Dhaka, Bangladesh

Assignment

On

Production Process flow chart & quality check points of garments manufacturing

Submitted By:

Abdullah Ali Akbar Reja

FMP-1, 3rd Sem.

Id- 2010-4-219

Submitted To:

Md. Tamim Jahan

Faculty, PFI

Submission Date: 01 July, 2010

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Table of Content

No Subject Page01 Introduction 0202 Quality & quality inspection 03-0703 Process flowchart for mans full sleeve shirt manufacturing 08

04 Quality check point in process flowchart 0905 SEWING SECTION (Operation breakdown OF MANS FULL

SLEEVE SHIRT)10-12

06 Quality check point in sewing section according to operation breakdown

13

07 1408 References & bibliography 15

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Introduction

A product must satisfy the consumer in terms of beauty, attractiveness, taste, shape, design and longevity of depending on the type of product.

A product devoid of quality has no demand among consumers and as such has no salability. So it is very necessary for every company to establish quality check or quality assurance department in the industry.

This assignment helps me to understand inspection methodology for sewing, finishing, and packing, help me to evaluate various production processes. It also helps me to source information and to collate, evaluate and manage it, communicate clearly and succinctly in both oral and written form.

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Quality & Quality Inspection

Quality:

Quality is an ideal, a condition of excellence. Product quality is based on a product attribute. User-based quality is fitness for use, manufacturing based quality is conformance to requirements, value based quality is the degree of excellence at an acceptable price.

ISO 9000:2000 Define it is “degree to which a set of inherent characteristics fulfill requirement.”

Quality inspection in apparel industries:

Quality inspection is done to control quality of garments. Checking of fabric, sewing thread, button, stitch, zipper, garments size etc according to required standard or specification is known as inspection. Quality inspection is important for every section of apparel industries.

There are three steeps in apparel industries to control quality, i.e.

1. Raw Material Inspection;

2. In Process Inspection;

3. Final Inspection;

Raw Material Inspection:

Fabric, sewing thread, button, trims, interlining, labels, tags quality check is done in raw material inspection steep.

1. Fabric Inspection:

Normally fabric inspection is done through Fabric Inspection machine. It is very important for every industries check fabric before cutting. In fabric inspection their checks several things i.e. in fabric are there any defect available or not. In fabric, fabric defects viz. off shad or shade variation, hole in fabric, barre effect etc. can be visual after entering into the store room. For those defects it will be problem able for making garments making. In fabric inspection there also check fabric strength, color, quantity, bayous. To check fabric there are different system i.e. 4 point system, 10 point system etc.

2. Sewing Thread Inspection:

During stitching fabric frequently brakeage of sewing thread is one of the great problems for garments manufacturing. So that it is necessary to check thread construction, sew ability, color, imperfection, finish, package density, winding, yardage of sewing thread.

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In thread construction thread number, thread ply, thread balance, thread tenacity, thread elongation, number of twist is necessary to check.

3. Trims & Accessories check:

Button, interlining, label & tags are also need to check so that quality can be maintain according to required quality. For button, button strength, button color, quantity etc are check.

In Process Inspection

Inspectioning different parts of garments before sewing are called in process inspection. It starts from marker making, than fabric spreading, fabric cutting, fabric sewing, pressing or finishing checking is done in process.

Marker Making:

For some marker fault quality of garments can be lower, i.e.

It is necessary to check all the parts of garments pattern are in marker.

In marker labeling or coding of pattern should be check

Pattern direction should be check.

The entire pattern are sated correctly should be check.

Pattern grain line is very important thing which must be considered during marker making.

During marker making every pattern pieces dimension should be accurate.

During marker making fabric length and width should be consider.

Fabric Spreading:

For those fault which effect garments quality occurs during fabric spreading and should be consider is given bellow;

During fabric spreading it should be spread according to marker length and width and fabric alignment should be correct in both sides.

Fabric should not be spread so tight or loose.

During fabric spreading because of uneven tension in fabric bias or bowing can be create.

Fabric must be spread in proper way so that fabric wastage can reduce.6

It should be consider are there any static electricity problem is available or not.

Fabric ply must be spread correctly

Fabric Cutting:

For high quality garments high quality cutting is necessary. To control fabric cutting quality good there must be consider some things;

Pattern dimension and cutting parts dimension is same or not.

Cutting parts edge how much smooth and clear.

Are there any parts add with other parts because of fusion problem.

Notch mark cutting is done accurately.

Drill mark is placed correct position & size or not.

Shorting/ Bundling:

It is necessary to check numbering, shorting, and bundling is done accurately.

Fabric Sewing:

In garments industries most large & important section is sewing section. In this section it is necessary to check all the machine operators’ work. In this section some common faults and problems must be considered, these are;

1. Sewing defects:

Needle damage;

Skipped stitch;

Thread breaks;

Seam pucker;

Wrong stitch density;

Uneven stitch;

Staggered stitch;

Improperly formed stitch;

Oil spot or stain.7

2. Seaming defects:

Uneven width;

Fault stitch line;

Back stitch must be given properly;

Twisting;

Check or strip matching;

Seam matching;

Wrong stitch face side or back side;

Thread color shade variation.

3. Assembly defects:

If finished component does not accurate size.

Garments do not accurate in size.

If any design skip to join.

Component is not joining in right place.

If lining is tight or loose.

If parts direction is wrong.

4. Pressing or Finishing:

Fabric burn or burn spot attach with body.

Any types of water spot.

Color shading occurs because of hot ironing.

Button is insecure or broken.

Garments are folding accurately.

Pocket is pressed smoothly and except fold.

Garments shape is accurate.

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Those things are plays important role that have to be check during in process.

Final Inspection

In final inspection generally inspect fully complete garments. Before final inspection there has no chance to check complete garments. It is important from the buyer to finally check. In final inspection normally garments size, form fitting, fabric faults are check.

Size:

For size, it is check according to what size is written in size label.

Shirt inspection check list

No Location Inspect for

01 Collar Both points are same or not, strip or check is match accurately, stitch, collar flat or not.

02 Size Size label is in correct place, and every parts size is correct or not.

03 Button & button hole Placed in right place or not, evenness of gap between one button to other, stitch is done correctly, are there any broken button or not.

04 Pocket Pocket upper edge horizontal or not, pocket position, size, stitch, stripe or check is match, flat or not.

05 Hem Stitch, are there any puckering occur or not, edge free from stitch.

06 Yoke & shoulder Stitch, puckering problem, skipped stitch.

07 Side seam Pattern matching, stitch, free from raw edge

08 Cuffs Strips or check matching, top stitch, flat or not.

09 Finished appearance Threads edge comes out or not, are there any oil spot or not, fabric fault, color matching, strip matching.

Packing: Before packing it is necessary to check fabric is free from broken needle. It is also need to check packing raw material is free from making any problem in garments and after packing it is packed accurately.

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Process flowchart for mans full sleeve shirt manufacturing

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Side Operation Operation Method

Design/ Sketch

Pattern Design

Sample Making

Production Pattern

Grading

Basic Block

Manual

Costing

Manual

Manual

Manual

Manual

Fabric Cutting

Raw Materials in Into Store

Marker Making/ Lay Planning

Fabric Spreading

Manual

Manual

Packing

Shorting/ Bundling

Sewing/ Assembling

Final Pressing/ Finishing

Final Inspection

Deliver to Buyer

Manual

Iron PressFusing

Lock Stitch, Over Lock, Button Holing, Button Attaching M/C

Ironing

Quality check point in process flowchart

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Operation MethodSide Operation & Quality Check point

Raw Materials in Into Store

Quality checking of Fabric, Button, Sewing thread, fusing paper, trims, label & tags etc

Side Operation & Quality Check point

Quality Check

Quality Check/ Fabric Inspection

Marker Making/ Lay Planning

Fabric Spreading

Manual

Manual

Fabric CuttingQuality Check/ Fabric Inspection

Manual

Marker Inspection

Quality Check

Packing

Shorting/ Bundling

Sewing/ Assembling

Final Pressing/ Finishing

Final Inspection

Deliver to Buyer

Manual

Manual

Iron PressFusing

Lock Stitch, Over Lock, Button Holing, Button Attaching M/C

Ironing

Inspection

SEWING SECTION (Operation breakdown OF MANS FULL SLEEVE SHIRT)

Operation BreakdownStyle No:  Buyer:  

Description:MENS F/SLV SHIRT WHITE & STYPE FABRIC(COLLAR,BAND, BOX PLKT) NONE FUSED,BOX PLKT KANSAI, DOUBLE BACK YOKE,PKT W/SML PKT,FRONT SIDE PANAL,FRONT LOOP

S/N Operation M/C Attachment         COLLAR    

01 MATCH & MARK COLLAR PARTS   MAN TABLE 02 MAKE LOWER COLLAR W/LINING LS1 NG-1/4''

03 TRIM / TURN LOWER COLLAR MAN CLR TURNING

04 PRESS LOWER COLLAR MAN CLR PRESS05 TS LOWER COLLAR-1/16 LS1 CR 1/4''06 TS LOWER COLLAR-1/4 LS1  

07 MAKE UPPER COLLAR W/LINING LS1 NG-1/4''

08 TRIM / TURN UPPER COLLAR MAN CLR TURNING

09 PRESS UPPER COLLAR MAN CLR PRESS

10 TS UPPER COLLAR-1/16 LS1 CR 1/4''

11 TS UPPER COLLAR-1/4 LS1

12 HEM COLLAR BAND W/LINING LS1 CR-5/16"

13 ATT.COLLAR BAND TO COLLAR LS1 NG-3/16"

14 TURN & TS COLLAR BAND LS1 CR-1/16"15 B/H COLLAR BAND-1 BH LBH-781

16 ATT. BTN ON BAND-1 BS LK-190317 TRIM BOTTOM OF C/BAND MAN MO-1950

       

  POCKET           18 MAKE PLIT ON SMALL POCKET X 2 LS1  19 TACK PLIT TWOSIDE 2 X 2 LS1  20 PRESS HEMOF SMALL POCKET-2 LS1 CL-1/16"21 PRESS SMALL POCKET-2 IRON TABLE

22SMALL POCKET POSITION MARK AT MAIN POCKET MAN TABLE

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23SMALL POCKET JOIN WEITH MAIN POCKET LS1 CR-1/16"

24 T/S SMALL POCKET LS1 CR-1/4"25 MAKE PLIT ON MAIN POCKET X 2 LS126 TACK PLIT TWOSIDE 2 X 2 LS127 PRESS HEMOF MAIN POCKET-2 LS1 CL-1/16"28 PRESS MAIN POCKET-2 IRON TABLE

FRONT LOOP AT SHOULDER

29 LOOP ROLLIN LS130 LOOP MAKE LS1

  BACK PART           

31ATC MAIN LABEL W/ INSERT SIZE LBL TO BK YOKE LS1 REG FOOT

32 ATC BK YOKE TO BK LS1  33 TOPSTITCH BK YOKE LS1         

  FRONT           

34 HEM T/S BOX PLACKET KANSAIFT 1/4"-1"-1/4"

35 HEM TS BTN PLKT LS1 FOLDER36 1/16" EDGE STITCH BTN PLKT LS1 CR-1/16"37 TACK CARE LABEL TO FRONT LS1 REG FOOT38 ATTACH MAIN POCKET LS1 CR-1/16"39 T/S MAIN POCKET LS1 CR-1/4"

40MATCH & MARK FRONT LOOP AT SHOULDER MAN TABLE

41 ATT SHOULDER WITH FRONT LOOP LS11/4' FOA FOLDER

42 T/S STITCH SHOULDER LS1         

SLEEVE

43 SLEEVE GAMBLE LS144 SLEEVE GAMBLE TUCK LS145 SLEEVE PLACKET ATTACH LS146 CUFF INTERLINING MAN IRON

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47 CUFF ROLLING LS148 CUFF MAKE LS149 CUFF TS LS150 CUFF JOIN LS1

  FINAL ASSEMBLY           

51 ATT./TS SLEEVE ARM- HOLE CS2 1/4" FOLDER52 ATTACH COLLAR TO BODY LS1 T- GUIDE53 ATT. TWIL TAPE TO CLR LS1 GUIDE

54 CLOSE COLLAR LS1 CR-1/16"

55 BOTTOM HEM LS1 T guide

56SEW BUTTON HOLE AT BODY X 6 & LOOP BH  

57 ATT. BTN TO BTN PLKT & LOOP BS CL-3/8

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Front side Back side

Sketch

Fig: Men’s Full sleeve shirt

Quality check point in sewing section according to operation breakdown

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TABLE

START

LS12

MAN9

MAN8

LS17

LS16

LS15

MAN17

POCKET START

BK PRT

F/LOOP

Q/C

TBL 1

COLLER START

MAN 3

MAN 4

LS114

LS113

LS112

LS111

LS110

BS16

BH15

LS118

LS120

LS119

IRON

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CLR END & Q/C

MAN/TABLE22

LS123

LS135

LS1 24

LS1 26

LS1 27

PKT END

IRON28

Q/C

LS1 29

LS1 30

LS1 31

LS132

LS1 33

Q/C

KANSAI 34

LS1 36

LS1 37

LS1 38

LS1 39

LS1 25

TB

L40LS1 4

1

LS1 42

Q/A

LS

143

LS

144

LS

145

IRON46

LS

147

LS

148

LS

149

LS

150

SLEEVE

FINAL ASSEMBLY

CS251

LS152

LS153

LS154

LS155

BH

56B

H

57B

S

Q/C

Q/C

Q/C – Quality checking point.

- Direction

Conclusion

This is a great opportunities for me doing this assignment on quality check. To complete this project I do my best. I have gathered much experience doing this assignment. I learn how to check quality for manufacturing Men’s shirt, process flowchart for garments manufacturing and quality check point. I understood inspection methodology for sewing finishing and packing.

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References & Bibliography

1. Cooklin, G. (1991) Introduction to Clothing Manufacture. Oxford: Blackwell Publishing Company.

2. Kashem, M. A. (1993) Garments & Technology. Dhaka: Grantho Nir Publishers.

Sketch:

3. Reja, A. A. A (2010) Men’s Full sleeve shirt. [Sketch]

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