QUALITY SYSTEMS FOR GARMENT MANUFACTURE.doc

8/10/2019 QUALITY SYSTEMS FOR GARMENT MANUFACTURE.doc

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QUALITY SYSTEMS FOR GARMENT MANUFACTURE

ACHIEVING THE RIGHT FINAL PRODUCT ON TIME

1. PLAN OF THE OVERALL FUNCTION OF QUALITY CONTROL

The cost of qu!"t#

Fu$ct"o$s of Qu!"t# Assu%$ceCo&&e%c"! '($t)es fo%& e*ect"(e co$t%o! s#ste&s

Eco$o&"c s+ects of qu!"t# ssu%$ce

The %o!e of qu!"t# co$t%o!

,. THE ROLE OF QUALITY CONTROL IN THE CONTE-T OF QUALITY MANAGEMENT

Out!"$e of qu!"t# co$t%o! s#ste&s %equ"%e&e$ts

Dt )e$e%te'

%"t"sh /t$'%' 002

3. FINAL PRODUCT /PECIFICATION/

Qu!"t# co$t%o! "$ the s&+!"$)4'e(e!o+&e$t 'e+%t&e$tF%o& s&+!e to fu!! +%o'uct"o$

The /+ec"5ct"o$ !#out

P%o'uct s+ec"5ct"o$ e6&+!es

P%ocess s+ec"5ct"o$ e6&+!es

E6&+!e )%&e$t s+ec"5ct"o$

/e& s+ec"5ct"o$ e6&+!es

Pe%fo%&$ce s+ec"5ct"o$ e6&+!es

7. THE MAIN RA8 MATERIAL 9 FARIC

F:%"c $' )%&e$t '"&e$s"o$s 9 f:%"c st:"!"t# $' 5$"she' ;"'th

F:%"c "$s+ect"o$ 9 e6&"$t"o$ of f:%"c o$ %ece"+t

0. A/IC /EAMING TECHNOLOGY

s"c tech$o!o)# of se&s

/t"tch fo%&"$) ct"o$

Qu!"t# chec


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G%&e$t e6&"$t"o$

/ee"$) co!o% $' the e*ect of t#+e of "!!u&"$$t o$ the ++%e$t sh'e of s&+!e

E*ects of "$te$s"t#> $)!e of "!!u&"$t"o$ $' t#+e o$ the ++%e$t sh'e of

s&+!e

E*ects o$ sh'e of othe% co!o%s "$ '?ce$t %es

Mou$t"$) $' '"s+!#"$) fo% ("e;"$)Co!o% ("s"o$

.= chec

Qu!"t# Co$t%o! Requ"%e&e$ts 9 O%'e% of P%"o%"t"es

THE CO/T OF QUALITY

INTRODUCTION

A &$ufctu%e% st#s "$ :us"$ess o$!# s !o$) s h"s +%o'uct qu!"t# st"s5es h"s

custo&e%s t the +%"ce the# %e +%e+%e' to +#.

F"!u%e to &"$t"$ $ 'equte qu!"t# st$'%' c$ the%efo%e :e '"sst%ous. ut

&"$t"$"$) $ 'equte st$'%' of qu!"t# !so costs e*o%t. F%o& the 5%st

"$(est")t"o$ to 5$' out ;ht the +ote$t"! custo&e% fo% $e; +%o'uct %e!!# ;$ts>th%ou)h the +%ocesses of 'es")$> s+ec"5ct"o$> co$t%o!!e' &$ufctu%e $' s!e> to

the %%$)e&e$ts fo% fte% s!es se%("ce to the custo&e%> e*o%t "s :e"$) s+e$t o$

e$su%"$) tht the co&+$#s +%o'uct 9 $' %e+utt"o$ 9 %e )oo'. If "t "s s+e$t

;"se!#> "t c$ %esu!t "$ s("$)s )%ete% th$ the "$c%ese "$ costs> $' he$ce "$ $

"&+%o(e&e$t to +%o5ts.

As +%o'ucts :eco&e &o%e $' &o%e co&+!e6> $' s custo&e%s 9 :oth Go(e%$&e$t

De+%t&e$ts $' "$'"("'u!s 9 :eco&e &o%e co$sc"ous of the e*ects o$ the"% o;$

eco$o&"cs of %ece"("$) +%o+o%t"o$ of 'efect"(e "te&s> the e*o%t %equ"%e' &ust

co$t"$u!!# "$c%ese.

The costs %e+%ese$te' :# th"s e*o%t c$ :e s")$"5c$t +%o+o%t"o$ of the +%o'uctss!es (!ue BDo #ou


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He%e ;e 'esc%":e the $tu%e of the costs "$cu%%e' "$ %"$) +%o'uct qu!"t# $'

%e!":"!"t# $' sho;s ho; costs c$ :e %e'uce' ;h"!st qu!"t# $' %e!":"!"t# %e

&"$t"$e' o% "&+%o(e'.

THE NATURE OF QUALITY CO/T/

Qu!"t# costs f!! $tu%!!# "$to th%ee &"$ )%ou+s. F"%st the%e %e Costs ssoc"te'

;"th tt"$"$) o% sett"$) $ 'equte qu!"t# st$'%'> so&et"&es c!!e' P%e(e$t"o$Costs. The# %e "$cu%%e' !%)e!# "$ '($ce of +%o'uct"o$> ;he$ the qu!"t# st$'%'

"s set. I$suc"e$t &o$e# s+e$t t th"s st)e o$> fo% e6&+!e> 'es")$ $'

'e(e!o+&e$t ;e!! )"(e %"se to u$$ecess%"!# h")h costs !te%.

The seco$' )%ou+ "s costs ssoc"te' ;"th &"$t"$"$) $ 'equte qu!"t#

st$'%'> so&et"&es c!!e' A++%"s! Costs. These %e the costs ssoc"te' ;"th

o% the costs ssoc"te' ;"th +utt"$) %")ht

$# 'e+%tu%e f%o& st$'%'. These "$c!u'e the costs of sc%+> %e+%ocess"$)> $'

)u%$tee c!"&s. The# %e the costs> ;h"ch %"se s %esu!t of sho%tco&"$)s "$> o%

"$suc"e$t e6+e$'"tu%e o$> the othe% t;o +hses. The# :e cuse' o$ the o$e

h$' :# +oo% 'es")$> +oo% +%o'uct e$)"$ee%"$)> +oo% o+e%t"(e t%"$"$) o%> o$ the

othe%> :# :' ;o% the &ost s")$"5c$t "&+%o(e&e$ts ;"!! usu!!# :e ch"e(e' :#co$ce$t%t"$) e*o%t o$ the %es of h")h cost. Fo% th"s +u%+ose $ $!#s"s of the

+%"$c"+! costs "s %equ"%e'. /tu'"es h(e sho;$ tht f"%!# t#+"c! %t"o :et;ee$ the

th%ee &"$ )%ou+s of costs "$ &$ufctu%"$) co&+$# "s 9

P%e(e$t"o$ Costs 0

A++%"s! Costs 32

F"!u%e Costs 9 =0

F"!u%e Costs> :ecuse the# %e t#+"c!!# the !%)est> ;"!! usu!!# )"(e the !%)est

%etu%$ fo% the e*o%t "$(o!(e' "$ %e'uc"$) the&. A$ e*ect"(e ;# of ttc stt"st"c! s&+!"$)

tech$"ques :e use' s &e$s of co$t%o!> "$'"ct"$) t%e$'s "$ +e%fo%&$ce


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$' ss"st"$) to &"$t"$ qu!"t#. # "&+%o("$) the co$t%o! of the +%ocess> 122 +e%

ce$t "$s+ect"o$ $o !o$)e% :e $ecess%#.

Tot! costs ;"!! :e !o;est ;he$ 'es")$ st* %e ;%e of the cost "&+!"ct"o$s of

the"% ;o% 'e(e!o+"$)> test"$)> &$ufctu%"$) $' "$s+ect"$)

+%ocesses. Ho;e(e%> the%e &ust c!e%!# :e +o"$t :e#o$' ;h"ch "t ;ou!' :e

u$eco$o&"c to "$cu% ''"t"o$! e6+e$se. F"!u%e costs &")ht +oss":!# :e e!"&"$te'

:ut t co$s"'e%:!e> +oss":!# +%oh":"t"(e> costs "$ othe% %es. The%e "s +o"$t t

;h"ch the ))%e)te of !! costs "s t &"$"&u& fo% the "$te$'e' se!!"$) +%"ce.

Ach"e("$) th"s &"$"&u& cost ;"!! "$(o!(e %e("e;"$) +%o'uct 'es")$s> $' "&+%o("$)

+!$$"$) +%ocesses> fc"!"t"es $' &etho's.

8he$ the "$"t"! ttc< o$ costs hs :ee$ successfu!> "t ;"!! :e !o)"c! to +%o("'e

&e$s fo% $!#s"$) costs $' fo% %e+o%t"$) o$ the& "$ o%'e% to 5%st!#> ;o%th;h"!e %e'uct"o$ "$ the ttc the e6+ecte' "$c%ese "$ othe% costs "s $ot e6cee'e'.

/ETTING /TANDARD/ OF CO/T

Th"s c$ :e 'o$e :# sett"$) st$'%' o% :u')et fo% ech cost "te& *ecte' :# the

ct"o$> $' :# co&+%"$) +e%"o'"c!!# the ctu! cost ;"th the st$'%'. D"*e%e$ces

:et;ee$ st$'%' $' ctu! cost %e the$ $ot"5e' to ++%o+%"te e6ecut"(es ;ho

c$ &o'"f# the tct"cs of the ttc< s $ecess%# to e$su%e tht the '"*e%e$ces %e

%e'uce' o% e!"&"$te'./t$'%'s :e of t;o :# the qu!"t# co$t%o!!e%> ;"th !! the

e6ecut"(es %es+o$s":!e fo% e$su%"$) tht the stu'# e6+ectt"o$s ;"!! :e %e!"e'.

:. The# :e set :# the &o%e9o%9!ess %:"t%%# 'ec"s"o$ of to+ &$)e&e$t to

%e'uce o(e%!! qu!"t# costs :# 9 s# 9 0 o% 12.

I$ co&+$# ;he%e e6ecut"(es %e +%o+e%!# t%"$e' $' &ot"(te'> the 5%st t#+e of

st$'%' "s !" "$ ;h"ch +%o)%&&e% fo% "&+%o(e&e$t "s

utoc%t"c!!# "&+ose'. Act"(e fo!!o;9u+ :# st%o$) +e%so$!"t# "s ch%cte%"st"c!!#

$ecess%# "$ th"s s"tut"o$K to see tht e6ecut"(es %e!!# 'o !! tht "s $ee'fu!.

/t$'%'s ;"!! usu!!# :e set u$'e% co$'"t"o$s> ;h"ch ssu&e ce%t"$ (o!u&e of

th%ou)h+ut $' ce%t"$ !e(e! of "$co&"$) qu!"t#. If e"the% of these fcto%s ch$)es

s")$"5c$t!#> the !e(e! $' :!$ce of costs ;"!! +%o::!# ch$)e !so> $' st$'%'s


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;"!! $ee' to :e '?uste' to su"t the $e; co$'"t"o$s.

A/CERTAINING QUALITY CO/T/

Cost 't ;"!! h(e :ee$ %equ"%e' ;he$ the 5%st stu'# ;s &'e to 'ete%&"$e the

cost "te&s &ost o+e$ to ttc "t :e co$(e$"e$t to h(e "t 'o$e :#

these 'e+%t&e$ts.

Ne6t s#ste& of cost co'"$) to s"&+!"f# $!#s"s &ust :e +%o("'e'. 8he%e co'e

s#ste& "s !%e'# "$ use "t %equ"%e &o'"f#"$) to e$:!e qu!"t# co$t%o! costs to

:e co!!ecte' "$ the &ost &e$"$)fu! fo%&. It "s "&+o%t$t tht the cuses of fu!ts

shou!' :e %e(e!e' $' th"s $ecess"tte "'e$t"5ct"o$ of the &ch"$e> o+e%to%

o% +%ocess ;he%e the !oss %ose.

F"$!!#> o$e &ust 'e5$e the +%oce'u%e to :e fo!!o;e' $' the %es+o$s":"!"t"es of !!

the *ecte' st*.

CONTROLLING CO/T/

The o$!# +u%+ose of %e+o%t"$) costs "s to +%o(o '"%ect> "$te!!")":!e fo%&

9 +%ese$te' to the +eo+!e ;ho h(e the utho%"t# $'


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9 "'e$t"f# the %es of e6+e$se> ;h"ch %e :e"$) %e+o%te'

9 sho; ctu! e6+e$'"tu%e co&+%e' ;"th tht +!$$e'

9 fc"!"tte the co&+%"so$ of :e$e5ts ;"th the +%"ce tht "s :e"$) +"' fo% the&

9 "$'"cte the cuses of e6cess"(e costs so tht fu%the% "$(est")t"o$s c$ :e &'e

$' co%%ect"(e ct"o$ t test %e?ect"o$s> fte%9s!es se%("ce> custo&e% %etu%$s etc. The esse$t"! 't

the# shou!' sho; "$c!u'es the cuse of f"!u%e> the (!ue !ost> $' the 'e+%t&e$t

o% +%ocess %es+o$s":!e B$ot $ecess%"!# the s&e> of cou%se> s the 'e+%t&e$t o%

+%ocess t ;h"ch the f"!u%e ;s '"sco(e%e' $' %e+o%te'.

/u++o%t"$) 't fo% th"s %e+o%t "$c!u'e %e+o%t"$) +o"$t> 'esc%"+t"o$ of +%o'uct>

+%t etc.> $' the %es+o$s":!e &ch"$e )%ou+ o% o+e%t"(e. /uch su++o%t"$) 't "s>

ho;e(e%> +%o::!# :est !eft out of %e+o%ts fo% e6ecut"(e ct"o$. It :e &o%e

(!u:!e "$ '"!#> u$9coste'> %e+o%ts fo% "$fo%&t"o$ $' ct"o$ t Jsho+9oo%J

!e(e!.

The seco$' t#+e "s the A++%"s! Cost Re+o%t. Th"s %eects the cost of o+e%t"$) the

qu!"t# $' %e!":"!"t# su%(e"!!$ce> s co&+%e' ;"th :u')ete' e6+e$'"tu%e. The

'"("s"o$ of ccou$t he'"$)s so&et"&es & test"$)> o% )%'"$) of +"ece +%ts> :ut such costs

c$ so&et"&es :e 'e%"(e' f%o& co&+%"so$ of ctu! $' st$'%' t"&es fo% thets $' "$c!u'e' "$ se+%te sect"o$ of the %e+o%t.

F"$!!#> P%e(e$t"o$ Cost Re+o%t "s %equ"%e'. /o &$# fu$ct"o$s of the t#+"c!

:us"$ess c$ :e "$te%+%ete' s co$t%":ut"$) to P%e(e$t"o$ Costs tht "t "s $o%&!!#

;"se to %est%"ct %e+o%ts to those %es ;h"ch %e :e"$) 'e!":e%te!# (%"e' s +%t of

the o(e%!! cost %e'uct"o$ +%o?ect. The sco+e of such ' hoc %e+o%ts c$ :e e$!%)e'

to "$c!u'e 't f%o& ;h"ch ch$)es "$ Qu!"t# tct"cs c$ :e +!$$e'. /uch %e+o%ts

&")ht "$c!u'e $ $!#s"s of the e*ects o$ +%o5ts of ch$)es "$ the s#ste& of

sett"$) &$ufctu%"$) to!e%$cesK the +%o::!e cost e*ects of "$t%o'uc"$) Ve$'o%

Rt"$) sche&eK %eco&&e$'t"o$s o$ the &ost eco$o&"c! +o"$ts fo% "$s+ect"o$ "$

seque$ce of o+e%t"o$sK $' $ "$(est")t"o$ "$to the eco$o&"cs of :u#"$) $e;test"$) fc"!"t"es.

Note tht "$ stu'"es "$(o!("$) cho"ce of &etho's ;e %e co$ce%$e' ;"th the

ch$)e "$ +%o5t %esu!t"$) f%o& the 'ec"s"o$ 9 tht "s the '"*e%e$ce "$ the +%o5t9$'9

!oss ccou$ts :efo%e $' fte% 'o+t"$) the ch$)e. The costs ;h"ch ;e use fo%

stu'"es of th"s $tu%e %e $ot !"


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u$su"t:!e fo% 5$'"$) the %e! cost> o% ch$)e "$ cost> s"$ce "$ &ost cses the cho"ce

;"!! cuse !"tt!e ch$)e "$ the 56e' +%t of o(e%he' costs> such s est:!"sh&e$t

$' &$)e&e$t e6+e$ses.

RECOMMENDATION/

He%e %e te$ ste+s tht c$ :e t to %e'uce s#ste&t"c!!# #ou% F"!u%e Costs

e. E(!ute the ++%o6"&te +%o::!e :e$e5t of ech ct"o$ "$ %e'uc"$) F"!u%e

Costs

e.). :# ho; &uch ;"!! the custo&e% )u%$tee c!"&s :e %e'uce' Ho; !%)e

%e'uct"o$ "$ sc%+ c$ :e e6+ecte' f%o& Roo& J-J

f. E(!ute the ++%o6"&te +%o::!e cost of ech of these ct"o$s se+%te!#>

e.). ;ht ;"!! e6t% 'es")$ '&"$"st%t"o$ cost Ho; &uch ;"!! h(e to :e s+e$t o$

$e; test )e%

). Choose the o$e o% t;o ct"o$s ;h"ch %e see$ to o*e% the +%o::"!"t# of !%)est

%etu%$ fo% the cost to :e "$cu%%e'

h. M


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those ;ho ;"!! :e %equ"%e' to t ".e. Costs of Att"$"$) Re!":"!"t#

Qu!"t# e$)"$ee%"$) $' test"$) th%ou)h +%e9+%o'uct"o$ st)esK &te%"!

s+ec"5ct"o$s $' 'es")$ to!e%$ce.

T%"$"$) Qu!"t# $' P%o'uct"o$ +e%so$$e! "$ qu!"t# tt"$&e$t.P%e+%"$) test s+ec"5ct"o$s $' qu!"t# st$'%'s.

/+ec"f#"$) test $' "$s+ect"o$ equ"+&e$t.

A'("s"$) o$ s+ec"5ct"o$s of the +%o'uct"o$ fc"!"t"es $ee'e' to &"$t"$ qu!"t#

st$'%'s.

Test"$) $' c!":%t"$) "$s+ect"o$ $' +%o'uct"o$ fc"!"t"es.

Qu!"t# '&"$"st%t"o$.

Re+!ce&e$t of h$' :# &ch"$e o+e%t"o$s.

Re+!ce&e$t of h$' o+e%te' :# uto&t"c &ch"$es.

P%o("'"$) &ech$"c! h$'!"$) fc"!"t"es.

P%o("'"$) 'equte +%otect"(e +c ".e. Costs of M"$t"$"$) Re!":"!"t#

Ve$'o% $' "$co&"$) "$s+ect"o$s.

I$s+ect"$) $' test"$) +%o'ucts $' fc"!"t"es.

F"e!' test"$).

M"$t"$"$)> %e9test"$) $' c!":%t"$) "$s+ect"o$ $' +%o'uct"o$ fc"!"t"es.

3. JF"!u%e CostsJ B;hethe% th%ou)h fu!t#9 9;o% cce+t$ce

st$'%'s> &ch"$e%#> +c


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"t "s so!'.

JRequ"s"te Qu!"t#J "s 'e5$e' s the 'es")$ $' co&+os"t"o$ of +%o'uct> ;h"ch hs

:ee$ tho%ou)h!# +%o(e' :# 'equte 'e(e!o+&e$t ;o% "$ o%'e% to est:!"sh "ts

%e!":"!"t# u$'e% the co$'"t"o$s to ;h"ch "t ;"!! :e su:?ecte' "$ use $' to (o"'

+%o'uc"$) too h")h )%'e of +%o'uct fo% the "$te$'e' &% :ut "t !e(es qu!"t# co$t%o! s $ecess%# :ut

e6+e$s"(e e("!

JTO EN/URE> AT MINIMUM PRACTICALE CO/T> THAT THE REQUI/ITE QUALITY OF

PRODUCT I/ EING ACHIEVED AT EVERY /TAGE OF MANUFACTURE FROM RA8

MATERIAL/ TO O-ED /TOC.

Th"s &e$s s"6 th"$)s

. Chec &te%"!s> &ch"$es o%

;o%


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To &6"&"e' the +%o'uct"o$ of )oo's ;"th"$ the s+ec"5e' to!e%$ces co%%ect!# the

5%st t"&e.

# co$s"'e%"$) such "$fo%&t"o$ "t c$ :e 'ec"'e' ;ht %equ"%es to :e &o$"to%e'.

Mo$"to%"$) the +%ocess "s the esse$ce of qu!"t# co$t%o!.

8e $o; se&s> )%&e$t

Co&&u$"ct"o$s $' fee':c< seque$ces 9 ;"thout ;h"ch the%e c$ :e $o co$t%o!

P%&ete%s 9 &esu%e&e$ts $' to!e%$ces

Reco%'"$) s#ste&s

/t$) 'ec"s"o$s $' the 'e(e!o+&e$t of ?o: s+ec"5ct"o$s

IMPLEMENTATION

Th"s "s the +%ct"c! co$t%o! ++!"ct"o$ to the '#9to9'# %u$$"$) of the fcto%# 9 $'

e6te$'s f%o& the :s"c co$ce+t of st#!e %")ht th%ou)h to the 'es+tch of the

co%%ect :o6e' stoc st#!es> co!ou%s> su"t:"!"t# of co&+o$e$ts $' 5t$ess of +%o'uct fo%

the &%


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%e!6t"o$ $' f:%"c +%o+e%t"es.

:. se;"$) +%o:!e&s

c. cuses $' +%e(e$t"o$ of se& :%e


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su:?ecte' "$ use. Th"s "s the Requ"s"te Qu!"t# of the +%o'uct.

,. A fu!! s+ec"5ct"o$ of the %equ"%e&e$ts of th"s qu!"t#> ;h"ch &ust :e c!e%!#

u$'e%stoo' :# e(e%#o$e co$ce%$e' ;"th the +%o'uct"o$ of the co$st"tue$t +%ts $'

of the co&+!ete e$' +%o'uct.

3. Co$5%&t"o$ tht the &$ufctu%"$) +%ocesses %e c+:!e of &eet"$) these

%equ"%e&e$ts.7. Fu!! cce+t$ce> :# !! those co$ce%$e' ;"th +%o'uct"o$> of the %es+o$s":"!"t# fo%

&eet"$) the st$'%'s set :# the s+ec"5ct"o$.

0. Chec 9 ".e. Fee':c< to P%o'uct"o$> 9 to

e$su%e tht th"s ct"o$ "s t

+%ocess $' o+e%t"(es to &"$t"$ FUTURE +%o'uct"o$ ;"th"$ the s+ec"5ct"o$.

@. I$st%uct"o$ "$ the use> ++!"ct"o$s $' !"&"tt"o$s of the +%o'uct.

. A stu'# of use% e6+e%"e$ce> fee':c< to the 'e+%t&e$ts co$ce%$e'> $' %+"'

%e&e'"! ct"o$.

A$ "&+o%t$t fetu%e to %e!"se "$ the est:!"sh&e$t of these +%"$c"+!es "s tht>

;h"!st to!e%$ces $' qu!"t# st$'%'s fo% )oo's )o"$) fo% 'es+tch ofte$ (%#

%+"'!#> 'e+e$'"$) o$ the u%)e$c# of c!!9o*> "t "s the 'ut# of Qu!"t# Co$t%o! "$

e$ct"$) "te&s 79 :o(e> to st:"!"se the to!e%$ces $' qu!"t# st$'%'s fo%

)oo's IN PRODUCTION> :se' o$ the %eco)$"se' Requ"s"te Qu!"t# $' th"s !%)e!#

est:!"she' f%o& the co$t"$u! e6+e%"e$ce )"$e' f%o& "te& :o(e. O$!# :#

+%o'uct"o$ +e%so$$e! th"s tot! cost "s usu!!# ch"e(e' ;he$

+%e(e$t"o$ costs f"!u%e costs ++%"s! costs> s "!!ust%te' "$ the :o(e

'")%&> $' "$ the '")%& :e!o;9

I$ th"s 5%& the tot! qu!"t# costs ;e%e ++%o6"&te!# 12 of tu%$o(e% B(e%# !o;.

# "$c%es"$) ++%"s! $' +%e(e$t"o$ s("$) o$ tot! costs of 10 ;s e*ecte'.Th"s "s 10 o$ 12 of tu%$o(e%> s# 1.0 of ,>222>222 ".e. 32>222 s("$) "$ cost>

"&+%o(e' +%o'uct> "&+%o(e' 'e!"(e%# t"&es> $' "&+%o(e' custo&e% st"sfct"o$.

A''"t"o$! :e$e5ts ;e%e

Qu!"t# Costs /ou%ces of Cost "$fo%&t"o$

CO/T OF FAILURE

Losses 'ue to fu!t# $' s+o"!t ;o%


13/80

E6&"$e%s %eco%'s

Me$'"$)

Re+%ocess"$)

. ''"t"o$! &te%"!s

:. e6t% !:ou%

c. '"s%u+t"o$ of +%o'uct"o$

A'&"$"st%t"(e Costs

. %ech"$) )%ee&e$t ;"th custo&e%s

:. %e+!c"$) 'efect"(es o% co&+!"$t '?ust&e$ts

c. oce '&"$"st%t"o$

Pe$!t"es of $ot &eet"$) 'e!"(e%# 'tes> e.). f"!u%e to &eet e6+o%t %%$)e&e$ts>

sh"++"$). 9

CO/T OF APPRAI/AL

1. Co$t%o! of outs"'e su++!"es> s!%"es $' equ"+&e$t !ess %ec!"&s f%o& su++!"e%s

e.). test"$) "$co&"$) &te%"!s etc

,. I$s+ect"o$

e.). 1st e6&"$t"o$ $' 5$! e6&"$t"o$.

3. F:%"c o% )%&e$t tests>e.). ;sh tests> #"e!' tests> $' ++e%$ce chec $# othe% chec


14/80

Equ"+&e$t

O+e%t"$) co$s"ste$c# co$t%o!s

Costs $' s!%"es of 'e+%t&e$t +e%so$$e!

E(o!("$) &o%e e*ect"(e +%ocesses

Qu!"t# ;%e$ess t%"$"$) 8)es> ccou$t> $' t%"$"$) costs

M"$te$$ce of &ch"$e%# to &"$t"$ +%o'uct qu!"t#> e.). %e9$ee'!"$) ;"!! :e 'oes "t +# o* Th"s quest"o$ $ee's $s;e%"$) :efo%e&uch t"&e> e*o%t $' &o$e# %e s+e$t.

1. Loo< t the +%ese$t s"tut"o$. Asce%t"$ the cost of f"!u%e "$ the %e ;he%e the

"$$o(t"o$ cou!' :e e6+ecte' to h(e so&e e*ect. A$!#se ("!:!e %eco%'s. If

these %e "$'equte co$s"'e% & :ut 'oes $ot s+o"! cse :#

+%ess"$) fo% "t :efo%e #ou %e too su%e> s"$ce t"&e $' c%e'":"!"t# c$ es"!# :e !ost.


15/80

It "s ;"se to see< t%"! 5%st> the$ the "'e c$ ?ust"f# "tse!f o$ "ts o;$ &e%"ts> o% c$

es"!# :e '%o++e' "f fo% $# %eso$ "t +%o(es to :e u$successfu!.

THE ROLE OF QUALITY CONTROL

1. I$ tot! qu!"t# co$t%o! sche&e> the tot! "$(o!(e&e$t of !! +e%so$$e! "s

%equ"%e' s +h"!oso+h#.

,. The st* co$ce%$e' "$ !! 'ut"es &ust :e )"(e$ utho%"t# to c%%# out the"%

fu$ct"o$s. These fu$ct"o$s shou!' :e 'e5$e'.

3. L"$es of co&&u$"ct"o$ $' %es+o$s":"!"t# shou!' :e est:!"she' to c%%# out $

e*ect"(e +o!"c#. Ho%"o$t! co&&u$"ct"o$ t !! !e(e!s of +e%so$$e! :et;ee$ Qu!"t#

Co$t%o!> P%o'uct"o$ $' othe% 'e+%t&e$ts "s $ee'e'. A!so the%e &ust :e (e%t"c!

!"$es> ;h"ch fo!!o; the !"$es of %es+o$s":"!"t# $' utho%"t#. I$ o%'e% to ch"e(e th"s

"&> the te%&s of %efe%e$ce u$'e% ;h"ch st* ;o% &ust :e est:!"she'. Th"s "s>

+e%h+s> :est cco&+!"she' :# ?o: 'esc%"+t"o$s.

7. It "s the ?o: of Qu!"t# Co$t%o! to est:!"sh the co%%ect "$fo%&t"o$ co$ce%$"$)

qu!"t# s"tut"o$> $' +%ese$t th"s c!e%!# to the"% co!!e)ues.

0. Pe%so$s outs"'e Qu!"t# Co$t%o! &ust :e utho%"se' to & the co$seque$ces of

ech :e"$) fu!!# u$'e%stoo'.

=. P#&e$t sche&es shou!' :e %e9e6&"$e' ;he%e $ecess%# to %e;%' qu!"t# s

;e!! s +%o'uct"o$> "$ :!$ce' ;#> s"$ce :oth %e co&&e%c"!!# "&+o%t$t.

QUALITY CONTROL DATA GENERATED

Dt "s )e$e%te' t ech QC +o"$t. Th"s &ust :e %eco%'e' "$ s"&+!e s#ste&s to

+%o("'e ("su! o$9)o"$) chec '"!s he")ht 9 set to s+ec"5ct"o$.

c. Loo+4cou%se !e$)th 9 Ru$9"$ !e(e!!e' $' to s+ec"5ct"o$> +os"t"(e fee' chec


16/80

F:%"c P%&ete%s> F:%"c o% G%&e$t !$< Chec +tte%$s &tch"$).

e. /e&s 5$"she' co%%ect!#> :se$ce of &"ss st"tch"$)> c%c


17/80

Y%$ Chec ;"th"$ co$es $'

:et;ee$ 'e!"(e%"es to :e ;"th"$ to!e%$ce of s+ec"5ct"o$. If co%se> #%$ ut"!"st"o$"&+"%e'. Chec< o$ %u$$"$) (e%)e.

,. u! $'

o$ 5!&e$tt"o$

3. Co$'"t"o$ Chec %u::"$)> +e%s+"%t"o$> !")hts 9

chec


18/80

/h'e $' s"e chec chec "&&e'"te!# o$ :e"$) )e$e%te'> "s uto&t"c!!# e$te%e' o$

%eco%'s s co$t"$u"t# ch%ts> e"the% "$ t:u!%> )%+h"c! o% co&+ute%"se' fo%&. Th"s

ct"o$ t $' e$:!es the cu%%e$t 't to :e co&+%e' ;"th

+%e("ous 't $' ;"th othe% %e!te' Q. C. 't. The ("su! "&+ct of the

+%ese$tt"o$ "s "&&e'"te $' c%etes %+"' fee'9:c< of ("t! "$fo%&t"o$ to

+%o'uct"o$ $' othe% "$te%este' &$)e&e$t +e%so$$e!.

RITI/H /TANDARD 002

I$t%o'uct"o$

%"t"sh /t$'%' 002 P%t , s+ec"5es qu!"t# s#ste&> ;h"ch "s 'es")$e' to +%o("'e

co&+%ehe$s"(e> co$c"se $' !o)"c! ++%och to tot! Qu!"t# Assu%$ce.

It %e!tes to &etho' of ;o%


19/80

1. Qu!"t# /#ste&

,. O%)$"st"o$

3. Re("e; of Qu!"t# /#ste&

7. Docu&e$tt"o$4Reco%'s

0. Equ"+&e$t

=. Pu%chse' Mte%"!s $' /e%("ces. M$ufctu%"$) Co$t%o!

@. 8o%< I$st%uct"o$s48o% ;h"ch &ust

:e +os"t"(e $' $ot co$'ucte' so!e!# s &tte% of e6+e'"e$c# %esu!t"$) f%o&


20/80

qu!"t# +%o:!e&.

7. Docu&e$tt"o$

To :e e*ect"(e "t "s esse$t"! to est:!"sh $' &"$t"$ c!e%> co&+!ete $' cu%%e$t

;%"tte$ %eco%'s of "$s+ect"o$ $' test +%oce'u%es fo% ech o+e%t"o$.

These %eco%'s shou!' "'e$t"f# 9

. C%"te%" fo% cce+t$ce4%e?ect"o$.

:. Act"o$ to :e t M


21/80

%e!e($t st$'%' o% 9s+ec"5ct"o$. The 'ocu&e$te' +%oce'u%e est:!"she' t th"s

st)e shou!' e$su%e tht $# "$s+ect"o$ o% tests co$'ucte' t $ e%!"e% st)e h(e

:ee$ +e%fo%&e' $' the 't o:t"$e' cte' u+o$.

,. /&+!"$) P%oce'u%es

/&+!"$) +%oce'u%es use' shou!' :e such tht $# "$fo%&t"o$ )"$e' f%o& the

s&+!e equ!!# %e!tes to the :u!< f%o& ;h"ch the# ;e%e t se)%e)te' $' '"s+ose' of. A'equte %eco%'s &ust

:e &"$t"$e' fo% su:seque$t %e("e;.

A$# %e+"% o% %e;o%< ct"("t"es to co%%ect $o$9co$fo%&"$) &te%"! &ust :e c!e%!#

"'e$t"5e' $' 'ocu&e$te'.

7. A!te%$t"(e I$s+ect"o$ P%oce'u%es $' Equ"+&e$t

8he%e #ou ;"sh to use !te%$t"(e "$s+ect"o$ +%oce'u%es $' equ"+&e$t (!"'

e("'e$ce &ust :e ("!:!e to e$su%e the# +%o("'e equ"(!e$t ssu%$ce of qu!"t#.

0. I$'"ct"o$ of I$s+ect"o$ /ttus

You &ust est:!"sh $' &"$t"$ +%oce'u%e to c!e%!# "'e$t"f# +%o'ucts t ech

st)e of &$ufctu%e e.). +%o'ucts $ot "$s+ecte'K +%o'ucts "$s+ecte' $' +sse'K

$' +%o'ucts "$s+ecte' $' %e?ecte'.

=. P%otect"o$ $' P%ese%(t"o$ of P%o'uct Qu!"t# 'u%"$)9 9H$'!"$)> /to%)e $'

De!"(e%#

P%oce'u%es $' "$st%uct"o$ &ust :e est:!"she' to 9

. C!e%!# "'e$t"f# &te%"!s $' +%o'ucts fo%& %ece"+t to 'es+tch.

:. Co$t%o! $' +%otect !! &te%"!s $' +%o'ucts 'u%"$) h$'!"$)> &$ufctu%e>

sto%)e $' 'e!"(e%#.

c. E$su%e 5$"she' +%o'ucts %e sto%e' $' 'e!"(e%e' co&&e$su%te to the qu!"t#st$'%'s 'e&$'e' :# the custo&e%.

1. T%"$"$)

A!! +e%so$$e! "$(o!(e' ;"th the &$)e&e$t of qu!"t# &ust :e e6+e%"e$ce' to

%ece"(e 'equte t%"$"$) to e$su%e the# %e co&+ete$t to +e%fo%& the"% %equ"%e'

ts


22/80

s+ec"5ct"o$.

A h$'!e s&+!e Bse!e' "f $ecess%# &ust :e est:!"she' s ;e!! s ;o% $' !!+e%so$$e! co$ce%$e' "$fo%&e' of the 'ut# $' t"&"$) of the"% +%t.

I$ the fo!!o;"$) +)es> '")%& of t#+"c! ste+s "s sho;$ to)ethe% ;"th 'et"!s of

the 'ut"es of Q.C. +e%so$$e! "$ th"s sche&e.

I$ ''"t"o$> Q.C. c$ :e "$(o!(e' "$ 'e(e!o+&e$t t $ e%!"e% st)e :# s&+!"$)

$e; #%$s. I$ co&:"$t"o$ ;"th ;e%e% t%"!s $' !:o%to%# tests> ssess&e$ts of

seso$! $' othe% )oo's c$ :e &'e> e.). tests &'e to sce%t"$ ;hethe% f:%"c

"s too he(# fo% s+%"$)> "s su"t:!e fo% t%ouse%s> '%+es co%%ect!# fo% '%esses o%

cu%t"$s> o% su"t:!e fo% use "$ :%")ht su$!")ht.

QUALITY CONTROL FUNCTION

1. Test P%o+e%t"es of Y%$

. If %out"$e chec

'e$"e%.

:. If "$co&"$) #%$ "s $ot chec te6 B'e$"e%> cou$t etc. $' +ss "$fo%&t"o$

to


23/80

th%e'> $' the o%'e% of se&"$) the +%ts. :

:. Note $# '"cu!t"es e$cou$te%e' e.). '"cu!t o+e%t"o$ to ttch co!!%.

1. Test fo% Ph#s"c! P%o+e%t"es of G%&e$ts

. Reco%' the '"&e$s"o$s of the )%&e$t s soo$ s "t "s co&+!ete':. Fo% 5:%e of h")h &o"stu%e %e)"$ 5$' the ;e")ht "$ co%%ect co$'"t"o$.

c. 8sh )%&e$t $' %echec< the &esu%e&e$ts.

1. L""so$ of Qu!"t# Co$t%o! ;"th Cost De+%t&e$t

. O$ co&+!et"o$> su++!# cost 'e+%t&e$t ;"th !! "$fo%&t"o$.

:. Fo% the co%%ect te6 Bcou$t> 'e$"e% of #%$> cost"$) :e &'e '"%ect!# o$

s&+!e. Fo% cou$t ;h"ch "s :o(e o% :e!o; the (e%)e B!thou)h ;"th"$ $

cce+t:!e to!e%$ce & %":s etc.> se& $' st"tch t#+es

:. "'e$t"f# #%$s "$ s&+!e

c. %eco%' !! co&+o$e$ts othe% th$ f:%"c e.). "+> :utto$s etc'. cou$t cou%ses $' ;!es +e% c& "$ ech st%uctu%e

e. 'ete%&"$e st"tch !e$)th $' cou$ts of #%$s use' :# u$%o("$)

f. est"&te !"


24/80

se!ect $e%est su"t:!e co&&e%c"! #%$ ("!:!e $' )u)e of &ch"$e to :e use'

fo% '+tt"o$ to %e+%o'uce s&+!e

o$ the :s"s of B c!cu!te st"tch !e$)th to :e use'

o$ the :s"s of B: c!cu!te the cou%ses $' $ee'!es %equ"%e' "$ ech st%uctu%e

c!cu!te cou%se !e$)ths %equ"%e'

,. /ett"$) u+ &ch"$e to +%o'uce )%&e$t. $' the cost %e!te' to "t h(e !%e'# :ee$

'ete%&"$e' ;he$ the s+ec"5ct"o$ "s +%e+%e'. If th"s "s $ot co%%ect!# 'ete%&"$e'

the co&+$# cou!' &


25/80

The s+ec"5ct"o$ shou!' co$t"$ e$ou)h "$fo%&t"o$ fo% $# co&+ete$t +e%so$$e! to

+%o'uce the %equ"%e' )oo's t $#t"&e ;"th"$ to!e%$ce.

To ss"st "$ +%e(e$t"$) s+ec"5ct"o$ :eco&"$) u$;"e!'#> s"&+!"5ct"o$ c$ ofte$

:e &'e :# o&"tt"$) those 'et"!s $ot su:?ect to ch$)e f%o& !"$e to !"$e. These %e

tu)ht to the o+e%t"(e s +%t of the"% "$'uct"o$ $' c$ :e 'e!e)te' to t%"$"$).

Much "$fo%&t"o$ c$ :e co$(e#e' $' 'ocu&e$t +%o("'e' fo% qu"c< %efe%e$ce "f st$'%' !#out "s !;#s use'. Th"s "s sho;$ :# the ;# ;e use such &ss"(e

;o% sect"o$!"se' Mste% /+ec"5ct"o$.

A fu%the% &etho' of s"&+!"5ct"o$ c$ :e use' "$ those cses ;he%e (%"ous !"$es o%

st#!es %e +%o'uce' f%o& %e!!# the s&e f:%"c o% o% :# us"$) the s&e

se&s> +%t f%o&> s# ?ust o$e o% t;o s&!! ch$)es.

The :s"c )%&e$t :!$< o% se;"$) 'et"!s c$ :e %eco%'e' fo% ech t#+e o%

f:%"c> )%&e$t :!$< o% se&> $' the$ )"(e$ su"t:!e %efe%e$ce $u&:e%. The

ctu! s+ec"5ct"o$ fo% +%t"cu!% !"$e ;"!! the$ c!! u+ o$!# th"s %efe%e$ce> to)ethe%

;"th $# ++%o+%"te !te%t"o$> s $ote' "$ the th"%' +%)%+h :o(e. Th"s "'e "s>

"$ ;#> 'e(e!o+&e$t of the sect"o$!"st"o$ of s+ec"5ct"o$.

Th"s "'e c$ :e 'e(e!o+e' fu%the% "$ %e)%' to #%$s $' se&s.

A!! the (%"ous st#!es %e !"

e(e$ thou)h &o%e th$ o$e t#+e of #%$ o% se& ;"!! :e %equ"%e' "$ )%&e$t.

Ech #%$ $' ech se& use' "s 5%st st"+u!te' 'equte!#> $' th"s %eco%'e' "$ $

++%o+%"te #%$ o% se& s+ec"5ct"o$ ;"th "ts o;$ %efe%e$ce. The )%&e$t of f:%"cs+ec"5ct"o$ ;"!! the$ &


26/80

SST8I/T FACTOR

A/TM GRADING

U/TER LEVELNE// CV

Th"$s B02 sett"$) +e% 1>222&

Th"c< Bsett"$) 3 +e% 1>222&Ne+s Bsett"$) 3 +e% 1>222&

8INDING

COEFFICIENT. OF FRICTION

TOLERANCE/ SI$ cco%'$ce ;"th /ttuto%# I$st%u&e$t ,1,7 13 9 Te6t"!e

P%o'ucts BI$'"ct"o$s of F":%e Co$te$t Re)u!t"o$s 13

SST#+"c! (!ue fo% cou$t 'e!"(e%# cce+t$ce :e"$) 1, of $o&"$! cou$t. /o&e

T%'e Assoc"t"o$s )"(e %u!es ++!"c:!e to the"% &e&:e%s.

/HADE/

TOLERANCE/

COLOUR FA/TNE//

BAssesse' o$ 1 6 1 %": f:%"c s&+!e f%o& #%$ su++!"e'

Ch$)e "$ sh'e st"$"$)

8sh"$) 9 Rt"$)

Pe%s+"%t"o$

Ru::"$)

D%# C!e$"$)

Gs fu&es

L")ht/t"$"$) ssesse' o$

PRODUCT /PECIFICATION 9 E6&+!e

COMMERCIAL DATA

GARMENT DE/CRIPTION


27/80


28/80

Loct"o$

Le)e$'

PERFORMANCE

/t:"!"t#

Co!ou% fst$ess 9 / 122=

P"!!"$)

E6te$s":"!"t# Bcu*s $' s


29/80

TAPE/

/PECIFICATION NO DATE

Loct"o$

8"'th/t%uctu%e

/h'e

Co!ou% fst$ess

IP/

/PECIFICATION NO

Loct"o$

Le$)th

T+es

/h'e

Co!ou% fst$ess

/t:"!"t#

Othe% %equ"%e&e$ts

PROCE// /PECIFICATION 9 E6&+!e

FARIC

REFERENCE/ /PEC NO

FARIC DE/CRIPTION

PRODUCT /PECIFICATION Nos. RELATING

/PECIFICATION NO DATE


30/80

MACHINE GAUGE

DIAM FEEDER/

/PEED

8IDTH ROLL LENGTH FINI/HEDMIN. U/EALE ROLL 8EIGHT FINI/HED

DOFFING REV/

DOFFING TIME

TECHNICAL MANUFACTURING REQUIREMENT/

/TITCH LENGTH G%ou$'

I$!#

COMPO/ITION FARIC G%ou$'

Bo* &4c I$!#

8IDTH Bo* &4c

FINI/HING REQUIREMENT/

PROCE//E/

FINI/HED FARIC PARAMETER/

C43c& 843c& ;t4sq.&

8"'th o(e%!!

PROCE// /PECIFICATION 9 E-AMPLE

MAE9UP ORDER

REFERENCE/ /PEC NO

MAE9UP ORDER FOR


31/80

/PECIFICATION NO

PRODUCT /PECIFICATION NO. RELATING 9

MANUFACTURING REQUIREMENT

O+e%t"o$ /e& /+ec. Ref. E6t%s4se& 5$"sh

PROCE// /PECIFICATION 9 E-AMPLE

/EAM /PECIFICATION

REFERENCE/ /PEC NO

/PECIFICATION FOR

/PECIFICATION REF. NO DATE

MAE9UP ORDER NO/.

/E8ING THREAD/

MANUFACTURING REQUIREMENT/

/TITCH

IGHT /40c&

RUN9IN

NEEDLE

TEN/ION

FARIC /TAILITY AND FINI/HED 8IDTH


32/80

F:%"cs 9 "ts '"&ete% $' )u)e B$ee'!es +e% u$"t !e$)th of c#!"$'e%

c"%cu&fe%e$ce. The f:%"c ;"!! :e +%t!# o$ eco$o&"c )%ou$'s $' +%t!# to (o"' :e"$) too 'e$se o% too !")ht

f:%"c.

The%e "s co&&e%c"! "$ce$t"(e to 5$"sh f:%"c s ;"'e $' s !o$) s +oss":!e. The

!oo+ st%uctu%e of "$ the st%etche' stte the fo%ces o$ ech !oo+ %e $ot

:!$ce'> $' so the f:%"c :eco&es u$st:!e> )"("$) "t te$'e$c# to %e(e%t to

&o%e $tu%!> %e!6e' stte 'u%"$) ;h"ch $ "$c%ese "$ f:%"c st"tch 'e$s"t# ;"!! t to)ethe% ;"th co$seque$t %e'uct"o$ o$ %e> ".e. sh%"$ "f "t "s to :e

;"thout e6cess"(e sh%"$ #%$ $' !oo+

!e$)th use'. Ec"e$t !#s shou!' :e +!$$e' o$ these '"&e$s"o$s> $' $ot o$ so&e

+%e'ete%&"$e' "'e!.

If sh%"$ the$ e6t% ;"'th $' !e$)th c$ :e

co$s"'e%e'. The f:%"c ch%cte%"st"cs c$ :e 'ete%&"$e' :# c!cu!t"o$s fo%& the

f:%"c )eo&et%# $' :# t%"!s> $' the 5$"she' '"&e$s"o$s to :e st"+u!te' &o'"5e'

cco%'"$)!#.

U$!ess these fcto%s %e fu!!# u$'e%stoo'> st"sfcto%# f:%"c s+ec"5ct"o$ ;"!! $ot

:e +oss":!e.

E-AMINATION ON RECEIPT OF FARIC

1. s"c P%o:!e&As &uch s 12 of "$co&"$) f:%"c c$ :e co$s"'e%e' to :e u$st"sfcto%#> :ut 'ue

to "$'equte co$t%o! o% co&&e%c"! +%essu%es !ess th$ 0 "s %etu%$e'. The 5)u%e

of 12 "s $ot su%+%"s"$).

The &te%"! cost s(e' :# 122 "$s+ect"o$ &o%e th$ s(e the cost of tht

"$s+ect"o$. Mo%eo(e% (!u:!e "$fo%&t"o$ c$ :e o:t"$e' to "' "$ +%o'uct"o$

+!$$"$) th%ou)h the fcto%#.

8he%e the qu!"t# of ech +"ece hs :ee$ est:!"she' :efo%e "t "s "ssue' to the


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cutt"$) %oo&> the cutte% c$ :e )"(e$ c!e% "$st%uct"o$s "$ the +%efe%%e' &$$e% "$

;h"ch $# fu!ts c$ :e :so%:e'.

,. E6&"$t"o$ /eque$ce9

8he%e 122 "$s+ect"o$ "s $ot fes":!e "$ the 5%st "$st$ce

P%oce'u%e fo% I$co&"$) F:%"cChec< !"st P"ece of

Ech +tte%$

O% co!ou%;#s

If st"sfcto%# "f $ot st"sfcto%#

Chec< e(e%# chec< e(e%#

5fth +"ece +"ece

If st"sfcto%#

Co$t"$ue chec $' to co$t%":ute to $ e$("%o$&e$t "$ ;h"ch "t c$ :e "$s+ecte' :# $e6&"$e%. Th"s %equ"%es the fo!!o;"$) ch%cte%"st"cs9

1. /u"t:!e e')e co$t%o! to +%o("'e 5$"she' %o!! of tt%ct"(e ++e%$ce

,. 8"$'"$) ch%cte%"st"cs> ;h"ch 'o $ot '"sto%t the f:%"c st%uctu%e o% '"&e$s"o$s>

;h"ch su))ests te$s"o$!ess ;"$' u+ th%ou)h> o(e%fee' "$ the cse of st%etch f:%"cs.

3. /to++"$) $' st%t"$) ;h"ch ;"!! $ot '"stu%: the %o!!> $o% the f:%"c st%uctu%e $o%

"ts '"&e$s"o$s


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7. Le$)th &esu%e&e$t ;"th the f:%"c "$ %e!6e' te$s"o$!ess stte

0. The qu!"t# of ;"$'9u+ shou!' :e such tht uto9!#"$) equ"+&e$t c$ :e use'

st"sfcto%"!#

=. 8"$'"$) ch%cte%"st"cs shou!' :e such tht $# fo%& of h$'!"$) :# the e6&"$e%

"s &"$"&"se'

. The &ch"$e shou!' :e s"&+!e to !o' $' u$!o'@. L")ht"$) shou!' :e co$t%o!!:!e $' of (%":!e "$te$s"t#> so tht the &ost c%"t"c!

fu!ts :e 'etecte' &ost es"!# ;"thout !oss of 'etect"o$ of !ess c%"t"c! fu!ts.

Fo% those f:%"cs ;h"ch %equ"%e t%$s&"tte' !")ht> the +$e! shou!' :e of ++%o+%"te

'"&e$s"o$ f%o& to+ to :otto& $' f%o& s"'e to s"'e.

The%e %e $u&:e% of c%"t"c! fetu%es of f:%"c e6&"$t"o$ &ch"$es +%t f%o&

the :o(e> :ut ;h"ch c$ :e e6+ecte' to :e "$co%+o%te' ;"th"$ &ch"$e ;h"ch "s

of st$'%' ;h"ch co$fo%&s to the :o(e %equ"%e&e$ts. These "$c!u'e $)!e of

s!o+e of the e6&"$t"o$ t:!e> '"st$ce of f:%"c f%o& e6&"$e%s +os"t"o$> s+ee'

%$)e of f:%"c &o(e&e$t> !")ht +os"t"o$s. The%e %e $u&:e% of t%"$"$) e6e%c"ses

tht h(e :ee$ su))este' fo% $e; e6&"$e%s to "&+%o(e the %$)e of the ;"'th of

the f:%"c tht "s stu'"e' 'u%"$) e6&"$t"o$ $' to %e'uce the t%"$"$) +e%"o'.

T%$s&"tte' !")ht 9 )e$e%!!# fo% Qu!"t# Co$t%o! fu!ts 9 e.). uo%esce$t !")ht "$s"'e

t%ouse%s. Reecte' !")ht 9 )e$e%!!# fo% co&&e%c"! fu!ts.

A/IC TECHNOLOGY OF /EAM/

THE PURPO/E OF /EAM/

The &"$ fu$ct"o$ of se& "s to ?o"$ +"eces of f:%"c u$o:t%us"(e!# "$ such ;#

s the +%ese%(e s f% s +oss":!e the :s"c +%o+e%t"es of the f:%"cs :e"$) ?o"$e'.

The%e %e &$# se&s $' st"tches> ;h"ch %e 'esc%":e' "$ co&+%ehe$s"(e %"t"sh

/t$'%' ./ 3@2 P%t 1 9 /t"tch T#+es> $' P%t , 9 /e& T#+es.

DE/IRALE FEATURE/ OF A /EAM

1. It &ust $ot +u!! +%t u$'e% the st%esses of se%("ce

,. It &ust $ot coc :%e< o% c%c< o$ st%etch"$)

0. The se& &ust $ot J)%"$J

=. The se& shou!' :e u$o:t%us"(e> u$!ess "t "s s+ec"5c!!# fo% 'eco%t"(e +u%+ose

TYPE/ OF /EAM/

I$ ./ 3@2 +%t ,> se&s %e '"("'e' "$to @ c!ss"5ct"o$s> "$ ech of ;h"ch the%e

%e &$# (%"t"o$s. Ho;e(e%> fo% +u%+oses of c!%"t#> ;"th ;eft


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the se&s use' :e co$s"'e%e' u$'e% the fo!!o;"$) fou% &"$ t#+es.

1. /u+e%"&+ose'

,. O(e%!++e'

3. utte'4F!t

7. E')e 5$"she'

8"th"$ ech of these )%ou+s the%e %e &$# (%"t"o$s of the :s"c the&e. M$# ofthe se&s :e +%o'uce' ;"th o$e o% &o%e st"tch t#+es.

RITI/H /TANDARD CLA//IFICATION OF /TITCHE/ ./ 3@2

/t"tches %e '"("'e' "$to s"6 c!sses> ;"th"$ ech of ;h"ch %e se(e%! t#+es of st"tch.

The ch%cte%"st"cs of ech c!ss %e "$'"cte' :e!o;> fo!!o;e' :# "!!ust%t"o$s of

co&&o$e% st"tch t#+es $' 'et"!s of the"% +%o+e%t"es $' ++!"ct"o$s.

/t"tch c!ss 122. Ch"$ st"tch

Th"s c!ss st"tch "s fo%&e' ;"th o$e o% &o%e $ee'!e th%e's $' hs fo% "ts )e$e%!

ch%cte%"st"cs "$t%!oo+"$)S. A !oo+ o% !oo+s of th%e' o% th%e' "s +sse' th%ou)h

the &te%"! $' secu%e' :# "$t%!oo+"$) ;"th succee'"$) !oo+ o% !oo+s fte% the#

%e +sse' th%ou)h the &te%"! to fo%& st"tch.

/t"tch c!ss ,22 H$' st"tch

These st"tches> h("$) !"tt!e ++!"ct"o$ "$ &ss +%o'uct"o$> %e $ot "$c!u'e' "$ the

succee'"$) sheets.

/t"tch c!ss 322 Loc o% secu%e' :# "$te%!oo+"$) ;"th !oo+s of o$e o% &o%e

"$te%!oo+e' )%ou+s of th%e's :efo%e succee'"$) th%e's of the 5%st )%ou+ %e )"$

+sse' th%ou)h he &te%"!.

/t"tch c!ss =22 F!t se& st"tch

Th"s c!ss of st"tch "s fo%&e' ;"th t;o o% &o%e )%ou+s of th%e's $' hs fo% )e$e%! ch%cte%"st"c tht t;o of the )%ou+s co(e% the %; e')es of :oth su%fces

of the &te%"!. Loo+s of the 5%st )%ou+ of th%e' %e +sse' th%ou)h !oo+s of the

th"%' )%ou+ !%e'# cst o$ the su%fce of the &te%"! $' the$ th%ou)h the

&te%"! ;he%e the# %e "$te%!oo+e' ;"th !oo+s of the seco$' )%ou+ of th%e' o$ the

u$'e%s"'e of the &te%"!. The o$e e6ce+t"o$ to th"s +%oce'u%e "s /t"tch T#+e =21

;he%e o$!# t;o )%ou+s of th%e' %e use' $' the fu$ct"o$ of the th"%' )%ou+s "s

+e%fo%&e' :# o$e of the th%e's "$ the 5%st )%ou+.

SFo% the s ;"thout ;h"ch "t "s "&+oss":!e to


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It "s esse$t"! fo% $# Qu!"t# Co$t%o! /#ste& tht 'equte %eco%'s shou!' :e

'e("se' $' f%o& ;h"ch the tot!s> '"!# $'

;ee fo% ech "te& c$ :e qu"c


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/"&"!% c%' fo% /u+e%("so%s %eco%'

BDIAGRAM

To o:t"$ the !!9"&+o%t$t o(e%!! +"ctu%e of o+e%t"(es o(e% +e%"o'> "t ;e!! :e

t"&e s(e% "$ the e6&"$t"o$ of these ;ee to e$te% the ;ee

o$ T%e$' Ch%t.

BDIAGRAM

E-AMPLE /INGLE OPERATION CHEC

BDIAGRAM

E-AMPLE REPAIR/ RECORD

BDIAGRAM

It "s ofte$ he!+fu! fo% /u+e%("so% to h(e chec

/UPERVI/OR/ CHEC LI/T

BDIAGRAM

BDIAGRAM OF REVER/E /IDE


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/EAM CHARACTERI/TIC/

/TITCH CLA// 122 9 CHAIN /TITCH

/t"tches ;"th"$ th"s c!ss h(e e6ce!!e$t e6te$s":"!"t# $' $et ++e%$ce :ut ;"!!

u$%(e! es"!# "f the th%e' "s :%o ".e. se;"$)

;"th te&+o%%# st"tches $'> "$ the


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+e$et%t"$) "t to the fu!! 'e+th.

APPLICATION/

Tu%$"$) u+ he&s o$ t%ouse%s> s !"&"te' s ;"th t#+e 321.

APPLICATION/

8"'e!# use' "$ fou$'t"o$ )%&e$ts $' "$ s;"&;e%.

/TITCH CLA// 721 MULTI9THREAD OR DOULE LOCED CHAIN/TITCH PROPERTIE/

1. The th%ee '"&e$s"o$! co$st%uct"o$ "s c!ose!# !!"e' to the co$st%uct"o$ of


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,. Re!t"(e!# h")h e!st"c"t# "f suc"e$t $ee'!e th%e' "s "$t%o'uce'.

3. Te$'s to e!"&"$te o% %e'uce +uc fo%

%eso$s of co&fo%t $'4o% ''"t"o$! secu%"t#> tht se& shou!' :e tte$e' $'

co(e%e'.

3. 8he%e t;o cut e')es %e fo!'e' to)ethe% $' se;$ 'o;$ s "$ :e!t !oo+s o$

t%ouse%s.

/TITCH CLA// 022 9 OVEREDGE /TITCH

These %e &o%e co&&o$!# %efe%%e' to s o(e%9!oc< st"tches !thou)h> to the +u%"st>

th"s "s $&e +ecu!"% to 8"!co6 $' G"::s &ch"$es.

Co$t"$e' ;"th"$ the c!ss "s the (e%# ;e!!


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E")ht t;"$ $ee'!e o(e%!oc< st"tches %e !"ste' "$ the %"t"sh /t$'%' 3@2 %$)"$)

f%o& t;o to fou% th%e's. The &ost ;"'e!# use' "s the fou% th%e's C!ss 020 ;h"ch

"s f%eque$t!# %efe%%e' to s J&oc< sfet# st"tchJ.

/TITCH CLA// 027 9 THREE THREAD OVERLOC

PROPERTIE/

1. Ve%# h")h e6te$s":"!"t# 9 u+ to 322 ;he$ su"t:!# '?uste'.

,. U++e% $' !o;e% !oo+e% th%e's "$te%9!oo+ to :"$' the t%"&&e' e')e of the f:%"c.

3. Goo' !te%! st%e$)th co$s"ste$t ;"th :")ht su"te' to the f:%"c :e"$) se;$.

APPLICATION

1. Th"s "s the &ost ;"'e!# use' se& "$ the hos"e%# secto% $' :e fou$' t $#

+!ce "$ cut $' se;$ )%&e$ts t ;h"ch t%"&&e' $' :ou$' e')e "s %equ"%e'.

/uch ++!"ct"o$s "$c!u'e sett"$) "$ of s!ee(es> c!os"$) s"'e se&s o$ T9sh"%ts etc.

,. Is ;"'e!# use' fo% s"&"!% ++!"ct"o$ "$ &o'e%$ sh"%t &$ufctu%e f%o& 5$e ;%+

A $' o$e !oo+e%

th%e'> . Loo+s of th%e' A %e +sse' th%ou)h the &te%"! $' :%ou)ht to thee')e ;he%e the# %e "$te% !oo+e' ;"th th%e' . The !oo+s of th%e' e6te$' f%o&

th"s "$te% !oo+"$) to the +o"$t of $ee'!e +e$et%t"o$ of the $e6t st"tch $' the$ "$te%

!oo+ ;"th th%e' A.

PROPERTIE/

1. E6te$s":!e se&

,. /t%uctu%e "s such s to & ;h"ch "s &"%%o%

"&)e of the othe%.

It "s use' fo% u$'e%;e% e.). (est :otto&s.


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/TITCH CLA// 017 9 T8IN NEEDLE OVERLOC BMOC /AFETY

CON/TRUCTION AND APPEARANCE

Requ"%es> "$ the cse of so&e th%ee9th%e' o(e%!oc< &ch"$es> $o &o%e th$ the5tt"$) of the seco$' $ee'!e to)ethe% ;"th the th%e' $' su"t:!e !! %ou$'

te$s"o$ '?ust&e$t.

PROPERTIE/

As T#+e 027 o(e%!oc< :ut ;"th the ''"t"o$! secu%"t# *o%'e' :# the !%)e% :")ht

%equ"%e' :# the seco$' $ee'!e. Is so&et"&es %efe%%e' to s &oc


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/e&s %e fo%&e' ;"th th%ee )%ou+s of th%e's> the )e$e%! ch%cte%"st"c :e"$)

tht o$e )%ou+ :%"')es the :utte' ?o"$ o$ the fce of the f:%"c> the seco$' )%ou+

:%"')es the :utte' ?o"$ o$ the %e(e%se of the f:%"cK the t;o )%ou+s %e

"$te%co$$ecte' th%ou)h the f:%"c :# the th"%' )%ou+ ".e. the $ee'!e th%e's. The

e6ce+t"o$ "s the C!ss =21 ;h"ch "s co&+%"se' of o$!# t;o )%ou+s> the fu$ct"o$ of

the 5%st )%ou+ :e"$) +e%fo%&e' :# o$e of the th%e's of the th"%' )%ou+.

Ce%t"$ C!ss =22 st"tches %e %efe%%e' to s co(e% st"tches :ut "t shou!' :e $ote'

tht> u$!" %e use' fo% such ++!"ct"o$s s )usset "$se%t"o$> %e"$fo%ce' sect"o$s "$

)"%'!es $' co%sets> s"'e $' shou!'e% se&s o$ (ests $' o$ so&e of the &o%e

e6+e$s"(e )%&e$ts.

/TITCH CLA// =2,

PROPERTIE/

1. /ecu%es cut $' fo!'e'9:c< %; e')e $et!# $' secu%e!#> to+ $' :otto& co(e%.

,. F!t $' co&fo%t:!e.

3. 8"!! $ot u$%(e! es"!#.

7. Ve%# )oo' e6te$s":"!"t#.

APPLICATION

A ;"'e!# use' st"tch "$ )"%'!es $' co%sets. A!so use' fo% 5$"sh"$) he& of s :ut uses &o%e se;"$) th%e'.

APPLICATION

Th"s ;"'e!# use' st"tch "s so&et"&es %efe%%e' to s Jt%"+!e "$te%!oc


45/80

othe% ++!"ct"o$s "$ !"$)e%"e> u$'e%;e% $' co%set%#> e.). )ussets "$ :%"efs $'

+$t# )"%'!es.

/TITCH CLA// =2= 9 NINE THREAD FLAT9LOC

PROPERTIE/1. F!t $' co&fo%t:!e 9 th"c +$t# )"%'!es $' co%sets.

3. Goo' qu!"t# su%)"c! $' su++o%t t")hts.

7. Goo' qu!"t# s;"&;e%.

/TITCH CLA// =2 9 /I- THREAD FLAT /EAM

PROPERTIE/

As C!ss =2=> ;h"ch se& the C!ss =2 ;s 'es")$e' to su+e%ce'e :# %eso$ of

s"&+!"c"t# $' "&+%o(e' e6te$s":"!"t#.

APPLICATION

As C!ss =2=.

The%e %e &ch"$es ("!:!e ;h"ch ;"!! +%o'uce s"&u!t$eous!# st"tches f%o& t;o

of the c!sses &e$t"o$e' :o(e> fo% e6&+!e> 721 Bt;"$ th%e' ch"$ st"tch "$

co&:"$t"o$ ;"th 027 !oc


46/80


47/80

The o(e%!oc< se& c$ :e t the :se

f:%"c "s '&)e'> the se& +uc 9 ".e. the se;"$) !"$e.

Th"s c$ :e too :") fo% co&fo%t $' esthet"c co$s"'e%t"o$s o% too s&!! so !!o;"$)

s!"++)e to occu%. A)"$> e6+e%"e$ce> ".e. ++e%$ce> fee!s $' st%etch"$) c%oss

the se& ;"!! 'ec"'e. If $%%o; :")hts h(e to :e use'> st"tches +e% "$ch $ee'


48/80

to :e "$c%ese' :o(e the 5%st est"&te o% st"tch ;"th &o%e th$ o$e $ee'!e

th%e' use'.

E6te$s":"!"t#

If th"s "s "$'equte the se& "s e"the% too t")ht o% c%c


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,. O+e%t"(e qu!"t# chec %e su:st$'%'.

RECORD CARD FOR 8EELY CHEC OF OPERATOR/ PERFORMANCE

BDIAGRAM

As ech fu!t "s $ote' "t c$ :e e$te%e' )"$st the ++%o+%"te "te& $o. I$ the

co!u&$ fo% the +%t"cu!% '# s 5(e9:%%e'9)tes> f%o& ;h"ch the tot!s> '"!# $'

;ee fo% ech "te& c$ :e qu"c

BDIAGRAM

E-AMPLE /INGLE OPERATION CHEC


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BDIAGRAM

E-AMPLE REPAIR/ RECORD

BDIAGRAM

It "s ofte$ he!+fu! fo% /u+e%("so% to h(e chec< !"st fo% ech o+e%t"o$ u$'e% he%

co$t%o!> s %e&"$'e%.

/UPERVI/OR/ CHEC LI/T

BDIAGRAM

BDIAGRAM OF REVER/E /IDE

ANALY/I/ OF RE/ULT/ OF QUALITY CONTROL CHEC/

Co&+%e 9

. +%ese$t %esu!ts ;"th e%!"e% o$es "$ the o$e set of %esu!tsK

:. '"*e%e$t &te%"!s o$ s&e &ch"$es ;"th the s&e o+e%t"(es

c. '"*e%e$t &ch"$es us"$) s&e &te%"!s ;"th s&e o+e%t"(esK

'. '"*e%e$t o+e%t"(es us"$) s&e t#+e of &ch"$e $' s&e &te%"!sK

e. %esu!ts ;"th outs"'e sou%ces to co$5%& o% &o'"f# st$'%'s.

Cou%ses of ct"o$If the %esu!ts sho; tht

1. the s"tut"o$ "s st"sfcto%# 9 $o ct"o$ "s %equ"%e'

,. !thou)h st"sfcto%# cco%'"$) to e6"st"$) st$'%'s> "&+%o(e&e$ts cou!' :e

&'e 9 %e'uce to!e%$ces o% !o;e% !e(e!s.

3. the s"tut"o$ "s u$st"sfcto%# 9 t +%ocesses> o+e%t"(es> co$'"t"o$s> &esu%"$) $' so o$. The !"

the (%"t"o$s %e ?ust s !"


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If %e+ete' &esu%e&e$ts of $# +%t"cu!% fcto% %e t

the %esu!ts ;"!! :e fou$' to c!uste% %ou$' 5)u%e ;e c!! the (e%)e> ;"th

s+%e' of %esu!ts o$ e"the% s"'e> ;"th '"&"$"sh"$) f%eque$c# s ;e &o(e ;# f%o&

the (e%)e. A )%+h of the %esu!t> sho;$ ho%"o$t!!# o$ the )%+h :e!o;> )"$st

the $u&:e% of occu%%e$ces of tht %esu!t> ;e o:t"$ t#+"c!!# the sh+e sho;$. The

s+ec"5e' to!e%$ces ou)ht to :e% so&e %e!t"o$ to the +e< "$ the cu%(e.To!e%$ces

If ;e 56 !"&"ts ;"th"$ ;h"ch ;e ;"!! cce+t +%o'uct s st"sfcto%#> the$ c!e%!# the

fu%the% +%t $' o$ ech s"'e of the (e%)e ;e set !"&"ts> o% to!e%$ces> the

)%ete% ;"!! :e the +%o+o%t"o$ of +%o'uct"o$ tht ;e ;"!! cce+t. If the to!e%$ces %e

set too c!ose> the$ ;e c$$ot )et "t !! %")ht 5%st t"&e :ut "f the# %e too ;"'e> the$

;e ;"!! )et> fo% e6&+!e> )%&e$ts ;h"ch ;"!! $ot 5t e(e$ thou)h &$ufctu%e' to

s+ec"5ct"o$.

Co$(e$t"o$! stt"st"c! ++%oches su))est tht to!e%$ces shou!' :e set f%o&

:ut outs"'e the

+%ese$t sco+e. 9

Act"o$ 'e%"(e' f%o& To!e%$ces

To!e%$ces> o$ce )%ee' u+o$> c$ :e use' to 'ec"'e cou%ses of ct"o$.

If &ch"$e (e%)e '%"fts> the &ch"$e ;"!! +%o'uce %e?ects ;"th $ot"ce:!e %e?ect

%te. To!e%$ces ;"!! "$'"cte ;he$ '?ust&e$t "s $ee'e'> $' :# ho; &uch. The

%")ht h$' cu%(e %e+%ese$ts ;o%< f%o& &ch"$e ;hose (e%)e hs '%"fte'. The;o%< out of to!e%$ce c$ :e see$.

I$ o%'e% to co$t"$ $' chec< $# '%"ft ;"thout the '$)e%s of o(e%9co%%ect"o$> the

%equ"%e' ct"o$ c$ :e su&&%"se' s fo!!o;s 9

1. If ;o%< "s ;"th"$ to!e%$ces

$o%&!!# $o ct"o$

,. If ;o%< o$ chec< "s out of to!e%$ce9


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. %e+et chec '?ust &ch"$e :# $ &ou$t

e6+ecte' to :%"$) ;o%< ?ust ;"th"$ to!e%$ce. S

:. co$t"$ue chec '"%t> !"$t etc. If "t hs> %ect"f# the s"tut"o$

$' the$ %echec $# '%"ft "$ the

(e%)e> "$ othe% ;o%'s tht the o(e%!! (e%)e %e&"$s e6ct!# the s&e. 9

TRAINING QUALITY /TANDARD/ AND FAULT ANALY/I/9

Qu!"t# "s of +%"&e "&+o%t$ce "$ $# s+ect of :us"$ess. Custo&e%s 'e&$' $'

e6+ect (!ue fo% &o$e#. As +%o'uce%s of ++%e! the%e &ust :e co$st$t

e$'e(ou% to +%o'uce ;o%< of )oo' qu!"t#.

QUALITY /TANDARD/

1. Qu!"t# co$t%o! $' st$'%'s %e o$e of the &ost "&+o%t$t s+ects of the

co$te$t of $# ?o: $' the%efo%e &?o% fcto% "$ t%"$"$).

# Qu!"t# /t$'%' ;e &e$ the est:!"sh&e$t of the th%esho!' t ;h"ch !e(e! of

se(e%"t# 'efect :eco&es u$cce+t:!e> ".e. fu!t. It "s the equ"(!e$t ofto!e%$ces ++!"c:!e to &esu%:!e fcto%s.

/#ste&t"c t%"$"$) "$(o!(es the t%"$"$) of +e%so$ "$ 9

. s"c $' "$s+ect"o$ fte%> ech

st)e of &$ufctu%e.

Qu!"t# c$$ot :e "$s+ecte' "$to +%o'uctK "t "s e"the% the%e o% $ot. It &ust :e :%e'"$to the &


53/80


54/80

such s 9

". I$co%%ect th%e'"$)

"". C%e!ess h$'!"$)

""". /!"++e' st"tches

"(. ' te$s"o$

(. /e& :%e ;h"ch the o+e%t"(e

"s> e6+ecte' to %eco)$"se $' t APPEARANCE> CAU/E> EFFECT> RE/PON/IILITY>ACTION> $' PREVENTION.

:. Mou$t"$) e6&+!es

Ge$e%!!#> e6&+!es ;"!! :e h$'!e' :# &$# t%"$ees $' ;"!!> u$!ess su"t:!#

&ou$te' $' +%otecte'> 'ete%"o%te (e%# %+"'!#. F:%"c s&+!es cou!' :e &ou$te'

t o$ :c

e$:!"$) the& to :e h$'!e' !&ost "$'e5$"te!# ;"thout 'et%"&e$t. A$ !te%$t"(e

;ou!' :e Js;"$)9outJ FACERAP c%'s &ou$te' o$ ;!!> ;"th the ctu! fu!t


55/80

e6&+!e :e"$) &ou$te' u$'e% the JA++e%$ceJ he'"$).

c. /to%)e of E6&+!es

F:%"c fu!ts "$ e$(e!o+es :e co$(e$"e$t!# sto%e' "$ 5!"$) c:"$ets> '%;e%s> o%

:o6es of su"t:!e 'e+th> ;"th the %e!te' FACERAP c%' :e"$) c!"++e' o$.

C%efu! sto%)e ;"!! cut 'o;$ the te'"ous $o$9+%o'uct"(e e*o%t of co$st$t!#

%e+!c"$) e6&+!es.'. Co!!ect"$) I$fo%&t"o$

The :c "$co%%ect &ch"$e

sett"$)> &ch"$e :%e fo% e6&+!e 9

%e?ect> u$+"c< $' %e9se;>

%e+o%t to I$st%ucto%4/u+e%("so%4Mech$"c.

PREVENTION 9 A$# ct"o$ ;h"ch c$ o% shou!' :e t


56/80

Of st"tch CAU/E

F"!u%e to +!ce ;ho!e st"tch o$ +o"$t EFFECT

8e< +%t "$ se& ;h"ch u$'e% +%essu%e ;"!! :%e< ;# RE/PON/IILITY

O+e%t"(e ACTION

Re&o(e f:%"c f%o& +o"$ts $' %u$ o$ PREVENTION

Chec< ech st"tch "s o$ co$st%uct"(e +o"$t ;he$ f:%"c "s %u$ o$

/UGGE/TED TEACHING METHOD/

Th"s shou!' :e c%%"e' out :# &e$s of %e )"(e$ :e!o; 9

. L"&"t the sess"o$ to 32 &"$utes. Th"s ;"!! "$(o!(e !"&"tt"o$ of the $u&:e% of

fu!ts> 'e+e$'e$t o$ the"% co&+!e6"t#.

:. H(e c%' fo% ech fu!t> sho;"$) co&+!ete $!#s"s.

c. /ho; the e6&+!e of ech fu!t $' '"scuss the cuse> ho; to %eco)$"se "t> $'

e6+!"$ ;hte(e% ct"o$ :# the o+e%t"(e "s ++%o+%"te.

'. P!ce e6&+!es of fu!ts %ou$' the %oo&> shuWe the $!#s"s c%'s> $' the$

)et the t%"$ees to &tch the c%'s ;"th the ++%o+%"te e6&+!es.

e. A +%t"cu!%!# e*ect"(e tech$"que "s to "ssue t%"$ees ;"th :!$< FACERAP c%'s>

sho; the fu!t> $' the$ s< the t%"$ee to co&+!ete the c%'s.

The$ co&+%e the t%"$ees co&+!ete' c%'s ;"th the &ste% c%' $' '"scuss.

A %$)e of e6&+!es f%o& (%"ous sect"o$s of the "$'ust%# "s )"(e$ :e!o; 9

LEVEL/ OF FAULT/ AND /ECOND/

U/E OF /AMPLING TECHNIQUE/

I$ &$# s"tut"o$s the cost %"' e6+e'"e$c# co$s"'e%t"o$s fo%ce us to ?u')e stte

of *"%s f%o& the %esu!ts of s&+!e tests 'es+"te the %"s :ut X

the &o%e cost!# the e6e%c"se. /tt"st"cs c$ )"(e us )u"'$ce o$ the o+t"&u& s"e of

s&+!e to t


57/80

I$ o%'e% to "!!ust%te the +%"$c"+!es "$(o!(e'> !et us co$s"'e% s&+!e of 02 'oe$

)%&e$ts e6&"$e' fo% s# tot! fu!ts !thou)h "t cou!' h(e :ee$ fo% $#

+%t"cu!% fu!t. /u++os"$) =.@ of the )%&e$ts :o%e fu!ts. The fu!t %te "$ the

s&+!e "s =.@ 8ht c$ ;e s# :out the fu!t %te "$ the +%o'uct"o$ %e+%ese$te'

:# tht s&+!e C!e%!# the ch$ce of "ts fu!t %te :e"$) e6ct!# =.@ "s (e%# s&!!.

If ho;e(e% ;e !!o; $#th"$) :et;ee$ =.0 $' .0 to :e c!!e' > ;e h(e "$ fct %$)e o% to!e%$ce of 9 2.0 $' c$ $o; use stt"st"cs.

ust s "$'"("'u! %esu!ts c$ :e )%+he'> so c$ the (e%)es of s&+!es :e

+!otte'. These (e%)es ;"!! h(e $ o(e%!! (e%)e> $' ;"!! the&se!(es :eh(e

cco%'"$) to the !; of %$'o& '"st%":ut"o$. Thus the"% o;$ st$'%' 'e("t"o$ c$

:e c!cu!te'.

Co$s"'e% t:!e 1. I$ th"s> the )%&e$t !e$)ths fo% +%t"cu!% st#!e $' s"e h(e

:ee$ %eco%'e' o(e% +e%"o'> $' the f%eque$c# of occu%%e$ce +!otte' "$ co!u&$ ,.

Fo% "$st$ce the%e ;e%e 02 )%&e$ts ;hose !e$)th ;s :et;ee$ 1.2 9 1.0 "$ches>

so 02 "s ;%"tte$ "$ co!u&$ , o++os"te 1.2 91.0. The st$'%' 'e("t"o$ of th"s

:tch of 022 )%&e$ts ;s 1.03 "$ches> $' the (e%)e ,2.27 "$ches. No; "f ;e

t $'

out of &o%e th$ o$e :tch of 022> $' )"$ +!ot the %es+ect"(e s&+!e (e%)es>

the s+%e' of %esu!ts co$t"$ues to 'ec%ese s sho;$ "$ co!u&$s 7> 0 $' =.

The st$'%' 'e("t"o$ of these s&+!e (e%)es c$ :e c!cu!te' $' ;s fou$'

to :e s sho;$ "$ t:!e II> co!u&$ 3. Co&+%"so$ ;"th co!u&$ 7 sho;s tht the%e "s

c!ose %e!t"o$ :et;ee$ the st$'%' 'e("t"o$ of the (e%)e of s&+!e of set

$u&:e% of &esu%e&e$ts $' the "$t%"$s"c 'e("t"o$ of the "$'"("'u!

&esu%e&e$ts.

C!e%!# ;e c$> :# '?ust"$) the s"e of s&+!e> %%$)e fo% the st$'%' 'e("t"o$of the s&+!e (e%)es to !"e :et;ee$ the !"&"ts ;e $ee'> 9 f%o&


58/80

E6&+!e of use of t:!e

M tht "s =01 o% 07 'o.

. F%eque$c# of s&+!"$)

Th"s ;"!! 'e+e$' o$ the (o!u&e of +%o'uct"o$> (%"ous cost co$s"'e%t"o$s $' the%eso$ ;h# s&+!"$) "s %equ"%e'. The s&+!e s"e 'oes $ot 'e+e$' o$ (o!u&e of

+%o'uct"o$> :ut s"&+!# %equ"%es tht the !"$e "s !o$) %u$. I$ th"s co$$ect"o$ !"$e>

o% %the% cte)o%#> c$ :e %e)%'e' s co$t"$"$) !! "te&s c%%#"$) su:st$t"!!#

the s&e fu!t t#+es $' fu!t %tes. Ofte$ the ;ho!e +%o'uct"o$ "s s&+!e' o$ the

:s"s of the o(e%!! fu!t %te.

The f%eque$c# of s&+!"$) ;"!! !%)e!# 'e+e$' o$ the 'es"%e' s+ee' of fee':c

$' 'ec"'e' "$ the !")ht of e6+e%"e$ce. Ge$e%!!# ;ee

su:9;ee )oes :o(e the )%ee' !e(e!.

/&+!"$) :e c%%"e' out "$ "ts o;$ %")ht to o:t"$ "$fo%&t"o$ othe%;"se $ot

("!:!e t $# st)e "$ the &$ufctu%"$) cht he c%%"e' out s %e)u!%

Q.C. chec< o$ $# 122 test"$) !%e'# "$ o+e%t"o$> 9 e.). 5$! "$s+ect"o$>

IN/PECTION AND RECORDING TECHNIQUE/

I$s+ect"$) fo% 'efect"(es

M $ee'!e &% '%o++e' st"tches> cuts> &o!es>

s;%f> '"%t>

Co!u&$s JM


59/80

Reco%'"$) Resu!ts of Pe%"o' Chec ;"!! t %e' o:?ect "$ ;h"te !")ht "s %e'. I$ %e' !")ht "t "s %e'. I$ :!ue !")ht

"t "s (e%# '%< o% e(e$ :!c "$ %e' !")ht "s %e'>

"$ :!ue !")ht "s :!ue $' :!c< o:?ect> "f fu!!# :!c "s !;#s so "$ $# !")ht. /o ;e


60/80

see co!ou% f%o& the !")ht %eecte'.

Fo% e6&+!e> &"'9#e!!o; su%fce !oo

Bthe :!ue4("o!et %ece+to%.

Co$s"'e% #e!!o; !")ht %eecte' f%o& &"'9#e!!o; su%fce. Th"s !")ht st"&u!tes :oth

the )%ee$ $' %e' %ece+to%s> $' the :%"$ s#s J#e!!o;J> s "f th"s occu%s "$ the

#e!!o; +%t of the s+ect%u&. I$ fct> the to$es of #e!!o;> ;hethe% o%$)e9#e!!o; o%

)%ee$9#e!!o; %e 'ete%&"$e' :# the %e!t"(e &ou$ts :# ;h"ch the %e' $' )%ee$

%ece+to%s %e st"&u!te'. I$ o%$)e9#e!!o; !")ht the %e' st"&u!us +%e'o&"$te> "$

)%ee$9#e!!o; he %e(e%se.

It fo!!o;s the$> tht )%ee$ !")ht $' %e'> :ecuse the# st"&u!te the"% %es+ect"(e

%ece+to%> cou!' :e :!e$'e' to )"(e these sh'es of #e!!o; ;"thout #e!!o; !")ht :e"$)

the%e t !!. The e#e ;ou!' st"!! see #e!!o; sh'es. Th"s ++!"es to !! the othe%

co!ou%s :et;ee$ ("o!et $' )%ee$ s ;e!! s )%ee$ $' %e'.

1. EFFECT OF COLOUR OF ILLUMINANT 9 METAMERI/M

Refe%%"$) :c< to the &"'9#e!!o; su%fce> "t cou!' :e o:t"$e' :# co!ou% )e$t o%

&"6tu%e> %eect"$) :oth "$ the )%ee$ $' the %e' :$'s> o% :# co!ou% %eect"$)

c%oss )%ee$ to %e'.

Th"s "s so "$ +u%e ;h"te !")ht. /u++os"$) the !")ht "s $ot +u%e> :ut "s J;%&J ".e.

+"$

;"!! $ot $o; &tch the 5%st> :ecuse &o%e %e' "s "$ the "!!u&"$t"o$> so &o%e %e' "s

%eecte' $' the co!ou% :eco&es %e''e%.

Th"s e*ect "s c!!e' &et&e%"s&

Th"s "s the %eso$ ;he$ #ou )o "$to sho+ to choose c!oth> ;!!++e%> fu%$"sh"$)s>

cu%t"$s> +"$ts> #ou &")ht !oo< t the +tte%$ c%'s "$ the sto%e !")ht $' the$ t


61/80

These e*ects ++!# &"$!# ;he$ est:!"sh"$) %ec"+es o% & the co!ou%

se$st"o$ (%# $' thus the ++%e$t sh'e. O$e c$$ot c!e%!# ?u')e co!ou%

u$!ess %oo& o% o:?ect "s ;e!! !"t. /h+es c$ :e '"sce%$e' "$ qu"te 'u!! !")ht> :ut

$ot co!ou%.

It hs :ee$ fou$' those :e!o; 022 !u&e$s +e% squ%e &et%e> co!ou% ?u')e&e$t f"!s.

Th"s !")ht "$te$s"t# "s o:t"$e' "$ f%o$t of ;"$'o; %ece"("$) $o%th !")ht o$ c!e% o%

!")ht!# c!ou'# '#> e6ce+t $e% su$'o;$ o% su$%"se. It "s )"(e$ "$ the (e%)e ;e!!9!"t

%oo& $' "$ co!ou% &tch"$) c:"$ets 9 e.). o$e !"t :# t;o =09;tt %t"5c"! '#!")ht

tu:es :out 32 "$ches o% 0c& :o(e the ("e;"$) su%fce.

. ANGLE OF ILLUMINATION AND VIE8ING9

Most su%fces> u$!ess fu!!# &tt> h(e so&e 'e)%ee of )%"$ o% of !ust%e. /o so&e

;h"te !")ht "s %eecte' f%o& the fce of the o:?ect o% +tte%$ "$ ''"t"o$ to "ts t%ue

co!ou%e' !")ht %eecte' f%o& the :o'# of the o:?ect. The :est ?u')e&e$t of co!ou%;"!! :e ;he$ !ust%e $' )%"$ e*ects %e &"$"&!. Co!ou% "s %eecte' t !! $)!es>

!ust%e $' )%"$ te$' to :e '"%ect"o$!

The %eco&&e$'e' st$'%' +%oce'u%e "s to ho!' the +tte%$s t 70 'e) to the

'"%ect"o$ of "!!u&"$t"o$ $' ("e; t %")ht $)!es to the +tte%$> ".e. f%o& '"%ect!#

o(e% "t.

C. ORIENTATION OF PATTERN OR /AMPLE

M$# f:%"cs h(e so&e 'e)%ee of J$+J. Th"s e*ect "s &ost +%o$ou$ce' "$ (e!(ets

$' &e!to$s. ut :%ushe' f:%"cs> Te%%# $' &$# othe%s h(e )%"$ o% $+. Th"s

;"!! e*ect the !ust%e %the% !" the !")ht $' '%< +%ts"$te%ch$)e "$ sh'e. Thus "t "s $ot '"cu!t to see ho; J$+J c$ cuse )%et

co$fus"o$> ;h"ch c$ o$!# :e (o"'e' :# e$su%"$) tht the +tte%$s :e"$) co&+%e'

%e o%"e$tte' ;"th the"% st%uctu%e o% $+ )o"$) "$ the s&e '"%ect"o$.

Th"s "s !so "&+o%t$t ;"th f:%"cs h("$) st%uctu%e such s %":s o% t;"!!s. The%e "s

'"*e%e$ce "$ the Jsh'o;J e*ects $' !so 'e)%ee of co$fus"o$ +%o'uce' :#

see"$) co$"ct"$) st%uctu%! !"$es.

D. EFFECT/ OF COLOUR OF ILLUMINANT


62/80

I!!u&"$t"o$ of '"*e%e$t co!ou%s 9 fo% e6&+!e '#!")ht co&+%e' ;"th tu$)ste$

5!&e$t $' ce%t"$ J;%& !")htJ uo%esce$t tu:es $' the h")h out+ut co!ou%

%e$'e%"$) uo%esce$t tu:es such s the TL @7> )"(e '"*e%e$t co!ou%s '"*e%e$t

++e%$ce & so tht &tch "$ o$e !")ht $ot :e

"$ $othe%.

Fo% th"s %eso$ "t "s "&+o%t$t to e$su%e tht s&+!es %e co&+%e' u$'e% the"!!u&"$t"o$s %e+%ese$tt"(e of those !" ("o!et $' :!ue %e)"o$s of the

s+ect%u& $' %e9e&"t e$e%)# s ("s":!e !")ht. The %e9e&"tte' %'"t"o$ "s !;#s

!o$)e% ;(e!e$)th 9 ".e. sh"fte' to;%'s the %e' e$' $' ;# f%o& the ("o!et e$' of

the s+ect%u&> co&+%e' ;"th tht 5%st :so%:e'. /o "f these )e$ts %e to e&"t "$

the :!ue e$' of the s+ect%u&> :so%+t"o$ ;"!! h(e to occu% "$ the ("o!et $' u!t%9

("o!et :$'s.

Thus "!!u&"$t"o$ co$t"$"$) u!t%9("o!et !")ht ;"!! ct"(te these )e$ts> ;he%es

those 'e5c"e$t "$ u!t%9("o!et ;"!! $ot> $' the +tte%$ ;"!! !oo< '"*e%e$t.

D#!")ht co$t"$s th"s %'"t"o$> tu$)ste$ 5!&e$t !")ht &uch !ess. /o "t "s $ecess%#

to st"+u!te the t#+es of !")ht to :e use' fo% th"s %eso$ too.

PART , 9 TYPE/ OF /TANDARD ILLUMINANT

A. Gs 5!!e' tu$)ste$ 5!&e$t !&+ o+e%t"$) t :out ,@02> "!!ust%te' :# $e;

=29;tt :u!: t co%%ect (o!t)e.

. Noo$ su$!")ht. Th"s "s o:t"$e' ;"th tu$)ste$ !&+s $' 5!te%s> $' ;ou!' :e

)"(e$ :# co!ou% te&+e%tu%e of :out 7@02.

C. Noo$ $o%th s


63/80

These "te&s %e 'e5$e' "$ c!use 1, JCo$'"t"o$s of V"e;"$) $' I!!u&"$t"o$ "$

Assess"$) Co!ou% Fst$essJ "$ ./. ,==1> ;h"ch "tse!f "s t"t!e' JP%"$c"+!es of Co!ou%

Fst$ess Test"$)J. It "s !so )"(e$ u$'e% the s&e c!use $' t"t!e "$ the /oc"et# of

D#e%s $' Co!ou%"sts Pu:!"ct"o$ J/t$'%' Metho's fo% the Dete%&"$t"o$ of Co!ou%

Fst$ess of Te6t"!esJ> $' "$ ./. 02 +%t 1 A%t"5c"! '#!")ht uo%esce$t tu:es fo%

co!ou% &tch"$).

MOUNTING FARIC/ FOR VIE8ING

The%e %e th%ee "&+o%t$t co$s"'e%t"o$s.

A%e e6+ose' to ("e;.

Th"s hs '"st"$ct e*ect o$ the ++%e$t 'e)%ee of &"ss9&tch> the !%)e% the %e

the )%ete% the ++%e$t '"s+%"t#.

The s"e of s+ec"&e$s to :e use' shou!' :e )%ee'> $' the$ &"$t"$e'

th%ou)hout ;"th &"$"&u& 'e("t"o$.

: Mou$t"$).

The e*ects of !ust%e> J$+J $' st%uctu%e %e 'et"!e'> to)ethe% ;"th &etho's of

&"$"&"s"$) e%%o%s th%ou)h the& e!se;he%e.

The t%ue co!ou% of f:%"c "s tht of the !")ht %eecte' f%o& the co$st"tue$t 5:%es.

Ho;e(e%> 'e+e$'"$) o$ the 'e)%ee of Jco(e%J> the co!ou% of the su%fce u$'e%$ethc$ sho; th%ou)h $' co$fuse the f:%"c co!ou%. Th"s ++!"es ;hethe% s+ec"&e$ "s

ctu!!# ttche' to su++o%t"$) su%fce> +!ce' o$ su%fce te&+o%%"!# fo%

("e;"$) o% ?ust he!' "$ the h$'s. Th"s "s :ecuse ;hte(e% "s :eh"$' the s+ec"&e$

"s !" f:%"c ("e;e' ;he$ he!' :o(e '% "t shou!' :e stte' s fu%the% +o"$t>

tht ;he$ $ot &ou$te' o% he!' o$ %")"' su%fce> the e%%o%s 'ue to "$co%%ect

("e;"$) c$$ot :e %e!":!# co$t%o!!e'.

It "s ("t! the%efo%e> e"the% tht the su%fces o$ ;h"ch +tte%$s %e e6&"$e' :e of$ )%ee' st$'%'"se' co!ou% such s )%e# o% ;h"te> o% tht suc"e$t !#e%s of

f:%"c %e :e"$) ("e;e' tht the su%fce "s "&&te%"!. The !tte% "s +%efe%:!e>

:ecuse "t +e%&"ts the &6"&u& '"sc%"&"$t"o$. /u%fces co$s"'e%:!# '"*e%e$t "$

co!ou% f%o& the f:%"cs %e'uce the ++%e$t '"*e%e$ce :et;ee$ those f:%"cs. A$

'equte $u&:e% of th"c


64/80

c V"e;"$) D"st$ce.

The )%ete% the '"st$ce> the !ess ++%e$t $# '"sc%e+$c"es. Th"s e*ect c$ :e

o(e%co&e :# "$c%es"$) the %e ("e;e' +%o+o%t"o$!!# so tht the J("su! $)!eJ of

the s+ec"&e$ "s the s&e. Th"s hs :e$e5c"! e*ect ;"th f:%"cs> ;h"ch h(e

+%o$ou$ce' st%uctu%e Be.). %":s> "$ tht co$fus"o$ 'ue to f:%"c su%fce st%uctu%e "s!ess.

COLOUR VI/ION

Th%ee se$so%s "$ the e#e> fo% %e'> )%ee$4#e!!o;> $' :!ue.

A:out , of &e$> .0 ;o&e$ use s"&"!% &ou$ts of st$'%' %e'> #e!!o;> $'

:!ue to &tch +%t"cu!% co!ou%s 9

NORMAL TRICHROMAT

0.0 of &$ BM %equ"%e '"*e%e$t +%o+o%t"o$s of %e'> #e!!o;> $' :!ue to &tch

+%t"cu!% co!ou%s 9 ANAMALOU/ TRICHROMAT.

Mtch"$) #e!!o; ;"th %e' $' )%ee$ 9 &o%e %e' PROTANOMAL 1M

Mtch"$) #e!!o; ;"th %e' $' )%ee$ 9 &o%e )%ee$ DEUTERANOMAL 7.=M

Mtch"$) c#$ ;"th :!ue $' )%ee$ 9 &o%e :!ue TRITANOMAL

,.=M %equ"%e o$!# t;o of the th%ee B%e'> #e!!o;> :!ue to &tch +%t"cu!% co!ou%s 9

DICHROMAT.

eh(e s "f %e' &"ss"$) PROTANOPE 1.,M

eh(e s "f )%ee$ &"ss"$) DEUTERANOPE 1.7M

eh(e s "f #e!!o; &"ss"$) TRITANOPE 2.27M

2.223M hs $o se$st"o$ of hue 9 MONOCHROMAT.

TE/T/ FOR COLOUR VI/ION

AO H9R9R P/EUDOI/OCHROMATIC PLATE/ BI/HIHARA

/u++!"e% H Le;"s Lt'

13= Go;e% /t%eet

Lo$'o$ 8C1


65/80


66/80

/u++!"e% T"$to&ete% Lt'

The Co!ou% Ru!e "s s!"'e %u!e ;"th t;o ,19ste+ +"$te' co!ou% sc!es of co$st$t

!")ht$ess> o$e f%o& +u%+!e to )%ee$ $' the othe% f%o& :%o;$ to :!ue. 8he$ use'

u$'e% st$'%' "!!u&"$t"o$ Be.). A%t"5c"! D#!")ht tu:es the +os"t"o$ of $

o:se%(e%s &tch o$ the t;o sc!es )"(es &esu%e of the #e!!o;$ess of theo:se%(e%s ("s"o$ B%et"$.

A//E//ING OPERATIVE EFFECTIVENE//

The ssess&e$t f!!s "$to t;o 5e!'s of ct"("t# 9

chec "t

;e!! :e usefu! to foste% co&+et"t"(e s+"%"t $' fo% the o+e%t"(es to co&+%e

the"% o;$ "$'"("'u! +e%fo%&$ce ;"th the (e%)e of the )%ou+> ;"th tht of )oo'

&e&:e%s of the )%ou+ o% ;"th the t%)et fo% the 'e+%t&e$t> $' to see the

(e%)es of the othe% )%ou+s.

Ch$)es ;"th the +ss"$) of t"&e> "$ &te%"!s> +%ocesses> &ch"$es> !"$es etc.>

to)ethe% ;"th !:ou% tu%$9o(e%> ;"!! !! cuse ch$)es "$ the s"tut"o$. Thus the%e "s

$ee' to %e+et these su%(e#s +e%"o'"c!!# 9 s# $$u!!#. The %esu!ts of the %e+ets

;"!! "$'"cte the o+t"&u& f%eque$c#.

THE /UPERVI/OR AND QUALITY CONTROL

I$t%o'uct"o$


67/80

The su+e%("so% hs &?o% %o!e "$ e$su%"$) tht the %equ"%e' qu!"t# of the +%o'uct

"s :e"$) ch"e(e'. /he ;"!! :e u$:!e to +!# tht %o!e "f 5%st!#> she "s $ot ;%e of

+%ec"se!# ;ht "s %equ"%e' $' the &e$s of &o$"to%"$) "t> $' seco$'!#> "s $ot

co$("$ce' of the $ecess"t# fo% "t.

E(e$ "f the :o(e co$'"t"o$s %e st"s5e'> he% e*o%ts ;"!! :e "$h":"te' "f she "s

%equ"%e' to 'e(ote the )%ete% +%t of he% t"&e to &u$'$e %o!es such s tht of

se%("ce )"%!> 9 !:e"t h")h!# +"' o$e. I$ sho%t> su+e%("so% &ust :e e$cou%)e'

$' +e%&"tte' to su+e%("se.

As %esu!t of s#ste&t"c 'e(e!o+&e$t the su+e%("so% shou!'> &o$)st othe% fcets

of su+e%("s"o$> :e

1. tho%ou)h!# f&"!"% ;"th the s+ec"5ct"o$

,. .tho%ou)h!# f&"!"% ;"th $' s :# so 'o"$) !# the fou$'t"o$ fo% $ o(e%!! "&+%o(e&e$t

"$ ;o%


68/80

,.0 Custo&e% '"sst"sfct"o$ ;"th qu!"t#.

,.= C$ce!!t"o$ of o%'e%s

,. Re'uct"o$ of +%o5t +oss":!# e(e$s !oss 'ue to e6cess"(e %e?ects.

,.@ A$# othe% +o"$ts ;h"ch se%(e to e&+hs"se the +"ctu%e.

3. The fu$ct"o$ of the Q.C. De+%t&e$t

It "s '($t)eous "f the su+e%("so% s+e$'s sho%t +e%"o' of t%"$"$) ctu!!#

;o% ;h"ch the su+e%("so%

c$> "$ tu%$> e&+!o# ;he$ tech"$) t%"$ees $' %et%"$"$)> e6+e%"e$ce' o+e%t"(es.

/uch 9 $' ;"thout %es+ect su+e%("so% c$$ot fu$ct"o$

ec"e$t!#.

7. Chec $' the o+e%t"(e qu!"t# %t"$) '?uste' '"!#. The

qu!"t# of +e%fo%&$ce of $ o+e%t"(e to'# ;"!! 'ete%&"$e ho; &uch of tht

o+e%t"(es ;o%< ;"!! :e "$s+ecte' to&o%%o;.

It "s "&+o%t$t tht s&+!"$) "s %$'o& 9 the +t"tu'e of so&e o+e%t"(es to tte&+t

to J:et the s#ste&J "s !e)e$'%#. I$ the :se$ce of t:!e of %$'o& $u&:e%s

+c< of c%'s :e use' to ch"e(e the s&e e$'.

0. Fu!ts

It "s ("t! tht !! fu!ts $' 'efects !" ;he%e "t hs $ot !%e'# :ee$ 'o$e> to e6+e%"e$ce &ch"$"sts. A&ch"$"st &ust :e :!e to %eco)$"se fu!ts fo% ;ht the# %e $' to t e.). to %e+o%t> %etu%$> co%%ect $'> ;he%e +oss":!e> to +%e(e$t

the"% %ecu%%e$ce.

Much 'u+!"ct"o$ of e*o%t "s (o"'e' "f the fu!ts !"


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1. Ge$e%! fu!ts

,. o: fu!ts

Ge$e%! fu!ts %e> fo% e6&+!e> those %esu!t"$) f%o& &ch"$e o% o+e%t"(e 'efects>

;h"ch :e co&&o$ to $# )%&e$t "$ the ;o% JF:%"c ;"!! :e sc%+J>

JG%&e$t ;"!! :e %e?ect o% seco$'J> JLoss of e%$"$)sJ. O+e%t"(es $ee' to :etu)ht the e*ect of fu!t# ;o%


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f. Act"o$. 9 L"st the ct"o$ o% ct"o$s to :e t o%

shou!' :e t $!#se the& $' %eco%' the "$fo%&t"o$ ;h"ch "s the$

use' fo% tech"$) +u%+oses. I$ !&ost !! cses the fu!ts ;h"ch %e of &ost

"&+o%t$ce %e the :o%'e%!"$e e6&+!es. E(e$ $e; ;o% u$!ess su"t:!#

&ou$te' $' +%otecte'> 'ete%"o%te (e%# %+"'!#. F:%"c s&+!es cou!' :e &ou$te'

t o$ :c thus e$:!"$) the& to :e h$'!e' !&ost "$'e5$"te!#

;"thout 'et%"&e$t. A$ !te%$t"(e ;ou!' :e Js;"$)9outJ FACERAP c%'s &ou$te' o$

;!!> ;"th the ctu! fu!t e6&+!e :e"$) &ou$te' u$'e% the JA++e%$ceJ

he'"$). Fo% +%otect"o$ $' co$(e$"e$ce the# cou!' :e e$c!ose' "$ c:"$et.

@. /to%)e of E6&+!es

F:%"c fu!ts "$ e$(e!o+es :e co$(e$"e$t!# sto%e' "$ 5!"$) c:"$ets> '%;e%s> o%

:o6es of su"t:!e 'e+th> ;"th the %e!te' FACERAP c%' :e"$) c!"++e'.


71/80

C%efu! sto%)e ;"!! cut 'o;$ the te'"ous $o$9+%o'uct"(e e*o%t of co$st$t!#

%e+!c"$) e6&+!es.

. /u))este' Tech"$) Metho'

Th"s shou!' :e c%%"e' out :# &e$s of o% &"$ +%t of the !esso$>%e )"(e$ :e!o;.

. L"&"t the sess"o$ to 32 &"$utes. Th"s ;"!! "$(o!(e !"&"tt"o$ of the $u&:e% of

fu!ts 'e+e$'e$t o$ the"% co&+!e6"t#.

:. H(e c%' fo% ech fu!t> sho;"$) co&+!ete $!#s"s.

c. /ho; the e6&+!e of ech fu!t $' '"scuss the cuse> ho; to %eco)$"se "t> $'

e6+!"$ ;hte(e% ct"o$ :# the o+e%t"(e "s ++%o+%"te.

'. P!ce e6&+!es of fu!ts %ou$' the %oo&> shuWe the $!#s"s c%'s> $' the$

)et the t%"$ees to +!ce the c%'s )"$st the ++%o+%"te e6&+!es.

e. A!te%$t"(e!#> "ssue t%"$ees ;"th :!$< FACERAP c%'s> sho; the fu!t> $' the$

s< the t%"$ee to co&+!ete the c%'s.

The$ co&+%e the t%"$ees co&+!ete' c%'s ;"th the &ste% c%' $' '"scuss s t

c :o(e.

=. /u&&%#

Goo' qu!"t# +%o'ucts o% +%ocesses c$ o$!# :e +%o'uce' :# the o+e%t"(es> tht "s

the /+"$$e%> the 8"$'e%> the $"tte%> the D#e%> the F"$"she%> the Cutte%> the

Mch"$"st> the P%esse% o% those ;ho fo!' $' +c $o o$e e!se. The# c$$ot+%o'uce qu!"t# ;"thout :e"$) fu!!# ;%e of ;ht e6ct!# "s %equ"%e'. Res+o$s":"!"t#

fo% the +%o'uct"o$ of )oo' qu!"t# !"es ;"th> $' "s "$ the h$'s of> the +e%so$

tech"$) the ?o:> +%"&%"!# :# )oo' co&&u$"ct"o$> :# & costs %e&"$ t $ cce+t:!e !e(e! $' custo&e%s :e st"s5e'.


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8EAR TE/TING

It "s u$%eso$:!e of &$)e&e$t to e6+ect the te6t"!e tech$o!o)"st to :e $ e6+e%t

"$ +%e'"ct"$) co$su&e% cce+t$ce $' st"sfct"o$ of ;ht "$ %e!"t# :e tot!!# $e; +%o'uct.

The +h#s"c! test +%oce'u%es> ;h"ch the tech$o!o)"st hs t h"s '"s+os!> h(e

:ee$ 'e(e!o+e' to )%et e6te$t to &esu%e the +e%fo%&$ce of %e!t"(e!#

u$co&+!"cte' f:%"c st%uctu%es $' thus $ot :e e$t"%e!# su"te' to the $e;

+%o'uct.

8e% t%"!s %e %e!t"(e!# %ece$t "$$o(t"o$ "$ te6t"!es. The# %e co&+!"&e$t%# to

!:o%to%# +h#s"c! tests $'> "$ the&se!(es +ossess :oth '($t)es $'

'"s'($t)es.

The se%("ce:"!"t# of s+ec"5c f:%"c c$ :e 'ete%&"$e' e*ect"(e!# $' ccu%te!#

:# ;e% test"$)> $' ;e% test"$) hs "$'"cte' tht f:%"c se%("ce:"!"t# "s ofte$

fu$ct"o$ of s+ec"5c e$' use.

G%&e$ts> ;h"ch h(e :ee$ ;e% teste'> %e e6t%e&e!# e*ect"(e too!s fo%

co$("$c"$) &e%ch$'"se%s of the '("s:"!"t# of c%efu! e$' use se!ect"o$. A f:%"c o%

)%&e$t co$st%uct"o$> ;h"ch "s co&+!ete!# st"sfcto%# "$ 'u!t ;e%> :e

'"sst%ous "$ ch"!'%e$s ;e%.

Co$(e%se!#> the s&e h")h !e(e! of st%e$)th o% %es"st$ce to :%s"o$ fo% !'"es

'%ess f:%"cs s fo% ch"!'%e$s +!# c!othes c$ %esu!t "$ u$$ecess%"!# h")h costs.

A st$'%' ;h"ch "s too !o; c$ %u"$ &$ufctu%e%s %e+utt"o$. O$e> ;h"ch "s too

h")h> c$ so !"&"t the st#!"st4'es")$e%4+%o'uce%4&$ufctu%e% s to & o% "t c$ %esu!t "$ u$%e!"st"c costs fo%

f:%"c> th%e's> !"$"$)s> etc.

8e% test"$) c$ h")h!")ht sho%tco&"$)s "$ so&e +h#s"c! test &etho's $'

+%o&ote ''"t"o$! co$5'e$ce "$ othe%s. It "s> "$ fct> $ o:?ect"(e of ;e% test"$) to

'e(e!o+ +h#s"c! test &etho's ;h"ch c$ :e co%%e!te' to e$' use $' ;h"ch c$ :e

++!"e' qu"c fo% !o$) %$)e 'ec"s"o$s "t &")ht +%o(e "$(!u:!e.


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74/80

st"+u!te' &esu%"$) +o"$ts "$ the s"e ch%t '")%&> $' chec< the &?o%

'"&e$s"o$s )"$st the s"e ch%t $' tht the# %e ;"th"$ the to!e%$ces )"(e$.

M?o% '"&e$s"o$s %e9

:c< !e$)th

s!ee(e !e$)th B!eft $' %")ht equ!

$ec< ;"'thchest o% u$'e% %& ;"'th

:otto& o% ;"st ;"'th

cu* ;"'th

"". Put o$ &o'e! B'u& o% +e%so$ $' chec< & of +tte%$"$) $' of :utto$s $'

:utto$ho!es

t")ht$ess $' st%e$)th of the ;e!ts. I

""". /c%ut"$"se o$ the t:!e fo%

#%$ $' f:%"c fu!ts

se&"$) fu!ts $' se& st%etch> 5$"sh"$) of se&s

st"$s

'"%t

sh'e $' sh'"$) :et;ee$ )%&e$t +%ts

t%"&s> "+s> +!c chec< the %eco(e%# f%o&e6te$s"o$> "&&e'"te!# $' fte% the st"+u!te' t"&e "$te%(!.

""". /c%ut"$"se o$ the t:!e 9$'9 o$ the fo%& o% :o%' fo%

#%$ $' hee! $' toe +ouches fu!ts

toe c!os"$) 9 se& 5$"sh"$) $' s&ooth$ess

st"$s> '"%t $' '#e &%


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sh'e of )%ou$' $' +tte%$"$) equ!"t# "$ the +"%

. U$'e%;e%

". O+e$ out o$ the t:!e> +t t )e$t!# $' &esu%e> ;"thout '"sto%t"o$ t the

st"+u!te' &esu%"$) +o"$ts "$ the s"e ch%t '")%&> $' chec< tht &?o%

'"&e$s"o$s %e ;"th"$ to!e%$ces.M?o% '"&e$s"o$s su))este'

Vests P$ts

Le$)th :otto& to shou!'e% De+th c%otch to ;"st

De+th of f%o$t $' :c< scoo+s De+th of s"'e se&

otto& ;"'th o% ;"st 8"st o% h"+ ;"'th

"". E6&"$e & "+s> stu's etc. 9 co%%ect "$se%t"o$> co!ou%> ;o%

9 Ge$e%! Fu!t $' /+ec"5c Fu!t Reco%'s.

. Ge$e%! Fu!t Reco%'

Th"s e$:!es the fu!ts 'etecte' to :e $!#se' "$ the &"$ +%o'uct"o$ %es to

est:!"sh %+"' fee':c< $' %e&e'"! ct"o$.

Fu!ts o:se%(e' %e $ote' s st%o $' the G%oss Tot! Fu!ts> '"("'e' :# the $u&:e% of )%&e$ts

)"(e the %es+ect"(e fu!t %tes fo% th"s %eco%'.

P%"o%"t# %es :eco&e "&&e'"te!# ++%e$t $' fo!!o;9u+ "$s+ect"o$s :eco&e $ecess%# co$seque$ce "$ the +%o'uct"o$ 'e+%t&e$ts> $' "$ the success"(e

%out"$e u'"ts us"$) the /+ec"5c Fu!t Reco%' /heets> "f co$s"'e%e' $ecess%#.

These :%e


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These %eco%'s c$$ot :e +!$$e' "$ '($ce $' 'e+e$' o$ the fu!t t#+es

'"sco(e%e'. The# ;"!! +e%&"t fu%the% :%e

The tot! fu!t %te "s co&+%e' ;"th the coste' $' ;"th +%e("ous %out"$e u'"t

%esu!ts.

A$# '"sc%e+$c# '"sco(e%e' "s chec e.). ;ht +%o'uct"o$ st)e "s the sou%ce> ;hethe% &te%"!s> +%ocess o%

s

Ch"ef E6ecut"(e

P%o'uct"o$ D"%ecto%

Fcto%# M$)e%

Q.C.4Tech$"c! M$)e%

These +eo+!e shou!' the$ e$su%e tht %e&e'"! ct"o$ "s t


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78/80

+%o'uce &e$"$)fu! s&+!e.

1. Dt /e%("ce fo% ct"o$ :# /u+e%("so%

Dt %"s"$) f%o& 5$! e6&"$t"o$ "s "$(!u:!e to the se;"$) %oo& su+e%("so%.

T#+"c!!# 5$'"$)s %e %eco%'e' o$ ch%t s sho;$ :e!o; $' the %te fo% ech fu!t

c!cu!te'.

E6&"$e% Fu!t Reco%''")%&

Co&+%"so$s of $# )"(e$ fu!t o$ success"(e %eco%'"$) sheets "$'"cte the !e(e! of

tht fu!t to)ethe% ;"th $# t%e$'s. It "s +e%h+s &ost &e$"$)fu! to &$# +eo+!e "f

these %esu!ts %e +%ese$te' "$ the Jt%e$'9)%+hJ fo%& "!!ust%te'>

E-AMPLE CONTINUITY GRAPH

'")%&

It "s $ot su))este' tht ech su+e%("so% shou!' )%+h he% o;$ "$s+ect"o$ %esu!ts "$

the s&e &$$e%> :ut so&e 'o> s +e%so$! chec ++%ec"te ;he$ he% &ch"$e "s $ot +e%fect $'> ;"th"$ %eso$>

t A++e%$ce>

Cuse> E*ect> Res+o$s":"!"t#> Act"o$ $' P%e(e$t"o$ u$'e% ;h"ch he'"$) fu!ts %e$!#se' s sho;$ :e!o;> o$e c%' +e% fu!t

'")%&

Usu!!# $ e6&+!e of the fu!t "s 5!e' "$ co$?u$ct"o$ ;"th the $!#s"s c%'. 8he%e

to!e%$ces e6"st> $' ?u')e&e$t "s su:?ect"(e> J&%)"$! +ssJ $' J&%)"$! f"!J

e6&+!es !so :e ttche'. Th"s s#ste& !e$'s "tse!f to (%"et# of "&)"$t"(e

;#s of tech"$).

3. E6&+!e /u+e%("so%s Chec< L"st9

PROCE// CONTROL /LIP 3 /LIP 7

1st CROTCH Chec< st"tch te$s"o$s $' st%etches :efo%e st%t"$) ;o%< &o%$"$) $'fte%$oo$. A!so chec< 141, :e)"$$"$)> 141, &"''!e $' 141, e$' of ech t%o!!e# fo%

$ee'!e '&)e.

,$' CROTCH Chec< st"tch te$s"o$ $' st%etch :efo%e st%t"$) ;o%< &o%$"$) $'

fte%$oo$. A!so chec< 141, :e)"$$"$)> 141, &"''!e $' 141, e$' of ech t%o!!e# fo%

$ee'!e '&)e.

/IDE /EAM Chec< st"tch te$s"o$ :efo%e st%t"$) ;o%< &o%$"$) $' fte%$oo$. Chec 141, &"''!e $' 141, e$' of ech t%o!!e# fo% $ee'!e '&)e.


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LEG ATTACH Chec< st"tch te$s"o$ $' st%etch :efo%e st%t"$) ;o%< &o%$"$) $'

fte%$oo$. A!so chec< 141, e!st"c "$ ech :u$'!e fo% s"e.

8AI/T ATTACH Chec< st"tch te$s"o$ $' st%etch :efo%e st%t"$) ;o%< &o%$"$) $'

fte%$oo$. A!so chec< 141, e!st"c "$ ech :u$'!e fo% s"e.

COVER /EAM Chec< st"tch te$s"o$ fo% c%c $' t '"%t etc. '%o++he$o&e$!!#> 9 ;"th !"tt!e o% $o out!# t !!. 9 Th"s shou!' :e e6+!o"te' to the fu!! :#

e(e%#o$e.

,. The &etho's of h$'!"$) $' stc qu"te s"&+!e co$s"'e%t"o$s ;"!! (o"' the

c%e!ess$ess tht !e's to s+"!!)e o$ to the oo%> o% o(e%h$)s to ;"+e the s"'es of

;!!s o% &ch"$es o% s;%f f%o& ho"st )tes.

3. E6&"$e ;#s of +%otect"$) )oo's> ;h"ch %e st$'"$). 8ht %e the &"$ t#+es


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of '"%t $' st"$s occu%%"$). T%ce the &o%e o:("ous cuses $' ttc< these. The%e

%e (%"ous +oss":"!"t"es "$c!u'"$)

. c!e$:!e +!st"c co(e%s o% :)s

:. '"s+os:!e co(e%s o% :)s

c. sto%)e :"$s of 9+!$$e'9 sh+e $' s"e fo% ese of h$'!"$) $' sto%)e> $' to)et the :est use of the"% c+c"t# :# 5tt"$) the )oo's to :e co$t"$e'. P!st"c o%

5:%e9:o%' co$t"$e%s %e %u))e'> $' h(e ofte$ &et the $ee'.

1. A!! )oo's st$'"$) shou!' :e chec :ut e(e$ so> "f successfu! o$!# o$

12 of occs"o$s> "s st"!! )o"$) to :e ;o%th;h"!e.

C!utte% &ust :e (o"'e' 9!!9 the t"&e. It "s $ecess%# to cu!t"(te '"sc"+!"$e of

%e)u!%!# s#"$) J;h# "s th"s he%eJ If the%e "s $o )oo' %eso$> the$ %e&o(e "t to the

:est +!ce 9 e(e$ "f th"s "s to s!()e> :ecuse s+ce "s (!u:!e. Th"s '"sc"+!"$e>

o$ce cu!t"(te'> :eco&es uto&t"c. It "s $ot )e$e%!!# %e!"se' ho; c!utte% s!o;s

'o;$ e(e%# ct"("t# :ecuse of co$fus"o$> of !os"$) th"$)s $' :e"$) "$(o!(e' "$

&o%e h$'!"$) $' &o(e&e$t th$ "s %e!!# $ecess%#.

,. Pe%so$! c!e$!"$ess !;#s +#s o*. 8hte(e% the o+e%t"o$ o% ct"("t#> so&e

thou)ht c$ usu!!# %e'uce the 'e)%ee of '"%t o$ the h$'s o% o(e%!!s ;"th

co$seque$t !ess %"s< of co$t&"$t"$) )oo's> ;hethe% #%$> f:%"c o% 5$"she'

%t"c!es. 9

COMMENT

M$)e&e$t of +%o)%ess"(e 5%&s ;"!! !;#s co$s"'e% thou)htfu! $' co$st%uct"(e

su))est"o$s> 9 f%o& !! !e(e!s of +e%so$$e!. Ho;e(e%> "t $ot :e +%ct"c! to

"&+!e&e$t e(e%# su))est"o$> +e%h+s fo% eco$o&"c %eso$s.

The ;ho!e +o"$t of the eco$o&"cs of c!e$!"$ess "s tht> ;h"!st "t cou!' :e

'$)e%ous!# "&+%ct"c! to )o to e6t%e&e !e$)ths> e(e%# su%(e# hs sho;$ tht "f

9!!9 +e%so$$e! ;"!! e6&"$e !! the"% ct"("t"es> !"tt!e e6t% t"&e $' t%ou:!e %e'uce

so"!"$) '%&t"c!!# ;"th co$seque$t s("$)s "$ seco$'s $' the cost of %eco(e%#. It

+%o("'es $ e6ce!!e$t %etu%$ o$ the e*o%t "$(o!(e'. I$ fct e6+e%"e$ce )"$ teches

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QUALITY SYSTEMS FOR GARMENT MANUFACTURE.doc

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