ESSAY OF QA DEVELOPMENT QA Development of Garments Manufacturing Author Mustafijur Rahman QA, Technical Services Specialist & Consultant LSSGB, ISO QMS 9001:2015, QM, OM, PM Certified Mail:mustafijcertifiedaudit@gmail.com Mobile: +8801954577058 (WhatsApp/IMO) LinkedIn: MUSTAFIJUR RAHMAN TABLE OF CONTENTS EMPHASIS 1. Introduction of QA ..................................2 2. Importance of QAD in Garment Industries 2 3. QA Definition .........................................3 4. QA auditor Standard working process .......3 5. QA Quality ............................................5 6. QA Development Skills.............................6 7. QA Training for development ....................9 8. Store QA ...............................................9 9. Cutting QA ...........................................10 10.Sewing QA ..........................................11 11.Finishing QA ........................................12 12.DQA & Importance of DQA ....................12 13.Rules of leadership of QA development ..14 14.Conclusion ..........................................16 2 EMPHASIS 1. INTRODUCTION OF QA QA means Quality Assurance. QA auditor assures quality by developing working process by doing root cause analyses and problem solving. QA activities starts before QC activities. Firstly QA auditor assured Quality then QC control Quality. QA is most important than QC. Only QA can develop and ensure garments quality in every stage before Goods making to finishing. By assuring quality on fabric, trims, accessories, cutting, sewing, finishing & working Process etc., QA auditor can assure timely shipment, customers satisfied Goods, make standard working environment, reduce costing etc. If this department are weak, they can not do timely shipment, they gets claim again and again due to produce bad Goods, they do lots of rejection and wastage and also sometime shipment canceled due to big mistakes. 2. IMPORTANCE OF QAD IN GARMENTS MANUFACTURING QAD ( Quality Assurance Department) is the part of Garments Manufacturing. without QAD, Garments manufacturing factory do not produce standard Goods because QA Auditor assure Goods manufactures condition before starting production such as Store QA assures fabric, trims and accessories Quality before starts cutting, cutting QA assures shade, GSM, pattern & marker, cut panel measurement, way, check etc. quality before starts sewing. Sewing QA auditor assure stitching, construction, Goods overall appearance, measurements and also reduce defect by root causes analyses, following TDR(Total Defect Reduce) TLS, RFT etc. method. Finally, finishing QA assure quality by conducting 2 hr audit, pre-final, SKU & ratios checking, properly cartooning, barcode and cartoon sticker verification etc. DQA( Dedicated QA) is the another part of QA, they do work like GPQ(Guideline for Production and Quality), they works buyer representatives. They work as 2 nd hand of buyers and make connection buyer to factory for the purpose of producing buyers standard Goods. 3 Therefore, QAD is the important part of the garments manufacturing. 3.QA DEFINATION Quality assurance is a way of preventing mistakes and defects in manufactured products and avoiding problems when delivering products or services to customers. Quality assurance is defined as all those possible planned and systematic actions necessary to provide adequate confidence that a product or service will satisfy given requirements for quality. 4. QA AUDITOR STANDARD WORKING PROCESS QAD, DQA and QA activities are: Sample inspection against Customer SOP, TP, Manual, Scratches ↓ Store trims card check, Implement 5S and FIFO, 8 wastage lean. ↓ Fabric, Trims & accessories test & check, maintain QMS system properly ↓ Fabric, Trims & accessories inspection & audit. ↓ GSM check, shade segregation ↓ Fabric Shrinkage Test ↓ Size set check ↓ PPM ↓ Marker check. ↓ Marker check and correction ↓ 4 Cutting relaxation, lay, spreading check ↓ Cutting component Quality and measurements check & audit ↓ Maintain Buyer/Customer General Instruction (SOP,TP/PDM,Sample etc.) ↓ Layout inspection, maintain QMS system properly. ↓ Incoming Cut panel quality and Measurements check ↓ Two-time and style wise accessories check ↓ 4 Time TLS (Traffic Light System) method Follow ↓ Follow RFT(Right In First Time) method ↓ Follow TDR(Total Defect Reduce) method ↓ Follow FIFO( First In First Out) method ↓ Ensure and implement 5S and 8 wastage lean manufacturing ↓ In process audit ↓ conducted 1st pcs/ style wise 1st bundle output report ↓ conducted Initial inline inspection & DPI. ↓ Two time process and machine check ↓ Hourly final audit by measurement 5 ↓ Implement 5S,8 wastage lean manufacturing, FIFO in finishing ↓ Incoming washing Goods shade and measurements, dimensional change check ↓ Finishing layout follow-up ↓ Button pull check ↓ Broken needle check, Metal pass, moisture check. ↓ Accessories compliance(SKU,Price Ticket ratio etc. Check) ↓ Every day final audit ↓ Pre-final inspection ↓ Final Inspection and closing. 5.QA QUALITY Top Quality Guru W. Edwards Daming said about Quality that quality is everyone responsibility. However, others Quality Guru Joseph M.Juran said about quality that quality is the fitness for use. Quality word wise meaning Q:Quality U:Unity A:Active 6 L:Liability I:Intelligence T:Truthfulness Y:Youthful Quality Assurance Audit have above those quality with smartness, problem solving skills, process developing skills, leadership skills, brainstorming skills and so on. 6. QA DEVELOPMENT SKILLS • Garments Manufacture based Skills: 1. Sample verification against Customer SOP, Manual, TP/PDM, and others instruction. 2.Fabric quality, classification, fault, fabric & garments test report justification skills. 3.Trims and Accessories quality, classification & fault justification skills. 4.Cutting procedure, GSM, Skewing, bowing, relaxation, shrinkage, lay height, marker & pattern verification, spreading check, cut panel check and measurements skills etc. 5.Sewing input cut panel measurements with before wash and sewing allowance, incoming trims and accessories check by trims card. Garments making layout check, sewing all marking and pattern check style and size wise Conduct an implement TLS( Traffic Light System), RFT( Right First Time), TDR ( Total Defect Reduce), 5S ,FIFO, Lean manufacturing 8 wastage etc., button pulls test, bond test, stitch strengths test, maintain broken needle policy and label attach policy, fabric nature wise needles selection, Follow sample, TP/PDM, SOP and other instructions to proper sewing, sewing DPI, Initial Inline etc. 7 6.Finishing Shade, measurement & dimensional change verify after received wash garments and before start finishing, finishing quality check layout followup, 2hr audit, metal check, moisture check, proper trims and accessories attach, follow approved folding method, verify SKU, Barcode, Prize ticket, cartoon sticker day final audit, pre-final audit etc. • Customer/Buyer Based Skills: I. Customer/ Buyer SOP(Standard Operating Procedure), Manual such as Quality Manual, QA Manual, Product Safety Manual, Pattern Matching Manual, Label attach Manual, Product safety manual etc. II. Customer/Buyer DCL ( Defect Classification List) III. Customer/Buyer TP(Technical File), PDM( Product Development Manual) IV. Customer/Buyers Special instruction about garments produce. V. Customer/Buyer based QMS( Quality Management System) & Technical audit. • Defect Based Skills 1.Appearance Defect 2.Construction defect 3.Trims and accessories defect 4.Fabric defect 5.Measurement defect 6.Color defect 7.Packing defect • Root cause analyses and CAP making skills I. 5Why 2How II. 80/20 rules III. Fishbone/ Cause & effect Diagram IV. PDCA 8 V. Problem Tress • Language & Computer Based Skills: I. Fluent at English verbally and written II. Have to Skills about Microsoft Office program such as MS Word, MS Excel, MS PowerPoint, Teams etc. III. Have to skills about E-mail handling, browsing & basic Windows Operating System. • Quality Improvement tools skills: 1.QA auditor must have knowledge about quality tools: I. Flow diagram II. Brainstorming III. Cause-effect diagram ( Fishbone diagram) IV. Data collection V. Graphs and charts VI. Pareto analysis (80/20 rules) VII. Scatter diagram VIII. Histogram IX. Box plot X. Stratification • Continuous Process and products improvement Skills: QA auditor must have knowledge about TQM, Six Sigma & Lean manufacturing. I. 5S II. PDCA( Plan, Do, Check & Act) III. DAMIC IV. 8 Wastage (Muda) V. JIT(Just In Time) VI. Kanban(Pull System) VII. Kaizen(Continuous Improvement) VIII. Gemba(The real place) 9 IX. Poka Yoka ( Mistake Proofing) X. VSM(Value Stream Mopping) XI. TPS ( Toyota Production System) XII. TPM(Total Productive Maintenance) XIII. SMART Goal( Six big losses) XIV. Factory assessment & Evolution XV. SOWT analyses etc. Above all, if any QA have above those skills he/she can develop process and Product quality very easily and easy way. 7.QA TRAINING FOR DEVELOPMENT I discussed about 5. QA Development Skills point, all the Skills of QA. If this skill can capture any QA. This can develop any Garment manufacturing easily. Unskilled QA do not ensure and process development. That’s why QA have to learn and capture below this point in practically and theories. QA have to take training about: 1.Garments manufacturing Quality Assurance skills 2.Customer/Buyer based skills. 3.Root cause analyses and CAP making Skills 4.Languages and Computer based skills 5.Quality improvement tools skills 6.Continuous improvement skills. Here, 6 point I discussed about Point 6 section. 8.STORE QA: Store QA plays vital rule of garment manufacturing because any order all fabric, trims & accessories come first to him. So, if he failed to justify those quality, 10 ultimately Products quality will be spoil. That’s why Store QA have to alert about verify those quality, quantities, faults and so on. Store QA Rule and Job responsibility: I. Accurate Inventory check, verify trims card. II. Fabric quality, shade, Shrinkage, bowing, skewing & GSM verify III. Fabric Inspection based on 4/2.5/10 point etc. IV. Fabric test and fabric test report verity V. Trims and accessories quality, quantity, faults check by 10% inspecting with zero tolerance VI. Trims and accessories test and keep test report. VII. Inspection fail and reject goods keep red zone marked area for brunt or back to supplier. VIII. Inspection pass Goods keep on rack by tagging Bin card. IX. Style and size wise accurate Fabric, trims & accessories supply to the production floor. X. Follow zone wise Goods keeping method XI. Implement 5S, FIFO and QMS system properlty. 9. CUTTING QA: Cutting QA plays another vital rule in garments manufacturing. If cutting is wrong sewing & finishing will be wrong. That’s why cutting QA have to ensure proper cutting before cutting Goods. Cutting QA rules and job responsibility: 1.Verify fabric nature, GSM, Shrinkage, Skewing, Bowing etc. 2.Ensure proper fabric relaxation 3.Marker inspection before cutting 4.Collect and review Fabric test report. 5.Fabric shade segregation and batch wise put sticker 6.Fabric Spreading inspection 11 7.Fabric lay follow up. 8.Cutting components quality and measurements check with sewing allowance and before wash measurement. 9.Ensure cutting QMS and product safety. If Cutting QA maintain and do his duty properly, Sewing & Finishing will be good. 10.SEWING QA: Sewing is the production field, if Sewing QA is skills full, The sewing quality increased automatically. That’s why Sewing QA rule is the important part. Sewing QA must have to know about Buyer/ customer acceptation. Beside he have to know about defect: 1.Appearance Defect 2.Construction defect 3.Trims and accessories defect 4.Fabric defect 5.Measurement defect 6.Color defect 7.Packing defect. Beside, sewing QA have to knowledge about Fabric nature, thickness and thingness because stitch tension, needles size and thread count. Sewing QA rules and job responsibility: 1.Measures all in coming cutting components with Sewing Allowance and before wash measurement. 12 2.Incoming trims and accessories check by trims card. 3.Garments making layout check, 3 times machine check, critical process mock up ensure. 4.Sewing all marking and pattern check style and size wise 5.Conduct an implement TLS( Traffic Light System), RFT( Right First Time), TDR ( Total Defect Reduce) 6.Implement FIFO, 5S, Lean manufacturing 8 wastage etc., 7.Button pull test, bond test, stitch strengths test, 8.Maintain broken needle policy and label attach policy 9. Fabric nature wise needles selection, correct thread selection as per trims card. 10.Follow sample, TP/PDM, SOP and other instructions to proper sewing, 11.Conduct sewing DPI, Initial Inline etc. 12.Sewing QMS system property implement. 11.FINISHING QA: 1. Finishing Shade, measurement & dimensional change verify after received wash garments and before start finishing, 2.Finishing quality check layout follow-up, 3. 2hr audit, metal check, moisture check, 4.Proper trims and accessories attach Check 5.Follow approved folding method, verify SKU, 6.Barcode, Prize ticket, cartoon sticker verify 7.Conduct day final audit, pre-final audit etc. 8. Maintain QMS system, FIFO, 5S method properly. 13 12.DQA & IMPORTANCE OF DQA IN GARMENT MANUFACTURING: DQA does all QA activities Sample Follow up section to Final shipment. He have to be perfect and well skilled about all section wise standard. DQA Job responsibility are: • Collect order file from merchant • DQA have to knowledge about QMS, Buyer standard, DCL etc. other above discussed QA skills. • Collect Section wise update such as production, plan, inspection etc.) • Verify fabric, trims & accessories and its test and inspection report. • Verify trims card and sample as per buyer SOP, TP, PDM, Order file etc. • Arranging a meeting with the buyer QC and giving the necessary tasks for the PP meeting. • Implement buyers standard in all area • Will be collect order summary from merchant/ planning. • Collect necessary documents for study from merchant/Buyer. • Study PPS, PPC, Tech pack, Buyers SOP, BOM, PO Sheet, Measurement by cross check to analyze risk & important point. • Collect necessary test & inspection report of materials. Then make CAP against of result. • Pattern check with above buyer M ok spec & test/inspection report. • Marker check with ok pattern based of fab inspection report. • Review cut panels measurement report. • Size set review with technician, QC & QA with b/4 & after iron measurement report to make CAP for bulk. • Call out PPM to conduct with related department to point to point discussion. • Follow up fabric in-house to shipment. • Follow up quality requirements in Cutting, Sewing, and finishing in the factory. • To follow up as per buyer’s manual, SOP, TP, PDM and quality sample. To ensure sample quality and timely delivery to the buyer. • Check all the quality points especially in Garments Sewing to Finish. • To ensure Section Wise Quality Inspection. • The last message of the buyer regarding quality control is reported in the related section. 14 • To ensure product quality before final inspection. • Arrange & approved the file before the inspection. • Ensure everything is in the QC/QA file. • Ensure Sample Approval from Buying House. • Communicate Buyer QC with quality issues. • Implement to buyer quality control manual in the garment factory (all Sections). • Work as a representative of Buyer QC in a Garment Factory • Follow up quality requirement in Cutting, Sewing and finishing in factory. • Conduct in-line inspection and assist the buyer representative in the Final inspection in the Factory. • Handle and execute all PP Meeting and Pilot Run meeting • In-line inspection of every lot of sewing and finishing section. • Communicate with the fabric department regarding the fabric quality and assist the fabric QA to ensure online quality control the fabric. • Approve the fabric and all accessories for the final bulk production. • Rectify the sewing defect and ensure the accurate shape and design of the product as per the client’s requirement. • Checking out all the accessories in-house for bulk production. • Check the fitting of the garment as per the buyer measurement chart. • Checking and matching the accessories such as sewing threads, buttons, care labels, size labels, main labels, photo board polybags, etc. comparing with a trim card as per customer requirements. • Maintain all work and report of buying house QC, work on behalf of buying house QC. • Ensure Finishing, folding, picking, cartooning and others. • DQA check garments product using all quality criteria, fill up all QC inspection checklist. • GPQ bears special authority about any quality issue by buyer QC, in absence of buyer QC. DQA is a good decision-maker in any quality parameters of the garments industry. That’s why DQA is most important person in garments manufacturing. 15 13.RULE OF LEADERSHIP OF QA DEVELOPMENT : QA Leader means Quality Assurance Leader, A perfect man he has vast knowledge about quality assurance and improvement. My discussed all skills must have one QA Leader and also he have knowledge about how to manage all QA in garments manufacturing. He able to trains all QA and Monitors all QA how the assures Goods standard and RCA and give CAPA for proper solution. He calibrate his all QA and analyses their skills, then he find out his QA leaking and weak point and teach them to develop and overcome their weakness. He follows his QA reports, advancement & what they do. If any claim call out, he searches the root QA reports, Follow up & assurance. Then he find out what is the DQA faults. Such as One customers callout for uneven sleeve in garments. After receiving this callout, QA leader, Call Cutting QA , Sewing QA, Finishing QA and DQA to show him their inline and follow up report about this style. By collecting all report he analyses all section wise QA report. If all report okay, he thinks all section QA did fake report, they did not follow up properly just make fake report. If its true they did not did their duties and responsibility properly just pass time and make fake report. QA leader have to follow their activities strongly. And also Leader have to trains them. If they not change, QA Leader have to change this QA. Otherwise, if QA leader find out cutting QA problem then he trains this QA and finally alert about this issue and to maintain his duties & responsibility property, so that they will not make mistake in future. QA Leader make chain on store QA, Cutting QA, Sewing QA, Finishing QA to DQA for only purpose of produce customer satisfied Product, Zero defect product, timely shipment, to reduce, process time, costing, short shipment and rejection etc. 16 Beside QA Leaders trains his QA about Good dress up, attitude, smartness and also about: 1.Garment manufacturing based QA skills 2.Buyer/Customer based QA skills 3.DCL based Skills 4.RCA and CAP making skills 5.Quality improvement tools using skills 6.Continues improvement and QMS based Skills 7.English Language and Computer based skills. Which I discussed about point 6 QA skills section. QA leader utilize his QA, trains his QA, develop his QA and ensure and improve Goods quality by his QA. 14.CONCLUSION: After lots of discussion, Skilled QA is most important for garment manufacturing. From this 7 skills such as 1.Garment manufacturing based QA skills 2.Buyer/Customer based QA skills 3.DCL based Skills 4.RCA and CAP making skills 5.Quality improvement tools using skills 6.Continues improvement and QMS based Skills 7.English Language and Computer based skills. 17 One Garments manufacturing based skills found on QA not perfectly other skills not found. That’s why our QA team do not catch any fault or wrong properly, do not improve any process properly, do not RCA properly, do not handover buyer satisfied Product, do not assure any process and technical issue properly. Therefore, To produce buyer satisfied Product, To do onetime delivery, do develop process by reduce process time, to reduce costing, to enhance factory image, there are no alternative option without Quality Assurance Department and Skilled QA. To achieve all those we need skilled QA in Garments Manufacturing. We have to stress to develop QA skills.
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