General View Of Quality Definitions of Quality Quality Assurance

Transcription

1 General View Of Quality The topics discussed in this chapter are only in the view of general ideas. These are not hard and fast rules. These may be different in different systems, organizations and regions. Pattern of quality and terms of quality have been explained for common parameters. Definitions 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). 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.

2 Quality Control Quality control (QC) is a procedure or set of procedures intended to ensure that a manufactured product or performed service adheres to a defined set of quality criteria or meets the requirements of the client or customer. QC is similar to, but not identical with, Quality Assurance (QA). It is part of Quality Management focused on fulfilling quality requirements. Importance of Quality Quality Control and Quality Assurance activities of an organization are essential to produce top quality products. Customers do not buy goods and services; but they want solutions to problems & fulfillment of needs and wants which is not possible without quality. Management is responsible for 94% of quality problems, and it is management's task to help people work smarter not harder. Quality Management Coordinated activities to direct and control an organization regarding to quality are called Quality Management. Quality System Organizational structure, responsibilities, procedures, processes, and resources needed to implement quality management are called quality system. A quality system is a means of applying common sense to your business operations in order to get consistent results. Quality Policy "The overall intentions and directions of an organization as regards quality as formally expressed by top management "General directions and goals of the organization referring to quality being officially published by the management Quality Audit "A systematic and independent examination to determine whether quality activities and related results comply with planned

3 arrangements and whether these arrangements are implemented effectively and are suitable to achieve objectives "The systematic examination and evaluation of all activities related to the quality of a product or service to determine the suitability and effectiveness of the activities to meet quality goals SOP (Standard Operating Procedure) Standard Operating Procedure is a written procedure for operations that are performed repeatedly. Standard Operating Procedure is a sum of documents that describe a specific method of accomplishing a task that is to be followed precisely the same way every time. Quality Parameters Quality Parameters are a sum of elements that are essential to check during the production. Quality parameters are defined by the quality management or higher management of an organization. 1. Knitting Quality 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 avoided. A summary of knitting quality inspection activities is given below with comprehensive details Inspection Method of Socks in Knitting a. Pick a piece from the Knitting machine. First of all examine entire surface of the sock apparently to find whether there is no such kind of major defect is running in sock which make the sock B-Grade. If you found any major defect in sock and this defect is continuously occurring in all socks on the machine. Immediately stop the machine and hang a red tag on it, which indicates that this machine is faulty and stopped by quality inspector. Inform the knitting mechanic about the fault with a faulty piece as a sample. If you do not found any major defect in sock so carry on the further inspection.

4 b. Now check the top part of the socks first, which is welt. Verify the construction of the welt (1x1, 2x1, and 3x1), construction of elastic at welt (every course/every other course), and type of elastic (nylon cover/polyester cover/lycra cover), count the courses of welt (welt in and welt out), count the courses of welt tip and welt motif according to the knitting trim card. Check the welt motif or any other pattern as per master knitting sample (Trim Card). Verify the yarn (main yarn, plaiting yarn, pattern yarn, shade of pattern yarn) of the welt. If there is any welt crowns are being made, confirm the height of the crowns as per sample provided or standard provided. In the end measure the welt Length (Height), Width and Stretch of the welt as per knitting specification sheet. Welt must be made ok at all costs. c. Afterward tie down comes. It is also called folding. Verify the yarn of the tie down/folding (nylon, polyester or cotton) as it is required. Sometimes socks to be dyed and plaiting yarn nylon is used in the body of the socks. In such kind of socks if polyester is used as tie down yarn. These socks will be rejected after dyeing because polyester will not be dyed with nylon dyeing recipe. So tie down yarn verification is essential to avoid such kind of rejection. One broken stitch of the tie down can be passed at risk. Two or more than two broken stitches can never be passed in tie down to assure the tie down/folding quality. Folding should be neat and clean. Neither shagged folding nor long loose floating stitches allowed in the tie down/folding. d. After tie down/folding inspection, now check the rib part of the socks. Confirm the construction of the rib (1x1, 2x1, 3x1 ), construction of the elastic (every course/every other course), and type of the elastic (nylon cover/polyester cover/lycra Cover) according to the knitting trim card. Check the rib motif or any other pattern as per master knitting sample (Trim Card). Verify the yarn (main yarn, plaiting yarn, pattern yarn, shade of pattern yarn) of the rib. In the end measure the rib Length, Width and Stretch of the rib as per knitting specification sheet. Also count the courses of the rib and motif of the rib to maintain the size of the rib & size of

5 rib motif. Ribs must me prominent other than flat ribs. Also check the needle division for the distance of the motif. Sometimes in one side the needles are less and in other side of the motif the needles are excess. This unbalanced division of the needles makes the motif not in centre. e. Hence you have inspected the rib, now start the inspection of the foot (terry) from the boot area. Verify the yarn of the foot. Measure the boot area according to the specs. Verify the heel type (pouch, real, Y type, plain heel) as per requirement. Check the quality of the heel it must not be loosed. If the loose heel is made it will be opened on the press frame and may be socks will be rejected. Needles of the heel must be prominent other than the body of the socks. If the heel and toe are made in contrast then it should be of same size. Check the terry type of the foot, as it is required. Measure the length of the arch support/foot elastic band as per requirement. Ensure the construction of the band. Foot pattern or any motif in the foot should be confirmed. Check the foot width, foot length and foot stretch. If the foot is made in half cushion then ensure that half cushion and full cushion portions are equal. Variation in cushion area may cause problem in stitching and pressing. If any bar or patti is made on toe, the size of this bar or patti must be equal. Check the foot knitting quality; it should be in fine condition. Loose or bad knitting is not acceptable. Confirm the bottom/sole pattern yarn and reinforced/splicing yarn if required. Also ensure the shade of cones of foot to avoid lining in foot or shade variation in foot. f. Now come to clip area. It is also very important in quality of socks. Stitching quality of the toe depends upon the quality of the clip. Check that clip is not too tight or too loose. It must be in medium condition. The length of the clip should be one centimeter. Rejected yarn should be used in clip because it is to cut after the toe closing. If the socks are to stitch on rosso machine then in knitting a rosso of two courses will be made prior to clip. More than two courses are not allowed in rosso to get better results in toe closing. During the inspection also check that the knitting operators

6 do not reverse the socks from toe side. It will loosen the clip and toe will not be closed properly at stitching. This may cause tumer problem in pressing. g. Check the weight of the socks as per requirements. Important: If a style is running on ten machines then take one piece from a machine. Get it ok as per specs and compare with all other machines to ensure the variation in welt tip, heel & toe, motif, rib length, welt length, foot length and total length of socks. Sometimes plaiting yarn comes over the main yarn. When we will dye these socks it will be prominent on the surface of the socks. It is also called sun proof out. Socks with sun proof out will be rejected. To control this fault run the black polyester cones in place of plaiting yarn on knitting machines. It will show the sun proof out on the spot. This problem occurs only in dyed socks 1.2. Knitting Inspection Parameters a. Knitting Plan Matching. b. Specification Sheets/Cards Inspection. c. Yarn Inspection. d. Trim Card Matching. e. Welt Inspection. f. Rib Inspection. g. Booth/Ankle Inspection. h. Terry Inspection. i. Change Over Inspection. j. Heel & Toe Inspection. k. Half Cushion & Full Cushion Inspection. l. Splicing/Reinforced Part Inspection. m. Sole Part Inspection. n. Rosso Inspection. o. Clip Inspection. p. Terry Type Inspection. q. Loose/Tight Knitting Inspection. r. Stretch Checking.

7 s. Weight Checking. t. Production Inspection. u. Size/Measurements Checking SOP (Standard Operating Procedure) Knitting Take the charge of the shift from the Inspector who is already on duty in previous shift and discuss main problems of his shift. After taking the charge get all the machines ok. Here the word ok means to check the following things on the machines one by one. Check the specification sheets on the machines, either they are hanged on the machines or not. If specification sheets are not hanged on the machines then immediately fulfill this requirement. Match the knitting plan and trim card with the production of all the machines. If found any variation immediately inform the knitting shift supervisor about it. Check the yarn on the machines as per requirement. If found any different yarn immediately stop the machine and change the yarn. Hold the production with wrong yarn and raise the NCR (Non Conformity Report). Inform the knitting supervisor about it. Machine must be stopped until the corrective action is taken. Check (03 or 04 or 06) pieces on each machine according to the inspection method of socks. If found any major fault on any machine check further two dozen on that machine. If found five pieces from two-dozen production inspection raise the NCR. Prepare the inspection report of all the machines. If you stop any machine due to any quality reason/or defect, always prepare the machine stoppage report to avoid complication with knitting mechanics and production staff. Inspect all the machines allotted to inspector at least two times in his shift. Prepare the inspection report of both the rounds.

8 Select any six machines of his row/section and inspect three dozen of each machine. Sort out the faulty pieces from this production and prepare the report of this inspection. Paste the stickers on the faults and submit all faulty pieces found from production to quality in-charge of the knitting section. Before giving charge to next shift, again match the trim card with production of all machines. Consult your seniors or section heads in case of any confusion. When a new style is started on the knitting machines. Take the first two pairs of the production of each machine and give it to the processing department for required process. After processing press the socks and check the finish specs of the socks. If there are some discrepancies, inform the concerned person and take corrective action. Check new style each time in this way in his shift Knitting Quality Reports Daily Knitting Inspection Report Daily Knitting Inspection Report Machine Wise Production Inspection Report Machine Stoppage Report Non Conformity Report Specification Sheet

9

10

11

12

13