Unit -2

WHAT IS THE QC PROCESS

The QC process, or quality control process, refers to the steps involved with
upholding consistent standards and specifications for the products and services
you provide to consumers. Any business can have a QC process, regardless of
the type of goods or services it offers.
The QC process involves identifying standards for quality, regularly reviewing
products to ensure they meet those benchmarks and removing any products that
don't meet quality expectations. It also involves ensuring that the people
creating goods or offering services have the necessary skills and training to
provide an excellent experience.
Benefits of having a QC process
To uphold consistent quality standards, you can develop QC processes for
companies, departments and even individual products. Here are some of the
benefits of using a QC process in the workplace:
Developing a reputation: When you have a QC process in place, you can
establish an industry reputation for producing consistent products that meet a
certain quality standard.
Establishing stakeholder trust: Quality control is an important aspect of
functional business operations. Having a functioning QC process builds trust
with stakeholders and business leaders by providing a clear path toward
achieving goals.
Improving customer relationships: By implementing and upholding a QC
process, you output functional, durable products to consumers. This can help
you develop positive relationships with consumers and create a lasting base of
dedicated returning customers who trust the quality of your products.
Creating automation: A good QA process makes it easier to delegate tasks and
automate business responsibilities. When you have a system to check the quality
of products at each step in the supply chain, you can help company operations
function without direct supervision.
HOW TO CREATE A QC PROCESS
Use these instructions as guidelines to develop a quality control process that
upholds superior outcomes for products and procedures:

1. Review industry standards

Research common quality standards for the item or service for which you're
creating the QC process. By understanding consumer expectations and knowing
the quality levels competitors have to offer, you can develop reasonable goals
and expectations. Remember that high-end products are likely to be better
quality than budget products, so look for direct competitors in a similar price
range for the most relevant quality control standards. Consider doing market
research with focus groups to determine the quality range that consumers find
acceptable for your specific offerings.

2. Choose the most important measures

When developing a QC process, it's common to use multiple factors to assess a
product's quality level. For QC procedures to be effective, make sure you
understand which factors are most important for the business's goals. This helps
you develop realistic priorities when making manufacturing or design
improvements.

For example, consider the QC process for the manufacturing department of

Oilslick Raincoats. Some of the priority factors the team considers when
designing their process include durability, fabric quality and sizing, because
these elements have a significant influence on customer satisfaction. The team
also considers the color match of the fabrics, but having a perfect color match is
less important to customers than having a durable garment that fits correctly, so
color has lower priority in the QC process.

Related: Example of a Quality Management System (With Definition and

Types)
3. Set detailed expectations
Next, clearly explain each quality standard. Establishing detailed expectations
makes it easy for everyone on staff to work together to achieve quality goals
and implement QC processes. Develop a document that everyone can access
and reference if they have questions about quality control. Include specific
numbers and descriptions as often as possible to provide direct guidelines for
success that everyone can follow.

For example, fast response time to emails is an important quality metric for a
customer service department. The QC process could include instructions to
respond to all messages within 24 hours as a specific quality requirement.
Related: Guide to Quality Assurance and Quality Control: Definition, Purpose
and How QA is Implemented
4. Align processes with outcomes
Develop instructions for workflows that coordinate with your quality
expectations. Determine what protocols result in the best quality outcomes that
consistently meet your standards, then write them down as company procedures.
Select equipment and tools that enable staff to accomplish goals. Consider
testing different operational methods to find the best practices for each aspect of
quality control. If multiple team members have different methods for
completing a task, see which technique produces the best quality in the most
efficient manner.
5. Develop training materials
To have an excellent QC process, it's important to prepare detailed training
materials so that all incoming staff members understand quality expectations.
Compile onboarding documents, handbooks and blueprints that explain how to
manufacture products, deliver services and complete quality checks. Describe
the steps in the quality control process and explain what to do when a product
doesn't meet the standards. This creates consistent QC results for the company
as people change positions and as teams expand.
6. Review and document data
Collect and analyze information about quality standards. Include details like the
percentage of products meeting quality expectations, average customer
satisfaction scores, product return rates and the level of variation in product
specifications. Gathering data provides you with insights about the effectiveness
of your QC process plan, which you can use to adjust workflows and give
feedback to staff. Use analytics tools and spreadsheets to sort and process
information automatically or develop visual representations of QC outcomes.
7. Gather and apply feedback
Ask both consumers and staff for feedback about how to improve product
quality. While analyzing data is useful, seeking opinions can give you an
additional perspective on ways to enhance your QC processes. As consumer
tastes and opinions change, you can use feedback to learn more about how they
define quality experiences. Use their advice to refine quality standards or find
new ways to improve.
SPECIFICATION SECTION QC BASICS
In a typical three-part specification organized under the Construction
Specifications Institute (CSI)’s SectionFormat, each part of the specification has
clear QA and QC roles.

Part 1 – General identifies procedures and processes that define the specific
administrative requirements unique for these products and activities and their
relationship to other products and activities. It is critical to understand that
reference standards are not enforceable QA or QC unless they are actively
referenced in the specification. Listing standards in the specification does not
make the standard enforceable. A standard must be contained in an action item
to be enforceable.
For example, listing ASTM C309, “Standard Specification for Liquid
Membrane-Forming Compounds for Curing Concrete” does not provide any
enforceable quality. Using the sentence, “apply curing compounds in
accordance with the requirements of ASTM C309 for Type 1 curing
compounds” is enforceable because it directly ties the application of the ASTM
standard.

Part 2 – Products identifies the materials and methods of the types and quality
of products and assemblies that are required for the project. Performance
requirements and system descriptions are highly effective quality control
requirements found in Part 2. They help to ensure consistent quality of
materials, fabrication, and installation.

Part 3 – Execution describes preparatory actions and how the products are
incorporated into the project. There are often very detailed and comprehensive
quality control articles listed in this part. How this section is developed can have
a significant impact on the quality of the construction. Primarily, this includes
how things are prepared to receive products, system, or finishes.
Coatings rarely fail due to bad products. Coatings fail due to poor or inadequate
preparation. Preparation is the number one quality control element of Part 3.
Quality assurance is understanding what appropriate preparation is and how to
specify it.

The Most Effective Quality Tool

Simply put, we must ask more and better questions! The type and extent of the
questions we ask can make a significant difference in how we approach quality
in the built environment. Quality procedures and processes in specifications can
provide the basis for the types of questions that need to be asked and answered
in designing and constructing a quality building. Quality assurance corresponds
 to the questions, and quality control corresponds to the answers. Never stop
asking quality questions.

QUALITY CONTROL TRAINING

The Quality control team needs to be trained to conduct inspections and audits
effectively. Quality control training helps them meet the objectives of the
company.

What is Quality Control Training?

Businesses build their brand reputation, competitive advantage, and customer

loyalty by providing high-quality products and services. They need a well-
trained quality control team that knows its responsibilities and the quality goal
of the company to ensure that the objectives are met. They achieve this through
a variety of quality control activities, including:

 Audits
 Inspections
 Testing
 Performance evaluations

This enables the QC team to ensure that the product or service is compliant with
the company’s quality policy and the regulations and standards relevant to their
industry and business. The quality control team can discharge its responsibilities
effectively when they know the procedures and processes associated with the
role. For this, some of the important factors include:

 The specific standards the business must align itself with

 The quality vision of the company
 The standard operating procedures and criteria for quality
 The documentation processes and the follow-up action needed
 Identifying recurring issues and flagging them for further action

This is where quality control training comes into play.

Quality control requires several different kinds of skills. As quality is an

enterprise-wide requirement covering a variety of functions, the QC team
should have a combination of these skills. Also, the quality and function-
specific requirements keep changing, and therefore, these skills also need to be
upgraded periodically to meet the ever-evolving needs.

The range of functions quality covers includes:

 Design
 Manufacturing
 Supplier
 Testing
 Inspections

The team must also be trained in the eight dimensions of quality, which include:

 Performance
 Features
 Reliability
 Conformance
 Durability
 Serviceability
 Aesthetics
 Perceived quality
A good quality control personnel must have analytical skills, be able to use
statistical techniques for monitoring, inspecting, and testing products and
processes. They must be trained in industrial math, operation analysis,
measuring, precision measurement instruments, and quality control tools.
What is Quality Control Personnel?
A quality control team, which looks at production procedures and operational
methods, includes quality control personnel. These experts ensure that a
facility's output complies with consumer, business, and industry standards. Any
products that don't follow the guidelines are discarded. Manufacturing quality
control personnel uphold client loyalty and the brand's reputation overall to
minimize costs and maximize efficiency.

What are the role and responsibilities of Quality Control Personnel?

 Conduct quality control checks on all the goods ready for shipping and
the arriving raw materials.
 Examine the designs, specifications, and drawings in detail to
comprehend the demands of the product.
 Reject all incoming raw materials that don't satisfy your standards for
quality and notify the appropriate department as soon as possible.
 meeting deadlines and resolving quality-related concerns
 Giving the quality assurance team training
 Creating a compelling design methodology.
 Prepare the inspection process documentation containing in-depth reports
and performance records.
 Make suggestions for the production process's improvement to guarantee
that quality control standards are satisfied.
 Educate the manufacturing team on quality control issues to improve the
product's quality.
How to Become Quality Control Personnel? Qualification
Communication Skills

Quality control Personnel has excellent written and verbal communication

abilities to locate what they need. They may occasionally need to register
procedures to the relevant department.

Organizing abilities

To conduct product evaluations and inspections, the quality control Personnel

should have excellent organizational abilities.

Physical power

Inspectors for quality control must be able to stand for extended periods. For
inspection purposes, they must be able to lift extensive and various types of
machinery.

Technical skills

Quality control inspectors should be well-versed in the types of equipment and

computer programs utilized and the organization's safety rules. They must also
be familiar with technical documentation, instructions, and drawings to
guarantee that goods satisfy quality requirements.

Training skills

Quality control inspectors may require their personnel to be trained in certain

processes and procedures. They must be capable of training personnel to avoid
errors and strive toward a more efficient process.

Attention to detail

A quality control inspector should be alert enough to detect product deviations

to fulfil certain criteria. They must be informed of any changes to procedures or
functions.

Mathematics skills

Basic math knowledge is essential in measuring and calculating specifications

during product development.

Other Skills

 Communication skills
 Problem-solving
 Analytical skills
  Computer skills
 Reporting skills
 Strong sense of accountability
 Customer focused
 Self-motivated

Training Course for Quality Control Personnel.

Level Program
Diploma in Environmental Quality Monitoring and Analysis
Diploma Engineering & Construction
Diploma in business auditing
Diploma Diploma in mechanical engineering
Diploma in business administration
Bachelor in Quality Management Systems for Medical Devices
Bachelor in Quality Management and Systems
Bachelor in electronic engineering
Bachelor in Pharmacy
Bachelors Bachelor in business auditing
Bachelor in mechanical engineering
Bachelor in business administration
Bachelor in aeronautics.
Bachelor in Engineering & Construction
Master in Environmental Quality Monitoring and Analysis
Master in Quality Analysis
Master in business auditing
Masters Master in mechanical engineering
Masters in business administration
Master in Quality Management and Systems
Masters in Quality Management Systems for Medical Devices
PhD in business auditing
PhD in business auditing
Ph.D. PhD in business auditing
PhD in business auditing
PhD in business auditing
 Advantages of becoming Quality Control Personnel.

 Multiple career choices

 You can get to know many people
 Professionals can take up certification courses
 You can grow your skills
 Workload reduces as you go higher position
 Putting the market's requirements first
 Ensures higher standards of performance in all areas
 useful in overcoming competition

Disadvantages of becoming Quality Control Personnel.

 Work can often get monotonous

 A high level of experience may be required
 Professional education is often mandatory for quality personnel
 Additional certification may be required to get the job
 Employee Resistance
 Reduces Creativity

WHAT ARE QUALITY STANDARDS

Quality standards refer to sets of guidelines, systems, methods, requirements, and
specifications followed by an organization to ensure consistent process and product quality.
Mostly prevalent in manufacturing, quality standards are established by industry regulatory
boards to help drive customer satisfaction and maintain compliance. Globally, ISO quality
standards are the most widely accepted set of standards applicable to various industries.

Why are Quality Standards Important

Any product or service that’s free from any manufacturing defect,
deficiency, or process variation is considered of good quality. This is
achieved through the holistic process of quality assurance and quality
control.
Thus, to ensure and maintain good manufacturing practices, a set of
manufacturing quality standards must be established and followed for the
purpose of uniformity across the entire manufacturing process.
Additionally, some of the benefits of quality standards include the
following:

 Continuous improvement of quality outcomes

 Efficient adherence to regulatory requirements and compliance
 Reduced process variation and product defects
 Improved worker productivity and safety
 Enhanced customer satisfaction
 Seamless flow of operations
PRINCIPLES

PRINCIPLES OF QUALITY STANDARDS

In setting quality assurance standards, the 7 principles of quality

management also apply to help establish a more fitting Quality
Management Standard (QMS) based on your business and industry. That
said, the principles of quality standards are the following:

 Customer Focus – This guides the organization in ensuring that customer needs
and expectations are met by setting quality standards aligned with them.
 Leadership – This pertains to the organization’s commitment to implement
leadership principles across the organization to promote a healthy culture of
collaboration.
 Engagement of People – This is key to maintaining worker engagement toward
providing better value to the organization and customers.
 Process Approach – This refers to the way of treating all projects and processes
as part of a holistic functioning system to drive all efforts into sustaining the
business.
 Improvement – This emphasizes the need for an organization to continuously
improve by encouraging proactive innovation and consistent recognition of
successful initiatives.
 Evidence-based Decision-making – This empowers people to value the
importance of data and analysis and how they can put them into practical
applications such as maintaining quality standards.
 Relationship Management – This enables organizations to look at the overall
supply chain management and how it affects the processes, stakeholders, and
suppliers.
What are Examples of Quality Standards?
Learn more about this list of quality standards most widely used in the
manufacturing, healthcare, food, and automotive industries.

ISO 9000 and 9001

The International Organization for Standardization (ISO) published the ISO

9000, the family of good management practices standards for QMS. The
ISO sets quality control standards for manufacturing companies to adhere
to so that they can maintain compliance with industry standards and
regulatory requirements. Under ISO 9000 is ISO 9001, which sets out
detailed requirements for establishing a QMS that specifically suits their
industry needs.

GMP and GLP

Another set of notable quality standards examples is Good Manufacturing Practices

(GMP) and Good Laboratory Practice (GLP).
GMP refers to the system of processes and documentation to ensure that
manufacturing products are being produced and controlled consistently against
quality standards. On the other hand, GLP is a set of principles that ensures non-
clinical laboratory studies are following quality standards and maintaining the
integrity of safety test data.

US FDA

Both the GMP and GLP are enforced by the US Food and Drug Administration
(FDA). That said, the US FDA sets out regulations that address manufacturing
practices, including personal hygienic practices, facility maintenance guidelines,
sanitary operations, and process controls during food manufacturing.

IATF 16949

The International Automotive Task Force (IATF) 16949 was created specifically for
the automotive industry. Apart from helping organizations maintain the quality of
automotive services and assembly parts, IATF 16949 also guides in continuously
improving how manufacturers carry out their processes toward reducing defects and
waste.

IAQG 9100

The International Aerospace Quality Group (IAQG) 9100 is a specific set of QMS
requirements for aviation, space, and defense organizations in the aerospace
industry. This can be applied to all supply chain levels to achieve optimal quality and
efficiency

QULAITY CONTROL INSPECTION

Quality control is a set of procedures an organisation undertake to ensure that its products
conform to a defined set of quality criteria or meet the relevant requirements of a client. Now,
there are many types of quality control activities. But they’re typically grouped into two
broader categories: quality inspection and testing.

In this article, we’ll focus on the first category of quality control, namely quality inspections.
We’ll provide you with an answer to the question “What is a quality inspection?” and cover
the most common types of quality inspections used in quality control.

What is Quality Control?

Before diving into the topic of quality inspections, it’s important that we understand how they
are related to quality control. All in all, quality control is an initiative undertaken by a
company to ensure that products meet certain standards. Or as quality control is defined
by the ISO 9000: “A part of quality management focused on fulfilling quality requirements.”

Generally, these are quality standards that are related to quality assurance and quality
compliance.

 Quality Assurance Definition: Ensure that the products or services meet specifications
and requirements.
 Quality Compliance Definition: Ensure the product’s quality conforms to
standards/rules set by an organisation, i.e. authoritative body.

Companies use a set of activities to assess whether or not the product is fit for its purpose and
defined standards. These activities often include quality inspections (more on this later).

It’s important to note that quality control procedures may differ depending on the product or
industry that it applies. If you want to learn more about a particular product or industry, go to
the following articles below:

 Quality Control in Garment Industry

 Furniture Quality Control
 Quality Control in Construction
 Pipe Welding Quality Control
  Glass Quality Control
 Food Quality Control
 Milk Quality Control

What Is Quality Inspection?

Quality Inspection is the process of evaluating and verifying if the inspected
materials and products conform with the specified requirements. It is achieved
through various methods, such as a quality inspector measuring, examining,
gauging, and testing the product’s characteristics.
Quality inspectors usually carry out a pre-established checklist which is based
on the specifications of the product and/or client.

They inspect the products to ensure whether they are fit for production or semi-
finished goods, as well as finished goods ready for shipment to customers.
Theresults of the inspection is then compiled into a sample report,
that indicate whether or not the product conform to the specifications.

What Does a Quality Inspector Do?

Quality inspectors are a critical part of ensuring that products are of high
quality and produced in compliance with standards. They conduct
inspections on manufacturing processes, product quality standards,
company policies and manufacturing processes, and others.

Their duties will vary depending on whether it is a company-employed

quality inspector or a hired quality inspector from a third-party agency for
a particular purpose (for example, quality inspections).

The duties of a quality inspector may include:

 Establish quality standards for all products and services provided by a

company.
 Create rules for standards and communicate them to the relevant staff to
ensure quality levels are maintained.
 Write documents to outline all standards clearly, creating references for
employees.
 Work with all management-level employees to ensure they are
maintaining any new standards and compliance with all relevant
regulations.
 Perform random quality inspection checks on products or services to
assess quality levels.

Why Is the AQL Sampling Method used in Quality Inspections?

Inspectors often test samples when they conduct quality inspections. The
sampling method used in quality inspections often follows the ISO 2859-1
standard called AQL, or Acceptable Quality Limit. This is a sampling
method technique that helps quality inspectors decide the maximum
number of defective units that is acceptable for inspecting a production
batch.

The reason why they use a sampling method is that it is the most cost-
effective method of evaluating production batches. They can also inspect
individual units, but this requires more time and money (more on this
later).

What Are the 4 Types of Quality Inspection?

There are, in total, 4 types of inspection in quality control

pre-production inspection, during production inspection, pre-shipment

inspection, and container loading/unloading inspections. As the name
implies, each of the quality control methods is carried out at a different
stage – and each of them has its own purpose in quality control and
supply chain management. Depending on the product, experience with
your supplier and other factors, one or all of these steps may apply to
your business needs.

Pre-Production Inspection (PPI)

The Pre-Production Inspection (PPI) is conducted before the
production process begins and helps to assess the quantity and quality of
the raw materials and components and whether they conform to the
relevant product specifications.

A PPI is beneficial when you work with a new supplier, especially if your
project is a large contract that has critical delivery dates. This inspection
can help to reduce or eliminate communication between you and your
supplier on issues regarding production timelines, shipping dates, and
quality expectations.

During Production Inspection (DPI)

During production inspection (DPI), also known as DUPRO, is a quality
control inspection conducted while production is underway. This step is
particularly useful for products that are in continuous production and have
strict requirements and/or when quality issues have been found prior to
manufacturing during an earlier PPI.

DPI inspections take place when only 10-15% of units are completed so
that any deviations can be identified, feedback given, and any defects can
be re-checked to confirm they have been corrected. It enables you to
confirm that quality, as well as compliance with specifications, is being
maintained throughout the production process. It also provides early
detection of any issues requiring correction, thereby reducing delays and
rework.

Pre-Shipment Inspection (PSI)

Pre-shipment inspections (PSI) are an important step in the quality

control process and the method for checking the quality of goods before
they are shipped. PSI ensures that production complies with the
specifications of the buyer. This inspection process is conducted on
finished products when at least 80% of the order has been packed for
shipping. Random samples are selected and inspected for defects against
the relevant standards and procedures.
Container Loading/Loading Supervision (LS)
Container loading and unloading inspections ensure your products
are loaded and unloaded correctly. Inspectors will supervise throughout
the whole process and ensure your products are handled professionally to
guarantee their safe arrival to their final destination.

This inspection will usually take place at your chosen factory while the
cargo is being loaded into the shipping container and at the destination
once the products have arrived and are being unloaded. This process
includes evaluating the condition of the shipping container and verifying
all the product information, quantities, and packaging compliance

Piece-by-Piece Inspections
In addition to the four types of quality control inspections above, another
procedure also exists.

A piece-by-piece inspection involves checking each and every item to evaluate a range of
variables including general appearance, workmanship, function, and safety. This inspection
process can be carried out either before or after the packaging inspection. In the circumstance
where the goods require particular attention to ensure compliance to specification or when the
goods are high-value, a 100% inspection service should be performed.

Once the products have passed the inspection process, they will be sealed and certified with a
sticker to ensure that every piece included in the shipment meets the specified quality
requirements. This inspection is particularly useful for goods that must be fully compliant and
meet strict customer and market quality requirements. It can be carried out at any stage of the
manufacturing process.

Garments Quality: Every garment buyer has its own quality

manual or procedure, a standard quality procedure should maintain in
the garments manufacturing industry to reach up to the mark in
quality control. Every person related to apparel manufacturing needs to
know about garments quality procedures, especially for them who work
in the quality department. Here I wrote all general garments quality
control procedure of Garments manufacturing from cutting to finishing
that’s how we do to maintain quality procedures
GARMENTS QUALITY CONTROL PROCEDURE

1. Checking fabrics, trims, and accessories as per buyer

requirement.
2. Make size set sample and review in PP meeting
3. Pattern correction based on size set garments measurement
4. Cut 300 pcs as a pilot run from all size range after PP meeting to
ensure all size measurement is correct then proceed to cut for
bulk.
5. Keep pattern library of a printed pattern in the CAD room
6. If fabrics shrinkage differs more than 2 %, a different pattern will
be made
7. Ensuring that fabric with accessories as per consumption okay to
proceed bulk then start cutting
 8. Cutting will be started after buyer QC approval of bulk cutting
9. Ensure all cut panels should be double-check with pattern &
maintain your record as per SOP
10. All cut panels to be quality inspected before inputting to the
sewing section.
11. Checking fabrics bonding strength with interlining after
fusing, fusing attached temperature record with thermal paper.
12. Keeping Go by sample for every running style to confirm
garments styling is accurate as per sample.
13. Ensure all marking instrument should be invisible especially
pen & chalk mark pencil use light mark but it should be
erased able daily basis, follow up oil leakage from the machine by
put blotting paper or fabric under the pressure foot, also double
check all the machine inside have any extra needle by the
magnet.
14. Ensure all machine tension with feed rock set up properly
by our actual fabric quality on a daily basis & keep a
record with mock-up
15. Needle control and Needle change record maintain
properly.
16. 100% garments quality inspection in both sewing and
finishing
17. 100% garments to be measured in finishing
18. Button pull test checking and record daily
19. Garments pass through metal detector machine
20. Keep packing accuracy as per buyer approval, check daily
and take buyer approval for folding and packing

Finishing Quality Control SOP of Apparel Industry

Finishing is the last step of the apparel industry. Quality Control is necessary for
every stage of garments production for the purpose of making a quality product,
finishing the garments, prepare for shipment, and finally deliver to the garments
buyer. So, finishing is a very important process in garments. To ensure finishing
quality control by the garments manufacturer a finishing quality control SOP of
the Apparel Industry is to prepared and followed accordingly. Here SOP means
Standard Operating Procedure. Ultimate quality control, garments decoration,
and ticketing are done in the finishing process of the apparel industry.
Finishing Quality Control SOP of Apparel Industry
For finishing quality control following standard operating procedures can be
followed for the apparel industry.

All Sewn Garments are to receive into finishing section after washing (if GMTS
needs finishing as per buyer’s requirement).
Washed garments to be checked for shade acceptance in a standard lightbox as
per buyer approved all shade standard. If a lot fails in AQL to meet shade
acceptance, then GMTS will send back to washing for rewash.
After passing shade of Garments and thread trimming, quality checking starts as
per style-wise process sequence but must maintain a size-wise bundle.
Excessive WIP (Work in Process) and dumping more than one bundle stacking
in one layer is not allowed in any operation of finishing.
Any defective garments will not pass from any operation without alteration and
QC pass.
Finishing Quality Control Standard of Garments
Pull test as per customer requirement
100% Garments quality inspection and thread trimming
100% Garments key point measurement
100% pressing as per customer requirement
Quality audit is to be done before moving garments to pack
Specific written instruction for every operation with garments form mockup as
visual instruction for ironing, attaching the sticker, measurement, quality
inspection, folding, and packing.
Approve trim card for every style with all finishing trims and accessories.
100 % of garments metal detection is to follow to ensure garments free from a
needle, sharp tools, and any types of metal as ensured product quality.
Packing of garments as per customer Stock Keeping Unit (SKU) and assortment
requirement.
Ironing (Pressing) Standard Operating Procedure (SOP) in Garments Finishing
Garments come in iron table size-wise by the bundle.
Only one size is allowed in a bundle.
Iron table marking before every style starting.
A carton in every iron table to keep defects and marking with an arrow sticker
to detect defects.
Out of tolerance Garments not be passed from the measurement section, the
Iron show having every measurement table.
Every Gate up Quality inspector having measurement tape and style-wise
measurement sheet.
Approved sample hanging with written instruction in Iron, Quality Inspection,
and packing area.
From Iron garments moving bundle wise up to packing.
Garments not are gathered by more than one style or color in every iron and
quality inspection table.
Finishing Quality Audit
Finishing AQL Auditors audit GMTS before moving GMTS to packing area
from every bundle using AQL 2.5. If the audit pass, GMTS will move forward
for packing. If Audit fails, an auditor will give back GMTS to the Quality
checkpoint area to recheck. After completing recheck, AQL Auditor will re-
audit. An auditor audit full PO lot as per buyer final audit sampling policy when
that PO is already 80% packed to check packed GMTS quality before a final
audit. If the Pre-final audit fails, then the full PO will be rechecked.

HQTS Quality Control Services in India

HQTS is your third party inspection company in India for all your quality-related needs.
Our services are designed to address challenges across the entire sourcing and
production cycle, while taking into account the unique context of Indian manufacturing.

Whether it’s a factory audit in India, product quality inspection, or obtaining governmental
certifications, we are dedicated to ensuring your products meet the highest standards of
quality and safety.

Supplier and Factory Audit in India

Our supplier and factory audits in India will help you ensure that your supplier in India is
legitimate and capable of meeting your specific needs and quality standards.

Major checkpoints of a supplier audit include:

 Company legality information

 Bank information
 Human resource
 Exportation capability
 Order management
The standard factory audit includes:

 Manufacturer’s background
 Manpower
 Production capability
 Machine, facilities & equipment
 Manufacturing process & production line
 An in-house quality system such as testing & inspection
 Management system & Capability
 Environment
Product Inspection in India
We help both domestic and foreign companies across all industry verticals to reduce
rejection rates through our range of product quality inspection services in India, each of
these services are dedicated at a different stage in the production cycle, these inspections
include:

 Pre-Production Inspection
 During Production Inspection
 Pre-Shipment Inspection
 Piece by Piece Inspection
 Container Loading Inspection
Governmental Certification Services in India
With years of knowledge in conformity assessment programs, HQTS India possesses an
in-depth understanding of regulations and technical standards and is authorised to
perform conformity assessment activities and issue certificates of conformity in countries
around the globe.

SASO Certificate Providers in India

We can help you to obtain the SASO certificate in India / SABER certificate in India and
issue the Saudi product certificate of conformity once your goods meet the relevant
product standards specified in the technical regulation.

Uganda PVoC Certificate in India

HQTS is one of only fix appointed companies in the world appointed by the Uganda
National Bureau of Standards (UNBS) to provide Uganda PVoC Certificate Services

Other Quality Control Services

In addition to the above-mentioned services, we offer specialised training in quality
management, social compliance audits, and product testing against industry
standards such as RoHS, REACH, CPSIA, DMF, Cl Prop 65, in our state-of-the-art
laboratories.

Get in touch with us today to explore how we can help you.

WARHOUSING AND SHIPPING IN QUALITY CONTROL

Quality control in the warehouse is important to the success of an ecommerce business.

However, some warehouse managers feel quality control slows operations.

Thus, it is rarely applied. Or in some cases, it is only partially applied and is often
discarded in the hustle and bustle of the warehouse.

You can apply warehouse quality control techniques during receiving, picking, and
packing. And creating quality control checkpoints in each stage of the shipping workflow
can reduce fulfillment errors.

The green areas in the image below signify stages where managers can implement
quality control measures. It is not uncommon to have more than one quality control
checkpoint.
This breakdown in quality control usually occurs at times when delivery speed
is the overwhelming focus.
The irony is that high-pressure situations, or fast-moving workflows, are
precisely when most problems occur.
Often when a company bypasses warehouse quality control in favor of quick
fulfillment, the wrong (or defective) products are shipped.
These mistakes are compounded if you’re running multiple warehouses or in
the process of trying to scale up to a larger operation.
But by looking at data, warehouse managers can see which errors occur most
often and when.
In turn, they’ll realize the importance of inspecting orders before shipping. This
is true even when — and especially when — orders are time-sensitive or the
workflow is moving at a higher than average speed.
The Seven Basic Tools of Quality
Dr. Kaoru Ishikawa identified seven warehouse quality control tools that
help organizations troubleshoot errors. Quality control benefits a warehouse in
that it should successfully catch issues early on and limit any future mistakes.
This can help tighten up inefficient processes or aid in diagnosing a specific
problem and improve warehouse efficiency.
Below are illustrations and examples of these seven quality control tools
[Link]-and-Effect Diagram
A cause-and-effect diagram (also referred to as the Ishikawa or a fishbone
diagram) shows the potential causes of a specific issue. To create a cause-and-
effect diagram, a warehouse manager brainstorms with his team to come up
with a list of every possible reason for an error.
For example, the warehouse team may be consistently forgetting to include
packing slips. Everyone works together to disqualify the less likely causes and
identify the most probable reason. Then they develop a solution to prevent the
problem from reoccurring.

2. Check Sheet
Check sheets are the most adaptable tool on Ishikawa’s list. Warehouse
employees can use check sheets to mark off daily tasks, count inventory, or (as
in the example below) record the days on which issue occurred.
The increase in responsibility on the part of workers is beneficial to encouraging
workers to check their work. Managers can use check sheets to identify patterns
and make more informed decisions about how to run the warehouse
3. Flowchart
A flowchart (sometimes called stratification or run chart) illustrates each
separate step in a workflow. Using a workflow can assist in determining which
part of the workflow requires more scrutiny.
It also helps warehouse teams make incremental changes instead of overhauling
the entire shipping workflow.

4. Control Chart
A control chart is a more sophisticated flowchart that shows how a workflow
changes over time. It includes a line for the average, a line for the upper control
limit (UCL), and a line for the lower control limit (LCL).
By comparing data on the current shipping workflow to these lines, warehouse
managers can differentiate between normal fluctuations and unexpected spikes.
5. Histogram
A histogram is a graph that shows how frequently a different value in a dataset
occurs. It is also highly adaptable, but warehouse managers can only use it
when the data is numerical and of the same type.
A warehouse manager can use a histogram to see which problems occur more
frequently than others. Then, he can adjust the shipping workflow accordingly.

6. Pareto Chart
Created by Italian economist Vilfredo Pareto, a Pareto chart is a histogram
that also shows the distribution of issues. The errors are listed in
descending order of frequency, and the line represents the cumulative
frequency.
Warehouse managers can use a Pareto chart to identify the most significant
problem(s) and prioritize fixing those first. This prevents the warehouse
team from resolving issues that won’t be as impactful
7. Scatter Diagram
A scatter diagram helps illustrate the relationship between two variables. You
can determine how intense two factors correlate or if they share a positive or
negative relationship.
This allows managers to know whether to further investigate the variables or
look for something more relevant. For example, warehouse managers can use it
to identify the relationship between the number daily orders and the number of
errors.

Warehouse Quality Control Processes and Procedures

Warehouse quality control processes are the procedures used to ensure that
products meet quality standards. Quality control is a systematic way of
monitoring and measuring the quality of products so that you can take steps to
improve it if necessary. It’s important for all companies in the warehousing and
distribution industry because they want to make sure consumers are happy with
the goods they receive when they order something online.
Warehouse quality control processes can be manual or automated—depending
on what kind of business you run and how much money you want to spend on
technology equipment.
As you begin to implement your warehouse quality control process, it's
important to have a solid understanding of the following terms:
 • Quality Control Processes: How the QA department will be involved in
all elements of the production process. This includes quality control
planning, product design, manufacturing, shipping and receiving
processes.
• Quality Control Procedures: A step-by-step guide on how each part of the
warehouse operations should be performed to ensure customer orders are
processed correctly. These documents should include instructions for how
employees should interact with machines and materials during each phase
of production planning (for example, checklists and flowcharts). They
may also include information about what kind of supplies or tools they'll
need to complete their tasks effectively (for example, checklists).
Keeping these documents up to date is essential because they provide
management with an organized way of tracking data such as machine utilization
rates and worker efficiency levels over time so they can identify areas where
improvements could be made (such as finding ways to reduce waste). If
something goes wrong with one consumer order, it's easy enough to just look
back at this document without having someone explain what happened again.
.

What Is Acceptance Sampling?

Acceptance sampling is a statistical measure used in quality control. It allows a
company to determine the quality of a batch of products by selecting a specified
number for testing. The quality of this designated sample will be viewed as the
quality level for the entire group of products.

A company cannot test every one of its products at all times. There may be too
many to inspect at a reasonable cost or within a reasonable timeframe. Also,
comprehensive testing might damage the product or make it unfit for sale in some
way. Testing a small sample would be indicative without ruining the bulk of the
product run.

SAMPLING PLAN IN QUALITY CONTROL

Ensuring the quality of components (whether these components are produced by

the company or bought in from suppliers) is a vital activity for most businesses
and an intrinsic part of the quality control process.
A sampling plan enables an organization to assess and determine the
quality of parts and products by evaluating only a percentage of the overall
quantity available and then, using the results of that assessment, reach
conclusions regarding the quality of the overall batch.
This often takes the form of physical inspection (which can be just physical
measurement combined with verification checks on documentation or involve
other processes such as destructive testing) in order to determine levels of
quality.
A sampling plan is a technique used to determine quality by observing and
assessing only a proportion of product/materials rather than 100% of the total
quantity.
Sampling is a concession between 0% inspection and 100% inspection, levels of
quality are inferred based on assessing only a percentage of the complete lot.
This concession is made due to business drivers (such as cost).
As its name implies, a sampling plan is a statistical technique which we can
use to help us decide if we can accept or reject material.
In practice, this means that
 We assess a small number of units to ensure compliance with
standards/requirements
 We then infer the quality standards of the lot
 We use the results to determine if we can accept the lot
There are various reasons for doing this. Assessing and inspecting materials
takes time, resources and cost. By making the process more efficient, savings
can be made.

WHAT IS A SAMPLING PLAN IN QUALITY

CONTROL?
These materials may take the form of goods manufactured by the business itself
or those bought in from third parties via the supply chain.

Where the organization has procured 50,000, it may make sense to undertake
sampling in order to measure quality more cost-effectively.

TYPES OF SAMPLING IN QUALITY CONTROL

Rather than a singular method for sampling, there are a number of alternative
methods that can be used;
Statistical
Most organizations, when using a statistical approach, will utilize the AQL
limit; you’ll see this sometimes called Acceptable Quality Limit or Acceptance
Quality Limit.
For more in-depth detail on this, head on over to this excellent article
[Link]
In practice, AQL is regarded as the worst quality level that is still considered
satisfactory or another way of putting it: the maximum percentage allowed to be
defective for the lot to be deemed acceptable.
While you can, of course, know the math, most companies will use an AQL
table that provides guidance on the statistical method used based on three key
parameters
 The lot size under assessment
 The inspection level you might apply
 The level of acceptable defects for your market
Note this applies to the product only (and not associated things like packaging
etc.).
By using the method, you will calculate the number of goods required for
inspection.
Random
A random sample, sometimes called ad-hoc, is just that. We assess a certain
percentage of the batch under investigation.
While this may represent an easy method – “we’ll just investigate 10%” this
method doesn’t necessarily provide you with the confidence that the sample size
is either correct or provides value to the inspector.
Random sampling faces several challenges, namely:
1. Bias – was the selection truly random, or did the reviewer select the
sample out of a particular bias?
2. Dispersion – samples may not be representative of the spread of quality
observable within a batch
3. Inconsistency among samples – samples are not consistent with the
overall quantity of product
First Off
First off, inspections are commonly carried out (often as part of an initial
product run or where changes have been made to the production process). First
off (as its name implies) – it assesses a sample of a produced lot, either the first
or first few of a batch, to ensure that requirements and controls have been met.
Batch
In this method, a batch is assessed of being representative of a production run.
A factory may make 10,000 widgets a week in batches of 500. A particular
batch is selected in order to assess the quality and likelihood of non-
conformance
Acceptance sampling
In this method, a manufacturer or producer will supply a number of completed
goods to its customer in order that they can be reviewed and a decision made
whether to accept or reject the overall batch. This method relies on sampling by
deciding on the quantity of defective items from the sample and extrapolating
that to the total batch. The customer will then decide if the quantity of defects
falls into an acceptable range.

PURPOSE OF SAMPLE PLANS IN QUALITY CONTROL

The ultimate purpose of using a sampling plan as part of your quality control
process is to provide a view of the quality of components being reviewed.
We all know the implications of poor quality products, whether it’s the impact
on the customer or increased costs of correction.

However, most businesses have significant quantities of products passing

through their organization and inspecting every single one isn’t practical (from
a cost or resource perspective).

Sample plans, therefore, provide a reasonable approach to most businesses,

protecting quality whilst being an effective process that doesn’t drain resources
or costs.

WHO USES SAMPLE PLANS IN QUALITY CONTROL?

Sampling is widely used in businesses due to the benefits obtained when facing
detrimental aspects of 100% inspection, such as:

 Destructive inspection where a quantity of product is destroyed during

testing and a business wants to limit this
 Costs associated with 100% inspection are not economical
That being said, however, there may be some regulated industries where
sampling is not appropriate (examples include businesses where defects may
result in injury or death e.g. certain Aerospace/pharmaceuticals).

Also, businesses where product volumes are low, may refer back to 100%
inspection.

WHEN TO USE A SAMPLING PLAN IN QUALITY CONTROL

Using a sample plan is obviously at the discretion of the assessor. However,

there are some things to think about when evaluating whether to use one:
  The level of defects you choose to (or are able to) accept – Not every
industry will accept defects (think about Aerospace and Pharmaceuticals,
which have a very low threshold, 0%, for defects as they may result in
harm to life). Other industries might accept levels of defects that can
support sample inspection.
 Your customer – Another consideration is the end customer and their
appetite for defects. If we look at high-volume industries like the garment
industry, there is an acceptance of levels (even if low) of defects. Other
customers may require very high levels of quality, and your inspection
processes will need to be tailored accordingly.
 Costs/Resource – If you are faced with large batch quantities (10,000’s
of pieces, for example), assessing each individual unit is not cost-
effective.
Considerations for Sample plans in Quality Control

In determining any Quality Control plan, planning ahead is always vitally

important. Planning allows you to understand your goals and methods and bring
out risks and considerations and help determine appropriate processes.

So, when you’re planning your sample plans, here are some considerations:

 Your objectives
 The impact of your end process
 Preexisting policies and standards
 The rationale behind the use of sampling
 Why are you rejecting other methods?
 Levels of accuracy required.
 Actual sample size vs safe sample size
 How reliable may your estimates be
 Variability of data and reasons for variation
BENEFITS OF SAMPLE PLANS IN QUALITY CONTROL

As we’ve described, there are several benefits of sampling plans, these include:

 A well-recognized quality control method

 Helps reduce costs and administration associated with 100% inspection
 Reduced levels of destructive tests required where appropriate
 Reduces inspection fatigue which drives error on 100% inspection
 Utilizes a selection of methods that allows you to choose something
suitable for your business
Issues with Sample plans in Quality Control

ISSUES INCLUDE:

 Sampling is not a precise picture that could be achieved through 100%

inspection
 Sampling doesn’t necessarily lead to 100% quality
 Samples may not be indicative of a lot
 Planning and documentation overhead
 This does not negate the need for good Quality characteristics and
acceptance criteria

WIDE QUALITY STANDARDS

Quality standards are sets of good management operations, methods, systems,

requirements, and/or specs set up by industry advisory groups to help
manufacturers achieve and show consistent production and product quality.
Some quality standards refer to a broad spectrum of manufacturing and service
organizations, while others are industry centric.

DEFINITION OF QUALITY STANDARDS

Quality standards are the documents that provide requirements, specifications,

blueprints, guidelines, or characteristics that can be used frequently to ensure
that materials, processes, products, and services are fit for their purpose.
A quality standard is a detail of the requirements, specifications, the
various guidelines and characteristics to meet its quality by the product in order
to meet the purpose of the product, process, or the service.
UNDERSTANDING QUALITY STANDARDS
Quality standards assure companies meet the minimum requirements to become
an integral part of almost every industry, from food to automobile to healthcare.
It’s clear that those standards are here forever.

Some organizations find the concepts of quality standards hard, or they consider
it as a complex system. But with proper information, help and a clear
understanding of why quality standards can benefit them, organizations can
learn to take advantage of quality standards rather than buck against them.

Who Sets Quality Standards?

Made by Industry groups, Governments or Consumer representative
organizations, and there are often structures for independent assessment by
regulatory bodies often with lawful (fire safety and food
standards) legal (professional registration or industry guarantee
compliance) or simply trade association favoring.

Principles of Quality Standards

Quality standards may consist of guidelines for quality planning, control,
and checking phases of production. They also may reward companies to
maintain continuous improvement initiatives through closed-loop quality
systems.

Some quality standards were formed in response to concerns about a significant

level of customer complaints. They often involve companies in implementing
effective complaint management mechanisms.
Here are seven quality management principles designed to guide companies
toward improvement;

1. Customer Improvement:
 Recognize customer needs and expectations and adjust company objectives with
them; then maintain customer satisfaction by meeting customer requirements
and building customer relationships.

2. Leadership:
Strong leadership means you have a distinct vision of your company’s future.
Apply leadership principles, including vision, goal-set, modeling, faith,
empowerment, and recognition.
3. Engagement:
Invest in employee empowerment, communication, accountability, and
recognition. This can then help to enhance employee productivity and
motivation.

4. Process Approach:
Developing processes for each area of your business, from sales to marketing,
finance to HR, will secure that resources are used most effectively, resulting in
cost-sufficient and consistent results. It also allows you to give time and
attention to bigger and more interesting tasks!

5. Improvement:
Continuous improvement is essential to the quality management system and
should be your organisation’s core aim. Applying processes for finding risks
and opportunities, spotting and solving non-conformities, and measuring and
monitoring your efforts means you will find ways to improve and make your
business even stronger.

6. Evidence-Based Decision Making:

Correct and reliable data is vital for making informed decisions. For example, to
solve the root cause of a non-conformity, you need the proper evidence. Always
make sure that information is accessible to those who need it and keep
communication channels open.
7. Relationship Management:
Your suppliers are the source of competitive advantages, but this involves a
relationship built on trust. Establishing such lasting relationships with suppliers
and other involved parties means stabilizing short-term financial gains with
long-term, mutually beneficial strategies.

Benefits of Quality Standards

Businesses apply standards to meet their customers’ quality requirements and
for a range of other reasons, such as;

 Providing safety and reliability of their products and services

 Complying with laws, often at a lower cost
 Controlling internal processes
 Satisfying environmental objectives
Businesses which follow quality management standards are often more able to:

 Multiply their profits

 Cut down losses or costs across the business
 Increase their competitiveness
 Gain market entry across the world
 Build consumer loyalty
Example of Quality Standards

ISO Certified

HERE ARE SOME OF THE MOST PREVALENT QUALITY STANDARDS;

ISO 9000
Developed by International Organization of Standardization, ISO 9000 is a
family of standards and ISO 9001 is within that family, both set for good
management practices for quality management systems.
IATF 16949
Formed by members of the International Automotive Task Force (IATF) and
accepted and published by ISO, IATF 16949 specifies the requirements for
quality management systems used by the automotive industry.

IAQG 9100
The International Aerospace Quality Group (IAQG) has
developed standards for quality management systems for aviation, space, and
defense industries. Like IATF 16949, the IAQG 9100 standard is set up
upon the ISO 9001 standard such that compliance with the former requires
compliance with the latter.
IRIS
The International Railway Industry Standard (IRIS) creates
a global system for evaluation of quality outcomes from manufacturers that
supply the railway industry.
FDA 21 CRF Part 11
US Foods and Drug Administration (FDA) standard applies to
FDA-regulated industries, including pharmaceuticals, medical appliances,
diagnostics, and biotech industries. It sets up requirements for manufacturing
software system control, validation, analyzing, auditing, and documentation.
GMP/GLP
Good Manufacturing Practices and Good Laboratory
Practices are the quality standards established by the US FDA for
healthcare product manufacturers, especially those using laboratories and
process manufacturing.