Presentation Quality Assurance
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The document summarizes the quality assurance processes at Delta Socks Ltd. It describes the department structure, with a director of quality assurance overseeing inspection of incoming materials, knitting quality, stitching quality, processing, pressing, packing, and final audits. It provides details on inspection parameters and requirements at each stage of production to ensure product quality.
Presentation Quality Assurance
- 1. Quality Assurance Delta Socks Ltd. Faisal Najeeb- Delta Socks Ltd.
- 2. Contents Definition & Objective Quality Policy Department structure Incoming Materials Inspection Knitting Quality Stitching Quality Processing Quality Press Quality Packing Quality Final Audit Loading Supervision Faisal Najeeb- Delta Socks Ltd.
- 3. 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). Faisal Najeeb- Delta Socks Ltd.
- 4. 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. Faisal Najeeb- Delta Socks Ltd.
- 5. Faisal Najeeb- Delta Socks Ltd.
- 6. 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 Faisal Najeeb- Delta Socks Ltd.
- 7. Incoming Materials Inspection Faisal Najeeb- Delta Socks Ltd.
- 8. 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 Faisal Najeeb- Delta Socks Ltd.
- 9. Yarn Inspection Report Faisal Najeeb- Delta Socks Ltd.
- 10. 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. Faisal Najeeb- Delta Socks Ltd.
- 11. Accessories Inspection Report In below picture, Accessories QA Checker is verifying the art work provided by the marketing. Faisal Najeeb- Delta Socks Ltd.
- 12. 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. Faisal Najeeb- Delta Socks Ltd.
- 13. 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. Faisal Najeeb- Delta Socks Ltd.
- 14. Knitting Inline Inspection Report Faisal Najeeb- Delta Socks Ltd.
- 15. Knitting NAHM Frame Verification & Specs Checking Faisal Najeeb- Delta Socks Ltd.
- 16. Knitting Production Report & NCR Faisal Najeeb- Delta Socks Ltd.
- 17. Knitting Stretch Checking, Trim Card Verification and Knitting Faults Inspection Faisal Najeeb- Delta Socks Ltd.
- 18. 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. Faisal Najeeb- Delta Socks Ltd.
- 19. 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 Faisal Najeeb- Delta Socks Ltd.
- 20. Continuity Shade Verification Faisal Najeeb- Delta Socks Ltd.
- 21. 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). Faisal Najeeb- Delta Socks Ltd.
- 22. Press Quality Inspection Report Faisal Najeeb- Delta Socks Ltd.
- 23. Press Inline Inspection Faisal Najeeb- Delta Socks Ltd.
- 24. 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. Faisal Najeeb- Delta Socks Ltd.
- 25. Packing Inline Inspection Packing Inline checker is verifying the prototype and packing instructions Faisal Najeeb- Delta Socks Ltd.
- 26. 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. Faisal Najeeb- Delta Socks Ltd.
- 27. 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 Faisal Najeeb- Delta Socks Ltd.
- 28. 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 Faisal Najeeb- Delta Socks Ltd.
- 29. 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 Faisal Najeeb- Delta Socks Ltd.
- 30. Faisal Najeeb- Delta Socks Ltd.
- 31. Faisal Najeeb- Delta Socks Ltd.
- 32. Final Inspection Report Faisal Najeeb- Delta Socks Ltd.
- 33. AQL (Acceptable Quality Level) Chart Faisal Najeeb- Delta Socks Ltd.
- 34. 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
- 35. 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 Faisal Najeeb- Delta Socks Ltd.
- 36. Size Chart of Socks Faisal Najeeb- Delta Socks Ltd.