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Various Methods of Inspection Systems for Apparels

By: K. Sakthivel

Abstract

All the retailers want to buy high quality products from manufacturers, to sell the product to their customers.The quality of the garments may vary depends on the price ranges. So we need to follow various methods ofinspection techniques, depends on the customers wants and needs. The inspection system gives the clear

judgment of the quality of the garment.

Introduction

Quality Assurance process the bulk pollution is examined before delivery to the customer to see if it meetsthe specifications. The consumers want to get high quality products in low price. The products should reachthe consumers with right quality depends on the cost.

Quality assurance covers all the process within a company that contributes to the production of qualityproducts. Which is conduct form beginning to end of the process (or) shipment? The inspect is carried out byrepresentatives of the current production and the result record on control chart. Which is a process to Assurethe product quality Acceptable or not.

The aim of garment inspection is to visually inspect articles at random from a delivery in order to verify theirgeneral conformity and appearance with instruction/description and/or sample received.

There are different types of inspection following by inspectors as requirement of consumers.

I. Pre-Production check:This is done before production starts. Where then is a final verification of the material used; style, cut andworkmanship of the garment or pre-production sample as per the customer Requirements.

II. Initial production check:This is done at the start of production where a first batch of garments is inspected; to distinguish possiblediscrepancies/variation and to allow fro the necessary corrections to be made bulk production. Theinspection is a preliminary stage covering mainly style and general appearance, workmanship,measurements, quality of fabrics, components, weight, colour and/or printing.

During production check:

This is done during production to ensure initial discrepancies/variations have been rectified. This inspectionis in fact the follow -up of the initial production check and is generally carried out a few days after the initialinspection, especially if discrepancies have been detected at that time.

Final Random Inspection:

This is carried out when the production of the total quantity of an order or partial delivery is completed. Asample lot will be selected from the order and a percentage of the garments will be inspected, thispercentage usually being stipulated by the buyer. The AQL sampling inspection may be applied or anotherinspection system designed by the buyer.

AQL Random Sampling Inspection:

The AQL random sampling inspection was derived from the mathematical theory of probability and is basedon the sampling scheme defined in military standard 105D (MIL -STD - 105D).

This method constitutes taking random sample from a lot of merchandise, inspecting them and dependingon the quality of the sample inspected, determining whether the entire lot is acceptable or not. The MIL -STD - 105D (also BS 6001, ISO 2859, DIN 40080) provides the sampling plans; and these determine thenumber of samples of be inspected in lot size, in addition to indicating and the acceptable quality level (AQL)which represents the maximum number of defects per hundred units that, for the purpose of the samplinginspection can be considered satisfactory as a process average.


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In general cases the buyer will determine which sampling plan and what AQL to adopt. The AQL 1.5 isapplied when severe inspection conditions are required on high-class expensive items. The AQL 2.5 isapplied when textiles of normal/good quality are involved. There are three types of sampling plans: i.e.single, double and multiple sampling plans. Each sampling plan can be performed at three levels, i.e.normal, tightened and reduced, depending on inspection requirements and quality of the products. In thegarments industry generally single and double normal sampling plans are applied. Therefore only examplesof these two will be provided. The sample size code letter table shows various lot sizes corresponding to aserious of code letters. There are seven inspection levels, four for general inspection (Already mentioned)and three for special inspection. For garment inspection, general inspection level II (normal II) is normallyapplied.

Single sampling plan - Normal inspection:

Assurance an AQL of 2.5 % and a lot size of 1200 garments and the sample size is 80 garments. If thenumber of defective garments found is 5 the total lot is "Acceptable" suppose if the defective garments foundis 6, the total lot is "Reject/ Re-Check".

Double sampling plan - Normal Inspection:

Assurance an AQL 4.0% and a lot size is 1200 garments and the sample size is 80 garments. If the Numberof defective garments found is 7, the total lot is "Acceptable" suppose if the defective garments found is 8the total lot is "Reject/ Re-Check".

For Example:

Total garments (lot Size) 1200 garmentsSample size (selected for inspection) 80 garmentsAQL 2.5 / 4.0

If the major defective found is 5 and minor defective found is 7 the total garments is "Acceptable". If thedefective exceed (Above 5 major and 7 Minor), the total garments is Reject / Re-check.

AQL CHARTCategory ofinspection

FRI(Final Random inspection)

Sample size levelNormal IIof shipment quantity AQL max.

Lot size 1.0 1.5 2.5 4.0 6.5

51-90*13+0

80

201

131

132

91-150130

321

201

202

203

151-280501

321

322

323

325

281-500501

502

503

505

507

501-1200802

803

805

807

8010

1201-32001253

1255

1257

12710

12514

3201-100002005

2007

20010

20014

20021

10001-350003157

31510

31514

31521

20021

35001 15000050010

50014

50021

31521

20021

150001 5000008004

80021

50021

31521

20021

500001 + More125021

80021

50021

31521

20021

AQL max = Acceptable Quality level.i.e.: maximum number of defective sample.* = Sample Size, + = AQL number


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Random Selection of Carton Box for InspectionOrder Quantity

Colour Size M L XL Total

Black 150 150 150 150 600

White 150 150 150 150 600

If a carton contains Black, S-10, M-10, L-10, XL-10White S-10, M-10, L-10, XL -10

Total No. of Cartons 15 BoxCarton Selection = nx2Where, n = number of cartons

10% of out of points for knitted goods and 5% of out of points (tolerance) are Acceptable.

The measurement tolerance level may very customer to customer.

Major defects:

Which fails to meet the mandatory regulations directly affecting the salability and safety of the merchandiseas the point of view of the customer. Which affect the salability but also affect the value of the merchandise

is considered as major defective, the major defects cannot be rectify. Ex: Fabric hole, Broken stitch, sizeJumped, Dye patches, etc

Minor Defects:

These defects shall deteriorate the serviceability of the merchandise with in few washing or laundry minordefects rectify. Ex: Stain, Skip stitch, wavy bottom hem. Etc

If the defect found front side of the garment (when packed) which is considered as major, if it is found backside of the garment which is consider as minor defects. Defects are considered major & minor as per thecustomer demands.

Conclusion:

Now-a-days most of the customer demand for high quality products in low prices. So we should maintain thequality from the beginning stage of the production then only the final product with reach the consumer withright quality and we can get the order continuously from our customers. The quality should monitor, in righttime and sequence by the manufacturer or quality Inspector (Buyer nominated persons) to avoid the furtherproblems and comments from the customers.

The garment manufacturers inspect there products "online" continuously by the responsible persons. Theproblems not only occur in garment stage. Which is affect from the fiber stage. So the quality, we shouldmaintain from fiber to final product, then only the right quality product will reach the consumers.

About the Author:

The author is a student of B. Tech, Final Year, in Department of Textile Technology, PavendarBharathidasan College of Engineering and Technology, Trichy, India.

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