Fabric
is the main raw material for apparel industry and it takes 60-70% of total
garment manufacturing cost. Once any fabric consignment received by factory
material department, they have to sent those to cutting QC within 48 hours to
make shade separation, lab test and physical inspection etc. To ensure that
only quality fabric is using in garments, We should take some protective action
and grow up fabric inspection department’s strength with qualified personnel. When
quality team receives any fabric consignment for inspection from store then
they will start below three different steps simultaneously to minimize finished
garments rejection, increase production capability, increase factories goodwill
and quality team faith etc.
1. Make shade swatch
card to identify if there are any different shade within a consignment.
2. Select some rolls
randomly if there is any running shading within the roll.
3. Send every shade to
laboratory to get shade variation report.
4. Shrinkage Test also
required to take a cutting approval.
After that Factory Qc
considered below issues and my responsibility is he done the right way,
1.
Visually inspects and grade from a viewing distance of one yard while the
fabric is in motion. Fabric may be stopped to grade when necessary to affirm
marginal defects and defects may be flagged.
2. Inspect and grade
the total lengths of each role or bolt sample.
3.
Assign points to the defects based upon their length within the plane of the
fabric according to the following option.
4.
Assign no more than a total of 4 points to any one linear yard of fabric,
regardless of the number or size of the detected individual defects.
5. Assign 4 points to
each consecutive linear yard in which a continuous running defect exceeds
9".
6. Assign the 4 points
to each linear yard of fabric where the useable width is less than the minimum
specified.
7. Assign 4 points to
each seam or other full width defect or seam if applicable.
Inspection
result and decided to which fabric is good for cutting:
Pass: Maximum 25 points
per standard length (where standard length is 100 yards).
Yellow
tag: if reject points over 25 and up to 36 point out of 100 yd. will be yellow
tag based on defect conditions, location and nature by considering the
following things.
1) The roll can be cut
by special marker.
2) Replacing defective
yd. can cut the roll, (by 100% panel inspection)
Red
tag: If reject points over 36 out of 100 yd. & worst than yellow tag roll,
which we can't use by above yellow tag's terms & condition this is
considered as red tag.
In that Stage cutting
approval given below issues considered:
Inspection
at cutting section we have to monitored carefully is they done their
responsibility in right way,
To
reduce the defect fabrics and save the production cost for smooth production
quality team are doing inspection in two steps.
Layer inspection:
The main object of this inspection is whether the layers are lying properly and
as per request length. Also during fabrics layering if there is any major
defect in fabrics QC stop the layer for layering. QC team doesn’t accept any
overlapping layer in this stage. For re-placing the reject parts QC use to keep
about five yards of fabrics from every roll.
Quality
inspector makes this report and submitted to cutting QC, concern cutting chief
and merchandising team.
Cut panel inspection:
After placing the serial number in every component of cut panel, inspection
process is started from this stage. Though rolls are accepted in initial
inspection still there are some defects on the roll. So quality team does sort
out those defective components during cut panel inspection. QC replace the
defect component from the balance fabrics, which QC kept from each roll,
depends on numbering. It is mentionable that QC does record how many layers
have completed from each roll to identify the fabric for replacement. The
report we are following call “cut panel inspection report”.
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