Garments Quality Management

 Idea of Quality

Quality

Ideal condition of Excellence.

Product quality is based on a product attribute.

• Use r-based quality is fitness for use, 
• Manufacturing based quality is conformance to requirements, 

 

ISO 9000:2000 Defines it as

"degree to which a set of inherent characteristics fulfill requirements,"

Quality Assurance & Quality Control

Quality Assurance: A set of activities designed to ensure that the development and/or maintenance process is adequate to ensure a system will meet its objectives. QA activities ensure that the process is defined and appropriate. Methodology and standards development are examples of QA activities. A QA review would focus on the process elements of a project . 

Quality Control: A set of activities designed to evaluate a developed product. QC activities focus on finding defects in specific deliverables - e.g., are the defined requirements the right requirements. Testing is one example of a QC activity, but there are others such as inspections.

Quality Inspection 

Thinking & Area 

Visual examination or review of raw materials, partially finished components of garments and completely finished garments in relation to some standards, specifications, or requirements, as well as measuring garments to check if they meet the inquired measurements." 

 

 Cost of Quality

Prevention Costs:Prevention costs are all cost incurred in the process of preventing poor quality from occurring.They include quality planning cost,such as the cost of developing and implementing a quality plan.Also included are the costs of product and process design,from collecting customer information to designing processes that achieve conformance to specifications.Employee training in quality measurement is included as part of this cost,as well as the costs of maintaining records of information and data related to quality.

Appraisal Costs:Appraisal costs are incurred in the process of uncovering defects.They include the cost of quality inspections,product testing,and performing audits category are the costs of worker time spent measuring quality and the cost of equipment used for quality appraisal.

Internal Failure Costs: Internal failure costs are associated with discovering poor product quality before the product reaches the customer site.One type of internal  failure cost is rework, which is the cost of correcting the defective item.Sometimes the item is so defective that it cannot be corrected and must be thrown away. This is called scrap, and its costs include all the material,labor,and  machine cost spent in producing the defective product.

Others types of internal failure costs include the cost of machine downtime due to failures in the process and the costs of discounting defective items for salvage value.

External Failure Costs:External failure costs are associated with quality problems that occur at the customer site. These costs can be particularly damaging because customer faith and loyalty can be difficult to regain. They include everything from customer complaints, product returns, and repairs, to warranty claims, recalls, and even litigation costs resulting from product liability issues. A final component of this cost is lost sales and lost customers. For example, manufacturers of lunch meats and hot dogs whose products have been recalled due to bacterial contamination have had to struggle to regain consumer confidence. Other examples include auto manufacturers whose products have been recalled due to major malfunctions such as problematic braking systems and airlines that have experienced a crash with many fatalities. External ' failure can sometimes put a company out of business almost overnight.

Total Quality Management(TQM)

                             Conceptualization of quality management as defined in ISO 9000:2005

Quality Management

 ↑

                                                                   Quality Assurance                            Quality Planing

 ↑

                                                                      Quality Control  

       

 The evaluation of Total Quality Management
(TPM)

TIME:	Early 1900s	1940s	1960s	1980s and Beyond
FOCUS:	Inspection	Statistical Sampling	Organizational Quality Focus	Customer Driven Quality
	Old Concept of Quality: Inspect for quality after production			New Concept of Quality; Build quality into the process, identify and correct causes of quality problems.

Basic Tools of TQM 

Seven Basic Tools of Quality is a designation given to a fixed set of graphical techniques identified as being most helpful in troubleshooting issues related to quality. 

They are called basic because they are suitable for people with little formal training in statistics and because they can be used to solve the vast majority of quality-related issues.

 Basic Tools of TQM

•  Check sheets- how often it occurs or is done?

• Pareto analysis- which are the big problems?

• Cause and effect diagrams- what causes the problems?

• Stratification- how is the data made up?

• Histograms- what do overall variations look like?

• Scatter charts -what are the relationships between factors?

• Process control charts- which variations to control and how?

  Check Sheet

  A generic Tool which can be used for collection and analysis of data - A structured and prepared form that can be adapted for wide variety of issues

  When to Use a Check Sheet  

  1. When data can be observed and collected repeatedly by the same person or at the same location
  2. When collecting data on the frequency or patterns of events,problems,defects,defect location,defect causes
  3. When collecting data from a production process
  
  

   Example of Check Sheet

  
  

  	Complaints Check sheet
  	Mon	Tues	Wed	Thurs	Fri	Total
  No. User	123	110	130	135	128	626
  Complaints
  No Complaints	17	20	24	21	23	105
  Percentage of Complaints	14%	18%	18%	16%	18%	17%

   

  How to prepare?

• Decide what event or problem will be observed - Develop operational definitions
• Decide when data will be collected and for how long 
• Design the form - Set it up so that data can be recorded simply.by making check () marks or Xs or similar symbols  
• Label all spaces on the form. 
•  Test the check sheet for a short trial period to be sure it collects the appropriate data and is easy to use.
• Each time the targeted event or problem occurs, record data on the check sheet

 Control Charts 

A graphical technique to study the changes to a process over time 

When to Use a Control Chart

• When controlling ongoing processes by finding and correcting problems as they occur
• When predicting the expected range of outcomes from a process
• When determining whether a process is stable(in statistical control)
  
• When analyzing patterns of process variation from special causes(non-routine events) or common causes(built into the process)
  
• When determining whether your quality improvement project should aim to prevent specific problems or to make fundamental changes to the process 

Example of Control Charts

How to prepare? 

• Choose the appropriate control chart for your data
• Determine the appropriate time period for collecting and plotting data 
• Collect data, construct your chart and analyze the data
• Look for "out-of-control signals" on the control chart. When one is identified, mark it on the chart and investigate the cause
• Document how you investigated, what you learned, the cause and how it was corrected.
• Continue to plot data as they are generated - As each new data point is plotted, check for new out-of-control signals
• When you start a new control chart, the process may be out of control. If so, the control limits calculated from the first 20 points are conditional limits. When you have at least 20 sequential points from a period when the process is operating in control, recalculate
  

Pareto Chart

A graphical technique used to identify the significance of individual factors 

 When to Use a Pareto chart

•  When analyzing data about the frequency of problems or causes in a process

•  When there are many problems or causes and you want to focus on the most significant
  

•   When analyzing broad causes by looking at their specific components
  

•   When communicating with others about your data 

  Example of Pareto Chart

  
  

  How to prepare?

  • Decide what categories you will use to group items
  • Decide what measurement is appropriate. common measurements are frequency, quantity, cost and time
  • Decide what period of time the Pareto chart will cover: One work cycle? One full day? A week?
  • Collect the data, recording the category each time (Or assemble data that , already exist) 
  •  Subtotal the measurements for each category
  • Determine the appropriate scale for the measurements you have collected.The maximum value will be the largest subtotal from step 5. Mark the scale on the left side of the chart
  • Construct and label bars for each category. Place the tallest at the far left, then the next tallest to its right and so on. If there are many categories with small measurements, they can be grouped as "other"  

Example

 

Example

Scatter Diagram