Quality Control And Audit İn Sewing For Trouser Manufacturing
To achieve zero defects standard of garments (trouser manufacturing) from sewing lines to laundry or finishing department, the process flow are as follows:
- All sub-assembly parts (front and back) will be inspected 100% at the end of the last operation of the sewing line. Any defects irrespective of however minor must be returned to appropriate operator/needle point to carry out the relevant repairs. The line manager, supervisor and QA must carry out an hourly check to ensure that repairs and defects are certainly returned to the operator for repairs/rectification.
- At the assembly lines depending on the style and at the PP meeting stage, it will be decided what critical operations are required to implement inspection. Again, this is 100% and responsibilities are as in point 1 above. Example: waist band attach and close in active waistband garments.
- At the end of the assembly line, 3 – 4 QCs will be fully trained and stationed for 100% inspect of the completed sewn garments focusing on all operations including those that were inspected in the sub-assembly. Any defects must be returned back to needle point for rectification or repairs. Again, training, education, and ownership must be passed down the line for ownership purposes. The number of QC’s above will be determined depending on the output of the line.
- Frequent quality checking: A Roaming QC assigned per two-sewing line to audit garments based on 25% of each lot/bundle at a critical workstation which is Waist Band, Seat Seam (Yoke Seam), Back rise, In seam or any other critical points in a sewing line randomly.
- An auditing process will take place based on 25% of each lot/bundle. If one defect is found in any bundle, then the respective bundle will be failed automatically and sent back for 100% re-screen. The defective garments must be returned back to needle points for rectification or repairs. If the bundle has “zero defects” then, and only then, the bundle will pass automatically and it is then transferred to washing or finishing.
Defects take back to at source: Tracking the defects back to the correct operator at needle points is very important to achieve ‘zero defect’ policy and improve the quality of the garments.
- If any operation has more than one operator, then they will put chalk mark/magic pen identification in the garments or panel to identify the respective operator. This identification mark will be identical for each operator to find the correct person.
- In-line, end line quality tables will have defective tags (tags quantity will be based on line output). A tag will be clipped to the defective panel or garment and sent back to the respective operator for repair. After rectification, the panel or garment will be sent to respective QC stations to recheck. If goods have zero defects then only it moves to the next operation. If again found any defects then it will go back to the respective operator.
Sewing in line audits | |||
Operation | Type of QC check | % Bundles audited | PCS Per bundle checked |
Front Panels | Inspection | 100% | All PCS CHECKED |
Back Panels | Inspection | 100% | All PCS CHECKED |
Waist Band Area | Inspection | 100% | All PCS CHECKED ( based on criticality) |
Roaming QC Per two line:a. Seat Seam (Yoke)
b. Back Rise c. Inseam d. Out seam e. Waist Band Any other critical area |
Audit | 70% | 25% of each bundle |
Sew End Line Inspection | Audit | 100% | All PCS CHECKED |
Lot acceptance after Sew end line inspection in Sewing | |||
Lot acceptance (Zero Defects) | Audit | 100% | 25% of each bundle |
Sewing quality inspection processes details | |||
Back & front panels | |||
Back panels: | |||
Quality Checking | Type | Procedure | Checking point |
Inspection | 100 % Inspection | Check every garment of a complete bundle. If any defects found then return to source and repair the defects and then passed to next process. | Back pocket high/low, deco, measure pocket distance, bar tack, seat seam, fabric fault, stitching, shading, sequence |
Front part: | |||
Quality Checking | Type | Procedure | Checking point |
Inspection | 100 % Inspection | Check every garment of a complete bundle. If any defects found then return to source and repair the defects and then passed to next process. | Front pocket, j stitch, bar tack at j-stitch, zipper check, inseam measure length, care label, double-single fly, sequence. |
Sew end line inspection & measurement | |||
Sew End Line: | |||
Quality Checking | Type | Procedure | Checking point |
Inspection | 100 % Inspection | Check every garment of a complete bundle. If any defects found then return to source and repair the defects and then passed to next process. | Check all points of the operations. |
Roaming QC: | |||
Quality Checking | Type | Procedure | Checking point |
Audit | 25% of each bundle must need to Audit | Randomly checked 70% of bundles | Measurement check at inseam, waist band & seat seam, back rise or any other critical areas. |
Lot acceptance (zero defects) after sewing end line inspection | |||
Lot acceptance (zero defects) | Type | Procedure | Checking point |
Audit | 25% of each bundle must need to Audit | If 1 defect found then the bundle will fail and return to a source at defects to repair. Only zero defects of the bundle will pass for the next operations. | Check all points of garments. |
News: Textile Today