed line. A1 A2 A3 A4 A5 A6 A7 60 120

B Inspect sewing production process M-08

Inspect sewing production process.

B1 B2 B3 B4 30 120

M-09 Finishing and packing.

Basic module

30 (2 Days field

visit ) 30

372 270 Total no. of Hours 642

Highlighted tasks on the table are major learning activities


Module Code : M-01 Approved on : To be revised on : Occupation : Quality Controller Module Title : Introduction to textile and apparel industry (Basic Module) Performance Objective: After successful completion of this module the

trainee will be able to • describe the textile & apparel industry • explain the garment manufacturing process

and the role of a Quality Controller. Content:

• Textile and Apparel Industry in Sri Lanka and its

contribution for Sri Lankan economy. • Importance of buyer and buyers’ requirements. • Changing demands expectation of the customer. • Role of a quality controller in the industry.

- Importance of Quality Controller. - Responsibilities of Quality Controller.

• Jobs available in the apparel industry for Quality Controller and career paths of Quality Controller.

• Introduction to fabric manufacturing process (fiber to finished fabric) and garment manufacturing process.

• Structure of a garment factory. • Product categories. (Inner wear, outer wear, sports wear)

Prerequisites: G. C. E. (O/L) with credit in Mathematics, ordinary passes in English language or one year experience as a Quality Checker in the garment factory and pass the selection test. Passing vision test Tools, Equipment & Teaching Learning Materials Required: Class room facilities (pen, pencils, paper sheet, eraser, wall charts, and hand out, transparencies, white board, and world map) video if available, multi media projector and computer Target Time: 30 hrs. (Institutional- including one day filed visit)



Module Code : M-02 Approved on : To be revised on : Occupation : Quality Controller Module Title : Communication Skills and Ethics (Basic Module) Performance Objective: After successful completion of this module the

trainee will be able to • Communicate effectively. • Maintain high ethical standards in the

workplace and throughout his/her career. Content:

• Definition of communication. • Barriers of communication. • Technical terms used in quality control jargon in the textile

& apparel sector. • Preparation of short write-ups in English. • Filling typical formats. • Listening & answering. • Norms of Quality Controller.

(Importance of the efficiency and accuracy of the Quality Controller’s works)

• Developing attitudes of Quality Controller (team work, time management, environmental concerns, patience, positive thinking, cleanliness)

Prerequisites: Completion of Module No. 01 Tools, Equipment & Teaching Learning Materials Required: Class room facilities (pen, pencils, paper sheet, eraser, wall charts, hand out, transparencies, white board) video, multi media projector, computer, reference books of communication, Relevant formats Target Time: 30 hrs.



Module Code : M-03 Approved on : To be revised on : Occupation : Quality Controller Module Title : Leadership (Basic Module) Performance Objective : After successful completion of this module the

trainee will be able to perform leadership skills efficiently and effectively in the workplace and throughout his /her career.

Content:

• Traits /qualities of a leader. • Situation analysis and leadership style. • Problem solving.

- Definition of problem. - Problem analysis. - Select the most appropriate solution. - Plan, Do, Correct and Act (P.D.C.A.) cycle.

• Decision making process.

Prerequisites: Completion of M-01, 02 Tools, Equipment & Teaching Learning Materials Required: Class room facilities (pen, pencils, paper sheet, eraser, wall charts, and hand out, transparencies, white board) and video, multi media projector, reference books about leadership

Target Time: 12 hrs. Special Comments: Should be spread throughout the course.



Module Code : M-04 Approved on : To be revised on : Occupation : Quality controller Module Title : General practices in the shop floor (Basic Module) Performance Objective: After successful completion of this module the

trainee will be able to demonstrate the understanding of general practices in the shop floor of the garment factory.

Content:

• Good house keeping practices. • Introduction to quality management systems followed by

the garment industry (ISO 9000, ISO 14000, WRAP). • Maintaining relevant records. • Safety and compliances.

- Personal protective equipment and safety. - Safety of production process in the garment industry. - Product safety. (Needle safety policies, chemical, metal

safety procedures)

Prerequisites: Completion of module 01, 02 and 03. Tools, Equipment & Teaching Learning Materials Required: sewing machine, pen, pencils, paper sheet, eraser, wall charts, hand out, transparencies, white board, video for good house keeping practices and safety ,multi media projector, reference books of ISO 9000, ISO 14000, WRAP , 5S’ concept, manuals of safety procedures. Target Time: 30 hrs.



Module Code : M-05 Approved on : To be revised on : Occupation : Quality Controller Module Title : Basic tools of quality controlling (Basic Module) Performance Objective: After successful completion of this module

the trainee will be able to use basic tools of quality control (statistical process control sheet) in the workplace and throughout his / her career.

Content:

• Check sheet. • Graphs. • Histograms. • Course and effect diagram. • Scatter diagram. • Control chart. • Pareto analysis.

Prerequisites: Completion of modules 01, 02, 03 and 04 Tools, Equipment & Teaching Learning Materials Required: Class room facilities (pen, pencils, paper sheet, eraser, wall charts, hand out, transparencies, white board, graph sheet, statistical tables) video, multi media projector, reference books of statistical process controlling Target Time: 60 hrs.



Module Code : M-06 Approved on : To be revised on : Occupation : Quality Controller Module Title : Quality standard for raw materials and cutting room

process (Basic Module) Performance Objective: After successful completion of this module

the trainee will be able to handle quality standards of raw materials and cutting room in the workplace.

Content:

• Checking parameters of accessories with trim card. • Fabric types and properties. • Fabric defects and shade variations. • Fabric Inspection system and procedure. • Acceptable quality levels (AQL) • Verification of pattern board against specifications. • Marker inspection, knowledge of marker making system. • Spreading inspection. • Cutting equipment. • Cutting inspection and cutting defects. • Fused components inspection. • Preparation of template.

Prerequisites: Completion of Module 01, 02, 03, 04 and 05 Tools, Equipment & Teaching Learning Materials Required: Accessories, trim card, various type of fabric, pull tester, vernior caliper, magnifying glass, technical package, template, pattern boards, cutting machine & equipment or manuals, video, markers, boxboard, pen, pencils, paper sheet, eraser, wall charts with fabric defect ,hand out with checking parameters of accessories , transparencies, white board, computer, multi media. Target Time: 90 hrs. (2 days field visit)



Module Code : M-07 Approved on : To be revised on : Occupation : Quality Controller Competency Area: Ensure quality standard to feed the line Module Title : Ensure quality standard to feed the line Performance Objective : After successful completion of this module the

trainee will be able to ensure quality standard to feed line according to relevant standards. Tasks to be performed:

Task No.

Task Standards

A1

Study approved sample and specification.

• Technical package should be

studied as per buyer’s quality requirement.

• The garment should be laid flat on the inspection table as to every component of the garment must be observable.

• The approved sample should be compared with the given specifications according to the buyers’ quality standards.

Measurement Construction Buyers’ comments Physical appearance

• Discrepancies should be clarified with the immediate superior as per standard organizational procedure.



Task No.

Task Standards

A2

Assist to sew trial sample (Production sample)

• Cut components and trims

should be checked against graded pattern and trim cards.

• Issues and discrepancies of cut components and trims should be clarified (if any) with relevant parties as per standard organizational procedure.

• Each and every operation should be checked as per buyers’ quality standards and approved sample.

• Issues and discrepancies of operations should be clarified (if any) as per standard organizational procedure.

• Identified issues, discrepancies and corrective actions/ conclusions should be recorded as per standard organizational procedure.

• Every operation should be performed as per buyers’ requirement and standard organizational procedure.

A3

Review trial sample(Production sample)

• The trial sample should be laid

flat on the inspection table as to all the components of trial sample must be observable.

• The trial sample should be observed comparing with the given specifications and approved sample as per buyers’ quality standards.

Measurement Construction Buyer’s comments Physical appearance

• Discrepancies should be clarified if any with the immediate superior as per standard organizational procedure.



Task No.

Task Standards

• Approval should be obtained in

consultation with appropriate authority with or without comments as per standard organizational procedure.

• If the trial sample is not approved, the trial sample should be adjusted or re produced in accordance with comments as per the approved sample and specifications.

A4

Participate in pre-production meeting.

• The identified problems should

be presented as per standard organizational procedure with suggested remedial actions if any.

• Approved remedial action for the identified problem should be noted down as per standard organizational procedure.

• The construction sheet, measurement sheet and trim card should be collected as per standard organizational procedure.

A5

Approve production mock-ups

• The stitched components should

be checked against the approved sample and technical package.

• The stitched component which is compatible with buyer’s standard /technical package should be selected.

• The selected stitched component should be certified as per standard organizational procedure.

• The certified stitched component should be endorsed by operator as per standard organizational procedure.



Task No.

Task Standards

A6

Review pilot production

• The stitched component should


• Inspected details in sewing process should be recorded as per standard organizational procedure.

• Quality standards of the products in process should be ensured as per standard Organizational procedure.

• Refer procedure specified in A-5 to endorse mock-ups.

• The finished garments should be inspected against technical package and trim card, approved sample and standard organizational procedure.

• Inspection details of the finished garments should be recorded as per standard organizational procedure.

• Pilot inspection report should be submitted to the superior as per standard organizational procedure

A7 Participate in pilot appraisal meeting.

• Identified problems should be

presented as per standard organizational procedure.

• Approved remedial action for the identified problem should be noted down as per standard organizational procedure

Related Knowledge for the module: • Fabric types, and behaviour and fabric defects • Accepted quality level (AQL) • Quality controlling tools. • Fabric inspection reports. • Sewing defects and operational procedures • Sewing threads and accessories, work aids /attachments ,templates • Garments Measuring.



• Standard inspection conditions. (procedures and equipment) • Inspection methods. (Ex: clock-wise checking, hanger checking,

appearance checking) • Type of mock – ups. • Approval status of trial sample.

Fully approval Approval with comments Not approved

• Preparation of pilot appraisal report. • Meeting procedures.

Prerequisites: Completion of module 01, 02, 03, 04, 05 and 06 Tools, Equipment & Teaching Learning Materials Required: original sample, colour continuity card, technical package (trim card, sketches, measurement sheet, comment sheet, construction details), graded pattern and pattern boards, sewing line, video, markers, boxboards ,standard measuring tape, standard inspection table, pull tester, vernior caliper, magnifying glass, arrow stickers, eraser, file, paper, Pencil, card board , Ruler, Invisible marker, highlighter, pen. Target Time: 180 hrs. (60 Institutional and 120 Industries)



Module Code : M-08 Approved on : To be revised on : Occupation : Quality Controller Competency Area: Inspect sewing process Module Title : Inspect sewing process Performance Objective : After successful completion of this module the

trainee will be able to inspect sewing process to ensure product standards following buyer’s specification and standard organizational procedure.

Tasks to be performed:

Task No.

Task Standards

B1

Inspect sewing operations

• The stitched components should


• Sewing defects should be marked by using stickers/ tags against the approved sample and technical package and be informed to the supervisor.

• Inspection details should be recorded in sewing process as per standard organizational procedure.

• Measurements of the garment should be checked as per the given standard measurement chart.

• Details of measurements in sewing process should be recorded as per standard organizational procedure.

• The quality standards of the product should be ensured in process until the completion of bulk production as per standard organizational procedure.



Task No.

Task Standards

B2

Review completed garment

• The completed garment and

approved sample should be laid flat on the inspection table to display all the components of the garment.

• The completed garment should be checked comparing with the given specifications and approved sample as per buyers’ quality standards and standard organizational procedure.

Construction Buyers comments Physical appearance

• Record inspection results as per standard organizational procedure.

• Measurements of the inspected garment should be taken as per standard measurement chart in the technical package.

• Measurement results should be recorded as per standard organizational procedure.

• Deviations if any should be informed as per standard organizational procedure.

• The records should be kept for future references as per standard organizational procedure.

B3

Fit on garments

• Standard measuring points

should be identified by studying the dummy.

• Approved sample should be fitted on to the dummy referring to the identified measuring points.

• The specified points should be marked on dummy which was the approved sample fitted as per garment type.



Task No.

Task Standards

• Total appearance, shape,

silhouette of the finished garment of the same size of approved sample, fitted to the dummy should be checked against the specified points with marked approved sample.

• Comments after the fit on should be recorded as per the standard organizational procedure.

• This activity has to be performed under the supervision of a superior.

• The finished garment should be met buyer’s fit requirements.

Related Knowledge for the module: • Types of quality auditing done by third party internally. • Fitting various garments to dummy. • Classification of defects (critical , major, minor) • Sewing defects and root causes. Prerequisites: Completion of module 01, 02, 03, 04, 05, 06 and 07 Tools, Equipment & Teaching Learning Materials Required: Dummy, pattern boards, cutting machine & equipment, video, markers, box boards standard measuring tape, standard inspection table, pull tester, vernior caliper, magnifying glass, pen, arrow stickers, eraser, file, paper, pencil, highlighter, card board , ruler, invisible marker, original sample, colour continuity card, technical package with trim cards. Target Time: 150 hrs (30 hours Institutional, 120 hours Industry)



Module Code : M-09 Approved on : To be revised on : Occupation : Quality Controller Module Title : Finishing and packing (Basic Module) Performance Objective: After successful completion of this module the

trainee will be able to handle quality standards of finishing and packing department in the work place.

Content:

• Methods of button holing, attaching. • Bottom leveling. • Knowledge of packing accessories. • Knowledge of packing & labeling methods. • Knowledge of pressing standards & Instruments. • Knowledge of washing standards. • Shipping instructions. • Special requirements (Metal free, Anthrax, Security)

Prerequisites: Completion of M-01, 02, 03, 04,05,06,07 and 08 Tools, Equipment & Teaching Learning Materials Required: Finishing & packing accessories, pen, pencils, paper sheet, eraser, wall charts, hand out, transparencies, white board, video, multi media projector, reference books of finishing, computer with relevant software, statistical tables, multi media. Target Time: 60 hrs.

(30 hours institution-2 days field visit, 30 hours industry)


NATIONAL COMPETENCY STANDARDS - nvq.gov.lk

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