Manual on Garment Quality Management

This is the 2nd subject matter of the Diploma Course on ‘Productivity & Quality Management major in Lean Manufacturing”.

Participants: Enrolled student of the Diploma Course in Productivity & Quality Management

Duration/Time: 24 Hours i.e. 32 Session

Objectives of this subject: By the end of this subject, participant will learn –

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

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

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

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Manual on Garment Quality Management

Subject: Garment Quality Management

ContentsModule: 1: Introduction to Quality1.1.What is quality?1.2. Importance of quality? 1.3.Eight dimensions of quality1.4.Quality assurance Vs quality control with example from garment manufacturing process1.5.Organizational structure of quality assurance (QA) department in garments1.6. Job responsibilities of quality management personnel in garments

Module : 2 : Tools & Techniques for Assuring Quality2.1 Standard Operating Procedure (SOP)

2.1.1 What is SOP?2.1.2 Why SOP’s?2.1.3 Advantages of having SOP’s

2.2 Root Cause Analysis (RCA)2.2.1 What is RCA?2.2.2 Benefits of RCA2.2.3 When should RCA be performed?2.2.4 How does it differ from what we do now?2.2.5 How does it work?2.2.6 Corrective action2.2.7 Common RCA tools2.2.8 Verification (before) vs. Validation (after)2.2.9 Follow-up plan2.2.10 Validation and celebrate2.2.11 Example

2.3 7 tools of QC 2.3.1 Cause and Effect Diagram2.3.2 Pareto Analysis2.3.3 Flowchart2.3.4 Run Charts2.3.5 Control chart

2.4 Total Quality Management (TQM)2.4.1 Evolution of TQM2.4.2 TQM philosophy - What's different?2.4.3 Tools and techniques of TQM2.4.4 The TQM system2.4.5 Why TQM effort fail

2.5 Total Productive Maintenance (TPM)2.5.1 Components of TPM2.5.2 TPM activities2.5.3 TPM benefits2.5.4 The 11 basic implementation steps2.5.5 The requirements for TPM to succeed

2.6 Quality Information System (QIS)

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Manual on Garment Quality Management

Module: 3: Quality C ontrol in Textile 3.1 Fabric Defects Criteria3.2 Defects in the knitting fabric

3.2.1 Yarn related defects3.2.2 Knitting elements related defects3.2.3 Machine setting related defects3.2.4 Dyeing related defects3.2.5 Finishing related defects

3.3 Textile Testing3.3.1 Minimum physical testing matrix3.3.2 Minimum chemical testing matrix

Module : 4 : Pre Production – Material Quality Control4.1 Fabric Quality Control

4.1.1 Introduction to fabric inspection4.1.2 Objective of fabric inspection4.1.3 Grading system

A) 4 point systemB) 10 point system

4.1.4 Necessary tools & equipments for fabric inspection4.2 Trims and accessories quality control

4.2.1 Check points of different trims and accessories

Module: 5: Quality Control in Garment Production Process -1 [Cutting Room] 5.1 Cutting Room Quality Control5.2 Basic Cutting Process Quality Defects

5.2.1 Marker making defects5.2.2 Common spreading defects5.2.3 Common cutting problems5.2.4 Bundling and ticketing5.2.5 Common problems of fusing

5.3 Print quality control5.4 Quality Control on Embroidery5.5 10 Points Print/ Embroidery Quality Check5.6 Basic Quality Problem on Embroidery

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Manual on Garment Quality Management

Module: 6: Quality Control in Garment Production Process – 2 [Sewing and Finishing] 6.1 Basic Quality Defects in Sewing6.2 Quality Control on different activities of Finishing Room6.3 Methods & Procedure in Garment Production Process

6.3.1. PP [Pre-Production] Meeting6.3.2. First Bundle Procedure6.3.3. Traffic Light System/ Inline Quality Control6.3.4. Broken Needle and Hazardous Metal Detection Policy

6.4 Finishing Section Quality Control Flowchart6.4.1 Ironing6.4.2 Final inspection6.4.3 Inline AQL6.4.4 Finishing accessories quality assurance6.4.5 Packing quality control

Module: 7: Quality Auditing ( AQL) 7.1 Final audit

7.1.1 Purpose of final inspection or final audit7.1.2 Terms and definitions

7.2 Sequence of final inspection of garments7.2.1 Packing list verify/ compare with PO sheet7.2.2 Audit preparation7.2.3 Carton checking7.2.4 Carton selection7.2.5 Packing and packaging check7.2.6 Sample selection (sample picking)7.2.7 Garments (selected sample) checking7.2.8 Record of defects non-conformances7.2.9 Measurement (dimensional) checking7.2.10 Defective sample draw for reference7.2.11 Pass sample garment through MD machine7.2.12 Carton fill-up7.2.13 Sticker & signature7.2.14 Reporting

7.3 What is AQL Chart & How to Use AQL Chart?

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