Inspection Procedures in sewing Room
Inspection Procedures in sewing RoomInspection refers to quality control in sewing room Advantages of in-process inspectionReduction of major surprises from the customers due to bad quality.Decrease in labor cost due to a decrease in repair rates.ASSQC--Inspection procedure in sewing Room1Inspection LoopASSQC--Inspection procedure in sewing Room2In-Process inspection (In line)
In-Process inspection means the inspection of parts before they are assembled into a complete product.
In apparel manufacturing , this means inspection at various points in the entire manufacturing process from spreading fabric to pressing /ironing.In-process inspection can be performed by either quality control inspectors or individual operators themselves after they perform their respective operation.This will help to identify the source of quality problems as early in the manufacturing process as possible.This will result in minimizing the need for later repairs & rework.ASSQC--Inspection procedure in sewing Room3
In-Process inspection (In line)During production or du-pro inspection
Visual evaluation or assessment of parts , components or materials during production.This process assesses conformance to standard & specification for the assembly process,Individual components are examined before the assembly for standard & specification In-line inspection helps eliminate the production of unacceptable merchandise,ASSQC--Inspection procedure in sewing Room4Few important steps in sewing section are as follows:LayoutLine balancingBundle trackingOptimum utilization of 6msEffective communication & co-ordinationMaintaining bufferQualityImproving productivity
ASSQC--Inspection procedure in sewing Room5Optimum utilization of 6ms6m s mean effective utilization of Men, Machine, Material, Method Money & Management in the departmentASSQC--Inspection procedure in sewing Room6Flow charts (Line plan)Flow charts can help understanding complete process Flow chart along with a set of standards & specification.Identify critical stage of processLocate problem areas & allocate check points.Flow charts show relationships between different steps in processASSQC--Inspection procedure in sewing Room7Sewing Room Quality Process ChartProduction FileCutting ReceiptPilot RunActual Prod. beginsWith Layout prep byLine Chief and Sup.Line PlanIssued to Finishing
PP MeetingCommentsKey Inspection Points -Style Start-up ChecklistQuality Specification Sheet100% End line report: ProvidingDHUMeasurement ReportPass100% Re-check and rectifyFailTrim CardDefectApproved PP Sample100 % In-processQuality Control100% End of LineVisual InspectionAfter assemblyRandom inline inspection(Based on AQL)Visual audit (2.5)Minor audit (4.0)Mock-ups at criticaloperations100% In- line report: ProvidingDHUSkip Bundle AuditLot pass ReportASSQC--Inspection procedure in sewing Room8Managing In-line quality depends on belowOrganizational structureProducts manufacturedTechnologyWork force level
ASSQC--Inspection procedure in sewing Room9Required parameters in terms of a standards & specifications For a Particular operation ,For example: Side seamStitch typeSeam typeThreadSeam allowanceStitches per inchStandard for appearancePlacement of front & back panelsAmount of material to be trimmed
Note:-- Operator must know above requirement Operator & supervisor are constantly reminded for company specific quality level to meet.ASSQC--Inspection procedure in sewing Room10Inspection Procedures in sewing RoomSewing Sewing DefectsSeaming defectsAssembly DefectsControl of Fusing OperationEmbellishmentPanel printing & embroideryASSQC--Inspection procedure in sewing Room11Sewing /Construction defectsIrregular stitchingHem or hidden stitching uneven.Broken stitchesExcessively tight or loose tensionNot straight or Not parallel topstitchingUse of wrong thread (i.e. wrong tkt or monofilament)Skipped stitchesNeedle cut or needle damageExcessive seam puckerEdge stitching irregular affecting appearance.Wrong seam or stitch type used.
ASSQC--Inspection procedure in sewing Room12Irregular seams
Curled ,puckered, crooked, pleated, twisted, Wavy or uneven seams.Open seam ( stitching thread open or absent)Excessive grinning of seams.Uneven seam margins.Seam wrong side out.Irregular or incorrect shape of sewing line(sometime called run-offs) in top stitching.
ASSQC--Inspection procedure in sewing Room13Seam puckering Replicas
ASSQC--Inspection procedure in sewing Room14Assembly DefectsComponent parts and assembly Missing parts Missing operation Operations not done per approved sample and specification Misalignment of parts, pockets, flaps, trims more than 7 mm Inconsistent nap directions if specified Interlining incorrectly positioned ,twisted, too full, too tight, cockling(wrinkle or puckering, as in cloth ).Lining too full, too tight, showing below the bottom of the garments, twisted, incorrectly pleated & so onASSQC--Inspection procedure in sewing Room15.AQL For Production that occurs in lots or batchesAOQLFor Continuous production systemQIP ImplementationCost of QualityRepair % and Rejection % StandardizationDefect TaxonomyConcept of DHU Proposed Process Design
ASSQC--Inspection procedure in sewing Room16QIPQuality improvement programeQIP Implementation Activities:Sewing and Finishing End of Line Repair and rejection record keeping & documentationFinalization of Work distribution sheetVisual Cards in sewingRandom Table IntroductionCharts and Slogans
ASSQC--Inspection procedure in sewing Room17Percent defectiveDefect % = Number of defective units X 100 Number of units inspectedASSQC--Inspection procedure in sewing Room18AQL Acceptable quality levelAQL is the maximum percent defective that, for the purpose of sampling inspection, an be considered satisfactory as a process average.Process average is the average percent defective of a product submitted by the supplier for original inspection.ASSQC--Inspection procedure in sewing Room19AOQLAverage outgoing quality levelFor Continuous production systemUnit production systemFormation of lots or batches for inspection would be artificial or uneconomical.Statistical or acceptance sampling plan applicable to continuous production - Continuous sampling plan (CSP)
AOQL means the maximum possible value of the average defective % in the outgoing product or shipments,For egAOQL is 4% means , in long run the average defect % of an out going product will not be more than 4% defective.
ASSQC--Inspection procedure in sewing Room20Continuous Sampling Plan (CSP)Beginning inspect all the units consecutively as produced & continue until X pcs in succession are found acceptable. ( For example 40pcs continuous inspection)Stop inspecting all pieces , but inspect only fraction of pieces produced ( i.e inspect 1 out of every 20pcs ---5%)When a sample pieces is found to be defective, resume inspecting all pieces until X are found acceptable in succession. Then resume sampling inspection.All defective pieces should be either repaired or replaced with good pieces.ASSQC--Inspection procedure in sewing Room21Sewing Room Quality - RecommendationsCreation of all possible Defect list.Use of Bundle Tracking sheet in line loading
Use of DHU as measure for quality performance at inline and end line points and taking it through three steps of improvement. Besides gauzing repair and rejection percentages:RecordingAnalyzing Problem Solvingcorrective action and responsibility
Standardizing the style start-up procedures with inclusion of following elements besides current ones:Key Inspection PointsQuality Specification SheetStyle start-up checklistASSQC--Inspection procedure in sewing Room22Sewing Room Quality - proceduresImplementation of Skip Bundle Inspection
Application of Quality Drills to enhance quality at source (operator)
Use of tally marks for capturing data at check points
Creation of daily summary and visibility to management
Requirement: Allocation of manpower as per job allocation sheet to cover all the planned activities and sustainability of systemASSQC--Inspection procedure in sewing Room2323Skip Bundle samplingIn skip bundle sampling , a variable proportion of production is inspected, not a fixed portion.
The extent of variability in the average fraction of inspected material is depended on the process average fraction of percent defective. The higher the % defective , the larger the proportion of production that must be inspected.
Inspection occur at a minimum when the quality level being maintained is at or better than, the level desired.
ASSQC--Inspection procedure in sewing Room24Skip Bundle sampling & inspection n = number of sample to be inspected from the bundleC =acceptance number or number of defective pieces allowed in n samples.S=skip interval m =clearance intervalE. g.-- n=12, c=0, s=4, m=2 n=30, c=1, s=4, m=2 ASSQC--Inspection procedure in sewing Room25Skip Bundle sampling & inspectionSelect a bundle at random & at random inspect 12pcs , if no defect, accept the bundle.
Then inspect every 4th bundle, if defect found reject & return the bundle.
Sort out bundle & repair the defective pieces
These repaired pieces are inspected & if acceptable, the bundle moves on the next operation.
Once the bundle is rejected, every bundle from that operator is inspected from then on until 2 consecutive bundle from that operator are found acceptable
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