Quality Assurance Test Procedure for Apparel Industries

24.5.16

Quality Assurance Test Procedure:

Yarn quality verification: Applicable test for yarn quality verification are as follows- For color fabric, For white fabric. Proper instruction in written are provided to the parties willing to do the job work for the particular style. The samples are got prepared from all the parties, who are willing to do job work for the particular style. The samples are checked properly and the orders are given accordingly...

For color fabric:

The sampling audit is done by the Q.A responsible for outside job work. If the job work fails as per the sampling criteria, the garments are checked 100% and the alterations are sent back to the party along with report. Refer to the Outside Job Work Audit Report . Every packed shipment is checked for ratio, color code, bar code, country code, carton making, folding, packing material used etc as per the required standard set by the company or as per buyer’s standard (if specified). Refer to the Packing Audit Report

Machine - apparatus used:NA
Machine - apparatus manufactured by:NA
Person responsible: Quality Assurance Test Procedure executive
Frequency:Every lot report is checked
Procedure:Every lot is accomplishing by a yarn quality report. This report is compared with the ATL yarn quality requirement chart.
Yarn quality of each lot is checked using random sampling by machine available in the padma textile mills ltd
Performance standard: ATL yarn quality requirement chart.
Checking report of field supervisor.
Requisition for sampling inspection.
In case of non conformity: Lot is returned
Document - form used :Yarn quality requirement chart
Yarn verification form:Non confirming yarn return form

For white fabric:

The field supervisors are sent to the respective places, where the job work is being done. At the time of receiving the garments after job work, the receiving person provides the following documents to Quality Assurance Department.

Machine -apparatus used :NA
Machine - apparatus manufactured :NA
Person responsible : Quality Assurance Test Procedure executive
Frequency: Every lot report is checked
Procedure: Sample production
Make 200 mt sample fabric from each white lot received.
Carry of subsequence processing: (sinze-desize, scour-bleach and final inspection. Refer to QC confa in Dispo module of T.I.M)
Performance standard: 15 points per 100 linear meters in final inspection.
In case of non conformity:Lot is rejected for white fabric production using yarn contamination test result.
Document -form used :Yarn contamination test result.

Every packed shipment is checked for its quality as per the required standard as per the company policy or as per the buyer’s standards (If specified). The various problems to be checked for are listed in the list of defects Refer to the Visual Audit Report Dyes quality verification:Applicable test for dyes quality verification are as follows:

Reactive dyes
Disperse dyes
Vat dyes
Pigment dyes

Reactive dyes:

Putting the disperse and reactive dyes together and other chemical in one bath but dyeing the polyester part first then proceed with cotton dyeing. In this process, selected dyes which are compatible with each other, are used. Disperse and Reactive are suitable for the process.

Machine / apparatus used: Dyeing padded, curing chamber.
Machine / apparatus manufactured by: Werner Mathis AG, Switzerland.
Person responsible :Lab assistant (pilot plant
Frequency:every new lot.
Procedure: Self shade with 30 gl solution is prepared and compared with previously approved lot strength of the dyes is determined in this way.
Fastness to water, wash and crock (rubbing) are checked for their acceptable level.
Performance standard: Consistency with previous approved lot
Minimum fastness requirement-Change in color
In case of non conformity:Lot is returned.
Document / form used: Reactive dyes shade continuity register.

Disperse dye:

A checkpoint is also established at the end of each production line and 100% checking is also done there. Refer to the End of Line Inspection Report

Different Reactive and Disperse Dyes are used for dyeing due to quality requirement, costing and availability.
Machine / apparatus used:Dyeing padded, curing chamber.
Machine / apparatus manufactured by: Werner Mathis AG, Switzerland.
Person responsible:lab assistant (pilot plant).
Frequency:Every new lot.
Procedure:self shade with 15 g/l solution is prepared and compared with previously approved lot strength of the dyes is determined in this way
Fastness to water, wash and crock (rubbing) are checked for their acceptable level
Performance standard:Consistency with previous approved lot
Minimum fastness requirement-Change in color
In case of non conformity:Lot is returned.
Document / form used:
Disperse dyes shade continuity register.

Vat dyes:

Machine / apparatus used:Dyeing padded, curing chamber.
Machine / apparatus manufactured by:Werner Mathis AG, Switzerland.
Person responsible:Lab assistant (pilot plant).
Frequency:Every new lot.
Procedure:Self shade with 10 gl solution is prepared and compared with previously approved lot strength of the dyes is determined in this way.
Fastness to water, wash and crock (rubbing) are checked for their acceptable level.
Performance standard: Consistency with previous approved lo
In case of non conformity:Lot is returned.
Document / form used:Vat dyes shade continuity register.

Pigment dyes:

Machine / apparatus used: Dyeing padder, curing chamber.
Machine / apparatus manufactured by :Werner Mathis AG, Switzerland.
Person responsible: Lab assistant (pilot plant).
Frequency: Every new lot.
Procedure: Self shade with 30 gl solution is prepared and compared with previously approved lot strength of the dyes is determined in this way.
Fastness to water, wash and crock (rubbing) are checked for their acceptable level. Heat stability test (fastness to calendaring / ironing is also checked)
Performance standard: Consistency with previous approved lot
In case of non conformity: Lot is returned.
Document / form used: Pigment dyes shade continuity register.
Swatch analysis:Sample analysis procedure:
Parameter checked: Count, concentration, composition, weave, type of dye used and finished type.
Machine / apparatus used: Pick, counter, weighing machine, gas burner etc.
Machine / apparatus manufactured by: N/A
Person responsible: Lab assistant
Frequency:As and when requisite by marketing department.
Procedure: Applicable test for swatch analysis process are as follows:

Fabric analysis

Refer to the following section for detailed procedure.
In case of non conformity: QA executive is informed in case of non conformity of the swatch analysis report with our procedure range. Marketing division is subsequently notified about inability to replicate the given swatch.
Document / form used: Swatch analysis report.

Physical test:

Marketing division sends swatch to the QA department according to the customer requirement.
Construction:
Construction (no of ends and picks) and weave are determined using pick counter
Count:
Count is calculate using following formula-
Total length (in ˝) × 0.015
Count =
Weight of sample (in gm)
Total length (cm) × 0.059
Weight of sample (in gm)
Warp and weft are taken out, their total length is measured individually and the sample is weighed in grams in a sensitive weighing machine.

Chemical analysis (Carbonizing test):

Carbonizing is carried out to determine the percentage of cotton and polyester percent in PC and CVC fabric / yarn. Sample are deeped in adequate amount of H2SO4 (70 %) for considerable amount of time than taken out washed and dried cotton dissolved in H2SO4 while polyester does not. Percentage of cotton is found out using following formula-

Types of dyes determination:

This report is used for timely analysis of the finishing quality and checkers performances. Apart from this measurement reports are also made by the Finishing QC from time to time. The finishing QC remains on the floor for all the time to maintain the system of finishing. Types of dyes used in the swatch are found out by using some process

At first 1-2 drops sodium hypochlorite are used to find out the how much color faded of the fabrics.
By using ( 6 g/l hydrous + 4 g/l caustic) chemicals at first have to make 1L solution. The swatch is dipped in the mixer of the above solution at boiling temperature for 5 min until the swatch is dissolved in it. At last fabric is washed.
By using N-N dimethyl Formamide:
N-N dimethyl formamide is taken
Boiling is done
Then fabric is washed.
At last fabric is dried
Pigment dye: No change

Disperse dye: Slightly change
Soluble dye:
Caustic + Hydross = unchanged
B.N-N dimethyl formamide= change like faded color.
Vat dye:
Caustic+ Hydross=Black
N-N dimethyl formamide= slightly change
Reactive dye:
color is not totally striped than it indicates reactive dyes.
Color is faded or removed by using caustic and hydross
N-N Dimethyl formamide = Unchanged, remain like before.
Types of finish determination:
Types of finish is determine by hand feel experience.

Offline Quality assurance test

Each final checker sticks its checker code no for identification. QC in the finishing audits the final garments randomly on daily basis and makes a report, which includes name and no of the checker found in the garment having problem. Refer to Finishing Audit Report. All the offline QA test for finished fabric of Auto Textile limited can be groped as-

Physical test
Chemical test
The detail of all application QA test for finished fabric are discussed in bellow-
Physical test:
The applicable QA physical test for finished fabric is as follows-
Tensile strength test
Tear strength test
Abrasion resistance test
Pilling resistant test
Crease resistant test
Tear strength tester:
Machine used : Tearing tester 1653.
Machine manufactured by : Person responsible

Auto is committed to total quality in all aspects of its operations to ensure complete customer satisfaction. This shall be achieved by systematically assessing the customers stated and implied needs and fulfilling them through continuous up-gradation of technology and improvement in methods and work environment. We shall strive to make a conscious effort for doing things right the first time, every time.

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