Inspection Procedures in sewing Room

Inspection refers to quality control in

sewing room
Advantages of in-process
inspection
1. Reduction of major surprises from
the customers due to bad quality.
2. Decrease in labor cost due to a
decrease in repair rates.
ASSQC--Inspection procedure in
sewing Room

Inspection Loop

ASSQC--Inspection procedure in
sewing Room

In-Process inspection (In line)

In-Process inspection means the inspection of parts
before they are assembled into a complete product.
In apparel manufacturing , this means inspection at
various points in the entire manufacturing process
from spreading fabric to pressing /ironing.
In-process inspection can be performed by either
quality control inspectors or individual operators
themselves after they perform their respective
operation.
This will help to identify the source of quality problems
as early in the manufacturing process as possible.
This will result in minimizing the need for later repairs
& rework.
ASSQC--Inspection procedure in
sewing Room

In-Process inspection (In line)

During production or du-pro inspection

Visual evaluation or assessment of parts ,

components or materials during production.
This process assesses conformance to
standard & specification for the assembly
process,
Individual components are examined before
the assembly for standard & specification
In-line inspection helps eliminate the
production of unacceptable merchandise,

ASSQC--Inspection procedure in
sewing Room

Few important steps in sewing

section are as follows:
1.
2.
3.
4.
5.
6.
7.
8.

Layout
Line balancing
Bundle tracking
Optimum utilization of 6ms
Effective communication & co-ordination
Maintaining buffer
Quality
Improving productivity
ASSQC--Inspection procedure in
sewing Room

Optimum utilization of 6ms

6m s mean effective utilization of

Men,
Machine,
Material,
Method
Money &
Management in the department
ASSQC--Inspection procedure in
sewing Room

Flow charts (Line plan)

Flow charts can help understanding
complete process
Flow chart along with a set of
standards & specification.
Identify critical stage of process
Locate problem areas & allocate
check points.
Flow charts show relationships
between different steps in process
ASSQC--Inspection procedure in
sewing Room

Sewing Room Quality Process Chart

Productio
n File

Line Plan

PP
Meeting
Commen
ts

Cutting Receipt Pilot Run

Defect

Approve
d PP
Sample

Mockups at
critical
operatio
ns

Trim
Card

Key
Inspecti
on
Points Actual Prod. begins
With Layout prep by
Line Chief and Sup.
100% Inline
report:
Providing
DHU
Skip
Bundle
Audit

Quality
Style
Specificati
Starton Sheet
up
Checkli
Measur
st 100% End
line
report:
Providing
DHU

ement
Report

100 % In-process
Quality Control
100% End of Line
Visual Inspection
Random inline After assembly
inspection
Lot pass
(Based on AQL) Report

Issued to
Finishing

ASSQC--Inspection procedure in
sewing Room

Pass Visual audit (2.5)

Minor audit (4.0)

100% Re-check
and rectify
Fail
8

Managing In-line quality depends on

below

Organizational structure
Products manufactured
Technology
Work force level

ASSQC--Inspection procedure in
sewing Room

Required parameters in terms of a

standards & specifications For a Particular
operation ,

For example: Side seam

Stitch type
Seam type
Thread
Seam allowance
Stitches per inch
Standard for appearance
Placement of front & back panels
Amount of material to be trimmed

Note:-- Operator must know above requirement

Operator & supervisor are constantly reminded for
company specific quality level to meet.
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sewing Room

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Inspection Procedures in sewing

Room

Sewing
Sewing Defects
Seaming defects
Assembly Defects
Control of Fusing Operation
EmbellishmentPanel printing &
embroidery
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sewing Room

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Sewing /Construction defects

Irregular stitching
Hem or hidden stitching uneven.
Broken stitches
Excessively tight or loose tension
Not straight or Not parallel topstitching
Use of wrong thread (i.e. wrong tkt or monofilament)
Skipped stitches
Needle cut or needle damage
Excessive seam pucker
Edge stitching irregular affecting appearance.
Wrong seam or stitch type used.
ASSQC--Inspection procedure in
sewing Room

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Irregular seams

Curled ,puckered, crooked, pleated,

twisted, Wavy or uneven seams.
Open seam ( stitching thread open or
absent)
Excessive grinning of seams.
Uneven seam margins.
Seam wrong side out.
Irregular or incorrect shape of sewing
line(sometime called run-offs) in top
stitching.
ASSQC--Inspection procedure in
sewing Room

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Seam puckering Replicas

ASSQC--Inspection procedure in
sewing Room

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Assembly Defects
Component parts and assembly Missing parts
Missing operation
Operations not done per approved sample and
specification
Misalignment of parts, pockets, flaps, trims more
than 7 mm
Inconsistent nap directions if specified
Interlining incorrectly positioned ,twisted, too full,
too tight, cockling(wrinkle or puckering, as in cloth ).
Lining too full, too tight, showing below the bottom
of the garments, twisted, incorrectly pleated & so on

ASSQC--Inspection procedure in
sewing Room

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1. AQL For Production that occurs in lots or

batches
2. AOQLFor Continuous production system
3. QIP Implementation
4. Cost of Quality
5. Repair % and Rejection % Standardization
6. Defect Taxonomy
7. Concept of DHU
8. Proposed Process Design

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sewing Room

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QIPQuality improvement programe

QIP Implementation Activities:

1. Sewing and Finishing End of Line Repair and
rejection record keeping & documentation
2. Finalization of Work distribution sheet
3. Visual Cards in sewing
4. Random Table Introduction
5. Charts and Slogans

ASSQC--Inspection procedure in
sewing Room

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Percent defective
Defect % = Number of defective
units X 100
Number of units
inspected

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sewing Room

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AQL Acceptable quality

level
AQL is the maximum percent
defective that, for the purpose of
sampling inspection, an be
considered satisfactory as a process
average.
Process average is the average
percent defective of a product
submitted by the supplier for original
inspection.
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sewing Room

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AOQLAverage outgoing quality

level
For Continuous production system
Unit production system
Formation of lots or batches for inspection would be artificial
or uneconomical.
Statistical or acceptance sampling plan applicable to
continuous production - Continuous sampling plan (CSP)

AOQL means the maximum possible value of

the average defective % in the outgoing
product or shipments,
For egAOQL is 4% means , in long run the average defect
% of an out going product will not be more than 4%
defective.
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sewing Room

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Continuous Sampling Plan

(CSP)
1. Beginning inspect all the units consecutively as
produced & continue until X pcs in succession are
found acceptable.
( For example 40pcs continuous
inspection)
2. Stop inspecting all pieces , but inspect only fraction of
pieces produced ( i.e inspect 1 out of every 20pcs
---5%)
3. When a sample pieces is found to be defective,
resume inspecting all pieces until X are found
acceptable in succession. Then resume sampling
inspection.
4. All defective pieces should be either repaired or
replaced with good pieces.
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sewing Room

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Sewing Room Quality - Recommendations

Creation of all possible Defect list.

Use of Bundle Tracking sheet in line loading

Use of DHU as measure for quality performance at

inline and end line points and taking it through

three steps of improvement. Besides gauzing repair
and rejection percentages:
i. Recording
ii. Analyzing Problem Solving
iii. corrective action and responsibility
Standardizing the style start-up procedures with

inclusion of following elements besides current

ones:
ASSQC--Inspection procedure in
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sewing Room
i. Key Inspection Points

Sewing Room Quality - procedures

Implementation of Skip Bundle Inspection
Application of Quality Drills to enhance quality at

source (operator)
Use of tally marks for capturing data at check points
Creation

of daily
management

summary

and

visibility

to

Requirement: Allocation of manpower as per job

allocation sheet to cover all the planned activities

and sustainability of system
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sewing Room

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Skip Bundle sampling

In skip bundle sampling , a variable proportion of
production is inspected, not a fixed portion.
The extent of variability in the average fraction
of inspected material is depended on the
process average fraction of percent defective.
The higher the % defective , the larger the
proportion of production that must be inspected.
Inspection occur at a minimum when the quality
level being maintained is at or better than, the
level desired.
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sewing Room

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Skip Bundle sampling &

inspection

n = number of sample to be inspected

from the bundle
C =acceptance number or number of
defective pieces allowed in n samples.
S=skip interval
m =clearance interval
E. g.-- n=12, c=0, s=4, m=2

n=30, c=1, s=4, m=2

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Skip Bundle sampling & inspection

Select a bundle at random & at random inspect
12pcs , if no defect, accept the bundle.
Then inspect every 4th bundle, if defect found reject
& return the bundle.
Sort out bundle & repair the defective pieces
These repaired pieces are inspected & if acceptable,
the bundle moves on the next operation.
Once the bundle is rejected, every bundle from that
operator is inspected from then on until 2
consecutive bundle from that operator are found
acceptable
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sewing Room

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