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Quality Programme for an

Apparel Industry

Presented By:
Amrita Mitra
Manish Kumar
Sanjani Sinha
•In manufacturing, a measure of excellence or a state of being free from
defects, deficiencies and significant variations.

•It is brought about by strict and consistent commitment to certain

standards that achieve uniformity of a product in order to satisfy specific
customer or user requirements.

•ISO 8402-1986 standard defines quality as "the totality of features and

characteristics of a product or service that bears its ability to
satisfy stated or implied needs."

•Quality is very important in apparel business. Customers demand and

expect is the supreme importance in garment business because of clothing
trends become change with short time period. There are various factors on
which quality fitness of apparel industry is based such as - performance,
reliability, durability, visual and perceived quality of the garment.
Quality Control is “The planned and systematic activities implemented
in a quality system so that quality requirements for a product or
service will be fulfilled.”

Mostly the process involves a thorough examination and testing the

product or the result of the service. The underlying goal is to ensure that
the examined and tested product or service reach the specific requirements.

There are several stages to control quality in garment manufacturing. They are
given below:

•Pre-production quality control

•Quality control during production
•Final inspection
•Quality control to developing a sampling plan
Company Profile

Name of the company:

Company Workforce:

Product dealing with:

Objectives of Quality Control Program

To maximize the production of goods within the specified tolerances

correctly the first time.

To achieve a satisfactory design of the fabric or garment in relation to the level

of choice in design, styles, colours, suitability of components and fitness of
product for the market.

The Quality System Requirements are based on the principle of PDCA Cycle.
Organizing & training quality control
•Ensuring proper flow of quality requirements to the QC department.
•Ensuring proper flow of quality requirements to the Production Department.
•Establishing quality plans, parameters, inspection systems, frequency, sampling
techniques, etc..
•Inspection, testing, measurements as per plan.
•Record deviations
•Feed back to Production Department.
•Plan for further improvement.
Establishing the Quality Requirements:

The first step for quality control is to understand, establish & accept the customers'
quality requirements. This involves the following steps.

•Getting customers specifications regarding the quality

•Referring our past performance
•Discussing with the Quality Control Department
•Discussing with the Production Department
•Giving the Feed Back to the customers
•Receiving the revised quality requirements from the customers
•Accepting the quality parameters

Quality control program for. is divided into three main phases namely:

1.Pre-production Phase
2.Production Phase
3.Final Inspection Phase

1. Pre-production Phase
Pre-production phase incorporates the processes involved before the actual
production starts. It includes:

•Fabric Inspection: A 4-Point Inspection System is used to identify defects

holes, stains, thick and thin places, bowing skewing.
•Fabric Testing: Fabric testing report is asked from Vendor as well as also
testing is also being done from Bureau Veritas.
•Accessories Inspection: All the accessories are checked on the basis of different
parameters like match with original sample, color, finish, dimension.
Fabric Quality Control Report
Accessory (Non Fabric Store)
2. Production Phase

Production Phase incorporates processes from spreading & layering, cutting,fusing,

sewing, in-line inspection.

•Spreading and Layering: Both the processes are monitored by Spreading sheet and
Lay slip to ensure correct layering and spreading has been done.

•Cutting Inspection: All the cut parts are inspected for both quantity and quality. The
measurements are checked with the actual pattern and a cutting inspection report is

•Fusing Inspection: The fused parts are checked for quality and a fusing inspection
report is generated.
Cutting Room Inspection Report
Spreading Slip
Lay Slip
Fusing Check Record
•Sewing Inspection: During the sewing process two inspection method
are followed:

In-Line Quality Audit : Quality checkers are placed after every 5-6
operations or after every sections like back, front, assembly to check the
pieces coming from each section and to ensure right quality goods are
produced. This is helpful as wrong products are identified immediately
and rectification is done.

End Line Quality Inspection: A 100 % inspection of the pieces

produced is done at the end of all the processes which ensures all correct
pieces are sent to finishing and wrong pieces are rectified and then sent.
This also ensures that production is given only of correct pieces.
In line Quality Audit Record
AQL Audit Form : Sewing
Daily End Line Inspection Report
3. Final Inspection Phase
Final Inspection Phase refers to the process involved after the pieces are stitched
and ready to be inspected. It has two processes:

Daily Finishing Final Checker Report: The pieces are checked and
passed or failed in respect to the problems found. The problems found are
then sent back to alter. The Qc check maintains a record of pcs checked vs
pcs passed i.e. QC pass.

Final AQL Audit: Final Quality check based on AQL 2.5 under General
Inspection Level is done. The batch size selected depend upon which type of
General Inspection Level is followed i.e. I, II or III. If the audit fails, a
recheck needs to be done and re-audit to be offered.
Daily Finishing Final Checker Report
5S Implementation
Workplace Diagnostic