Está en la página 1de 17

Dhaka, Bangladesh

Assignment
On
Production Process flow chart & quality check points of
garments manufacturing

Submitted By: Submitted To:

Abdullah Ali Akbar Reja Md. Tamim Jahan

FMP-1, 3rd Sem. Faculty, PFI

Id- 2010-4-219

Submission Date: 01 July, 2010


2
Table of Content

No Subject Page
01 Introduction 02
02 Quality & quality inspection 03-07
03 Process flowchart for mans full sleeve shirt manufacturing 08

04 Quality check point in process flowchart 09


05 SEWING SECTION (Operation breakdown OF MANS FULL 10-12
SLEEVE SHIRT)

06 Quality check point in sewing section according to operation 13


breakdown

07 14
08 References & bibliography 15

3
Introduction

A product must satisfy the consumer in terms of beauty, attractiveness, taste, shape, design and
longevity of depending on the type of product.

A product devoid of quality has no demand among consumers and as such has no salability. So it
is very necessary for every company to establish quality check or quality assurance department
in the industry.

This assignment helps me to understand inspection methodology for sewing, finishing, and
packing, help me to evaluate various production processes. It also helps me to source information
and to collate, evaluate and manage it, communicate clearly and succinctly in both oral and
written form.

4
Quality & Quality Inspection
Quality:

Quality is an ideal, a condition of excellence. Product quality is based on a product attribute.


User-based quality is fitness for use, manufacturing based quality is conformance to
requirements, value based quality is the degree of excellence at an acceptable price.

ISO 9000:2000 Define it is “degree to which a set of inherent characteristics fulfill requirement.”

Quality inspection in apparel industries:

Quality inspection is done to control quality of garments. Checking of fabric, sewing thread,
button, stitch, zipper, garments size etc according to required standard or specification is known
as inspection. Quality inspection is important for every section of apparel industries.

There are three steeps in apparel industries to control quality, i.e.

1. Raw Material Inspection;

2. In Process Inspection;

3. Final Inspection;

Raw Material Inspection:

Fabric, sewing thread, button, trims, interlining, labels, tags quality check is done in raw material
inspection steep.

1. Fabric Inspection:

Normally fabric inspection is done through Fabric Inspection machine. It is very


important for every industries check fabric before cutting. In fabric inspection their
checks several things i.e. in fabric are there any defect available or not. In fabric, fabric
defects viz. off shad or shade variation, hole in fabric, barre effect etc. can be visual after
entering into the store room. For those defects it will be problem able for making
garments making. In fabric inspection there also check fabric strength, color, quantity,
bayous. To check fabric there are different system i.e. 4 point system, 10 point system
etc.

2. Sewing Thread Inspection:

During stitching fabric frequently brakeage of sewing thread is one of the great problems
for garments manufacturing. So that it is necessary to check thread construction, sew
ability, color, imperfection, finish, package density, winding, yardage of sewing thread.

5
In thread construction thread number, thread ply, thread balance, thread tenacity, thread
elongation, number of twist is necessary to check.

3. Trims & Accessories check:

Button, interlining, label & tags are also need to check so that quality can be maintain
according to required quality. For button, button strength, button color, quantity etc are
check.

In Process Inspection

Inspectioning different parts of garments before sewing are called in process inspection. It starts
from marker making, than fabric spreading, fabric cutting, fabric sewing, pressing or finishing
checking is done in process.

Marker Making:

For some marker fault quality of garments can be lower, i.e.

• It is necessary to check all the parts of garments pattern are in marker.

• In marker labeling or coding of pattern should be check

• Pattern direction should be check.

• The entire pattern are sated correctly should be check.

• Pattern grain line is very important thing which must be considered during marker
making.

• During marker making every pattern pieces dimension should be accurate.

• During marker making fabric length and width should be consider.

Fabric Spreading:

For those fault which effect garments quality occurs during fabric spreading and should be
consider is given bellow;

• During fabric spreading it should be spread according to marker length and width and
fabric alignment should be correct in both sides.

• Fabric should not be spread so tight or loose.

• During fabric spreading because of uneven tension in fabric bias or bowing can be create.

• Fabric must be spread in proper way so that fabric wastage can reduce.
6
• It should be consider are there any static electricity problem is available or not.

• Fabric ply must be spread correctly

Fabric Cutting:

For high quality garments high quality cutting is necessary. To control fabric cutting quality
good there must be consider some things;

• Pattern dimension and cutting parts dimension is same or not.

• Cutting parts edge how much smooth and clear.

• Are there any parts add with other parts because of fusion problem.

• Notch mark cutting is done accurately.

• Drill mark is placed correct position & size or not.

Shorting/ Bundling:

It is necessary to check numbering, shorting, and bundling is done accurately.

Fabric Sewing:

In garments industries most large & important section is sewing section. In this section it is
necessary to check all the machine operators’ work. In this section some common faults and
problems must be considered, these are;

1. Sewing defects:

Needle damage;

Skipped stitch;

Thread breaks;

Seam pucker;

Wrong stitch density;

Uneven stitch;

Staggered stitch;

Improperly formed stitch;

Oil spot or stain.


7
2. Seaming defects:

Uneven width;

Fault stitch line;

Back stitch must be given properly;

Twisting;

Check or strip matching;

Seam matching;

Wrong stitch face side or back side;

Thread color shade variation.

3. Assembly defects:

If finished component does not accurate size.

Garments do not accurate in size.

If any design skip to join.

Component is not joining in right place.

If lining is tight or loose.

If parts direction is wrong.

4. Pressing or Finishing:

Fabric burn or burn spot attach with body.

Any types of water spot.

Color shading occurs because of hot ironing.

Button is insecure or broken.

Garments are folding accurately.

Pocket is pressed smoothly and except fold.

Garments shape is accurate.

Those things are plays important role that have to be check during in process.

8
Final Inspection

In final inspection generally inspect fully complete garments. Before final inspection there has
no chance to check complete garments. It is important from the buyer to finally check. In final
inspection normally garments size, form fitting, fabric faults are check.

Size:

For size, it is check according to what size is written in size label.

Shirt inspection check list

No Location Inspect for

01 Collar Both points are same or not, strip or check is match accurately, stitch,
collar flat or not.

02 Size Size label is in correct place, and every parts size is correct or not.

03 Button & button hole Placed in right place or not, evenness of gap between one button to
other, stitch is done correctly, are there any broken button or not.

04 Pocket Pocket upper edge horizontal or not, pocket position, size, stitch, stripe
or check is match, flat or not.

05 Hem Stitch, are there any puckering occur or not, edge free from stitch.

06 Yoke & shoulder Stitch, puckering problem, skipped stitch.

07 Side seam Pattern matching, stitch, free from raw edge

08 Cuffs Strips or check matching, top stitch, flat or not.

09 Finished appearance Threads edge comes out or not, are there any oil spot or not, fabric fault,
color matching, strip matching.

Packing: Before packing it is necessary to check fabric is free from broken needle. It is also
need to check packing raw material is free from making any problem in garments and after
packing it is packed accurately.

9
Process flowchart for mans full sleeve shirt manufacturing

Side Operation Operation Method

Design/ Sketch Manual

Pattern Design
Basic Block Manual

Sample Making

Costing
Production Pattern

Grading Manual

Raw Materials in Into


Store

Marker Making/ Lay


Manual
Planning

Fabric Spreading Manual

Fabric Cutting Manual

Shorting/ Bundling
Iron Press
Fusing

Sewing/ Assembling Lock Stitch, Over Lock,


Button Holing, Button
Attaching M/C

Final Pressing/ Finishing Ironing

Final Inspection Manual

Packing Manual

Deliver to Buyer

10
Quality check point in process flowchart

Side Operation & Operation Method


Quality Check

Raw Materials in Into


Store
Quality checking of
Quality Check Fabric, Button, Sewing
thread, fusing paper,
trims, label & tags etc

Marker Making/ Lay


Marker Inspection Manual
Planning

Quality Check/
Fabric Spreading Manual
Fabric Inspection

Quality Check/ Fabric Cutting Manual


Fabric Inspection
Shorting/ Bundling
Iron Press
Fusing

Quality Check Sewing/ Assembling Lock Stitch, Over Lock,


Button Holing, Button
Attaching M/C

Final Pressing/ Finishing Ironing

Final Inspection Manual

Inspection Packing Manual

Deliver to Buyer

11
SEWING SECTION (Operation breakdown OF MANS FULL
SLEEVE SHIRT)
Operation Breakdown
Style No:
Buyer:
MENS F/SLV SHIRT WHITE & STYPE FABRIC(COLLAR,BAND, BOX
Description: PLKT) NONE FUSED,BOX PLKT KANSAI, DOUBLE BACK
YOKE,PKT W/SML PKT,FRONT SIDE PANAL,FRONT LOOP
S/N Operation M/C Attachment

COLLAR

01 MATCH & MARK COLLAR PARTS MAN TABLE


02 MAKE LOWER COLLAR W/LINING LS1 NG-1/4''
03 TRIM / TURN LOWER COLLAR MAN CLR TURNING
04 PRESS LOWER COLLAR MAN CLR PRESS
05 TS LOWER COLLAR-1/16 LS1 CR 1/4''
06 TS LOWER COLLAR-1/4 LS1
07 MAKE UPPER COLLAR W/LINING LS1 NG-1/4''
08 TRIM / TURN UPPER COLLAR MAN CLR TURNING
09 PRESS UPPER COLLAR MAN CLR PRESS
10 TS UPPER COLLAR-1/16 LS1 CR 1/4''
11 TS UPPER COLLAR-1/4 LS1
12 HEM COLLAR BAND W/LINING LS1 CR-5/16"
13 ATT.COLLAR BAND TO COLLAR LS1 NG-3/16"
14 TURN & TS COLLAR BAND LS1 CR-1/16"
15 B/H COLLAR BAND-1 BH LBH-781
16 ATT. BTN ON BAND-1 BS LK-1903
17 TRIM BOTTOM OF C/BAND MAN MO-1950

POCKET

18 MAKE PLIT ON SMALL POCKET X 2 LS1


19 TACK PLIT TWOSIDE 2 X 2 LS1
20 PRESS HEMOF SMALL POCKET-2 LS1 CL-1/16"
21 PRESS SMALL POCKET-2 IRON TABLE
SMALL POCKET POSITION MARK AT
22 MAIN POCKET MAN TABLE
23 SMALL POCKET JOIN WEITH MAIN LS1 CR-1/16"
12
POCKET
24 T/S SMALL POCKET LS1 CR-1/4"
25 MAKE PLIT ON MAIN POCKET X 2 LS1
26 TACK PLIT TWOSIDE 2 X 2 LS1
27 PRESS HEMOF MAIN POCKET-2 LS1 CL-1/16"
28 PRESS MAIN POCKET-2 IRON TABLE

FRONT LOOP AT SHOULDER

29 LOOP ROLLIN LS1


30 LOOP MAKE LS1

BACK PART

ATC MAIN LABEL W/ INSERT SIZE LBL


31 TO BK YOKE LS1 REG FOOT
32 ATC BK YOKE TO BK LS1
33 TOPSTITCH BK YOKE LS1

FRONT

FT 1/4"-1"-
34 HEM T/S BOX PLACKET KANSAI 1/4"
35 HEM TS BTN PLKT LS1 FOLDER
36 1/16" EDGE STITCH BTN PLKT LS1 CR-1/16"
37 TACK CARE LABEL TO FRONT LS1 REG FOOT
38 ATTACH MAIN POCKET LS1 CR-1/16"
39 T/S MAIN POCKET LS1 CR-1/4"
MATCH & MARK FRONT LOOP AT
40 SHOULDER MAN TABLE
1/4' FOA
41 ATT SHOULDER WITH FRONT LOOP LS1 FOLDER
42 T/S STITCH SHOULDER LS1

SLEEVE

43 SLEEVE GAMBLE LS1


44 SLEEVE GAMBLE TUCK LS1
45 SLEEVE PLACKET ATTACH LS1
46 CUFF INTERLINING MAN IRON
47 CUFF ROLLING LS1

13
48 CUFF MAKE LS1
49 CUFF TS LS1
50 CUFF JOIN LS1

FINAL ASSEMBLY

51 ATT./TS SLEEVE ARM- HOLE CS2 1/4" FOLDER


52 ATTACH COLLAR TO BODY LS1 T- GUIDE
53 ATT. TWIL TAPE TO CLR LS1 GUIDE
54 CLOSE COLLAR LS1 CR-1/16"
55 BOTTOM HEM LS1 T guide
SEW BUTTON HOLE AT BODY X 6 &
56 LOOP BH
57 ATT. BTN TO BTN PLKT & LOOP BS CL-3/8

Sketch

Front side Back side

Fig: Men’s Full sleeve


shirt

14
Quality check point in sewing section according to
operation breakdown
CO START
LL
ER LS1 Q/A
TBL 1 LS1
ST 2

LS1

LS1

LS1

LS1

LS1

LS1
LS1
4
AR
MAN 3 2
T LS1

43

44

45

47

48

50
49
5 4
LS1

4
0
1
MAN
4
LS1 LS1 46
6 3

TBL
IRON
9
SLEEVE
LS1 LS1
7 3

C
/
Q
8
LS1
8 3 1 F
MAN
7
I
5
LS1 CS2
9 3 2 N
MAN
6 5 A
1 LS1 LS1 5
LS1
L
3
0 3
5 A
S
T
LS1
1 LS1 3
KANSAI 4 S
1 A 4
E
5
LS1 Q/
LS1
B LS1
1 3 C M
L 5
2 3
B
5 B
E
K L
LS1
1 LS1 2
P
3 Y

56
LS1 3 57
R
T
1 LS1
LS1 3 BH
BS

15 BH 4 1
LS1 Q/
1 C
3
6
F/
BS
7 MAN
0
1
C
/
Q

LO
CLR END & Q/C OP
1 LS1 2
POC 8 LS1 9 8
IRON
KET LS1 2
STA 2 Q/C – Quality
9
RT 7
1
checking point.
C
/
Q

LS1
LS1
1
2 PK
0
- Directio
2
T
2
N 6
O
LS1 EN n
D
LS1 2
IR 2
5
2 MAN/TABLE

LS1
3
2 2
LS1
4 15
Conclusion
This is a great opportunities for me doing this assignment on quality check. To complete this
project I do my best. I have gathered much experience doing this assignment. I learn how to
check quality for manufacturing Men’s shirt, process flowchart for garments manufacturing and
quality check point. I understood inspection methodology for sewing finishing and packing.

16
References & Bibliography
1. Cooklin, G. (1991) Introduction to Clothing Manufacture. Oxford: Blackwell
Publishing Company.

2. Kashem, M. A. (1993) Garments & Technology. Dhaka: Grantho Nir Publishers.

Sketch:

3. Reja, A. A. A (2010) Men’s Full sleeve shirt. [Sketch]

17