TQM and Details of TQM in Apparels

 

TQM

There are many approaches in the business domain in order to achieve and exceed the quality expectations of the clients.

For this, most companies integrate all quality-related processes and functions together and control it from a central point

 

The Origin

The origin of the TQM goes back to the time of the First World War. During the World War I, there have been a number of quality assurance initiatives taken place due to the large-scale manufacturing required for war efforts.

The military fronts could not afford poor quality products and suffered heavy losses due to the poor quality. Therefore, different stakeholders of the war initiated efforts to enhance the manufacturing quality.

First of all, quality inspectors were introduced to the assembly lines in order to inspect the quality. Products below certain quality standard were sent back for fixing.

Even after World War I ended, the practice of using quality inspectors continued in manufacturing plants. By this time, quality inspectors had more time in their hands to perform their job.

Therefore, they came up with different ideas of assuring the quality. These efforts led to the origin of Statistical Quality Control (SQC). Sampling was used in this method for quality control.

As a result, quality assurance and quality control cost reduced, as inspection of every production item was need in this approach.

During the post World War II era, Japanese manufacturers produced poor quality products. As a result of this, Japanese government invited Dr. Deming to train Japanese engineers in quality assurance processes.

By 1950, quality control and quality assurance were core components of Japanese manufacturing processes and employees of all levels within the company adopted these quality processes.

By 1970s, the idea of total quality started surfacing. In this approach, all the employees (from CEO to the lowest level) were supposed to take responsibility of implementing quality processes for their respective work areas.

In addition, it was their responsibility to quality control, their own work.

Basic Principles of TQM

In TQM, the processes and initiatives that produce products or services are thoroughly managed. By this way of managing, process variations are minimized, so the end product or the service will have a predictable quality level.

Following are the key principles used in TQM:

·       Top management – The upper management is the driving force behind TQM. The upper management bears the responsibility of creating an environment to rollout TQM concepts and practices.

·       Training needs – When a TQM rollout is due, all the employees of the company need to go through a proper cycle of training. Once the TQM implementation starts, the employees should go through regular trainings and certification process.

·       Customer orientation – The quality improvements should ultimately target improving the customer satisfaction. For this, the company can conduct surveys and feedback forums for gathering customer satisfaction and feedback information.

·       Involvement of employees – Pro-activeness of employees is the main contribution from the staff. The TQM environment should make sure that the employees who are proactive are rewarded appropriately.

·       Techniques and tools – Use of techniques and tools suitable for the company is one of the main factors of TQM.

·       Corporate culture – The corporate culture should be such that it facilitates the employees with the tools and techniques where the employees can work towards achieving higher quality.

·       Continues improvements – TQM implementation is not a one time exercise. As long as the company practices TQM, the TQM process should be improved continuously.

The Cost

Some companies are under the impression that the cost of TQM is higher than the benefits it offers. This might be true for the companies in small scale, trying to do everything that comes under TQM.

According to a number of industrial researches, the total cost of poor quality for a company always exceeds the cost of implementing TQM.

In addition, there is a hidden cost for the companies with poor quality products such as handling customer complaints, re-shipping, and the overall brand name damage.

PRIMARY ELEMENTS OF TQM

1.     Customer-focused: The customer ultimately determines the level of quality. No matter what an organization does to foster quality improvement—training employees, integrating quality into the design process, or upgrading computers or software—the customer determines whether the efforts were worthwhile.

2.     Total employee involvement: All employees participate in working toward common goals. Total employee commitment can only be obtained after fear has been driven from the workplace, when empowerment has occurred, and when management has provided the proper environment. High-performance work systems integrate continuous improvement efforts with normal business operations. Self-managed work teams are one form of empowerment.

3.     Process-centered: A fundamental part of TQM is a focus on process thinking. A process is a series of steps that take inputs from suppliers (internal or external) and transforms them into outputs that are delivered to customers (internal or external). The steps required to carry out the process are defined, and performance measures are continuously monitored in order to detect unexpected variation.

4.     Integrated system: Although an organization may consist of many different functional specialties often organized into vertically structured departments, it is the horizontal processes interconnecting these functions that are the focus of TQM.

1.      

·       Micro-processes add up to larger processes, and all processes aggregate into the business processes required for defining and implementing strategy. Everyone must understand the vision, mission, and guiding principles as well as the quality policies, objectives, and critical processes of the organization. Business performance must be monitored and communicated continuously.

·       An integrated business system may be modeled after the Baldrige Award criteria and/or incorporate the ISO 9000 standards. Every organization has a unique work culture, and it is virtually impossible to achieve excellence in its products and services unless a good quality culture has been fostered. Thus, an integrated system connects business improvement elements in an attempt to continually improve and exceed the expectations of customers, employees, and other stakeholders.

5.     Strategic and systematic approach: A critical part of the management of quality is the strategic and systematic approach to achieving an organization’s vision, mission, and goals. This process, called strategic planning or strategic management, includes the formulation of a strategic plan that integrates quality as a core component.

6.     Continual improvement: A large aspect of TQM is continual process improvement. Continual improvement drives an organization to be both analytical and creative in finding ways to become more competitive and more effective at meeting stakeholder expectations.

7.     Fact-based decision making: In order to know how well an organization is performing, data on performance measures are necessary. TQM requires that an organization continually collect and analyze data in order to improve decision making accuracy, achieve consensus, and allow prediction based on past history.

8.     Communications: During times of organizational change, as well as part of day-to-day operation, effective communications plays a large part in maintaining morale and in motivating employees at all levels. Communications involve strategies, method, and timeliness.

BENEFITS OF TOTAL QUALITY MANAGEMENT

Total quality management benefits and advantages:

·       Strengthened competitive position

·       Adaptability to changing or emerging market conditions and to environmental and other government regulations

·       Higher productivity

·       Enhanced market image

·       Elimination of defects and waste

·       Reduced costs and better cost management

·       Higher profitability

·       Improved customer focus and satisfaction

·       Increased customer loyalty and retention

·       Increased job security

·       Improved employee morale

·       Enhanced shareholder and stakeholder value

·       Improved and innovative processes

Total Quality Management (TQM) Benefit: Methodology Creates an Adaptive Organization

ASQ has collected a series of total quality management case studies to illustrate the impact a TQM system can have on your organization.

BENEFITS OF TOTAL QUALITY MANAGEMENT

Total quality management benefits and advantages:

·       Strengthened competitive position

·       Adaptability to changing or emerging market conditions and to environmental and other government regulations

·       Higher productivity

·       Enhanced market image

·       Elimination of defects and waste

·       Reduced costs and better cost management

·       Higher profitability

·       Improved customer focus and satisfaction

·       Increased customer loyalty and retention

·       Increased job security

·       Improved employee morale

·       Enhanced shareholder and stakeholder value

·       Improved and innovative processes

Total Quality Management (TQM) Benefit: Methodology Creates an Adaptive Organization

ASQ has collected a series of total quality management case studies to illustrate the impact a TQM system can have on your organization.

1.     Top management learns about and decides to commit to TQM. TQM is identified as one of the organization’s strategies.

2.     The organization assesses current culture, customer satisfaction, and quality management systems.

3.     Top management identifies core values and principles to be used, and communicates them.

4.     A TQM master plan is developed on the basis of steps 1, 2, and 3.

5.     The organization identifies and prioritizes customer demands and aligns products and services to meet those demands.

6.     Management maps the critical processes through which the organization meets its customers’ needs.

7.     Management oversees the formation of teams for process improvement efforts.

8.     The momentum of the TQM effort is managed by the steering committee.

9.     Managers contribute individually to the effort through hoshin planning, training, coaching, or other methods.

10. Daily process management and standardization take place.

11. Progress is evaluated and the plan is revised as needed.

12. Constant employee awareness and feedback on status are provided and a reward/recognition process is established.

 TOTAL QUALITY MANAGEMENT SYSTEM STRATEGIES

Imprints of TQM concepts can be found in modern approaches to quality management, such as the Malcolm Baldrige National Quality Award (MBNQA) criteria, ISO 9001, Six Sigma and lean manufacturing, as well as the examples below.

Total Quality Management (TQM) Implementation Strategies

Strategy 1: The TQM element approach

The TQM element approach takes key business processes and/or organizational units and uses the tools of TQM to foster improvements. This method was widely used in the early 1980s as companies tried to implement parts of TQM as they learned them. Examples of this approach include quality circles, statistical process control, Taguchi methods, and quality function deployment.

Strategy 2: The guru approach

The guru approach uses the teachings and writings of one or more of the leading quality thinkers as a guide against which to determine where the organization has deficiencies. The organization makes appropriate changes to remedy those deficiencies. For example, managers might study Deming’s 14 points or attend the Crosby College. Afterward, they would work on implementing the approach learned.

Strategy 3: The organization model approach

In this approach, individuals or teams visit organizations that have taken a leadership role in TQM and determine their processes and reasons for success. They then integrate these ideas with their own ideas to develop an organizational model adapted for their specific organization. This method was used widely in the late 1980s and is exemplified by the initial recipients of the Malcolm Baldrige National Quality Award.

Strategy 4: The Japanese total quality approach

Organizations using the Japanese total quality approach examine the detailed implementation techniques and strategies employed by Deming Prize-winning companies and use this experience to develop a long-range master plan for in-house use. This approach was used by Florida Power and Light—among others—to implement TQM and to compete for, and win, the Deming Prize.

Strategy 5: The award criteria approach

When using this model, an organization uses the criteria of a quality award (e.g., the Deming Prize, the European Quality Award, or the Malcolm Baldrige National Quality Award), to identify areas for improvement. Under this approach, TQM implementation focuses on meeting specific award criteria.

Although some argue that this is not an appropriate use of award criteria, some organizations do use this approach and it can result in improvement.

 

Basic idea of Quality and QMS part and how to face the interview with other company

1.     What is Quality?

Answer:

In short, Quality is customer satisfaction. Or Quality is the fitness for use.

Quality is the ability of a product to meet customer satisfaction for that product.

 

Importance of quality in apparels: The garments manufacturer is supplier of buyer or retailer. Buyer analysis the users demands & provide requirement to the supplier before ordering their desire products. The ultimate considerable thing is users’ satisfaction & keep up the brand reputation. Wearer ever don’t want to buy poor quality products if buy anyhow negative concepts can be born in the wearer mind on that brand & fall down the brand reputation. No brand wants to reduce their reputation. So, buyer or retailer do not purchase any product except their desire quality.

 

So, there is no way to ignore quality. Quality must be controlled during operation whether it is done by the operators, supervisors, pressing man, packers, checker, or inspector etc. In case the quality of product not being controlled during operation then it will affect following point –

·       High alter & DHU percentage

·       Increase rejection percentage

·       Increase cost for rework

·       Increase working hour

·       Delay to complete production

·       More shocking thing is Factory may lose customers.

·       Ultimately cost of manufacture will increase

So, Factory must need an appropriate quality control team who can run the process with buyer requirement to achieve customer satisfaction & keep existence.

2.     Who are the father of quality?

Answer:

Following persons are the father of the quality –

A.    Philips Crosby

B.    Dr. Juran

C.    Edward Deming

D.    Rj. Mortiboys

 

3.     What is QMS? Responsibilities & importance of QMS in apparels?

Answer:

QMS stand for Quality Management System also known as technical audit.

A quality management system is defined as a formalized system that documents, process, procedures & responsibilities for achieving quality polices & objects

 

Importance of QMS: QMS work based on customer’s requirement, system & management of quality controls & assurance. Factory must fulfill technical requirement of customers. If factory wants to continue business with buyer there is no chance to ignore because of buyer orders depends on technical audit score. All buyer sets QMS guidelines & implemented by QMS responsible.  QMS department is Responsible for all quality, technical audit, and process audits of factory.

 

Job Description of QMS:

·       Follow up, monitor, and supervise QMS requirements of whole factory from warehouse to shipment.

·       Total Quality Management & technical requirement, Implementation and Continual Improvement.

·       Develop quality SOP / manual at all section.

·       Train up all quality inspectors, quality staff about basic quality requirements, quality concepts, and quality policy.

·       Perform internal audit & work with all department head for improvement.

·       Keep all quality documentation, SOP of quality, technical files & document control.

·       Work with quality team to reduce DHU & monitor TLS system.

·       Implement 5S system & train all department relevant person.

·       Implement lean manufacturing & six sigma for better quality.

 

4.     What is quality controls?

Answer:

Quality control is a continuous process to ensure the quality of a product.

 

5.     What is garment?

Answer:

Garments is pieces of clothing. Garments are made from fabrics by cutting the fabric and stitching together.

 

6.     What is Wash? How many types of wash are there in Apparels?

Answer:

The technology, which is used to modify the appearance outlook, comfort ability is called wash. There are many types of wash –

·       Normal wash

·       Enzyme wash

·       Stone wash

·       Over dyeing

·       Bleach wash

·       Pigment wash etc.

 

7.     What is defect/Alter?

Answer:

Defect: Any kind of alter is defect. Anything which is discrepancy from standard, harmful for wearer, reduce sales ability, reduce usability are called defect.

 

Major Defect:

The defect which reduces the usability & sales ability of a product is called major defect.

Example: 1. Skip stitch. 2. Broken stitch. 3. Puckering.

 

Minor Defect:

The defect which does not reduce the usability & sales ability of a product but its discrepancy from standard is called minor defect.

Example: 1. Uncut thread inside garments.

 

Critical Defect:

Anything which can harm the wearer of the product is called Critical defect.

Example: 1. Any kind of mistake. 2. Insects 3. Broken needle.

 

8.     How much types of Inspection are there in garments?

Answer:

There are four types of inspection –

Inspection: Inspection is a practical method of selecting a certain quantity of Raw Materials or Finished Goods in a certain way before finally selecting any Raw Materials or Finished Goods.

 

A.      Pre-production Inspection:

Pre-production is done before the bulk starts. It is done to check for final verification & meet customer requirement of bulk fabric, trims & accessories, styling, manufacturing way, washing, workmanship, measurement etc. against approved sample & wash standard.

 

B.      Initial inspection:

Initial inspection is done at the starts of production when the first output come out the end line quality table. There raise the possible discrepancies, variation & take necessary action to meet customer requirement for specific style. It’s a preliminary stage of styling details, general appearance, workmanship, measurement, fabric & trim component etc.  Whatever discrepancies identify initially could take action & get solution during starts of bulk production.

 

C.      During production inspection:

During production inspection is done during production to ensure initial discrepancies have been corrected and rectified. All the initial discrepancies should fix at the same time & follow by GPQ or line QA during bulk production.

 

D.     Final Random inspection:

Final random inspection is done when the quantity of an order has been enclosed completely. As per the selected AQL from customer sample quantity should be select & inspect. Also, result will be considered as per the AQL system.

 

9.     What is the difference between Defect & Defective?

Answer:

Defect: Any kind of alter is defect.

Defective: Garments that has one or more defects is called defective garments.

 

10. What is the difference between QA & QC?

Answer:

 

Quality Assurance: Quality assurance (QA) is a systematic process to determine a product meets specified requirements.

 

Quality Control: Quality control is a continuous process to ensure the quality of a product.

 

Difference between:

 

Quality Assurance (QA)	Quality Control (QC)
QA is process oriented.	QC is products oriented.
QA ensure all the quality process.	QC ensure the product quality.
QA works proactively.	QC works reactively to identify defect.
QA establish good Quality management system.	QC find & eliminate source of quality problems.
Verification is an example of QA	Validation is an example of QC
QA provides the overall guidelines used anywhere	QC is a production-focused process.

 

11.Define 5S system?

Answer:

5S is a systematic form of visual management utilizing everything from floor tape to operational manual.

 

5S comes from 5 Japanese word if translate in English these are Short, set in order, shine, Standardized & Sustain.

 

Sort:

Sort refers to sorting items according to characteristics & importance. For every section Sort out unnecessary item, define daily needed items, weekly needed items, monthly needed items & keep separately. Keep record & eliminate unnecessary items for exist & new items.

 

Set in order:

Set in order refers clearly identified by a label & keep everything in an organized way. Never mix different category items in one place. Divide lines, aisles mark, emergency exit identified & free from obstacles also stairway should clearly identify etc. It will help us everything to find out easily.

 

Shine:

Shine refers to cleanliness. All items & workplace like floor, wall, stair, ceiling, rack, cabinet, machine, equipment, tools, material, product, lighting should be clean. Hang a checklist on dashboard & follow it as per schedule. Perform pest control internally & externally & keep the record as well.

 

Standardized:

After first three steps standardized is about visualization by display information like work procedure, SOP, caution, flow chart, signs, color coding etc. for easy understand of everyone’s. Perform 5S audit every day, score & post in every place & keep record as well. It will help to increase operating efficiency of that industry.

 

Sustain:

Sustain refers to retain all the prior steps of 5S. Also, Success stories are being displayed in every section of the 5S board. Give rewards and recognition is part of the 5S system to sustain 5S.

 

12. Define Leadership & the characteristics of a Leader?

Answer:

A leadership is on who knows the way, goes the way & shows the way is called a leader.

 

Characteristics of a leader:

 

A.    Honesty & Integrity & Transparency:

Integrity is the practice of being honest & show a consistent & uncompromising behavior.

When a person become a leader, he tries to retain the leadership. Integrity is regarded as honesty, truthfulness, and accuracy in one’s actions.

 

B.    Confidence:

Confidence is the belief in himself. Being confident requires sense of capabilities & feeling secure in that knowledge. Being confident is more important. When a leader is confident on his reasonable decision, he can meet challenges & difficulties. But he needs to be enough confident in term of the knowledge.

 

C.    Skills and Abilities:

A leader needs to possess skill on his responsibilities & some other mandatory skills like communication skill, time management, problem solving, analytic, alternate thinking, presentation skill, technical skill etc.

 

D.    Commitment and Passion:

Commitment is referred to dedicate himself to something. Before make commitment, must think deeply about commitment & effective reason to commit on that. Fulfil commitment increases the acceptance on himself.

 

E.    Accountability:

Accountability refers job duties & responsibilities. A leader needs to implement his job duties in an organized manner & his main object should be achieved desire outcomes.

He could face different types of problem, achieve his desire outcome exceed all the problem is the characteristics of a leader & it’s called accountability.

 

F.     Creativity and Innovation:

Creativity refers idea to create something new which can make your work easier & more effective. Creativity & innovate new thing is very important for a leader. To improve work procedure & task, consume by less time & cost in operation a leader have to find out new creation.

G.    Empathy:

Empathy refers ability to understand the feelings of others. In an organization many people face lots of problem & difficulties. When an employee comes to a leader with problem, before providing them solution leader should think that the employee has personal responsibilities as well & should pay attention on this. When they leader assigning them a duty, he should provide sufficient time advise in a manageable manner.

 

H.    Emotional Intelligence

I.      Humility

J.     Vision and Purpose

K.    Teamwork

L.     Good communication skills.

M.   Decision making ability etc.

N.    Empowerment.

 

13. Characteristics of an Auditor?

Answer:

A.    Open Minded

B.    Ethical

C.    Diplomatic

D.    Perspective

E.    Versatile

F.     Professional

G.    Collaborative

 

14. Describe 7 Quality tools?

Answer:

 

A.    Cause & effect analysis / diagram: A cause-and-effect diagram looks like a fish that’s why it’s called Fishbone Diagram, also called Ishikawa diagram. This is a visual tool to categorized potential cause of problem to identify its root cause. The diagram finds out potential factor for problem which is leading to an overall effect.

 

How to work on fishbone: If any problem found first need to think about the defect o find out types of cause based on below 6 things –

                                I.         Machine

                              II.         Manpower

                             III.         Environment

                            IV.         Method

                              V.         Materials

                            VI.         Measurement

 @ Need to discuss with sir how to make a fishbone diagram

 

B.    Flow chart: Flow chart is visual workflow of the process. It represents all the steps of process along with conditions related steps through a diagram or picture. The flow chart shows all process accordingly & process are connected arrow. Also, it shows conditional process if not happen any problem, then need to follow accordingly else need to follow the conditional process. It helps to keep our process on right track.

 

C.    Pareto chart: A pareto chart is a bar graph & it consists with bars. Both bars show individual values. Left vertical bar indicate the number of discrepancies / defects found & right vertical bar indicate the cumulative percentage of total discrepancies / defects. In quality controls, it can be used to as a source of top defect, top complaint from buyer etc.

 

D.    Histogram: Histogram is a graphical chart. It consists of vertical bars of different height & each bar indicate a different group of data. It shows continuous data of similar category. It helps to summarize data & represent in bar & indicate in which are need pay attention.

 

E.    Check sheet / Tally sheet: Check sheet is a simple form to collect data in real time where the data is occurred. It is designed to keep data accurately, easily & efficiently. It can be either quantitative or qualitative. When the data is quantitative the check sheet is also called a tally sheet. We can computerize, analysis from this raw data for further action.

 

F.     Scatter chart:

 

G.    Control chart:

 

15. What is Lean? Describe all criteria of lean?

Answer:

Lean can define as a set of management practices to improve efficiency and effectiveness by eliminating waste continuously. In short, Lean is the procedure to get more out from lower cost. The goal of lean is eliminated waste.

 

Principal of Lean:

 

A.    Value: Value is what the customers are willing to pay against it. The priority is

finding better ways to deliver right valuable product to the customer.

 

B.    Value stream mapping:

C.    Create flow:

D.    Pull system:

E.    Perfection:

 

·       8 wastages of Lean: -

 

A.    Unnecessary Transportation: Transportation means any tools or materials that can be required carrying by hand or vehicle. Transition waste increases when you need to move things from here to there. It can be happened for poor lay out, poor process planning, Incorrect process flow etc. Transportation increase costs, needs time & product or tools may damage.

 

B.    Over defects: Defects is a wastage in garments. It increases lead time, Rework costs, material consumption & sometimes we can face delay of shipment which is threat for factory.

 

C.    Over Production: It can happen when operator produced blindly but output cannot be processed due to receivers are not ready or don’t need this production at this time.

 

D.    Waiting: Sometimes we can observe works are interrupted due to material missing, waiting for approval, Machine problem, Operation stops for defects etc. reasons. Factory can overcome this problem by well-organized everything.

 

E.    Excess Inventory: Order too may & earlier accessories from supplier need large space in warehouse then maintain warehouse become tough & cost can be increased.

 

F.     Excess Movement: If a process needs extra employee for extra steps, it is just waste of money & time.

 

G.    Over Procedure: Over procedure can happen due to poor designed of process & document. As a result, there can be happen over procedure like multiple variation of one task, several signature, entry duplicate data, process more goods then required.

 

H.    Unused talent: This is not related to process issue. Not utilize exist talent can be called as a waste. A factory can step their desire position by utilize talent. If assign employee to wrong task or he don’t get chance it is not possible to work out his talent.

 

 

16. What is DMAIC?

Answer:

DMAIC stand for Define, Measure, Analyze, Improve & Control. It’s a methodology that used to improve existing process.

 

Define: Before we start work on a problem, we must know the definition of that problem, why we are working on it, where is the focusing area, what is the scope etc. All of these are in define phase.

 

Measure: The measure phase is about ensure correct data. We make decision based on facts & data. We must ensure that we are taking decision based on correct data otherwise we could make incorrect decision that will effect on our whole process.

 

Analyze: The collected data and process map to determine root causes of defects and opportunities for improvement.

 

Improve: Improve focus on getting the best potential solution from more solution to solve the root cause of the problem.

 

Control: Control is about ensuring that the solution is sustainable in the long time.

 

17. Describe Six sigma?

Answer:

Six sigma is a set of techniques & tools which is used to reduce defect. It’s a quality improvement process of product by reducing defect, minimizing variation & improving capability in the manufacturing process.

 

Tools of six sigma: -

 

A.    Standardized work:

B.    Problem solving & improvement

C.    Value Streaming mapping

D.    5S

E.    5 Why

F.     Control chart

G.    GAMBA chart

H.    DMAIC – Define, Measure, analyze, Improve, Control

I.      PDCA – Plan, Do, Check, Act

J.     Husin kanri

K.    Kanban

L.     Catch ball

 

18. Describe the 14 principals of Quality?

Answer:

 

   The 14 principals of quality –

 

A.    Create a constant purpose towards improvement.

B.    Adopt the new philosophy.

C.    Stop depending on inspection

D.    Use single supplier for anyone items

E.    On job training

F.     Improve constantly & forever

G.    Implement leadership

H.    Eliminate fear

I.      Break down barriers between departments.

J.     Remove barriers to pride of workmanship

K.    Get rid of unclear slogans

L.     Eliminate management by objectives.

M.   Implement education and self-improvement

N.    Make "transformation" everyone's job

 

 

 

 

 

 

 

19. How many parts have in a zipper? Write down classification zipper?

Answer:

Parts of a zipper:

A.    Stops

B.    Slide

C.    Pull

D.    Tape

E.    Teeth

 

Classification of zipper:

 

Types of Zippers based on Element/Teeth Material –

 

A.    Metal zipper

B.    Molded Plastic Zipper

C.    Invisible Zipper

D.    Coil Zippers

 

20. Classification of button?

Answer:

There are five types of buttons –

A.    Flat button

B.    Shank button

C.    Stud button

D.    Toggle button

E.    Decorative button

 

21.Write down fowling abbreviation?

Answer:

 

·       LAR - Lot Acceptable Rating.

·       OQL – Observation Quality Level.

·       DQA – Dedicated Quality Assurance.

·       DCL – Defect Classification List.

·       CAP – Corrective Action Plan.

·       FSQA – Food safety Quality Assurance.

·       PSQA – Product Safety Quality Assurance.

·       FRI – Final Random Inspection.

·       FE – Factory Evaluation.

·       GMP – Goods Manufacturing Practice.

·       TOP – Top of Production.

·       SKU – Stock Keeping Unit.

·       PI – Performa Invoice.

·       BPM – Business Partnership Management.

·       SOP – Standard Process Operation.

·       VQA – Vendor Qualification Assessment.

·       DI – Direct Input.

·       QAFA – Quality Assurance Factory Assessment.

·       TSS – Target Sourcing Services.

·       TTC – Target Testing Certificate.

·       PO – Purchase Order.

·       OTS – On Time Ship.

·       CMS – Commitment Management system.

·       SPI – Stitch per Inch.

·       KPI – Key performance Indicator.

·       DHU – Defect per Hundred Unit.

·       DUH – Defect Unit per Hundred.

·       IE – Industrial Engineering.

·       PDCA – Plan-Do-Check-ACT

·       DMAIC – Define-Measure-Analyze-Improve-Control

·       RQS – Requirements for quality system

·       NQC – Nominated quality controller

·       MMR – Minimum manufacturing requirements

·       RQC – Roaming quality controller

·       LQC – Line quality controller

·       TQI – Table quality inspector

·       GSS – Gold seal sample

·       SPC – Stitch per CM

·       RCA – Root cause analysis

·       CM – Cost of Making / Manufacturing

·       BGMEA – Bangladesh garments manufacturers & Exporters Association

·       BGMEA – Bangladesh Knitwear manufacturers & Exporters Association

·       RMG – Ready-made garments

·       SCSS – Solid color solid size

·       SCAS – Solid color assort size

·       ACSS – Assort color solid size

·       ACAS – Assort color assort size.

 

22. What does mean by GPQ? What are the job responsibilities of a GPQ?

Answer:

GPQ stand for “Guideline for production & Quality control”

In short, the works of GPQ is implement buyer quality requirement in factory. GPQ works as a helping hand of buyer QC from the factory end. Factory should appoint buyer wise GPQ individually.

 

Job description of a GPQ:

 

A.    Arrange PP meeting with buyer QC and do the necessary task of PP meeting.

B.    Implement buyer quality requirement in cutting, sewing, and finishing of garments.

C.    Follow up buyer sample requirement, ensure sample quality, and deliver at the right time to the buyer & Take sample approval from buying house.

D.    Check & ensure first output garments.

E.    Provide proper guideline of all quality relevant person like Inspector, Controller, in charge etc.

F.     Conduct section wise quality inspection to keep garments defect in the control.

G.    Make style file.

H.    Conduct all required testing.

I.      Conduct pre-final audit.

J.     Arrange final inspection with all requirements of the buyer.

K.    Work with buyer QC during final inspection.

L.     Contact with buyer QC about any quality issue.

M.   Work as a buyer QC representative in the factory.

 

23. Describe accordingly Garments Quality Control Procedure?

Answer:

A.    Checking fabrics, trims, and accessories as per buyer requirement.

B.    Make size set sample and review in PP meeting

C.    Pattern correction based on size set garments measurement

D.    Cut 300 pcs as a pilot run from all size range after PP meeting to ensure all size measurement is correct then proceed to cut for bulk.

E.    If fabrics shrinkage differs more than 2 %, a different pattern will be made

F.     Cutting will be started after getting buyer QC approval of bulk cutting

G.    Ensure all cut panels are ok with pattern & maintain your record as per SOP.

H.    All cut panels should be inspected & fulfil the bundle with replaced panels.

I.      Checking fabrics bonding strength after fusing, keep fusing attached temperature record with thermal paper.

J.     Checks & ensure the styling of garment is ok.

K.    Ensure all marking instruments should be invisible especially pen & chalk mark pencil use light mark, but it should be erased able daily basis, follow up oil leakage from the machine by fabric under the pressure foot.

L.     Ensure all machine tension with feed dock set up properly by our actual fabric quality daily & keep a record with mock-up

 

24.What is Fabric? Types of Fabric?

Answer:

Fabric is cloth or other material produced by weaving or interloping together cotton, nylon, wool, silk, or other threads.

 There are three types of Fabric –

A.    Woven Fabric

B.    Knit Fabric

C.    Non-woven Fabric

 

25.Write down about woven fabric?

Answer:

Woven Fabric are produced by weaving. it consists through two series of thread. One is weft thread which is run across the width of the fabric (horizontal) & the other one is warp thread which is run the length of the fabric (Vertical). The woven fabric is dimensionally stable.

 

·       Woven fabrics are very durable.

·       Woven fabrics are less stretch

·       woven fabric gets crease & wrinkle easily so it may have to be ironed more frequently

·       woven fabric absorbs less water than knit fabric

·       Woven fabrics are hard than knit fabric

 

There are many types of woven Fabric –

A.    Denim Fabric

B.    Gabardine Fabric

C.    Muslim Fabric

D.    Poplin Fabric

E.    Taffeta Fabric

F.     Tissue Fabric

G.    Kashmir silk Fabric

H.    Flannel Fabric

I.      Drill Fabric

J.     Leno Fabric

K.    Buckram Fabric

L.     Cambric Fabric

M.   Casement Fabric

N.    Chiffon Fabric

O.    Khadi Fabric

 

26. Write down types of Knit fabric?

Answer:

Knit fabrics are produced by interloping one or more sets of yarn.

 

Mainly there are two types of knitting –

A.    Weft Knitting

B.    Warp Knitting

 

·       Knit fabrics are stretchy & flexible

·       Knit fabrics are Wrinkle resistant

·       Knit fabrics are soft

·       Knit fabric are Easy to maintain

·       Knit fabrics are easy to damage

·       Knit fabric are difficult to sewing

 

A.    Single Jersey Fabric

B.    Double Jersey Fabric

C.    Interlock Fabric

D.    Rib Fabric

E.    Twill Fabric

F.     Birds eye Fabric

G.    Fleece Fabric

H.    Lacoste Fabric

 

27. What is yarn & Thread? Write down the classification of yarn?

Answer:

 

Yarn:

Yarn is an assembly of fibers that are laid or twisted together to form a continues strand.

Yarn used in weaving & knitting.

 

Thread:

Thread is a long very thin piece of a material such as cotton, nylon, or silk, especially one Threads are used to form the stitches that hold the fabric parts together.

 

Yarn & Thread:

Every thread is made of yarn. We can refer the yarn as thread, but we cannot refer the thread as yarn.

 

There are many types of yarn –

A.    Carded yarn

B.    Super carded yarn

C.    Combed yarn

D.    Semi-combed yarn

E.    Super combed yarn

F.     Compact yarn

 

            Yarn making procedure:

A.    Blow Room         

B.    Carding

C.    Drawing

D.    Combing

E.    Simplex

F.     Spinning

G.    Winding

 

28. What is fabric inspection?

Answer:

Fabric Inspection is systematic observation of fabrics to decide whether it meets Client’s specification in terms of count/construction, color, design, measurement specifications, hand/feel and other specific quality parameters laid down by the clients.

 

29. How many types of fabric inspection are there?

Answer:

There are various types of fabric inspection system such as –

A.    2.5 fabric inspection system.

B.    4-point fabric inspection system.

C.    10-point fabric inspection system

 

30. Describe 4-point fabric inspection system?

Answer:

In this system the quality level of fabric is determined based on a certain number of penalty points for every 100 yards of cloth.

 

এই সিস্টেম এ প্রতি ১০০ গজ কাপড়ের জন্য নির্দিষ্ট সংখ্যক penalty points এর ভিত্তিতে কাপড়ের quality level নির্ধারন করা হয়

 

4-point fabric inspection system are the most used in the garments industries which is performed following ASTM D5430-93.

 

H&M Requirements overview:

 

H&M prefer 10% fabric visual inspection of bulk fabric. If fabric quantity below 1000m then 100% should be inspected. If found average defect & inspection get fail as per requirement an additional 15% must be inspected. If fabric fails again, 100% of quantity should be inspected or reject the quantity. Two inspectors could inspect maximum 2 hours continuously. After that either there should be break schedule or perform by another two inspectors for next two hours.

 

       General requirements of fabric inspection area:

 

A.    In the inspection area should be proper lighting as per customer requirement.

B.    The frame of the fabric inspection machine through which the fabric travels should be bent at an angle of 45 to 60 degrees.

C.    In the top of inspection table there should be two F96 fluorescent light & sometimes can be needed to use back light under the table

D.    Fabric inspection machine speed should not be more than 15 meter per minutes.

E.    All defects found during inspection must be documented clearly.

F.     Inspection reports must be kept at least 6 months

 

Bowing:

Bowing is a common fabric defect. When the weft yarn of the fabric gets displayed from a line to the fabric selvedge then it’s called bowing defect.

Skew:

Skew is a common fabric defect. When the weft yarn of the fabric gets angularly displaced from a line to the fabric side or edge then it’s called skew defect.

 

                    Purpose of inspection:

A.    Find out the defects.

B.    Rectify the defect or defective fabrics.

C.    Grading/Grouping the fabric.

D.    Take decision the fabric acceptable or rejected.

E.    Avoid the repeated defects through corrective action plan.

 

 

Size of Defect	Penalty Points
Defect up to 3 inches	Penalty point 1
Defect 3 to 6 inches	Penalty point 2
Defect 6 to 9 inches	Penalty point 3
Defect over 9 inches	Penalty point 4
Holes and openings (largest dimension)
Defect up to 1 inch	Penalty point 2
Defect over 1 inch	Penalty point 4

 

                     How to calculate fabric inspection pass or fail:

                   (Total pointes from roll       36        100) / (Fabric length in yards       Fabric width in inches)

·       In every single yard maximum countable penalty point is 4.

·       Defect size considerable to both width and length.

·       Only major defect will be count as penalty points.

·       1 yard equal 36 inches.

 Major defect category:

A.    General Defect. (Spot, Knot, Slub, Hole, Rapping, Cockled yarn, set mark, Kink etc.)

B.    Running Defect. (Lycra out, Lycra Drop, Needle broken mark, Sinker mark etc.)

C.    Uncountable Defect. (Running shade, Fuzziness, Hand feel problem, Dia mark, Bowing etc.)

D.    Full width Defect.

 

Familiar: Miss yarn, thick yarn, foreign yarn, spot, lycra deformation, lycra missing, needle drop, stop mark, fabric fault, running shade, hand feel, skew, bowing.

Acceptable Points	Grade
0 – 20 Points	Grade A
21 – 28 Points	Grade B
Over 28 Points	Grade C

 

             Reports of Fabric Section:

A.    Fabric Inspection Report.

B.    Fabric Shade Grouping Report.

C.    Fabric Shrinkage Test Report.

D.    Fabric Test Reports.

Fabric Test Reports:

Ø  Dimensional stability/Shrinkage to laundering/Washing.

Ø  Tear Strength

Ø  Tensile Strength

Ø  Appearance

Ø  Skew Test

Ø  Distortion Test

Ø  Color fastness to water/Light/Crocking/Perspiration/Laundering.

Ø  Seam strength

Ø  Seam Slippage etc.

 

31. Fabric Shrinkage Test system.

Answer:

Fabric shrinkage define as a piece of fabric changes in length or width during the laundry process.

 

·       Once bulk fabric is in house cut specimen from each fabric roll keeping on shrinkage template board.

·       The specimen must be fully relaxed before cut & Specimen should be 50cm X 50cm.

·       Send the specimen for wash.

·       After getting washed specimen measure the difference between before & after wash.

·       Calculate the shrinkage percentage using below mentioned law.

·       Shrinkage acceptable percentage is till 3%.

·       For normal fabric minimum 10% of bulk fabric, Low stretchability fabric minimum 30%, High stretchability fabric 100% of bulk fabric should be tested.

·       When fabric shrinkage exceeds the tolerance or show too high then 100% should be perform 100% test.

Law to calculate shrinkage:

 

Before wash MMT – After wash MMT * 100

                            Before Wash MMT

             *Note: The same way to calculate length & width.

 

32. What is yarn count.

Answer:

Count is a number which indicates the mass per unit length or the length per unit mass of yarn. It also expresses weather the yarn is thick or thin.

 

Another Definition: Count is the mass of a single length of yarn or the length of a single mass.

কাউন্ট হল সুতার একক length এর ভর বা একক ভরের length প্রকাশ করে

 

There are mainly two types of yarn count system –

A.    Direct system

In the direct system length should be constant & we have to convert the mass.

 

There are three types of direct count –

a.     Tex count    b.  Denier count   c.    Pound per spindle count

 

B.    Indirect system

In the indirect system mass should be constant & we have to convert length.

 

There are three types of indirect count –

a.     English count   b.   Metric count   c.   Coarse count.

 

33. What is GSM.

Answer:

GSM stand for “Gram per square meter” (g/m2).

GSM means the weight in gram per square meter of fabric.

GSM is one of the primary fabric quality parameters. When we need to purchase a fabric or need to get the fabric development done, we must mention your fabric GSM requirement.

GSM value depends on fabric content like cotton, elastane, nylon, spandex etc.

 

GSM inversely proportional to stitch length. If stitch increase than GSM will be increase on                                             the other hand if stitch length decreases than GSM will be decrease. Normal tolerance for GSM is   +/- 3%. So, a 300 GSM material can vary in weight between 291 and 309 GSM.

 

GSM measure steps:

 

A.    Cut the fabric with the GSM cutter (gram per square inch).

B.    Weight the fabric with the electric balance.

C.    The cut sample is 100 sq. cm.

D.    The result is the GSM of that particular fabric.

 

            How to calculate GSM:

A.    Multiply by 100 of Average weight of sample.

 

Ø  Firstly, you have to cut 5pcs swatches by sing GSM cutter from the different parts of fabrics.

Ø  Now, Measure the weight of each cutting swatches with the help of weighing balance in one by one method.

Ø  Calculate the average weight of cutting swatches.

Ø  Now, by multiplying “average cutting swatch weight” with 100, we can easily get the actual fabric’s GSM.

 

Fabric’s GSM = Average cutting swatch weight × 100

 

 

Another System:

 

 

34. What is shade blanket? How to make shade blanket?

Answer:

For every style, after receiving all the bulk fabric to ensuring all the fabric rolls are in acceptable color range, we should make shade blanket. From each roll cut 8” x 6” & roll number should be marked on the backside & join all fabric swatches together by overlock stitch.

 

35. What are Trims?

Answer:

Trim is all the components of a garments except fabric that are attached to a garment.

For example – thread, button, zipper, rivet, label, elastic, interlining, draw cord etc.

 

36. What are Accessories?

Answer:

The materials, which are used to make a garment attractive for sale and packing, other than fabrics and trims, are called Accessories.

For example – Price ticket, size tag, safety pin, leg sticker, arrow sticker, iron sticker, poly sticker, back board, hanger, poly bag, clip, collar stand etc.

 

37. What Is Inventory?

Answer:

After receiving any kind of item from supplier verifying the quantity & right items as per invoice before quality inspection is called inventory.

 

38. Describe Trim/Accessories inspection procedure?

Answer:

Inspection is a practical method of selecting a certain quantity product in a certain way before finally selecting any products.

 

Trim/Accessories Inspection:

All Trims and Accessories should be inspected by lot wise. Customer can suggest different procedure for inspect. Basically, there are two types of trim/accessories – Countable & uncountable. Inspect the countable items through 1.5 AQL & for uncountable item can follow sample size 10% randomly from whole qty or 10% from every size/box/cartoon/packet which is depends on customer requirement.

 

·       If inspection get fail than should inspect 100% items as per SOP.

·       If any critical defect found will be consider as 0 tolerance & whole lot will be rejected.

·       Inspector should calculate root Cause & Make CAPA & provide document to the appropriate authority for further action against supplier.

·       Rejected trims must have to keep in dedicated reject trim keeping area & should follow the buyer recommended disposal process.

·       All trims must be checked using buyer approved light source.

·       Branded trims like Brand label should keep in a secure area with lock & key. Key must be handled by nominated person only.

·       Every inspection record should be noted in a register book & keep till customer requirement date.

·       Trims should store separately as follows:

A.    Trims are not inspected (waiting for inspection) in one place (Quarantine Area).

B.    Trims inspected & passed in one place.

C.    Trims inspection failed should keep in non-confirming area with red mark.

 

Tools of Trim/Accessories Inspection:

 

A.    Approved Trim card/Sample

B.    BOM sheet

C.    Style’s technical file

D.    Defect classification list

E.    Defect picture

F.     Weight Machine

G.    Measurement Tape

H.    Light Box

I.      Vernier Scale

J.     Pull test Machine.

Trim/accessories Defects:

A.    Printing Mistake                       I.   print Spot

B.    Letter Mistake                          J.   Spot

C.    Color Mistake                           K.   Broken

D.    Color Problem                          L.   Measurement problem

E.    Size Mistake                            M.   Off Position

F.     PO Mistake                              N.   printing Blur

G.    Style Mistake

H.    Logo Mistake

               Critical Defects:

A.    Incorrect country of Origin

B.    Fabric composition

C.    Care instruction / symbol problem

D.    Size discrepancy

               Points to be maintained:

A.    Quarantine Area

B.    Inventory

C.    Approved Trim card

D.    Trim Inspection

E.    CAPA report

F.     Non-confirming box with invoice & register & authorized by nominated person.

G.    BIN card

H.    Metal pass report

I.      Nikal test for zipper

J.     Color fastness test for DTM items

K.    Trims store separately Buyer/style/PO wise.

L.     Brand trims secure with lock & key system

M.   Inspect 10% from Each size/cartoon/bag/poly or not need to verify.

N.    Sharp tools report New & returned

O.    Sharp tools box & verify as per the document.

P.    Housekeeping

 

39. Describe FIFO & LIFO system?

Answer:

 

FIFO: FIFO stand for “First in first out”

The product that came first it will be issue first this is called FIFO system.

 

LIFO: LIFO stand for” Last in first out”

The product that came last it will be issue first this is called LIFO system.

 

40. Describe the importance of store management system in apparels?

Answer:

Store management system is significant in garments industry. it is essential to maintain a well-organized and well-equipped inventory system. Proper storeroom management in apparel industry can reduce wastage of materials and lead time. The main responsibility of this department is to store all the raw material & handover those materials to the relevant department when they required.

·       Reduce wastage

·       Further Need to learn from sir

 

41. Describe cutting procedure accordingly?

Answer:

A.    Follow cutting plan & relax the fabric as per requirement.

B.    Collect marker from CAD room

C.    Fabric Spreading will be done based on Shade grouping.

D.    Check all spreading checkpoint like Table marking -Ends -Leaning –Tension -Narrow Goods -Remnants -Counts -Ply High -Marker Placing -Fabric Flaws & make the spreading report.

E.    Maintain lay chart roll wise.

F.     After finishing lay spread the marker by spread man.

G.    Before cutting, operator will attach clamp, Gum tap on the layer.

H.    Cutting Quality will check marker and verify the marker.

I.      After completing cutting quality inspector will check top, middle & bottom using hard pattern.

J.     Do numbering & bundling, identify each bundle by style, cutting number, bundle number, size, serial number, shade number & parts name.

K.    Inspect 100% cut panel by quality inspector.

L.     If any defective panel found, will be replaced from lay chart wise.

M.   Light color bundle should be bind with light color string & dark color bundle should be bind with dark color string.

N.    Keep the bundle style wise in the cut panel keeping rack & should be covered by poly.

O.    Then deliver all cut panel as per plan.

 

42. How many qualities check point are in cutting section?

Answer:

 

Quality checkpoints of cutting section may divide by 5 category-

A.    Fabric Quality Inspection

B.    Marker Quality Inspection

C.    Spreading Quality Inspection

D.    Cutting quality Control

E.    Cut Panel Quality Inspection

 

43. Describe fabric Relaxation procedure?

Answer:  

 

 

 

 

 

 

 

 

 

 

 

44. Describe fabric quality inspection in cutting section?

Answer:

After receiving fabric from the store to cutting section, quality inspector should be check roll to roll fabric shade group, Fabric GSM & Diameter check.

 

Shade grouping: Factory purchase many rolls for a style. There is possibility of shade variation among the rolls of same style. Also, fabric shrinkage & GSM can be different. By doing fabric grouping we may know how many types of shade there in the style are. It helps to minimize waste, avoid shade variation, marker efficiency & meet lead time in the cutting section.

Shade band prepare prior to cutting. Sometimes, the shade of the fabric goes out of tolerance of color matching. In those cases, factory needs to take approval from buyer whether all shade bands are okay for cutting. Buyer may reject fabric shade which falls out of tolerance.

45. Describe marker quality inspection in cutting section?

Answer:

Marker is a paper which contains all necessary pattern for all sizes for a particular style of garments. Marker made by CAD room. Marker laid on the top of the fabric layers. Marker inspection may run a parallel way for saving time.

 

Marker quality check points:

A.    Marker length & width

B.    Marker efficiency & consumption

C.    Marker type

D.    Lay quantity

E.    Marker ratio

F.     All individual parts of garments are marked in marker.

 

46. Describe spreading quality inspection in cutting section?

Answer:

Proper spreading is important to cut the fabric, sewing & keep proper shape. For spreading requires a flat, smooth surface. Spreading layer quantity depends on fabric & buyer requirement. When marker check is done then start the spreading check.

 

Spreading quality check points:

A.    Check the number of lay as it should not exceed the standards.

B.    Check lay end

C.    Check lay tension

D.    Check lay height

E.    Check lay length

 

47. Describe 100% cut panel quality inspection in cutting section?

Answer:

After cutting the lay must check 100% cut panel by quality inspector. If inspector found any defective panel, he should send the defective panel for replace. After getting replaced panel check the panel & put into bundle according to the panel number & the rejected panel should keep in non-confirming box & update the record. During replace cut panel should use hard pattern. After complete checks send for final bundling & keep it to cutting rack.

 

Cut panel quality check points:

A.    Pattern check

B.    Shade check

C.    Size wise ratio check

D.    Fabric check (Visible defects).

E.    Bundle check.

 

48.What is lay? Classification of lay?

Answer:

In the cutting section a specific number of fabric plies laid on cutting table & cut at a time is called lay. A lay is also called a cut.

 

Layer: In the lay, every single ply defines as a layer.

 

Lay length: The length of the fabric ply in lay is called lay length. The lay length is planned according to the marker length.

 

Lay Height: After complete spreading of fabric on cutting table we get a certain height of the lay. The height of the lay depends on fabric thickness. Different fabric & customers have various requirement on lay height.

 

There are 3 types of lay –

A.    Single lay

B.    Half lay

C.    Full lay

 

**Sewing

 

49. What is Sample/Types of samples?

Answer:

Sample is one kind of standard which represents a batch of products their quality, style, design, or any other characteristics of the product.

Sample which is approved by buyer is called approved sample.

 

There are many types of samples –

A.    Fit sample

B.    PP sample

C.    Showroom sample

D.    Size set sample

E.    Gold seal sample

F.     Shipment sample

G.    Counter sample

H.    Top sample

I.      Photo sample

J.     Sales sample

K.    Development sample

L.     GPT sample

 

 

 

50. Describe PP meeting & checklist of PP meeting?

Answer:

PP meeting refers to a pre-production meeting.

Pre-production meeting is a discussion meeting of every important issue to the bulk production through present of all section head & representative of buyer where discuss all about the manufacturer process, potential production problems, technical risk factors & possibility for specific style for further proceed.

 

In the meeting must present all the department head & representative of customers.

Meeting can be held in the supplier factory or buying house.

 

Checklist of PP meeting:

 

A.    Approved sample

B.    Approved trim card

C.    QA file

D.    PO sheet

E.    Tech pack/PDM

F.     Buying house comments on approved sample

G.    Approved wash standard / Shade band

H.    Shade blanket / shade card

I.      Size set or pilot garments covering all size

J.     Measurement spec

K.    Before & After wash Measurement report

L.     Workmanship report on Pilot garments

M.   Shrinkage test report

N.    Fabric test reports

O.    Fabric & trims inspection & inventory report

P.    Button pull test report (If applicable)

Q.    Pattern

 

Activities of PP meeting:

A.    Fabric inspection & sample process

B.    Potential production problems according to the fabric behavior

C.    Fabric quality, Shrinkage, shade, wash issue

D.    Measurement grading

E.    Fabric Relaxation

F.     Measurement

G.    Print / Embroidery (If applicable)

H.    Sample comments

I.      Critical operation

J.     Risk factors with analysis

K.    QA check

L.     Pressing

M.   Folding

 

Major works of PP meeting:

 

·       PP sample evaluation with an approved sample

·       Measurement evaluation

·       Garments construction checking with approved sample

·       Checking the washing effect as per buyer requirement

·       Pattern correction

·       Giving instruction to every department of their specific responsibility.

 

51. Document control checklist of sewing line.

  Answer:

A.    Style file

B.    End line Quality report

C.    Inline Quality report

D.    CAP report for inline & End line both

E.    Traffic light report

F.     Traffic light CAP report

G.    Style check report

H.    Risk assessment report

I.      Style awareness report

J.     Historical Document

K.    OB sheet

L.     MCP

M.   Bundle control report

N.    Measurement report

O.    Mockup

P.    Standard garments

Q.    Defective garments

R.    Work instruction

S.    Job responsibility

T.     Defect library

U.    Defect classification list

V.    Machine maintenance log

W.   Preventive maintenance schedule

X.    Machine calibration record

 

52. What is size set?

Answer:

Size set sample is a set of sizes that factory provide to the customer or use to develop the product in factory. Size set sample make by covering all colors & sizes, use all actual fabric & accessories for styling sample.

 

 

53. What is pilot run?

Answer:

Before starts bulk production factory go for a pilot run covering all the sizes to ensure measurement & construction of garments. The main purpose is to fix the measurement within the tolerance. Buyer procedure is before bulk cutting start pilot run has to pass through buyer otherwise bulk cutting cannot proceed.

 

Purpose of pilot run:

A.    To avoid mistakes.

B.    To ensure the measurement of bulk production.

C.    To ensure garment construction

 

54. What is PP sample in textile?

Answer:

PP sample is the short name of Pre-Production sample. pp sample is a standard which is followed to make a specific batch of garments.

PP samples used to check the product style, functionality, production process, construction etc.

 

55. What is the definition of label? Classification of label.

Answer:

A label is a communicator between the buyer and the product. It contains various types of information of that garment, such as buyer name, country of origin, types of fabric, types of yarn, fabric composition, garments size, special instruction about care, etc.

There are many types of labels –

A.    Main Label

B.    Size label

C.    Care label

D.    Composition label

E.    Flag label

F.     Date label

G.    Side label

H.    Special label

Main Label: Main label is the identification of buyer. No garments are                                                                produced without main label. Main label contains brand name, Brand                                                                logo, Trademark, Brand beginning year, Fit information etc.

Size Label: Size label shows the size of the garment. But sometimes                                                                size can be mentioned on main label in that case size label is not                                                                       required. It contains size.

Care Label: Care label contains washing care with symbol, drying                                                                    instruction, pressing instruction, Fabric content, Buyer name, logo,                                                                    Style, PO, sometimes size etc.

Composition Label: composition Label contains the composition                                                                       of the garments.                                                                                                                                                   Example: 100% Cotton, 65% Cotton & 35% Polyester etc.

Date Label: Date label contains the manufacturer date of the product.

Flag Label: The flag label is a very small label that contains                                                                              Brands name or Brands logo of the buyer.

Special Label: Sometimes the buyer is advised to use the special                                                                       label in the garments to attract the customers to their items.                                                                                    Special labels are 100% silk, 100% Cotton, and 100% Leather, etc.

56. Describe needle procedure in textile.

Answer:

Needle is the carrier of sewing threads. The stitching is done by the help of needle. Different types of needles are used in various factors.

 

Different parts of a needle:

A.    Butt

B.    Shank

C.    Long groove

D.    Eye

E.    Short groove

F.     Point

 

 

Needle procedure:

 

Needle changing procedure:

 

If need to change needle line operator should inform to the line mechanic. Mechanic will open the needle & it will be change from needle room by operator then mechanic will put the needle in the machine. Operator / Supervisor cannot open or put needle in the machine.

 

All types of changed needle should keep in a secure cabinet & except the authorized person no one can open the cabinet. There should be two authorized person whose picture should be displayed.

 

All the replaced needles should be documented with proper details in a register also that needle must post with document through appropriate system. Different customers have different requirement to store the document but generally at least 1 year keep the record. After that dispose the report with needle to present relevant person & must keep disposal document.

Use box to carry the needle & needle man can provide one needle against one needle.

 

 

 

Broken needle procedure:

 

If any needle broken during operation operator should stop his work inform line mechanic & supervisor. Altogether must try their best to find out the part of broken needle around the machine & garments, bobbin case, fit dog, through etc. through hand detector or magnet.

 

If found all parts of broken needle man will keep record in register with all broken parts of needle. Safety or compliance officer must observe regularly needle man activities.

 

If broken parts of needle won’t be found supervisor & compliance or safety officer should take all the garments even bundle around the machine to metal detector machine for check. In the meantime, line mechanic will put a needle to the machine & keep continue production.

 

All the garments must pass into the metal detector machine to present safety & compliance officer. If needle won’t found, then garments can send to the production floor.

 

If get positive result from metal detector check the garments & find out physically the all parts all broken needle. If all parts found, then can send the garments to production floor.

If not found after getting positive result, keep the garments into the non-confirming box & keep document as well.

 

Idle needle procedure:

 

IF any machine doesn’t need in operation, we consider it as an idle machine. Mechanic will open the needle from idle machine & must carry through a needle carrying box & handover to needle man. Needle man should store the needle with proper system & keep document as well. Safety officer, compliance or mechanic manager should regularly observe the idle needle document.

 

Unusable needle procedure:

 

There should be a team by admin manager, compliance officer, safety officer, security, maintenance manager & others relevant department responsible person if need.

In every 3 month all the unusable needles will be disposed with present all the team member outside of factory in a dedicated area.

 

57. What is trim card? What kind of thing contains the trim card?

Answer:

 A trim card is used to show approved trims by attaching all garment trims and accessories on the trim card.

·       Trim card contains all the accessories physically & approved by merchandiser or buyer.

A.    All types of all labels covering all sizes.

B.    Button, Rivet, Zipper, eyelet, draw cord.

C.    Heat seal, fabric, interlining.

D.    Price ticket, Hand tag, Price sticker, Leg sticker, Size tag etc.

E.    All the threads need to make the garments etc.

Uses of trim card:

 

·       Storeroom use the approved trim card to verify incoming trims, accessories & issue to sewing line.

·       Quality supervisor needs the trim card during line lay out.

·       Quality inspectors need the approved trim card during checking garments.

·       During style check must follow the trim card to ensure all the accessories.

·       GPQ or buying QC use trim card during pre-final or final inspection.

 

58. What is mockup? Why should we use mockup?

Answer:

Mockup is a quality sample for a specific process. During operation operator needs a sample on his process which he should be followed. It is a one kind of standard. Operator should not proceed his work except mockup. It must be posted Infront of operator.

 

59. What is the definition of seam? Write down classification of seam?

Answer:

Seam is joint between two or more parts of fabric layers, leather, or other materials together with stitches. There are many types of seams –

A.    Lapped seam

B.    Bound seam

C.    Decorative seam

D.    Super impost seam

E.    Flat seam

F.     Busted seam

G.    Plain seam etc.

 

60. What is stitch? Classification of stitch?

Answer:

Stitch can define as a loop which is create by thread & yearn.

 

There are many types of stitch –

A.    Lock stitch

B.    Hand stitch

C.    Chain stitch

D.    Single thread chain stitch

E.    Multi thread chain stitch

F.     Covering chain stitch

G.    Over edge stitch

 

61. What is DHU? How to calculate DHU?

Answer:

DHU: DHU stand for “Defect per hundred unit”. It means number of defects found per 100 garments. Need two things to measure DHU percentage - one is the quantity of defect you found & another one is the quantity of garments you inspected. Duh percentage should be below 3% in sewing section.

 

DHU = Total defects found * 100 / Total garments inspected

 

62. What is OQL? How to calculate OQL?

Answer:

OQL stand for “Observed Quality level”. OQL is the percentage of defects that are found during inspection.

 

OQL = Total defects found * 100 / Total Sample garments

 

63. Describe about quality inspection in sewing line?

Answer:

Sewing Is the key process of every garment industry. Sewing makes the full garments construction. Cutting section just cut the fabric as per marker. Finishing section mainly for complete the makeup & increase the beauty of garments by ironing & ticketing items.

 

Inline inspection:

Inline quality inspector checks 100% garments of partially stitched garments & defect free garments forward to the next process. In the assembly line generally check points are kept for the critical operations. Inspector should write the operator identification in which process he found defects & take a corrective action plan with documentation. Through the documentation they can easily find out how many defects operator has done Then one day. After that the result will be added for monthly summarization for the quality evaluation process. The hourly record is very important for make root cause.

 

Endline inspection:

Endline quality inspector checks 100% stitched garments. He also should write operator identification from which process problem coming often then he can take corrective action easily. Compare both inline & endline reports to see the efficiency of quality inspector. It also will help to summarize the monthly quality evaluation.

 

Traffic light system (TLS): This system used to stop producing defect at from the source & measure the operator performance. In the system every operator has one card to measure of his performance. In every two hours nominated Inspector go through all the operators & check randomly 5 pieces garments on that process. If he does not find any defect, he put green mark on card & hang a green tag on the top of machine it indicates the process is going well. If he found one defect, he put yellow mark on the card also hang a yellow flag on the top of machine & aware the operator about standard. If found more than one defect put red mark & hang a red tag on the top of machine. It indicates the process is not going well need to improve.  After next in the next hour, he finds the process is ok then he put yellow mark on card & hang a yellow card on the top of machine.

   @ Green tag cannot provide directly after red card. Red - Yellow - then green card.

 

Roaming Inspection: Checker roam around the line & check garments randomly from every operation it’s called roaming inspection. He concentrates only that operation at which he is checking.

 

64. Describe Quality SOP in sewing line?

Answer:

Whenever a new style layout will be done following quality activities should be maintain –

 

A.    After starting a new style should arrange a meeting with all quality inspector, Quality supervisor, QA, production supervisor, line chief, PM etc. Discuss about the risk factors, PP comments, Critical points, aware all of them & keep meeting document as well.

B.    Quality inspectors compare 1^st output garments with the sample & approved trim card. If found any discrepancies immediately solve the problem through discuss with his senior.

C.    Quality inspector also checks SPI, thread, label, rest of the trims & first bundle.

D.    Measure all the point at least 5 pieces from all sizes & keep document. If found any process out of tolerance immediately adjust the pattern correctly through discuss with senior.

E.    Bundle cut must maintain as per the cutting report. Short & mistake bundle won’t pass from checkpoint.

F.     Make mockup for every process & hang in front of operator. It should be done by quality controller.

G.    Quality inspector checks 100% garments & not allowed to pass any defective garments.

H.    Any process or size mistake body found send to the operator & after correcting again check & pass the garments.

I.      Every quality inspector report should be updated in every hour. Quality controller should review & sign in every hour.

J.     Find out root cause of top defect, take corrective action plan & keep document as well.

K.    Every running style approved & counter sample approved trim card should display & good & bad mock should hang Infront of every quality inspection table.

L.     Calibrated Measurement tape should hang of every Quality responsible person in sewing line.

M.   Quality inspector job responsibilities & job description should display in local language in front of every inspector.

N.    Defect display board, Defect classification list also need to display in front of quality inspector.

 

65. Describe the styling check (Construction) procedure?

Answer:

After getting first output garments quality controller should take approved PP sample, PP comments, approved trim card, tack pack & measurement spec. He checks every process with PP sample, measure every point & compare with measurement, SPI of all process according to the pp sample spec. Also, he checks every point-to-point position. Checks all the trims with approved trim card like thread, zipper, all types of labels, heat seal (If applicable), draw cord, eyelet etc. If he found any discrepancies at any process immediately take corrective action & fix the process.

 

 

 

 

**Finishing & Packing

66. What are the activities by finishing & packing section in apparels?

Answer:

The main activities of finishing section are thread trimming, ironing, checking garments ultimately. On the other hand, the main activities of packing section are tagging, folding, cover by poly & packing, prepare for shipment & finally deliver the garments to buyer. Mainly the section does the makeup of garments & enclosed the life circle of a garment.

 

67. Finishing quality process standard.

Answer:

 

Finishing section should be perform following activities for quality control –

 

A.    Pull test & pin setting as per customer requirement.

B.    100% garments thread trimming.

C.    100% garments quality inspection.

D.    100% garments key point measurement.

E.    100% garments pressing as per customer requirement.

F.     AQL audit before pack the garments.

G.    Approve trim card should be available at finishing section.

H.    Work instruction, job responsibilities, good & bad mockup, check method, trimming method, pressing method, pressing standard should be displayed at finishing section.

I.      Every style packing approval, folding approval, folding method, packing method etc. should be displayed at packing section.

J.     100% garments metal detection should be maintained.

K.    Check packing accuracy of 100% garments.

L.     20%- or 2-hours audit process should perform.

M.   Keep document against every quality inspection.

N.    Non confirming box & document should maintain for both metal detector & finishing area.

 

68. Describe metal detector procedure?

Answer:

Metal detection is very important part of every garments. It is the final steps to ensure the garments are free from any metal parts. The metal detector machine should install in the packing section.

 

Metal detector machine calibration: There is few types of ferrous card like 1.0 mm, 1.22 mm to calibrates metal detector machine. Buyer prefers which card need to use for their product. Also, there are few types of calibration like 9 point system, 10 point system, 24 point system etc.

 

 

 

After completing the wash of garments, the washing section send garments to the finishing section. Finishing section receive the garments & keep in a dedicated area for further steps & this area is known as wash receive area.

 

69. Describe the shade check procedure in finishing section?

Answer:

After receiving any lot from washing there is process to check shade acceptance of that garments. Before start check must has to be in hand wash standard, approved shade band, & shade must be checked in a light box with proper lighting. They should check shade, hand feel, brushing, whisker, chevron, washing tie & others washing related process. If found discrepancies, they should inform to QA & QC manager & they will take further steps through with washing relevant person.

 

70. Describe the work of trimming section at finishing section?

Answer:

Trimming garments properly is essential for good quality.

Factory should have nominated person for trimming. Generally, it done by helper. There can be different stage inside & outside trimming by separate trimer or both sides can be done by one trimer. Almost every buyer prefers clockwise trimming system. In the section should be displayed clockwise check method, good & bad mockup & trimmers job responsibilities in local language.

Before appoint trimmer should arrange a training with them to aware them about trimming method, their responsibilities & importance of trimming.

 

71. Describe all inspection points at finishing section.

Answer:

 

Primary Quality inspection:

Between trimming & pressing there is a quality check point named primary quality check. In this point quality checks inside of garments. Checks clockwise all the process & keep document hourly basis. Good & bad mockup, Clockwise check method, work instruction, job description in local language should be displayed in front of quality inspector.

 

Final Quality inspection: After pressing quality inspector checks the top side of that garments its known as final quality inspection. They are also following same method & need all same things in the final quality checks station.

 

Get up Quality inspection:

 

20% lot / 2 hours audit: After completing a certain quantity garment from every style/PO/lot QA a team do an audit as per customer preferred AQL. If it become fail quality team will rework 100% lot quantity & reoffer to QA.

 

72. Explain the pull test.

Answer:

Button pull test is used to ensure the pulling strength of button, rivet, eyelet etc. attached with garments. For the pull test you must follow buyer requirement pulling strength. If buyer does not provide requirement, you should follow your company standard. Standard procedure is continues pulling 10 seconds in 90 newtons. If any items fail, that should be removed from production & keep separated as reject.

 

73. Explain the pin setting.

Answer:

Pin setting need to maintain for snap button. Snap button made by metal. Various types of snap buttons use in garments. It is one of the major safety issues in garments. It ensures the snap button are in the right process into cloth.

 

For pin setting should follow the technical data sheet provided by supplier & need a vernier scale to measure.

 

74. Describe the garments folding method?

Answer:

 

75. Describe the garments Packing method?

Answer:

 

 

 

76.What documents need in hand before starting pre-final inspection?

Answer:

 

   Required documents for pre-final Audit:

·       Packing list

·       PO Sheet

·       BOM sheet

·       UPC check sheet

·       Master file

·       Approved trim card

·       Wash standard

·       Shade band

·       PP sample

·       Tech pack / PDM /

·       Measurement spec

·       Garments test reports (As per requirement)

·       Any kind of approval (If available)

 

77. What is shade? What is running shade in fabric rolls?

Answer:

 

Shade:

Shade is depth of color or hue. It’s a very common word in dyeing washing, printing & finishing in a garment.

 

Running Shade:

When different shade occurs in same rolls or meter to meter shade variation in a roll is called running shade.

Basically, when dyes cannot migrate properly in the whole fabric roll becomes uneven shade.

 

78. What is shade variation? How to eliminate fabric shade variation of fabric?

Answer: The difference between the approved shade & produced shade is called shade variation.

Shade variation in garment comes due to shade variation in the fabric in an order.

Also, for woven garments due to dyeing & washing shade variation can be happened in garments.

 

Steps to eliminate fabric shade variation:

Shade variation can be controlled if an SOP is set & follow accordingly from fabric inspection to finishing.

A.    During fabric inspection check the variation & categorize them based on fabric shade. If there is wide range shade which is out of tolerance reject the rolls or should take approval from buyer.

B.    Prepared shade band with all shade & take approval from buyer.

C.    While spreading fabric fir cutting, spread same shade fabric rolls.

D.    After cutting number the all the parts of fly to keep same sequence number of all parts.

E.    For replacement of defective parts fabric should take from same rolls or shade & keep same place in bundle.

F.     100% garments all parts ply number should be checked during operation in sewing.

G.    Bundling system should be implement in sewing line.

 

Washing shade variation:

Shade variation is a common issue in dyeing & washing. Shade matching depends on the accuracy of the man’s eye. Shade may have different comments from different person. So, dyeing expert is needed for this purpose.

Shade should be check after dyeing & washing & finishing. In the washing section shade should be segregated grade wise & follow the approved shade band range.

 

Pre-cautions to avoid shade variation:

A.    Fabric team should categorize shade grade wise.

B.    During cutting should not mix different grade rolls in same spreading.

C.    100% cut panel of all parts should number properly.

D.    In sewing must follow the ply number & has to avoid number mistakes.

E.    After wash, washing team will check 100% garments & pass the garments according to Approved shade band & wash standard.

F.     In the finishing section, there should be washing QC team who will check shade before pack the garments.

 

79. What is bundle & bundle cut in sewing section?

Answer: In this system, bundle of garments parts moves in sequence from one sewing operator to the next. Each operators receive a bundle of semi-finished garments he performs her process of every single piece garment in bundle then handover to the next operator. Bundle size could vary from 2 to 100 pieces according to requirement. Each bundle contains same style & same size.

A ticket number allocate with every roll which represents style, size, shade, cutting no, pattern, number of cut pieces etc. it is called bundle cut.

 

80.What is oil marks? How to avoid oil marks.

Answer: generally, oil is used to the sewing machine moving parts to get smooth performance. Sometimes oil comes to contact with garments & get oil stain.

 

Pre-cautions to avoid oil stain:

A.    We can use dry-head machine.

B.    Cleaning machine 2-3 times every day.

C.     Before leaving workers can place a piece of clothing under the pressure foot.

D.    Keep your floor dry & clean.

E.    Don’t open machine head into the sewing line. We can use a separate place for maintenance the machine.

 

81.What is puckering? How to avoid puckering.

Answer: Puckering is an irregular seam surface. The unwanted waviness of the fabric along the seam line is called seam puckering.

 

Reason of puckering:

1.     Tension tight.

2.     Feed dog speed.

3.     Operator handling

4.     Uneven allowance of panel parts.

 

To eliminate puckering:

1.     Reduce the tension of machine.

2.     Reset the feed dog speed.

3.     Aware to the operator about the operation system.

4.     If panel parts uneven then correct the pattern.

 

82. What is Skip stitch? How to Skip stitch.

Answer: Skip stitch can define as a failure of loop formation.

 

Reasons of skip stitch:

A.    Wrong placement of needle or unusable needle.

B.    Inappropriate thread size

C.    Machine speed.

D.    Long stitch length

E.    Feed dog & pressure foot.

F.     Fabric thickness.

 

To eliminate Skip stitch:

A.    Change the needle & adjust properly.

B.    Adjust machine feed dog speed & pressure foot.

C.    Use appropriate needle according to fabric thickness & thread size.

 

83.What is pattern in garments? Describe the pattern.

Answer: Pattern is a hard paper on which different component of garments of a particular style are sketched according to the measurement of the garments.

 

Mainly there are two types of patterns –

A.    Working pattern: Working pattern is made according to the exact dimension of particular style without allowance. This is use for sample making

 

B.    Production pattern: Production pattern is made according to the exact dimension of particular style with allowance. This is used for garments production.

 

Working Pattern	Production Pattern
1. This pattern is made according to the exact dimension without allowance.	1. This pattern is made according to the exact dimension with allowance.
2. It is used to produce sample garments.	2. It is used for large production of garments.
3. No cutting, sewing, trimmings mark and allowance have been given.	3. Cutting, sewing, trimmings mark and allowance has been given.
4. No grading is done.	4. Grading is done.

 

There are two methods to make pattern –

Flat method: In this method the pattern of different parts of garments are made by technological drawing by manual or computerized method. In this method fast pattern is possible.

Modeling method: It is a very old &widely used method. In this method block made by standard body measurement of dummy is called toile. Toile is warned out from the body of dummy &individual pattern is drawn on hard paper. It is very efficient but higher time is required.

 

84.What is interlining?

Answer: Interlining is one kind of accessories used between two fabric layers in garments to support, reinforce, and control areas of garments and retain actual shape. It may be applied to base fabric by sewing and bonding.

It can also define as a fabric. The fabrics used as interlining are made of cotton, nylon, polyester, wool, and viscose.

 

 

Types of Interlining:

There are two types of interlining –

A.  Fusible interlining

B.  Sewn / Non-Fusible interlining

 

 

85.Describe the fusible interlining?

Answer: Which interlining can be fixed with garments component / fabric through heat & pressure with a specific type is called fusible interlining.

For fusing recommended temperature is 1650 to 1700 C. Fusing time can be 2 to 20 seconds as pr requirement, and pressure depends on the fusing technique.

 

Advantages of Fusible interlining:

 

·       Appearance, shape, and quality are the same as others.

·       Available in the market.

·       Cheap.

·       Fusing time is less.

·       Labor cost is low.

·       Production is high.

·       Overall performance is better than non-fusible interlining.

·       Easy technique and no need of especially skilled operator.

·       Fusible interlining is used as a work aid.

 

 

Disadvantages of Fusible interlining:

 

·       High temperature is required.

·       Special care is needed during attaching interlining.

 

 

86.Describe the Non-fusible / Sewn interlining?

Answer:

The interlining can be attached with the garments component / fabric by sewing. For the preparation of stitched interlining, a piece of fabric is treated with starch and allowed to dry, and finally sewn with the main fabric.

 

Advantages of Non-fusible / Sewn interlining:

 

Ø  To make flame retardant garments.

Ø  Simple and easy technique.

Ø  No elaborate machine is required.

Ø  Possible to use in steel or re-rolling or highly heated industry.

 

Disadvantages of Non-fusible / Sewn interlining:

 

Ø  Quality is not good.

Ø  Not suitable for large production.

Ø  Not available in the market, so we need to prepare it.

Ø  More time required.

Ø  High workload and labor cost.

 

 

 

 

 

 

 

87.What is AQL? Classification of AQL?

Answer:

AQL stand for ‘Acceptable Quality Level’. AQL is one of the most used terms of selecting cartoon & sample quantity & consider result for a batch of product in garments.

 

Mainly there are two types of AQL –

·       General AQL level

A.    Level l

B.    Level ll

C.    Level lll

 

·       Special AQL level

A.    S1

B.    S2

C.    S3

D.    S4

 

 

Also, there are different types of AQL level –

A.    1 AQL.

B.    1.5 AQL

C.    2.5 AQL

D.    4 AQL

E.    6.5 AQL

F.     10 AQL

AQL consists by 5 parts:

A.    Lot size.

B.    Sample size.

C.    AQL

D.    Accept number

E.    Reject number.