Showing posts with label Quality Control. Show all posts
Showing posts with label Quality Control. Show all posts

Friday, June 7, 2013

Internal Quality Audit of Garments


Objective

To ensure that each department works according to the Quality Management System.

Scope

This procedure applies to all internal audit activities within the departments participating in the quality system.
Responsibility

The MR of Muazzuddin Texttile Limited is responsible for the preparation of audit schedules and selecting independent auditors for all departments. The Auditor is responsible for audit and follow up procedures.
Procedure

4.1.1 All departments will be audited at least once in a year. Audits of any or all departments may be carried out more frequently on the advice of Chief Executive /Management Representative or as a result of previous audits.

4.1.2 MR of the organization with his coordinator prepares the Internal Quality Audit Schedule on yearly basis which contains the audit dates and name of the auditors. The schedule is presented to all department Heads.

4.1.3 In case of any change Internal Quality Audit Schedule MR/3/09 may be revised and reissued.
4.1 Audit

4.2.1 Auditor/audit team perform audit, conducts opening meeting with auditee/ departmental head and note down audit results.

4.2.2 Detail of persons interviewed, documents checked and other audit activities are recorded on Audit Activity Log, MR/3/10.

4.2.3 Any nonconformity found during the audit is reported on Nonconformity Report, MR/3/11. Department heads will decide on corrective action and target dated.

4.2.4 For each audit, an Audit Summary Report, MR/3/12 is prepared.

4.2.5 The non conformities are discussed with the auditee in a closing session after conducting the audit and copy of the non-conformity reports are also presented to the auditee on the same day. The auditor prompts the auditee for review of the non conformities raised and agrees on the corrective action and target date suggested by the auditee.

4.2.6 In case of disagreement over a non conformity between Auditors and Auditee, the issue is finally resolved by the Management Representative.

4.2.7 Copy of Audit Summary Report may be provided to the Auditee while original is retained by MR.

4.2.8 In case of second party audit the same procedure is adapted and same reports are used.

4.3 Follow up:

4.3.1 Follow up audit is conducted either by the auditor who conducted the first audit or by other independent auditor assigned by MR, thereby closing NC forms by target dates as stated in.

4.3.2 If in the follow up audit it is observed that action taken on any nonconformity is not effective or not taken then a Corrective & Preventative Action Form, MR/3/07 is raised.

4.3.3 For statistical purposes as an aid to improvement, the Audit Statistics Report, MR/3/13 is completed for each audit.

4.4 Second Party Audit

4.4.1 The second party audits are done by the consultant or any approved source, which is independent of the activities of the organization. The records are maintained as per this procedure.

4.4.2 The Management Representative is responsible for the follow up.

5.0 Related Documents

Internal Quality Audit Schedule (MR/3/09)

Audit Activity Log (MR/3/10)

Non Conformity Report (MR/3/11)

Audit Summary Report (MR/3/12)

Audit Statistics Report (MR/3/13)

CPA Request Form (MR/3/07)

Sunday, May 5, 2013

AQL | Acceptable Quality Limits or Level

Major concept of Acceptable Quality Limit or Level:
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It is the allowable percent defective in a lot. This is introduced according to American military Standard of product inspection rules. There are generally 6 AQL used in textile which are as follows:- 1%,1.5%,2.5%,4%,6.5%,and 10%. Among them 2.5%,4%,6.5% and 10% are widely used and accepted according to price and type of garments.

Uses of AQL: In this system, sample is selected statistical method by using random sampling technique from a lot. After proper inspection along with the test results, the decision is taken, whether the lot will be accepted or rejected. Now a days this system is widely used in garments sector before the delivery. Although it is used from raw material to finished product also.

Acceptable sampling system consists of five parts:
1. Lot size
2. Sample size
3. AQL
4. Acceptable number
5. Reject number

Quality Inspection of factories:
According to JIS, Inspection is defined as “ to measure goods by some methods and by comparison with the results obtained against the criteria to judge whether the individual goods are defective or not

In textile factories the fabrics are inspected at the grey state, after pretreatment, coloration and finishing. After inspection the fabrics are classified according to their quality. Therefore fabrics are inspected to meet the requirements of the customers.

The fabrics are categorized in the following way depending upon the faults:

I. Fresh or First quality: Fabrics, hemming major, minor faults according to buyer specification and requirements.
II. Short length or two parts: It is a piece of cloth having a shorter length( More then 50 cm ). Jar parts become equal to fresh quality. Generally buyers gives (3-5)% discount value for the short length.
III. Seconds: Fabrics containing much objectionable minor defects and (8-15)% discount is allowed.
IV. Fents: Cut pieces of fabric measuring 90 cm or more but less than 150 cm lengths. For fents trade discount is (15-30) %.
V. Rags: Cut pieces of fabric measuring 25 c or more but less than 90 cm. This categories are sold by weight and realization is only about 50% of fresh fabric.
VI. Chilly: These are pieces of 25 cm length fabric less than this. These fabrics are bought & sold and trade discount generally given is ( 50-80).

Quality Parameters of Woven Fabrics to be inspected are as follows:

(1) Dimensional characteristics:
a) Length b) Width c) Thickness

(2) Weight of fabric:
a) Weight/unit area b) Weight/unit length

(3) Fabric strength & Elongation
a) Tensile strength b) Tearing c) Bursting

(4) Threads/inch:
a) Ends/inch
b) Picks/inch

(5) Yarn count
a) Warp count
b) Weft count

(6) Crimp
a) Warp count
b) Weft count

(7) Handle

a) Stiffness
b) Drape

(8) Crease resistance & crease recovery

(9) Air permeability

(10) Abrasion resistance and pilling.

(11) Shrinkages/Dimensional stability

(12) Different fastness properties:-
a) Washing fastness
b) Light fastness
c) Perspiration fastness
d) Rubbing

(13) Flameability

(14) Water resistance or absorption power

(15) Design of fabric

(16) Appearance of fabric

Quality parameters for knitted fabric to be inspected:


1. Strength & elongation
2. Course density
3. Wales density
4. Loop length
5. Deformation
6. GSM
7. Yarn count
8. Design

Wish You Good Luck..................................
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