Supplier Quality Assurance Procedure

by Engr. Kh. Mashiur Rahman | May 2, 2019 | Blog

Supplier Quality Assurance

Purpose – Supplier Quality Assurance

Supplier Quality Assurance Procedure -The purpose of this procedure is to confirm actual bulk ratings for pilot and bulk components with the production unit to ensure correct amount of raw material is available for each contract and accurate costing are maintained. The purpose of this procedure is to ensure that the company receives products from suppliers that consistently comply to specified requirements. We sale Garments Quality Control Inspection Report Software ..

Scope

This procedure applies to all products supplied to the company (UK and Offshore). This procedure covers all pilot and bulk components.

Responsibility

It is the Responsibility of the Merchandise Manager / Fabric Technologist to ensure that the suppliers from whom products are purchased are governed by the supplier appraisal system. It is the responsibility of the Financial Accountant, Operation Manager, Merchandising Manager, Pattern Technical Manager, Cutting Room Manager, Senior Industrial Engineer & Merchandisers to ensure the implementation of this procedure.

Procedure

The information for these assessments is collated by the Merchandise, Finance, Factory, Fabric Technologist Design and UK Head Office Team.

• In each of the above categories there is a scoring system based on certain criteria.
• The Merchandising Team issue an actual rating Confirmation sheet to production unit and request return within 1 month of style going into bulk production.
• Inspecting the pilot run products for visual, construction and measurement problems.
• In case of any regular measurement problem, checking the patterns.
• Informing Quality Manager about problems found in the pilot run product and suggesting solutions.
• Discussing various complications, this can arise during production, with Quality Manager.
• Auditing every P.O (Shipment) of packed garments for visual quality, packing and measurements as per the. Standard set by the company or as per buyer’s standards
• In case of failure of any shipment, to discuss it with Quality Manager and to decide about the further course of action required for correcting the quality problem.
• Deciding and informing area in charges about the preventive action to be taken by them in next running orders of the same style, as the problem found in the packed shipment during final audit.
• Discussing the problems found in the packed shipment with Quality Manager.
• Discussing the various ongoing problems with buying house Q.C to find out solutions and quality standard requirements of buyer for a particular style.
• All confirmed ratings are to be returned direct to costings department for assessment.
• Twice a Year the supplier is assessed by the head of purchasing against each of these criteria for each of the four categories and a total score is awarded.
• On totalling the overall score for each supplier, a vendor rating result is published detailing at which point on the vendor-rating table each supplier is Supplier Quality Assurance Procedure
• The supplier will be categorized under the number of transactions that have been carried out during that assessment period

Cutting Quality Control

• The spreading of the fabric in cutting is audited by the Cutting Q.A randomly for all the layering and marking problems like problems in table marking, marker placing, ends, splices, narrow goods, leaning, tension, counts, remnants, fabric flaws etc. Report of the same is made and discussed. Refer spreading Quality Control Format
• Bundles f cut pieces are checked randomly by the Q.A (Cutting) as per auditing system for all the cutting defects like miscut, matching plies, ragged cutting, notches etc. Report of the same is made and discussed. Refer to Cutting Quality Control Format

Conclusion

Supplier Quality Assurance – Once the result is published, where possible, suppliers are called to the purchaser’s premises to discuss their ranking and corrective actions to improve their positions must be agreed and documented.

Garment Quality Control Checklist for a Factory

by Engr. Kh. Mashiur Rahman | Apr 19, 2019 | Blog

Garment quality control checklist

• Garment quality control checklist – Any type of final inspection problem (Recheck) Quality dept. become responsible not production. Read more about Top 100 QC Tools & Quality Tools …
• All recheck done by QC not others (final /internal)
• For skip / broken stitch – production people not take proper and prompt action.( reply that quality will check after that production will take necessary action)
• Any problem find out by QC – if supervisor not capable to correct it then QC will go to solve it by senior management.
• For defect (shade) – supervisor ask to go to senior management for solving the problem.
• Daily rolling inspection Report
• Daily in process Report
• End table Report
• Measurement inspection Report
• Hourly lot pass Report
• Daily Alter analysis Report
• Pre-Final & Final inspection Report
• 100% finished goods measurement record key point
• Fusing Test Report
• Button pull test Report
• Metal Detaction calibaration Report
• Rejection Fabric Report &Re-processing Report
• Reject Goods Keeping Report
• Maintenance wants tolerance for skip stitch 100/2 but who will ensure it.
• Supervisors work as helper not supervises the problems and sewing line.
• Hourly full quantity garments not supply to output
• Label mistake not solve permanently
• Any garment quality control checklist problem find out by QC, supervisor call to operator for continuing production.  
• A, B & C shade – production continue for hoping pack separately.
• Held up garments in QC box – supervisor not care of it on time to repair.
• Tendency of supervisor that responsibility shouldering to QC for defect.
•  Bundle not controlling in sewing line.
• Tang top piping not match as per cutting / summery not maintained.
• Traffic light system – Red flag problem not solve immediately.
• After identify defect – production transfer it to front without rectification.
• Operator always negligence about defect and tell to talk with supervisor.
• For reject – responsibility goes to production and QC not maintenance.
• R&D persons give importance about production not quality.
• Any garment quality control checklist problem – production people tell my responsibility is to do production not quality.
• More defects occurred but no one care of it.
• Fabric 4 point system Procedure
• Fabric Relaxation (S.O.P)
• Cutting Section Bundling (S.O.P)
• Cutting Spreading (S.o.p)
• Cutting Rejection Goods (Parts) Replacement (S.o.p)
• Cutting Parts number matching at sewing line( S.o.p)
• Care Label Main Label & any Decoration Label (S.O.P)
• Accessories Inspection Procedure
• Problem of operator not communicate to supervisor but only communicate to QC.
• Knowledge of styling very poor of supervisor cannot identify the problem.
• Relationship between production and QC very unfortunate.
• Finishing area defect not care by production and depend on finishing solving operator.
• Supervisor tendency is to pas s with defect as a result operator will occurs same defect.
• Defect not solve on time (garments kept in bag and solve end of the day)
• Inventory Report
• Accessories Inspection Report
• Fabric shrinkage Report
• Lab test Report
• Fabric inspection Report
• Fabric relaxation Report
• Marker check Report
• Spreading Layer Report
• Cut panel inspection Report (3 pcs system)
• 100% cut panel inspection Report
• 100%cut panel Quality check Report
• Cutting defect analysis Report
• Label issue register not maintain properly.
• Huge defect occurring due to style change.
• Create more defects due to operator change frequently.
• Any type of garment quality control checklist problem not solve on time but check with other floors.
• During any confrontation, supervisor call to QC – get out from my line.
• No headache about spot defect by production concern.

Garment Quality Inspector Job Responsibility

by Engr. Kh. Mashiur Rahman | Apr 14, 2019 | Blog

Quality Inspector Job

• Quality Inspector – To stop defective cut parts from leaving the cutting room.
• To ensure that cut parts meet sewing room requirements in terms of size, notches and drill holes.
• Select 9 parts from the garment at random for inspection and enter on the cut quality report.
• Garments Quality Control Inspection Report Software operation
• Place the pattern on the top ply for the first part. Align the pattern on one edge (reference edge) and check for deviations on other edges.
• For each deviation from the pattern that exceeds the tolerance, note a defect for that part under “Top”.
• Check the same part (top ply) for position and depth of notches and position of drill holes. Record defects, if any, under corresponding column.
• Repeat steps II, III and IV for a ply from the middle of the stack and the bottom ply. Record defects, if any.
• Repeat steps II, III, IV and V for the remaining parts.
• Show size defects to the cutter and cutting room supervisor. The cutter should rectify the defects immediately.
• Compute DHU (defects per hundred units) and record this.
• Notes:
• Tolerance for straight knife machine is +/- 3 mm and for band saw, +/- 2 mm.
• The cut Garment Quality Inspector report is sent to the Factory Manager as a part of the daily Cutting Room performance report (Appendix IX).
• The middle ply is taken without disturbing the stack of cut parts so that defects, if any, can be rectified by the cutter.
• Parts are inspected based on the requirement of the sewing room. If the sewing room does not require that collars, cuffs etc. is cut exact, inspect these accordingly.

HOW TO CONDUCT A FINAL INSPECTION?

• As a practice, a final inspection must be done in the following sequence-
• Packing Integrity
• Workmanship Garment Quality Inspector
• Spec Measurement

FINAL INSPECTION REPORTS-

• Below is a guideline for the auditor on how to use the inspection reports.-
• Use the approved Final Inspection summary report
• Use the detailed check list as a guide to cross check with garment and information on hand
• Use the spec measurement report.
• All three documents must be sent electronically to the QC dept. for IC issuance purpose by PDF format.
• PE QAs must also ensure to verify the factory QA’s performed the compulsory 100% packing inspection and 10% packing integrity audit and all reports are properly recorded and filed prior to accepting a shipment
• The Final Inspection Detail Check-List (Tops, Bottoms) must be used as a guide during a Final Inspection.
• The inspector must put a check mark against YES only if no issues were found for that area or operation.
• A check mark must be placed against NO if issues were found in that area or operation.
• If an operation is not applicable, then a check mark should be placed against N/A