Presentation Quality Assurance

Quality Assurance
Delta Socks Ltd.

Faisal Najeeb- Delta Socks Ltd.

Contents
Definition & Objective
Quality Policy
Department structure
Incoming Materials Inspection
Knitting Quality
Stitching Quality
Processing Quality
Press Quality
Packing Quality
Final Audit
Loading Supervision

Definition of Quality
There are different definitions of quality as under:

Most common and general definition is “general acceptance level of
a buyer is called quality”

(Phil Crosby) says that "conforming to specifications" is called
quality.

Quality means "fitness for use" in the view of (Joseph Juran).

We need never ending improvement to establish better economy.
Quality makes it possible (W. Edward Deming).

Quality is never an accident; it is always the result of an intelligent
effort. (John Ruskin).

Quality Assurance
In developing products and services, Quality Assurance is any
systematic process of checking to see whether a product or service
being developed is meeting specified requirements. Many
companies have a separate department devoted to Quality
Assurance. A Quality Assurance system is said to increase customer
confidence and a company's credibility, to improve work processes
and efficiency, and to enable a company to better compete with
others. Quality Assurance was initially introduced in World War II
when munitions were inspected and tested for defects after they
were made. Today's Quality Assurance systems emphasize catching
defects before they get into the final product.
A program for the systematic monitoring and evaluation of the
various aspects of a project, service, or facility to ensure that
standards of quality are being met. This is a part of Quality
Management focused on providing confidence that quality
requirements will be fulfilled.

Structure of Quality Assurance Department

DGM Q/A

Assistant Assistant
Lab Testing
Manager Manager

Knitting QA Press
Stitching
Batch Audit
Processing Packing QA Final Audit
Accessory QA
Sr. Officers & QA Officer &
QA Officer Officer QA Officer Officer Sr. Officer Officer
Jr. Officers Jr. Officer

Sr. CheckersCheckers
Sr.
CheckersCheckersCheckers CheckersCheckers
Sr. Sr. Jr. Checkers
CheckersCheckers

Incoming Materials Inspection


Yarn Inspection
When yarn is received in the factory, quality department inspect the
yarn for its better results. Yarn occupies the intermediate position in
the manufacture of socks from raw material. Yarn results are therefore
essential, both for estimating the quality of raw material and for
controlling the quality of socks produced. The important characteristics
of yarn being tested are,
Yarn Twist
Linear Density or Yarn Count
Yarn Strength
Yarn Elongation
Yarn Evenness
Yarn Hairiness
Yarn Grading
Hardness of Yarn


Yarn Inspection Report


Accessories Inspection
All packing accessories are inspected on specified
AQL. If accessory lot is failed on specified AQL, it
is returned to supplier or sorted out in the factory
on behalf of supplier. All kind of accessories like
bandroll, backboard, barcode stickers, color
stickers, shipping marks stickers, hangers, cartons
and printed polybags are strictly inspected to avoid
any inconvenience or reworking in packing.


Accessories Inspection Report

In below
picture, Accessories QA
Checker is verifying the
art work provided by the
marketing.


Knitting Quality Assurance
Knitting quality is the most important element in quality
inspection. If this section is controlled in better way, a lot
of problems and quality complications can be solved.


Knitting Inline Inspection
Knitting in line inspection is carried out to assure all the specs of the
socks as given below.
Knitting Plan Matching.
Specification Sheets/Cards Inspection.
Yarn Inspection.
Trim Card Matching.
Welt Construction Inspection.
Rib Construction Inspection.
Booth/Ankle Inspection.
Terry (Foot Construction) Inspection.
Change Over Inspection.
Heel & Toe Type Inspection.
Half Cushion & Full Cushion Inspection.
Splicing/Reinforced Part Inspection.
Sole Part Inspection.
Rosso Inspection.
Clip Inspection.
Terry Type Inspection.
Loose/Tight Knitting Inspection.
Stretch Checking.
Weight Checking.
Production Inspection.
Size/Measurements Checking.

Knitting Inline Inspection Report


Knitting NAHM Frame Verification & Specs Checking


Knitting Production Report & NCR


Knitting Stretch Checking, Trim Card Verification and Knitting Faults
Inspection


Batching Audit
When production is moved from knitting and batches are made
in batch section. After batch completion QA team perfom audit
on batch for knitting defects. Every batch qualifies the batch audit
and then moved to next section.


Toe Closing Quality Parameters
Stitching Type Confirmation
Stitching Yarn Confirmation
Stitch per Inch Counting
Strength of the Seam
Loose and Tightness of the Seam
Shape of the Seam
Extra Cutting at Toe Seam
Balance of the Toe Seam
Long Corner at Toe Seam
Zigzag of the Seam
Crooked Seam Inspection
Improper Stitching Control
Pleat/Knot at the Toe Seam.
Long Toe Seaming Chain/Threads
Cropping Of the Seam Chain Thread
Flying Thread at Toe Seam
Oil at Toe Seam


Continuity Shade Verification


Pressing (Boarding) Quality Parameters
Style Assurance as Per MTA.
Frame Confirmation.
Time Control.
Temperature Control.
Pressure Control.
Steam Control.
Size Specs Inspection as Per Specs Sheet.
Overheat Checking.
Loose Pressing Care.
Unbalanced Motif, Color Heel & Toe Control.
Tumer Observation.
Rotation of Rib & Color Sole Control.
Folding of the Socks as Required (Heel Left or Right).


Press Quality Inspection Report


Press Inline Inspection


Packing Inspection Parameters
Checking of shade mixing, size mixing and style mixing.
Packing type/style must be confirmed (How many pair packing and what kind of
accessories to be used).
Accessories inspection like screen out printing of printed polybags, shade in printed
polybags, shade in bandrolls, wrong bandroll, mix bandroll, wrong size of
polybag, wrong barcode, wrong carton, mixing of cartons, carton size loose/tight, miss
printed cartons and damage cartons.
Size specs checking.
Packing inspection on table like italic bandroll affixing101,reverse bandroll
affixing, loose or wrong shoot pins, tearoff1 polybags, barcode missing, sticker
missing, wrong sticker used, open polybags, wrong tag affixing, improper affixing of
header card, wrong location of stitch of header card, incorrect label, incorrect
composition affixed, incorrect washing instructions affixing, incorrect country of
origin, tape peel off, improper tape affixing, improper sealing, wrong assortment and
polybag folding to the wrong side.
Quantity inspection like short pieces in packs, short packs in dozens, short dozens in
cartons.
Shipping marks of the cartons.
Filling of cartons.
Scanning of Barcodes.
Metal detection.


Packing Inline Inspection

Packing Inline checker is verifying the
prototype and packing instructions

Final Inspection Parameters
Final inspection is the stage where we check each and every thing as per
standards. Most common parameters which are verified on final inspection are
as under.

Visual Inspection Parameters
1- Style Identification
2- Strapping (If required)
3- Quantity inside the cartons assurance
4- Wrong Cartons
5- Cartons Size Loose/Tight
6 Tape Peel Off
7- Improper Tape Affixing
8- Improper Carton Closing
9- Damage Cartons
10- Misprinted Cartons
11- Mixing of Cartons
12- Open Cartons
13- Cartons Shade Mixing
14- Cartons Size Mixing
15- Reverse Shipping Marks Affixing
16- Wrong Shipping Marks
17- Shipping Marks Missing
18- Unusual Shipping Marks
19- Accurate Numbering.

Detail Inspection Parameters
1- Welt Construction
2- Welt Measurements
3- Rib Construction
4- Rib Measurements
5- Foot Construction
6- Foot Measurements
7- Leg Measurements
8- Heel Type
9- Terry Type
10- Patterns
11- Shade Matching
12- Socks Type
13- Size of Socks
14- Weight of Socks
15- Fit Size
16- Socks Cross Stretch
17- All kind of faults (Knitting, Stitching, Processing, Pressing


Packaging Inspection

Bandroll/Backboard/Headercard
1- Bandroll/Backboard/Headercard Shade
2- Wrong Bandroll/Backboard/Headercard
3- Damage Bandroll/Backboard/Headercard
4- Mixing of Bandroll/Backboard/Headercard
5- Uneven/Italic Bandroll/Backboard/Headercard Affixing
6- Reverse Bandroll/Backboard/Headercard Affixing
7- Scratch Marks on Bandroll/Backboard/Headercard
8- Misprinted Bandroll/Backboard/Headercard
9- Open Bandroll/Backboard/Headercard

Barcode
1- Barcode Missing
2- Wrong Barcode
3- Mix Barcode
4- Improper Affixing of Barcode
5- Reverse Barcode Affixing
6- Barcode Unscanable/Poor Scanning
7- Misprinted Barcode


Packaging Inspection
Stickers
1- Wrong Sticker
2- Sticker Missing General
3- Mixing of Stickers 1- Shade mixing
4- Improper Sticker Pasting 2- Size mixing
5- Reverse Sticker Pasting
6- Misprinted Sticker
3- Style mixing
7- Unusual Stickers 4- Wrong Assortment
5- Short Pieces in Packs
Hangers 6- Short Packs in Dozens
1- Wrong Hanger Size 7- Short Dozens in Cartons
2- Improper Hanger Affixing 8- Incorrect Label
3- Wrong Direction of Hanger 9- Incorrect Composition Affixed
4- Hanger Miss
5- Damage Hanger
10- Incorrect washing Instructions
6- Poor Quality Hanger 11- Incorrect Country of Origin
Polybag 12- Wrong Direction113 of Heel
1- Printed Polybag Shade 13- Wrong Shoot Pins
2- Wrong Printed Polybag 14- Loose Shoot Pins
3- Misprinted Polybag 15- Shoot Pins Miss
4- Tear Off Polybags
5- Open Polybags
6- Wrong Size of Plain Polybag
7- Crooked Sealing
8- Open Sealing
9- Poor Quality Polybag

Final
Inspection
Report


AQL (Acceptable Quality Level) Chart


Container Loading Report
Container Loading Report (Linewise)
Date:_________________ Customer::_______________ Seal No.:____________________

Vehicle No.:_________________ Container No.: ___________________________________
Sr. Line
P.O No. Style No. Colour DPC Cartons Total
No. No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Total

Loaded By: ___________________ Security Guard:____________________

Faisal Najeeb- Delta Socks Ltd._________________
Counter Signature:__________________ Godown I/C

Packing List Format

PACKING LIST OF
DATE : Bilty #
Container # Type of Container
SEAL # VEHICAL #
DRIVER LICENCE # DRIVER N.I.C #

S/r # SYSTEM # DEL # Po # Style # Size Description F.WT. DPC CTN DZN N.Wt G.Wt

1

TOTAL 0 0
PAIR 0

Prepared By CHECKED BY


Size Chart of Socks


Presentation Quality Assurance

Recommended

Recommended

More Related Content

What's hot

What's hot (20)

Viewers also liked

Viewers also liked (20)

More from MCL Socks

More from MCL Socks (12)

Presentation Quality Assurance