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GARMENT PRODUCTION PROCESS AND QUALITY ASSURANCE
MASTER TEXTILE MILLS LTD.GARMENTS DIVISION M-6
Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.
MASTER TEXTILE MILLS LTD. (GARMENTS DIVISION)
MASTER TEXTILE MILLS LTD. (GARMENTS DIVISION)
2Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.
Garment Production is a process where fabric is being converted into Garments.
Garment manufacturing includes number of processes from order receiving to dispatching shipment of the finished garments.
Process flow charts will help us to understand how raw materials are moved from one process to another process, until fabric and accessories are transformed into the Garments.
In presentation “Working of Quality Assurance” in garment production process is shown with snaps. Numbering is given to QA working and their snaps are also given.
GARMENT PRODUCTION PROCESS
3Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.
DEFINITION:
Quality assurance is an organization's guarantee that the product or service it offers meets the accepted quality standards.
OBJECTIVES:
1. Achieve the Right Final Product on Time.
2. Plan and Monitor the Overall Systems of Functioning of Quality System.
3. Customer’s Satisfaction.
4. Focus on Gradual and Continuous Improvement.
QUALITY ASSURANCE
4Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.
GARMENT PRODUCTION PROCESS FLOW CHART
Note: Numbered Boxes are Quality Check Points.
SAMPLING
- FIT SAMPLE - SIZE SET SAMPLE
PP SAMPLE APPROVALFABRIC AND TRIMS
IN-HOUSE
MATERIAL SOURSING
PPC (PLANNING ) - MAIN POWER - MATERIAL - MACHINES
MATERIAL INSPECTION
MARKETING ORDER RECEIVING
CUTTING
PP MEETING
1
TRIAL RUN (PP SIZE SETS) - APPROVED SAMPLE’S CUSTOMER COMMENTS VARIFY
FAILFAIL
PASSPASS
STITCHING
WASHINGFINISHING
PACKING
SHIPMENT DISPATCH
SHIPMENT AUDITS
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5Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.
In Garment Production Process First Role of Quality Assurance is: 1. Inspection of Fabric
2. Inspection and Testing of Garment Accessories.
1. For fabric Inspection we have Fabric Inspection Department (FID):
FABRIC INSPECTION DEPARTMENT (FID): FABRIC INSPECTION: HEADERS COLLECTION
AND PREPARATION:
2. FABRIC SHADING
1. FABRIC INSPECTION
3. FABRIC SHRINKAGE
4. FABRIC WIDTH
5. FABRIC LCR VARIATION
MATERIAL INSPECTION
1
6Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.
FID FINALINSPECTIONREPORT:
DECLARATIONAFTER ALL TESTS AND PROVIDES INFORMATIONOF SHRINKAGES.
MATERIAL INSPECTION
FABIC SHADING
FABRIC SHRINKAGE 1
7Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.
2. Inspection and Testing of Garment Accessories. For this we have QA Lab. QUALITY ASSURANCE LAB.: This performs three types of tests:
Tests performed are given as under:
…………………………………………………………………………………………………………………………………………………..
23. FLAME RETARDANT
25. AZO DYES
24. FORMALDEHYDES
FROM OUT SOURCE
22. LEAD & CADMIIUM
26. PATHALATES
8. SKEW TEST
3. STRETCH AND RECOVERY
6. FABRIC COUNT
4. ABRASION.
9. PH OF FABRIC
10. GSM
7. PILLING
1. DIMENTIONAL STABILITY TO WASHING
11. CMC
2. SEAM SLIPPAGE AND STRENGTH
5. FABRIC COMPOSITION
MATERIAL INSPECTION
3. ACCESSORIES TESTS
1. FABRIC & GARMENT TESTS
2. CHEMICALS TESTS
19. DRY CLEANING
COLOUR FASTNESS TESTS
20. WATER
16. PERSPIRATION
17. WASHING
18. CROCKING
13. TENSILE STRENGTH
12. TEAR ING STRENGTH
FABRIC STRENGTH TESTS
15. STRETCH STRENGTH
21. LIGHT
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8Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.
FINAL LAB. TEST REPORT:
MATERIAL INSPECTION
ZIPPER STRENGTH
ELASTIC STRETCHABILIYPULL TEST
NICKEL TEST
FERROUS TEST
THREAD STRENGTH
Q.A LAB. ACCESSORIES TESTS:REV: 00
Date
Art#
Yarn Count Shade
Construction End Use
Ref
METHOD # REQUIRED Results
ASTM D 3776
ISO 3071
Out Seam
ISO 12945-1
ISO 12947-2
Approved by:
Tear StrengthWarp
ISO 13937-1Weft
ISO-13935-1
Front Rise
Back Rise
Out Seam
Seam SlippageWarp
Seam Strength
In Seam
Loops
ISO 105 E04
Back Rise
ISO 105 EO1
ISO 13934 -2
ISO 6330 @ 40 °C
Weft
Abrision
Stretch PropertiesStretch
UnrecoverablaDu Pont 10
Prepared by : Checked by :
Remarks ;
ISO 13936-1
Final Result
Pilling (ICI)
Staining
MASTER TEXTILE MILLS ( GARMENTS DI VISION M- 6 )
Customer
Order#
Seat Width
Front Rise
Process
Waist
Color fastness to Water
Dimensional Stability to Washing
Color fastness to Rubbing Dry
Wet
Shade Change
Weave
Composition
pH Value
Staining cotton/poly
Warp
ISO 6330 @ 40 °C
ISO 105 X12
GSM
Apperance After Washing
Shade Change
Tensile Strength ( Grab )
TEST
Laboratory Final Test Report QR/LABG/03
Sample Descriptions
Selvedge Type
ISO 105 E04
Color Fastness to Perspiration (Acidic)Shade Change
Staining cotton/poly
Weft
Appreance
Color Fastness to Perspiration (Alkaline)
Shade Change
Staining cotton/poly
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10Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.
Before Bulk Cutting PPC Department arranges a meeting with merchandiser, customer’s auditor, QA, IE and Production Department. In this meeting all Customer Comments are discussed on a size set of pre-
production garments or on a trail run.
This meeting is called “PP-Meeting”.
QA Cutting Master Verifies Comments and Pattern After Amendment.
PP MEETING WITH CUSTOMER
PRE-PRODUCTION MEETINGS
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11Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.
CUTTING DEPATMENT PROCESS FLOW CHART
PATTERN VERIFICATION
EMBROIDERY CHECK
FUSING
EMROIDERY
NUMBERING
SHADE MARKING
CUTTING
STITCHING
PATTERN VRIFICATION
SPREADING
SORTING & BUNDELING
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BUNDELINGCHECK8
SPREADING
CHECK
5
CHK SHADE MARKING
6
CAD / CAM
NUMBERINGCHECK
PASSPASS
FAILFAIL
PASSPASS
FAILFAIL
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MEASUREMENTSVRIFICATION
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73
Note: Numbered Boxes are Quality Check Points.
12Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.
QUALITY ASSURANCE CUTTING AND EMBROIDERY
EMBROIDERY
SHADE MARKING INSPECTION AND PATTERN CHECK
SPREADING INSPECTION
BUNDLES INSPECTION NUMBERING CHECK7
5 6
8 9
MEASUREMENTS VERIFICATION4
13Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.
STITCHING DEPATMENT PROCESS FLOW CHART
INSPECTIONINLINE
INSPECTIONTABLE
FRONT SECTION
ASSEMBLY 2
STITCHING
INSPECTIONTABLE
ASSEMBLY 1
INSPECTIONINLINE
FRONT AND BACK SECTION
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SMALL PARTS
BACK SECTION
STITCHING LINES
WIP STACKING FINAL BATCHAUDIT
20MEASUREMENT
CHECK
12
FINALINSPECTION
18
WASHING
PPS COMMENTS VERIFY
INSPECTIONINLINE
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INSPECTIONINLINE
15
INSPECTIONINLINE
15
PPS COMMENTS VERIFY
PPS COMMENTS VERIFY
PPS COMMENTS VERIFY
PPS COMMENTS VERIFY
INSPECTIONTABLE
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INSPECTIONTABLE
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10
10
10
10
10
19
13 14
Note: Numbered Boxes are Quality Check Points.
14Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.
QUALITY ASSURANCE STITCHING
STITCHING INLINE INSPECTION IN ALL FRONT BACK AND ASSEMBLY SECTIOINS
SMALL PARTS BACK SECTION FINAL
SMALL PARTS FRONT SECTION INSP. SMALL PARTS FRONT SECTION INLINE CUSTOMER COMMENTS VERIFICATION
SMALL PARTS BACK SECTION INLINE
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13 14 15
15Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.
QUALITY ASSURANCE STITCHING
FINAL INSPECTION TABLE
ASSEMBLY 1 INSPECTION TABLE
MEASUREMENT CHECK
FINAL BATCH AUDIT
FRONT AND BACK SECTION INSPECTION TABLE
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19
17
18 20
16Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.
1ST BATCH MMT
WASHING
RUBBIING
SCRAPPING INSPECTIONINLINE
SHADING
SPRAYING
WASHING
HYDRO AND DRY
FINISHING
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PASS
SHADE BOOTHS
SHADING AT SHADE BOOTHS
1ST BATCH MEASUREMENT AND INLINE INSPECTIONS
PROCESS FLOW CHART WASHING DEPARTMEN & QA WASHING
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21
21,22
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Note: Numbered Boxes are Quality Check Points.
17Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.
PROCESS FLOW CHART FINISHING DEPATMENT
TRIMMING INSPECTION TABLES
A/W ACCESSORIES INLINE INSPECTIOON
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FINAL BATCHAUDIT
FINISHING
TRIMMING
INSPECTION TABLES
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MEASUREMENT
FINAL CHECKING
PACKING
PRESSING
LEATHER PATCH & LABELS ATTATCH
INLINEINSPECT.
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BUTTONING
MMT + INLINEINSPEC.
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MEASUREMENTTABLES
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SUPER CHECKTABLES
28 30FINAL INSPECT.
TABLES
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B-2SECTION
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FAILFAIL
PASSPASS
FAILFAIL
PASSPASSNote: Numbered Boxes are Quality Check Points.
18Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.
QUALITY ASSURANCE FINISHING
MEASUREMENT CHECK TABLES PRESSING MMT & INLINE INSPEC.
FINAL CHECK TABLES FINAL BATCH AUDIT
SUPER CHECK TABLES
B-2 RECONCILIATION
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29 30 31
19Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.
PACKING DEPARTMENT, QA PACKING AND FINAL AUDITS
After final audits packed cartons will transferred to finish goods store. Finish Goods Store will receive packing lists, will check weight of each carton and will ship on the time of delivery.
PACKING
PACKING
DISPATCH
INLINEINSPECTION
SHADING
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CARDING
INTERNALAUDITS
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PACKING INLINE
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INTERNAL INLINE INSPECTIONS AND FINAL AUDITS
33
20Prepared By: KHALID MEHMOOD Master Textile Mills Ltd.