Knitwear Production Planning

ACCEPTABLE QUALITY LEVEL (AQL) WHAT IS QUALITY The best money can buy Meeting a specification or conformance of specification Craftsmanship The degree of excellence that an item possesses No more than 1% defective lot User based def:-whatever the costumer says or wants Producer based def:-meeting specifications to requirement Value based def:- considers cost and price of a product ISO- degree to which a set of inherent characteristics fulfill requirements CONSUMERS PERCEPTION OF QUALITY Price Technology Psychology Time Orientation Contractual Ethical Testing for packaging quality Report test statistics End term inspection No inspection 100% inspection Constant percentage checking Random spot checking Audit sampling Statistical/acceptance sampling

QUALITY REQUIRED AT EACH STAGE WE HAVE DIVIDED QUALITY PARAMETERS ACCORDING TO THE FOLLOWING DEPARTMENTS: YARN KNITTING DYEING AND PROCESSEING

Oct 2011

ACCEPTABLE QUALITY LEVEL (AQL)

Knitwear Production Planning

SPREADING & CUTTING PRINTING EMBROIDERY SEWING FINISHING

WHAT IS AQL Acceptable Quality Level is a statistical Tool, which is used to measure the degree of variance found in a lot using a random sampling method. By Pradip V. Mehta AQL is the maximum per cent defective that for the purpose of sampling inspection can be considered satisfactory as a process average o Generally expressed in % o Used in apparel industry are 1.5,2.5, 4.0,& 6.5 depending on price and item o For low price items and childrens wear AQLs of 6.5 and 10.0 may be quite appropriate o However, for higher price items AQLs of 1.5 and 4.0 may be appropriate. HISTORY OF AQL AQL was originally applied by U.S millitary for the testing of bullets during World War II. If every bullet was tested in advance, no bullets would be left. If on the other hand none were tested, results would be disastrous due to malfunction of the bullets Based on this, us government issued the standard for sampling procedure and tables for inspection as:In 1963MIL STD-105D In 1989 modified to MIL-STD 105E Re-designed in Feb 1995 as ANSI/ASQC Z 1.4

Oct 2011

ACCEPTABLE QUALITY LEVEL (AQL)

Knitwear Production Planning

ANSI/ASQC Z 1.4

STAGES OF AQL SAMPLING Select the appropriate sampling plan Determine the AQL % Determine the sampling plans parameters Establish the sample size, accept and reject criteria Randomly select the parts Inspect each part for the given feature Accept or reject the remaining parts SAMPLING PLANS Sampling plans are hypothesis tests regarding a product acceptance or rejection Sampling provides a check on the adequacy of the quality control procedures 1. METHODS OF CHECKING PRODUCTS No Checking in this no inspection is done, and nothing is known about the product until it reaches the hands of costumer 100% inspection in this every unit is inspected, done for very expensive items, done where lives are involved, it is costly,

Oct 2011

ACCEPTABLE QUALITY LEVEL (AQL)

Knitwear Production Planning

TYPES OF SAMPLING PLANS Constant percentage sampling in this 10% samples are taken from the lot for inspection, samples for small lots are very small, samples for large lots are too large Random spot checking it is in between no inspection and 100% inspection, used when supplier is certified for providing quality product, used when the process capability is so good that other method of inspection is not necessary Audit sampling-it is done on routine basis, quality report is issued for further improvement Acceptance sampling-it is based on probability and is widely used sampling technique ACCEPTENCE SAMPLING PLAN Single sampling : Lot size is produced for checking Sample size is selected If the no. of defects in the sample exceed the acceptance no. the entire lot is rejected If the no. of defects in the sample do not exceed the acceptance no. the entire lot is accepted SINGLE SAMPLING CHART

Oct 2011

ACCEPTABLE QUALITY LEVEL (AQL)

Knitwear Production Planning

DOUBLE SAMPLING CHART Lot size (N) is produced for checking Two sample sizes ( n1, n2) and two acceptance numbers ( c1, c2) are specified First sample of size n1 is taken If the no. of defects in the first sample size exceeds c2, lot is rejected and second sample size is not taken If the no. of defects in the first sample size do not exceeds c1, lot is accepted and second sample size is not taken If the no. of defects in the first sample size is more than c1 but less than or equal to c2, second sample n2 is selected

RANDOM SAMPLING OF CARTON BOX FOR INSPECTION If second sample size n2 is inspected:1. If defects in combined first and second sample size do not exceed c2 the lot is accepted 2. If defects in combined first and second sample size exceed c2 the lot is rejected

Continuous sampling

Oct 2011

ACCEPTABLE QUALITY LEVEL (AQL)

Knitwear Production Planning It is used where product flow is continuous and not feasible to be formed into lots Two parameters are specified in this, first is the frequency of checking (F) and second is the clearance no. ( I ). Frequency F is expressed as 1/10,1/20, 1/X etc. and I is a number such as 20 or 50 When inspection begins, the product is checked 100% until (I) parts are to be found defect free. At this time one out of X shall be inspected. If F=1/10, then one out of 10 parts will be checked. The sampling will continue until a defect is found. When a defect is found, 100% inspection shall be resume and the cycle starts over. When ( I ) parts are to be defect free, the sample 1/X shall start again

RANDOM SAMPLING OF CARTON BOX FOR INSPECTION Total order qty:- 1200 pcs Black S-150/M-150/L-150/XL-150=600 pcs White S-150/M-150/L-150/XL-150=600 pcs S= 300, M= 300, L= 300, XL= 300. If a carton contains Black, S-10. M-10,L-10,XL-10 White, S-10. M-10,L-10,XL-10 sample size for 1200 pcs =80 pcs Total no. of carton -15 Size wise garments selection= No. of size pcs/total pcs *sample size 300/1200*80=20 pcs /size /color

Oct 2011

ACCEPTABLE QUALITY LEVEL (AQL)

Knitwear Production Planning

WHY

IS IT NEEDED To Minimize Internal Rejections To ship extra 3% shipment To save time, that can be used in other processes To eliminate Re-work In Finishing To eliminate financial losses for re-working To minimize delay in shipments To make goodwill in the business and in the market

Oct 2011

ACCEPTABLE QUALITY LEVEL (AQL)