SHANTO-M ARIAM UNI VERSITY OF CREATIVE

TECHNOLOGY

Module Name: Apparel Quality Management

Module Code: AMM-2203

Topic Name: Quality control in different section of RMG

industries.

Submitted to:
S.M. Sudrul Amin
(Lecturer)

Shanto-Mariam University of Creative Technology

Submitted by:
Owazkarani Jihad
ID: 202051002
Semester: 4th
Batch: 39th
Dept.: AMMT

Submission Date: 29/08/2021

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Quality may be defined as the level of acceptance of a goods or services. For the textile and apparel
industry, product quality is calculated in terms of quality and standard of fibers, yarns, fabric
construction, color fastness, designs and the final finished garments. In Bangladesh, different
garments factory follow different quality control and management systems especially different
inspection systems for garment inspection. This article contains the quality control processes
as well as quality management procedures followed by different garment factory of Bangladesh
and the feasibility of these processes. KEY WORDS: Quality Control, Quality Management, Garment,
Garment Defects, Inspection, AQL.

INTRODUCTION

Quality control in terms of garment manufacturing, pre-sales and posts sales service, delivery,
pricing, etc are essential for any garment manufacturer, trader or exporter. Certain quality related
problems, should never be over looked. The consumers want to get high quality products in low
price. The products should reach the consumers with right quality depends on the cost. Quality
management is the aspect of the overall management function that determines and
implements the quality policy. Quality assurance covers all the process within a company that
contributes to the production of quality products. The inspection is carried out by
representatives of the current production and the result record on control chart. The aim of
garment inspection is to visually inspect articles at random from a delivery in order to verify their
general conformity and appearance with instruction/description and/or sample received.

METHODOLOGY

At first all the data are collected from different reports and documents of different garment
factories. When these data become not sufficient, some other data are collected by close
observation and over telephone. This is a descriptive and analytical study. The sample size is 07
(seven). The collected data are processed with MS Excel and all biased & incomplete data deleted
from the data bank.

THEORY

Certain quality related problems, often seen in Garment manufacturing like sewing, color, sizing, Or
garment defects should never be over looked.

Sewing defects

Open seams, wrong stitching techniques, non- matching heads, missing stitches, improper creasing
of the garment, improper thread tension etc. are some of the sewing defects.

Colour defects

Variation of colour between the sample and the final garment, wrong colour combinations and
mismatching dyes.

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Sizing defects

Wrong gradation of sizes, difference in measurement of various parts of a garment like sleeves of XL
sizefor body of L size garment can deteriorate thegarments beyond repair.

Finished garment defects

Broke or defective buttons, snaps, stitches, Different shades within the same garment, dropped

stitches, exposed notches, fabric defects, holes,

faulty zippers, loose or hanging sewing threads,

misaligned buttons and holes, missing buttons,

needle cuts, pulled or loose yarn, stains, unfinished

buttonhole , short zippers, inappropriate trimmings

Etc. all can lead to the end of a brand name even

before its establishment.

Methods of quality control

Basically two methods are used for garments quality control –

a) Testing b) Inspection.

Piece goods quality control

On receipt of fabrics in the ware house, at least 10% are inspection as per “4 Points” system/10
Points system/2.5 Point system/6.0 Point system. The most commonly used 4 Points system as per
below - SIZE OF DEFECT PENALTY 3 Inches or less 1 Point Over 3, under 6 Inches 2 Point
Over 6, under 9 Inches 3 Point Over 9 Inches 4 Point A maximum of 4 points are changed in
one linear yard.

Cutting quality control

In cutting section quality is insure in two stages.

a) Spreading quality control: Following the point are checked during spreading I. Table marking.
II. Ends III. Tension IV. Leaning V. Narrow Goods VI. Counts VI. Ply height VII. Remnants VIII.
Fabric flaws IX. Market placing

b) After cutting quality control: After each cutting blocks and bundles are checks on the
following points. I. Mis cut II. Ragged cutting III. Pattern checks IV. Matching Plies V. Notched.

In process quality control (Sewing)

During the swing “In process quality control” is done by the line QC’s through 7 pcs
inspection system. For critical operations system. For critical operations 100% process

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inspection are carried out. The following parameters are also checked in sewing process – a)
Machine check. b) Tension. c) SPI checks d) Needle check. e) Cleanness. d) Table inspection. f)
Inspection before wash. 100% process inspection are carried out. The following parameters are
also checked in sewing process – a) Machine check. b) Tension. c) SPI checks d) Needle check. e)
Cleanness. d) Table inspection. f) Inspection before wash.

Quality control of finishing sections

Following inspection/au Quality control of finishing sections: Following inspection/audit is done

to attain AQL (1.5/2.5/4.0 etc). a) Process inspection: Garments are checked process wise in the
finishing section to identify defects and pass only the passed garments. b) Two hourly audit: Every
after two-hours audit is done on finishing lot to attain AQL the required AQL. c) Days final
audit: At the end of the day accumulated lot of finished garments are statistically audited to
attain required AQL. d) Lot final audit: On completion of packing of one complete lot of garment,
QA manager conduct statistical audit based on required AQL garments. Garments are offered
for final inspection by buyer /clients for shipment only when these are through in this audit.dit is
done to attain AQL (1.5/2.5/4.0 etc). a) Process inspection: Garments are checked process wise in
the finishing section to identify defects and pass only the passed garments. b) Two hourly audit:
Every after two-hours audit is done on finishing lot to attain AQL the required AQL. c) Days
final audit: At the end of the day accumulated lot of finished garments are statistically audited
to attain required AQL. d) Lot final audit: On completion of packing of one complete lot of
garment, QA manager conduct statistical audit based on required AQL garments. Garments
are offered for final inspection by buyer /clients for shipment only when these are through in this
audit.

MAJOR FINDINGS

IN Bangladesh most of the garment factories use different tools for quality management but
not in organized way. When needs, they use these tools haphazardly. • In Bangladesh most of
the garments factories use 4-point system for inspecting fabrics of garments. • Most of the buyers
are importing garments from Bangladesh with AQL (acceptable level) 2.5. • Most of the
garments manufacturers are doing inspection during the manufacturing process of garments. •
Other tests such as shrinkage tests, colour fastness tests, azo free tests are done according to the
buyers’ requirement.

RECOMMENDATIONS

Every garment factory should implement different tools like 5’S, 6 Sigma etc for perfect
quality management. • As inspection is always visual, sometimes machine can be used for
inspection of garments. • The 4-point system has some limitations so that this system should be
used with proper care. RECOMMENDATIONS • Every garment factory should implement different
tools like 5’S, 6 Sigma etc for perfect quality management. • As inspection is always visual,
sometimes machine can be used for inspection of garments. • The 4-point system has some
limitations so that this system should be used with proper care.

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CONCLUSION

In Bangladesh every garments manufacturer should give first preference to its valued customers.
Now-a-days buyers are very much quality conscious. If it becomes possible to maintain a high
Quality system of inspection policy, the buyers shall be motivated to place more orders in
Bangladesh. So, it is possible to set different modern quality procedures and quality management
techniques in Bangladesh for the betterment of its RMG sector.

REFERENCES

1. An introduction to quality control for the apparel

industry Pradip V. Mehta - 1985 .

2. Managing quality in the apparel industry, Pradip

V. Mehta, Satish K. Bhardwaj – 1998.

3. Various Methods of Inspection Systems for

Apparels; K. Sakthivel, online publication.

4. Garments & Technology; Prof.M. A. Kashem-

2009

5. Garments Merchandising, Prof. M. A. Kashem-

2009

6. Technology of Clothing Manufacture 2nd ed,

Harold Carr and Barbara Latham.

7. Garment Technology for Fashion Designers,

Gerry Cooklin.

8. TQM: Towards Zero Defects By: C. K. Karekatti

http://en.wikipedia.org/wiki/Six_Sigm

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