Manual on Garment Quality Management

This is the 2nd subject matter of the Diploma Course on Productivity & Quality Management major in Lean Manufacturing. Participants: Enrolled student of the Diploma Course in Productivity & Quality Management Duration/Time: 24 Hours i.e. 32 Session Objectives of this subject: By the end of this subject, participant will learn

About the definition of quality, Quality Control & Quality Assurance Tools & Techniques for Quality Management Quality Control Management in Garments Manufacturing Process About the different defects in different departments in garment factory The AQL & Final Inspection

Teaching Methods: Lecture Discussion & Conversation Brainstorming Question & Answer PowerPoint presentation /Multimedia presentation Video presentation Group work Sample display/presentation Etc

Necessary Tools & Equipments: White Board Flipchart board Flip chart paper & paper marker Computer Multimedia projector & Screen Writing pad, pen & pencil White board marker (multicolor)

Meta card board & meta card

Board pin Training Manual

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Manual on Garment Quality Management

Subject: Garment Quality Management Contents Module: 1: Introduction to Quality 1.1. What is quality?

1.2.Importance of quality?
1.3. Eight dimensions of quality 1.4. Quality assurance Vs quality control with example from garment manufacturing process

1.5. Organizational structure of quality assurance (QA) department in garments 1.6. Job responsibilities of quality management personnel in garments
Module : 2 : Tools & Techniques for Assuring Quality 2.1 Standard Operating Procedure (SOP) 2.1.1 What is SOP? 2.1.2 Why SOPs? 2.1.3 Advantages of having SOPs 2.2 Root Cause Analysis (RCA) 2.2.1 What is RCA? 2.2.2 Benefits of RCA 2.2.3 When should RCA be performed? 2.2.4 How does it differ from what we do now? 2.2.5 How does it work? 2.2.6 Corrective action 2.2.7 Common RCA tools 2.2.8 Verification (before) vs. Validation (after) 2.2.9 Follow-up plan 2.2.10 Validation and celebrate 2.2.11 Example 2.3 7 tools of QC 2.3.1 Cause and Effect Diagram 2.3.2 Pareto Analysis 2.3.3 Flowchart 2.3.4 Run Charts 2.3.5 Control chart 2.4 Total Quality Management (TQM) 2.4.1 Evolution of TQM 2.4.2 TQM philosophy - What's different? 2.4.3 Tools and techniques of TQM 2.4.4 The TQM system 2.4.5 Why TQM effort fail 2.5 Total Productive Maintenance (TPM) 2.5.1 Components of TPM 2.5.2 TPM activities 2.5.3 TPM benefits 2.5.4 The 11 basic implementation steps

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Manual on Garment Quality Management

2.5.5 The requirements for TPM to succeed 2.6 Quality Information System (QIS) Module: 3: Quality Control in Textile 3.1 Fabric Defects Criteria 3.2 Defects in the knitting fabric 3.2.1 Yarn related defects 3.2.2 Knitting elements related defects 3.2.3 Machine setting related defects 3.2.4 Dyeing related defects 3.2.5 Finishing related defects 3.3 Textile Testing 3.3.1 Minimum physical testing matrix 3.3.2 Minimum chemical testing matrix Module : 4 : Pre Production Material Quality Control 4.1 Fabric Quality Control 4.1.1 Introduction to fabric inspection 4.1.2 Objective of fabric inspection 4.1.3 Grading system A) 4 point system B) 10 point system 4.1.4 Necessary tools & equipments for fabric inspection 4.2 Trims and accessories quality control 4.2.1 Check points of different trims and accessories Module: 5: Quality Control in Garment Production Process -1 [Cutting Room] 5.1 Cutting Room Quality Control 5.2 Basic Cutting Process Quality Defects 5.2.1 Marker making defects 5.2.2 Common spreading defects 5.2.3 Common cutting problems 5.2.4 Bundling and ticketing 5.2.5 Common problems of fusing 5.3 Print quality control 5.4 Quality Control on Embroidery 5.5 10 Points Print/ Embroidery Quality Check 5.6 Basic Quality Problem on Embroidery

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Manual on Garment Quality Management

Module: 6: Quality Control in Garment Production Process 2 [Sewing and Finishing] 6.1 Basic Quality Defects in Sewing 6.2 Quality Control on different activities of Finishing Room 6.3 Methods & Procedure in Garment Production Process 6.3.1. PP [Pre-Production] Meeting 6.3.2. First Bundle Procedure 6.3.3. Traffic Light System/ Inline Quality Control 6.3.4. Broken Needle and Hazardous Metal Detection Policy 6.4 Finishing Section Quality Control Flowchart 6.4.1 Ironing 6.4.2 Final inspection 6.4.3 Inline AQL 6.4.4 Finishing accessories quality assurance 6.4.5 Packing quality control Module: 7: Quality Auditing ( AQL) 7.1 Final audit 7.1.1 Purpose of final inspection or final audit 7.1.2 Terms and definitions 7.2 Sequence of final inspection of garments 7.2.1 Packing list verify/ compare with PO sheet 7.2.2 Audit preparation 7.2.3 Carton checking 7.2.4 Carton selection 7.2.5 Packing and packaging check 7.2.6 Sample selection (sample picking) 7.2.7 Garments (selected sample) checking 7.2.8 Record of defects non-conformances 7.2.9 Measurement (dimensional) checking 7.2.10 Defective sample draw for reference 7.2.11 Pass sample garment through MD machine 7.2.12 Carton fill-up 7.2.13 Sticker & signature 7.2.14 Reporting 7.3 What is AQL Chart & How to Use AQL Chart?

Prepared by College of Fashion Technology & Management

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Manual on Garment Quality Management

Prepared by College of Fashion Technology & Management

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