Professional Documents
Culture Documents
(MD. ………………..)
Date: ..................
Managing Director
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QUALITY MANUAL
INTRODUCTION
With the increased demand of Bangladesh garments in the whole world market out side the country,
number of garments factories is growing rapidly but Q.A. management system cannot be developed in the
same speed due to the lack of Q.A. management system. It is the quality of our product and service along
with the efficiency of the work force, which is the foremost objective of XYZ aims to produce products
and service of the high standard, which meets all the specifications, including environmental concern and
safety XYZ’s commitment to its valued customer always been :
• Maintaining the highest achievable quality possible.
• The most competitive pricing in the world market.
• Shortest lead-time with on time delivery.
• The best environment for ethical standard in accordance with world compliance
standards.
OBJECTIVE
Objectives of this policies are :
• To understand customer’s perspective of quality.
• To provide better quality of products and service.
• To provide good and safe working environment to the workers, which includes
human value, respect, justice, cleanliness, discipline and equality between workers
and others.
• To implement quality control system with the aim to achieve zero defect level
through efficient management, research, development and continuous
improvement.
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COST AND QUALITY
The above graph shown that there is an optimum quality of a product. Above this
optimum, the increased the cost, there will be no increase of quality. But below the
optimum, lower the quality lesser the cost. The basic quality problem is to set correct
balance between the cost and quality i.e. to find out a suitable quality/cost ration for the
product which will satisfy the consumer both for cost and quality.
MANAGEMETN RESPONSIBILITY
Section : 1
PURPOSE
The organization’s quality policy is documented and communicated to each person in the
organization. The organizational structure, responsibilities and authorities have been
described to ensure every key personnel know his job and the same could be cross
checked by his higher management. To check the effectiveness of the quality system, it
has been suggested to conduct a meeting after every fortnight with the responsible
officers taking care of quality system in their assigned position.
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SCOPE
This section covers the organizational structure and responsibilities of all personnel who
supervises, perform and verify works at different stages for the improvement and
maintenance of quality.
The following positions held with in XYZ. plays a managerial role in the maintenance of
product quality and the quality control system through chain of command. Quality
management system illustrated in the flow diagram Annexure: 1.01
1. MANAGING DIRECTOR: will ensure the absolute adherence to the quality control
system by exercising his authority through his channel of command.
2. G.M.Q.A CENTRAL: Number one for whole group.
a) Preparing quality manuals for the group
b) Taking approval from the MANAGING DIRECTOR for implementation of the
system stated in the manual.
c) Implementation of statistical quality control system in the factories here it is
applicable.
d) Training of QC personals for continuous improvement to achieve zero defect
level.
e) Training of QC personals on statistical quality control system and graphical
method for achieving target quality level desired by the buyer.
f) Collections of buyers quality guide lines from buyers website or manual and
convey it to Manager QA central, Manager QA factory and Monitoring for proper
implementation to achieve buyers quality level.
g) Maintain liaison with buyers QA team for technical problems for which their
help is needed.
h) Monitoring the job of Manager QA central, Manager QA factory to evaluate
their performance and report it to concern authority.
i) To help authority to recruit right person for right job of QA department.
j) To inform to concern directors and chairman of the group the over all quality
position of the factories by MIS.
k) Inform the concern director if any factory is unable to perform up to the
desired level of quality by corrective action request or verbally.
l) Study quality related books, journals, manuals and research for continuous
improvement.
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3. MANAGER QA CENTRAL: Number one for the whole group.
a) Collection of spec sheet, shade band card, trims card, fabric test report and
approval sample from the concern merchandiser and compare production
sample with the Approval samples as well as technical sheet.
b) Not to allow any deviation from the approval sample if there is no written
confirmation form the buyer.
c) Collection of fabric inspection report to judge whether fabric is acceptable for
production on the ground of shade, defect and other factors.
d) In line inspection to see whether the garments quality is as per buyers
requirement or not. Incase of any deviation, take corrective and preventive
action.
e) Briefly describe the buyer requirement and quality control procedure to
Manager QA factory for proper monitoring to produce garments as per
requirement of buyer.
f) Report to Manager Quality, all his findings and inspection report for taking
corrective actions and monitoring.
g) Collecting of buyer’s quality guideline documents, going through these and
explain these to manager Q.A factory, and monitoring the same for correct
implementation.
h) Conduct pre-shipment inspection before buyer’s inspection to be confirmed
about the lots defect level, whether it is as per buyers desired level or not. It
not, sends the lot for recheck for correction (alter) and re-inspect the same lot
after correction.
i) Allotment of his QC team to all our mother and sub contract factories (if any).
Monitoring the quality of production in all our factories and subcontract
factories as well.
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correction. Conduct pre shipment inspection after completion of the lot and
take necessary corrective measures before buyer’s final inspection.
h) Details study of test cutting, sample, wash and non wash and consult with
Manager QA Central, GM/PM of the factory if there is any discrepancy to find
out appropriate solution.
i) Keep close co-ordination with Manager and GM QA, central for continuous
improvement.
5. QC MIS & MONITORING: Number one for each factory (Controlled by GM QA,
CENTRAL)
a) Monitoring the job of MIS Asst./Inspector, and monthly MIS report to GMQA.
b) Process capability study of every line by calculating C.V of lines defect
percentage.
c) Study of Technical sheet and approved sample of buyer. Compare first of
production sample with approved sample, with respect of technical sheet
approved trim card and shade.
d) Monitoring in-process 7 pcs inspection, counter check table inspection.
e) Checking of line wise Monthly operator’s performance and Monthly table defect
analysis.
f) Monthly defect analysis, C.V of defects line wise and factory wise
g) Moving average line and factory wise to observe the trend of defect.
h) Defect analysis after 100% process inspection in finishing.
i) Monitoring accessories, fabric and cutting inspection.
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c) Keep close co-ordination with Sewing for rectifying defects in Finishing
and make defect analysis in Finishing to take corrective and preventive
action in sewing.
d) Conduct training of all finishing QC Inspectors for continuous
improvements.
9. SR. Q.I SEWING: Two/Three for each line (Depending on no. of machines in line)
a) Carry out instructions of Manager QA Factory.
b) Conduct process capability study of the Line by calculating C.V
(Co0Efficient of variation) of hourly defect percentage.
c) Monitor quality performance of operators for continuous improvement and
incentives to operators for their performance.
d) Supervise the cutting bundles numbering, size and serial for proper control
in the sewing.
e) Review the production sample according to approval sample and shade,
f) C he c k m ac hi n e c l ea nl i n es s , n ee dl e c o nd i t i o n a nd s i z e , pr op e r
t hr ea d count and shade.
g) Conduct process inspection having idea from table inspection report
and defect analysis, about the source of high ranking of defects.
h) Observe the trend of defects from the moving average of defects in
the table inspection and take special care in those particular
processes in the line.
10. ACCESSORIES INSPECTOR: Number one in each factory.
a) Sampling of accessories as per US-MIL-STD-105E Normal
Inspection Level II AQL 2.5 or specified by buyer.
b) Inspection of accessories as per approved trim card by the buyer
c) Segregation of non conforming accessories and keep it separately with non
conforming tags.
d) Preparing inspection report and submit it to Manager QA, factory.
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d) Preparing shade grouping report and submit it to Manager QA.
e Fabric inspection by 4-point system and making fabric inspection report
f) Segregation of non-conforming rolls with red tag and keep ii) a safe place.
13. TARLE QI, OUTPUT : Number two/three for each line (inside and out side) 100
Inspection of outside and inside of garments.
a) Segregation of non-conforming garments and returns to line QC for taking
corrective and preventive action.
b) Re inspection of non-conforming garments after correction.
b) Fill up the line wise hourly inspection format,
c) Affix allotted QA numbered arrow sticker to mark all defects where
applicable.
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QUALITY SYSTEM
Section 2
PURPOSE
SCOPE
The Quality procedure of each factory will be reviewed by the concerned persons of
Management of that factory. Describing the quality systems of all factories of XYZ, this
manual includes a brief description of the functions and mode of operation of the
factories management personnel with respect to quality.
QUALITY PLANNING
Documented quality planning is stated by this manual, accompanying procedure,
work instructions
and quality, all of which comprise theXYZ
Quality System. Thus, quality planning is, documented and implemented by all
Executives and Managers playing a role in the maintenance of product quality and the
quality management system.
To achieve the goal of zero defect level following steps has been taken".
For massive awareness building regular discussion and
meeting are conducted with the concern people.
Regular training session is being conducted on Statistical
Quality Control System
Introduce it as a tool to achieve the goal.
Introduce incentives for inspectors and operators for the best
performing line.
Introduce operators' quality performance chart to find
out source and type of defect for taking preventive and corrective
measures.
Reorganize process/7pcs inspectors job allocation,
work procedure to make them more accountable for effective control on
process inspection with the help I operators quality performance chart.
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Weekly defect analysis of process inspection, table
inspection and final inspection to find out the irregularities of inspection if
any and. to take corrective measures.
Monthly defect analysis and moving average, line and
factory wise, to monitor improvement and trend of defect.
For graphical representation of hourly defect percentage
in control chart to set upper control limit at 1.0%, central line is 0.65% and
lower control limit at 0.0% to brine down defect level towards zero by
continuous improvement
Quality planning also includes the following
Assignment of responsibility for conducting checks.
Stages at which checks are to be carried out.
Methods to be followed in conducting the checks.
Frequency of the checks.
Criteria for acceptance/rejections.
Related documents to be checked.
Documents to maintain as evidence of the checks.
Corrective & preventive action to be taken subsequent to the check.
RECEVING INSPECTION
Section 3
PURPOSE
To establish and maintain documented procedures for receiving inspection in
order to verify that the specified requirements for the product are met.
SCOPE
This section applies to the product being produced in the garment factories of XYZ
ltd.
RECEIVING INSPECTION
ACCESSORIES
Before receiving accessories all necessary tests and inspection is conducted lot wise by
the accessories inspector of the factory under the guidance of QA Manager of Factory
as per US-MIL-STD-105E at buyers desired AQL. If result found acceptable, then the lot is
accepted otherwise lot is rejected and kept in marked area with a red tag for. the
safety. So that non-conforming goods are not used in process. Accessories
inspection report is illustrated in Annexure: 3.01
FABRIC INSPECTION
OBJECTIVE
The aim of fabric inspection is to check the quality, quantity and packing by visual,
measurement a color check confirming with the specification and general appearance of
the approval sample given by buyer.
INSPECTION PROCEDURE: -
Fabric to of graded will be examined from a distance of approximately three feet while
runner-Up cover the perch of a fabric inspection machine. The inspector will run the
fabric at a speed compatible with his ability to distinguish.
POINT CALCULATION
INDIVIDUAL ROLL
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= Points per 100 Sq. Yard
• The knit dyeing unit is required to present the inspector with a shipment packing list
when eighty (80%) percent of the rolls are packed from which the rolls to be
inspected will be chosen.
• Once the inspector has selected the rolls for inspection, no adjustment may be made
to the number of rolls to be inspected or to the rolls selected for inspection.
• At no time during the inspection may any yardage be removed from any roll other than
for recording and measuring shade tolerances.
• All rolls inspected will be graded and assigned penalty points.
If no specifies standard provided for knit fabric, the average point value per shipment
not exceeds 40 points per 100 linear yards. Individual rolls exceeding 40 points shall be
rejected.
DEFECTS CONDITIONS
•No more than 4 points will be penalized within one yd.
•Severe defects are assigned max 4 points for each yd.
•Any hole and any running defect will be penalized 4 points
•Whole roll having running defect or continuous defects in more than 10 yds will be
considered reject.
SPLICE ALLOWANCE
• It will not be allowed more than one splice.
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• No part of a spliced roll can be shorter than 40 yds except specified by customer.
ROLL LENGTH
• Roll found to deviate more than 2% from the roll ticket yds shall be rejected.
• The entire shipment shall be rejected if the total measured yds in the sample
t
audi deviates 1 % or more from the ticket yds.
HAND FEEL
The hand feel will be checked between roll with a reference sample. If there is a
noticeable difference, the roll will be classified as second quality.
SHADE HATCHING
Roll to roll with head to end, side to side, side center side will be checked during visual
quality inspection for preliminary. Final checking will be taken in the light box against
gray scale rating. Under light source D-65.
Various types of textiles are divided into the following five groups. Individual rolls
exceeding the specified point count level shall be graded as second quality. A shipment
shall fail the inspection if the shipment penalty count points exceed the specified point
count level
REJECTION RATE:
If total rejected inspection yardage is over 10% of total inspected yardage, then overall
result is concluded as "Rejected"
RUNNING DEFECTS:
• Any defect found to repeat and/or run in a continuous manner will constitute a running
defect. All running defects must be assigned four points to every yard in the roil when
the running defect occurs.
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• Any roll having a running or repeating defect through more than three continuous
yards shall be rejected regardless of point occurs.
• No roll that contains more than four full width defects per one hundred linear yards
shall be accepted as first quality.
• Any roll found to contain defects, in any increment of one hundred yards, with and
average of more than one major defect per ten linear yards will be rejected.
• No roll shall be accepted that contains a major defect in the first or last three yards of
the rolls. A major defect is considered to be any three or four point defect
• No roll shall be accepted as first quality that exhibits a noticeable of loose or tightness
along either or both selvedges or ripples, puckers, folds or creases in the body of
the fabric that would prevent the fabric form lying flat when being spread in a
conventional manner.
FABRIC WIDTH:
• Fabric width will be checked a minimum of three times during the inspection of a roll,
beginning, middle and end. The roll width will be checked more often if the fabric is close
to the specified minimum width of if the fabric width is uneven.
• Rolls `paving a measurement of less than the specified width will not be accepted.
• For knit fabric, rolls having a measurement of 1" wider than the specified
diameter will not be accepted. But for the stretched woven fabric, it can be
accepted 2" wider than the specified purchased width.
• For knit fabric, rolls having a measurement of 2" wider than the specified
purchased width will be accepted. But for the Lycra knitted fabric, it can be accepted
3" wider than the specified width.
PROCESS INSPECTION
Section 4
PURPOSE:
To establish and maintain documented procedures for process inspection in order to.,
verify that the specified requirements for the product are met.
SCOPE:
This section applies to the product being produced in the factories of XYZ.
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PROCESS INSPECTION
• Spreading Inspection
• Cutting Inspection.
• Sewing Inspection.
• Table Inspection.
• Two hour Inspections
•
SPREADING INSPECTION
Following ten points must be taken care of by the cutting quality inspector at the time of
spreading.
• Table marking
• Ends
• Leaning
• Tension
• Narrow goods
• Remnants
• Counts
• Ply height
• Marker Placing
• Fabric Flaws
CUTTING INSPECTION
Cutting inspection should be on the basis on random sampling on desired AQL. If the lot is
passed on sampling inspection then it is send for sewing operation, if not passed the whole lot is
re-inspected and rejected parts are replaced by good parts. In cutting inspection there are two
types of check BLOCK CHECK & BUNDLE CHECK. Following points are inspected in block
check such as Size, Parts, Pattern check, Mis cut, Ragged cutting, Notches, Matching plies.
Following points are checked in the bundle check such as Size, Parts, Total quantity, Inspect
quality, Defect quality. Cutting check is illustrated in (Annexure: 4.02). However it is
recommended to check 100% cutting parts under the light box table.
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SEWING INSPECTION:
i) He will mark red in the room against date of inspection with defect code and frequency
as a symbol for warning and recheck. He will hand over remaining units of the bundle
to supervisor for check and taking corrective action.
i) He will inspect next three bundles as follow up audit of the same operator and mark
yellow in three rooms if no defective units are found in next three bundles.
ii) He will mark green in the room against date if no defective unit is found in the bundle.
d) The inspector will make operators monthly analysis to compare it with tables
monthly defect analysis to find out whether there is any lacking in the sewing
inspection procedure. Illustrated in the (Annexure: 4.04)
e) QC Supervisor Sewing will monitor 7 pcs inspection, whether it is being done properly
or not.
TABLE INSPECTION
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FINAL INSPECTION
Section 5
PURPOSE:
To establish and maintain documented procedures for final inspection in order to verify that the
specified requirements for the product are met.
SCOPE:
This section applies to the product being produced in the XYZ Ltd. Factory facilities.
ACTIVITIES:
i) Day Final.
ii) Lot Final.
DAY FINAL:
LOT FINAL:
Lot final is conducted by Central Q A Manager when the lot is passed by Factory Q.A Manager
before shipment or in case any buyer gives the authority to the factory to conduct final
inspection before shipment. It is also conducted when buyers inspection is conducted
before shipment. It is conducted as per US-MIL-STD-105E on desired AQL. If lot is passes, they
are ready for shipment and placed before buyer's representative for final inspection before the
shipment.
Day final and lot final inspection procedures are illustrated in Garments Inspection Procedure
Chapter,
STEP-I
Inspector should collect the following before going for the inspection.
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b. First of production (FOP) garments sample as per size and color from the
concern person or authority.
C. Approved color swatches, shade band card, trim card from the concern person or
authority.
d. Garments and Fabrics test report from the factory or agent.
STEP-II
STEP-III
a. Collect packing list from the factory and check carton against the packing list.
b. Compare FOP sample with the approval sample and find out if there is any
deviation.
C. Check the shipping mark with the work sheet.
d. Select the carton for inspection by square root of .the total carton and select
carton number with the help of random number table illustrated in Sampling
Technique chapter.
e. Put signature on both the side of carton opening.
f. Bring the carton in the inspection room which should be sufficiently lighted, tidy and
clean.
d. Unseal the carton and check assortment, poly packing, hang tag, labels, color
tone etc.
e. Select the garments for fit audit size and color wise with respect to prescribed.
AQL of fit audit as per US-MIL-STD-105E illustrated in Acceptance Sample
chapter.
f. Conduct fit audit and identify total major and minor defects.
g. The defects will be called major if it exceeds tolerance and touch another size in
case of measurement.
k. The defect will be called minor if it exceeds tolerance but does not touch another size in
case of measurement.
I. Major and minor defects criteria for Visual audit have been illustrated below.
M. If the total points major and minor exceeds points as per prescribes AQL, lot will be
rejected for fit audit.
n. Select garments sample size for workmanship with the help of US-MIL-STD105E,
illustrated in Acceptance Sampling chapter.
I Inspect garments pcs by pcs.
ii. Put arrow sticker on the defect position.
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iii. Classify defects as major and minor and score accordingly.
IV. if the total points, each major=10 and minor=0.5 exceed the prescribed points
as per desired AQL reject the lot.
v. Complete data sheet of both visual and fit, take signature from the factory
representative on the sheet.
vi. Replace defective garments in the carton by good-garments.
vii Collect some defective garments for reference hand over these to the Person
concern for corrective and preventive action.
Different type of fabric defects for WOVEN, KNIT and DYEING or FINISHING are
explained as Annexure: 5.00
FABRIC DEFECTS:
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1. . In a lined garment, the liner must not extend below hem of the shell.
2. Interlining apparent from out side of garments.
3. Missing one or both pads.
ZIPPERS
POCKET A ND F LA P
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COMPRESSION ATTACHMENT OF HARDWARE
1. Clasp/snap, rivet which is defective, damaged incorrectly placed or attached.
2. Eyelet missing or misplaced.
3. Velcro placement closure not within 50% of total area mates.
4. Draw cord not free to move as designed.
5. Length of drawstring not as specified,
6. Ends of drawstrings not secured (missing stopper).
PRINTING DEFECTS:
STITCHING
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17. Button or button hole not aligned, causing noticeable bulge.
18. Conspicuous variation in length of collar points.
19. Conspicuous high/low pockets (A-Zone).
20. F -ant legs uneven off more than 1/4 inch on any fabric.
21. Part ^,f garment caught in any unrelated operation or stitching (unauthorized stitches).
22. Seams and stitching not as specified type.
23. Tight/Loose tension.
24. 24, Top stitching not uniform greater than -3/4 inch affecting appearance.
25. Permanent needle hole (needle cut, burrs).
26. Seam allowance (All zones) - join seam < 1 /2 inch. / double needle setting <
inch. Zipper setting < 1/4 inch.
FINISHING AND PACKAGING
1. Not pressed / folded / hang / assorted as specified.
2. Over pressing or under pressing/poor pressing defects including-shine, color change,
scorching or any other conspicuous "Hard" pressing defect.
1. Labs, tickets, tags, logo, hanger size clip missing/incorrect, illegible or not specified.
2. Item not dry when packed.
1. Adhesive labels or adhesive residue visible from 3 inch. (?2 inch in any view).
2. Searn should be pressed open.
3. Burn or scorch mark.
4. Shine marks on the surface of the garment.
5. Sweaters pressed out of size.
PACKAGING
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DEFECT CLASSIFICATION LIST (MINOR)
FABRIC:
1. Broken
LABEL.
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THREADS:
1. Outside, Uncut thread over '/4 inch.
2. Inside Uncut thread over 1/2 inch seen hanging below a cuff or hem or visible as
Presented.
STITCHING:
CONSTRUCTION:
(FRONT, BACK AND ASSEMBLY DEFECTS)
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2. Collar points distinctively ill-shaped or not uniform.
CONSTRUCTION
1. Corded, piped or other insert trim conspicuously uneven, loose or tight.
2. Under collar showing outside of top collar, topstitch seams not balanced top to bottom
(rolled).
3. Collar noticeably off center when attached to garment.
4. Center back neck seam not covered by collar.
5. Cuff facing uneven, twisted or poorly sewn.
POCKET DEFECTS
HEM DEFECTS
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BUTTON/BUTTONHOLE DEFECTS
FINISHING
SAMPLING TECHNIQUE
The purpose of sampling is to draw correct conclusion about the population from the'
sample, now if the sampling is not proper, we may be misguided for taking action on-
the basis of wrong sampling. Again a inspector can not check all the items produced in
a factory in the whole day, it will cause more man power, more cost, more time and
more labor. If proper, sampling technique is used to draw sample, it will not only
reduce these fa cto rs, w i ll al so red u ce the mo n o ton o u sne ss o f th e in sp e cto r . On e
o f th e m o s t important thing of sampling technique is the business of the inspector. Inspector
can not take sample as per his wish, he must follow the random number table
and probability each item to be drawn is equal. There are various types of
sampling of which, sample random sampling, stratified random sampling,
systematic sampling are commonly used.
SIMPLE RANDOM SAMPLING :- Is a method of selection n units out of N, such that
every one of the Cn samples has an equal chance of being chosen. It is the
simplest type of probability sampling and is the basis of most of the other sampling
methods. In practice a single random sample is drawn unit by unit. I he units of the
population are numbered I to N.A series of random numbers between I and N are
drawn with the help of random number table or computer which produces such table.
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them in order then 015, 098, 335, 443, 471. Again we want to select sample of seize
10 from a population 500, for this we have to select three digit number i.e. from 001 to
500. Let us start from row 30 arid column 11 then our first number will be 732 but it is
not in our serial no so we will exclude it, by going down we will have 752, 640, we will also
exclude these.
Next 268, 454, 013, 201, 017, 194, 361, 452, 419, 312 excluding all the numbers
which are out of serial. Arranging the numbers in order 013, 017, 194, 201, 268, 312,
361, 419, 452, 454 these are the sample numbers which we want to select randomly.
ACCEPTANCE SAMPLING:- Is the art or science that deals with procedures in which
decision to accept or reject lots or process are based on- the examination of
samples. 100 percent inspection is generally not justified because of time and cost as
well as for t h e s h o r t a g e o f t r a i n e d ma n p o w e r . G o o d sa m p l i n g i n sp e c t i o n , w h e r e
t h e i t e m s inspected are examined carefully may even provide. Better assurance -of
product quality than 100 percent inspection with carelessness. The purpose of
acceptance sampling is to specify course of action not to control lot quality.
Acceptance sampling plan merely accepts c, , rejects lots. Generally we like to ensure
that lots of manufactured goods do not contain an excessively large portion of
defective items. This is achieved mainly through the technique of sampling
inspection. Acceptance sampling has indirect effect on improvement of quality
through its encouragement by high rate of acceptance of good quality and through
discouragement of bad quality by high rate of rejection. It also reduces the risk of
rejection of good lots and accepting of . bad lots on the basis of sample.
LOTS SIZE :- Is the number of units in the lot and is denoted by "N"
SAMPLE SIZE :- The number of units in the sample and is denoted by "n"
SAMPLING INSPECTION PLAN:- A specific plan which states (a) the sample size (b) The
criteria for accepting, rejecting, or taking another sample, to be used in
c
inspe ting a lot.
ACCEPTANCE NUMBER :- The large number of defectives (or defects) in the sample
or samples under consideration that will permit the acceptance of the inspection lot
is called acceptance number, and is denoted by "Ac".
REJECTION NUMBER :- The smallest number of defectives (or defects) in the sample
or samples under consideration that will require the rejection of inspection lot is called
rejection number, and is denoted by "Re".
PRODUCER'S RISK :- The probability of rejecting a lot under the sampling inspection
plan when the fraction defective in the lot is actually with in specified limit is called
producer's risk and is denoted by "Pp"
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CONSUMER'S RISK :- the probability of accepting a lot with higher fraction defective
than the specified limit under the sampling inspection plan is called consumer's risk.
And is denoted by "Pc".
ACCEPTABLE QUALITY LEVEL :- The maximum percent defective that, for purpose
of sampling inspection, can be considered satisfactory as a process average is
called acceptable quality level anti is denoted by AQL.
AVERAGE SAMPLE NUMBER:- The expected value of the sample size required for
Coming to a decision, i.e, for acceptance or rejection of a lot, under the sampling
inspection plan is called average sample number and is denoted by ASN. The curve obtained
by plotting ASN against "P" is called ASN curve. Lower the ASN curve better is the
sampling inspection plan.
C R I T O R I A F O R S H I F T I N G TO N O R M A L I N S P E C T I O N F R O M TIGHTENED
INSPECTICN:- When tightened inspection is in effect, normal inspection shall be
instituted when 5 consecutive lots or batches have been considered acceptable on
original inspection, criteria for shifter to reduced inspection:- When normal inspection is
on effect, reduced inspection maybe institute when,
(a) The preceding 10 lots or batches have been on normal inspection and has
been accepted on original inspection.
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(b) The total number of defects in the samples from the preceding 10 lots or batches are
equal to or less than the desired level.
(c) Production is at a steady rate.
(d) Reduced inspection is considered desirable by the responsible authority.
For the use of 'US-MIL-STD-105E we have to choose level of AQL first, next step is to find out
sample size code letter according to lot size from the sample size code letter table, then:
with" the help of sample size code letter and AQL level, to find out acceptance number
and rejection number form the normal or tighten, single or double sampling table of US-MIL-
STD-105E.
Section 6
9.1 PURPOSE:
To prevent the dispatch of nonconforming products to the customer.
9 .2 S C OP E :
This section applies to the products which do not conform the require quality.
9.3 ACTIVITIES:
9.3.1 Non-conforming goods are identified during the checking of receiving section. Process
inspection or final inspection.
• When a major nor conformance is discovered i.e. (one that requires a managerial"{.,
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executive decision regarding it's disposition) it is so identified and segregated," subject to
the appropriate management decision, the defective goods are reworked, accepted on
concession, re-graded or rejected.
• W`here appropriate, the customer is consulted concerning any concession.
CONCLUSION
Quality has always been a primary requirement and consider to be the life of a garment. There is
no denying the fact that XYZ Ltd. had
4 Quality Control System in the production process since its birth but there might
been following
have been differences in those applications in her five factories. Compiling this quality manual
is a humble effort to put almost all necessary details of Quality Control System to ensure that
all our factories have a written Manual/ Guideline in black and white to follow. In the beginning
we will not concentrate on the statistical Quality Control System. We will follow this after a while
when we have enough and required manpower to exercise that. Any positive inclusion in this
manual which will help the factories in improving quality is always welcome; but has to done with
prior approval from the Managing Director, XYZ Ltd. We all need to educate and train our work
force in line with this Quality Manual to try ands streamline our quality system. Our united and
sincere effort only can help to improve in the sector of quality.
XYZ Ltd.
QUALTIY MANUAL Prepared by :
Prepared Date :
Checked by :
Issued date :
Approved by :
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