Final traning ppt QUALITY

Vendor Technical Training Enhancing Quality and Efficiency in Garment Manufacturing Presented by: Lakshman Muramatti (Fitting Specialist) MAAG – Man Brand : MAAG Date: 22/07/2024.

Table of Contents Introduction to Vendor Technical Training Objectives of Technical Training Benefits of Technical Training Key Training Topics Quality Checkpoints in Garment Production Quality Inspection Criteria Garment Quality Control Procedure Conclusion.

Introduction to Vendor Technical Training Definition: Vendor technical training focuses on educating vendors or clients about the technical aspects of garment production, quality control, and efficient use of machinery and tools. Importance: Ensures high-quality garment production, improves efficiency, and builds long-term partnerships..

Objectives of Technical Training 1. Quality Standards Awareness 2. Defect Identification and Prevention 3. Precision in Craftsmanship 4. Consistent Quality Control Processes 5. Proper Documentation and Reporting 6. Root Cause Analysis 7. Customer Feedback Integration 8. Continuous Improvement Culture 9. Training on Latest Trends and Technologies 10.Effective Use of Tools and Machinery 11. Sustainability and Compliance.

Benefits of Technical Training 1.Enhanced Product Quality Higher Standards: Training ensures that garments meet high-quality standards consistently. Fewer Defects: Improved skills lead to fewer defects and higher overall product quality. 3.Cost Savings Reduced Errors: Fewer mistakes lower costs associated with defects and rework. Efficient Production: Streamlined processes reduce overall manufacturing costs. 4.Time Savings On-Time Delivery: Efficient production processes ensure timely order completion. Right Product at the Right Time: Accurate production ensures the right product is delivered as expected..

Benefits of Technical Training 5.Meeting Expectations Product Quality: Ensures products meet customer expectations consistently. Quality Assurance: High-quality standards ensure customer satisfaction. 6.Improved Efficiency Streamlined Processes: Training on efficient workflows reduces production time. Optimal Resource Use: Better utilization of materials and machinery minimizes waste. 7.Saving Sample and Courier Costs Reduced Samples: Fewer samples are needed as quality improves. Lower Courier Costs: Efficient production reduces the need for urgent shipments, saving on courier costs..

Benefits of Technical Training 8.Market Position Premium Pricing: High-quality products can often command higher prices, increasing profitability. Market Share: Superior quality can help capture a larger market share, as consumers prefer reliable and well-made products. 9.Better Communication and Collaboration Teamwork: Training fosters better communication and collaboration among team members. Understanding Roles: Clear understanding of each team member’s role enhances productivity. 10.Long-term Partnerships Reliability: High-quality, consistent products foster long-term relationships with clients and suppliers. Trust: Reliable production processes build trust with partners..

Key Training Topics Grading & Tolerance Pattern Technician Check points Fabric & trims Inspection Inline Audit Defects Reduction and Action plan How to measure QA check points Sample Information Tag Final Inspection.

TOP GRADING POM GRADING S M L XL XXL 3XL TOL(+/-) SHOULDER SEAM TO SEAM 2 -4 -2 2 4 6 0.5 SHOULDER SLOPE – REGULAR 0 0 0 0 0 0 0 SHOULDER SEAM FORWARD 0 0 0 0 0 0 0 NECK WIDTH SEAM TO SEAM 0.5 -1 -0.5 0.5 1 1.5 0.25 FRONT NECK DROP HPS TO NECK SEAM 0.5 -1 -0.5 0.5 1 1.5 0 BACK NECK DROP INSIDE 0 0 0 0 0 0 0 NECK RIB HEIGHT 0 0 0 0 0 0 0 CHEST 2.5 CM BELOW ARMHOLE 3 -6 -3 3 6 9 1 BOTTOM SWEEP STRAIGHT 3 -6 -3 3 6 9 1 FRONT LENGTH FROM HPS 2 -4 -2 2 4 6 1 ARMHOLE STRAIGHT 1 -2 -1 1 2 3 0.5 SLEEVE LENGTH FROM SHOULDER SEAM 1 -2 -1 1 2 3 0.5 BICEP 2.5 CM BELOW ARMHOLE 1 -2 -1 1 2 3 0.5 SLEEVE OPENING 0.5 -1 -0.5 0.5 1 1.5 0.25 MINIMUM NECK STRETCH 0 0 0 0 0 0 0 SLEEVE HEM HEIGHT 0 0 0 0 0 0 0.25 BOTTOM HEM HEIGHT 0 0 0 0 0 0 0.25 Note : All measurments are half and and in cm TOP GRADING.

BOTTOM GRADING –NUMARIC SIZE POM GRADING 36 38 40 42 44 46 48 TOL(+ / -) WAIST AT WIDTH -STRAIGHT 2.0 -6.0 -4.0 -2.0 2.0 4.0 6.0 1.00 WAIST BAND HEIGHT 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.00 LOW HIP 20CM FROM TOP WAIST BAND 2.0 -6.0 -4.0 -2.0 2.0 4.0 6.0 1.00 THIGH CIRCUMFERENCE 2.5CM BELOW CROTCH 1.0 -3.0 -2.0 -1.0 1.0 2.0 3.0 0.50 KNEE 36CM FROM CROTCH POINT 1.0 -3.0 -2.0 -1.0 1.0 2.0 3.0 0.50 LEG OPENING 0.5 -1.5 -1.0 -0.5 0.5 1.0 1.5 0.50 FRONT RISE INCLU W/B 1.0 -3.0 -2.0 -1.0 1.0 2.0 3.0 0.50 BACK RISE INCLU W/B 1.5 -4.5 -3.0 -1.5 1.5 3.0 4.5 0.50 INSEAM LNEGTH 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.50 J STITCH WIDTH 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.00 J STITCH LENGTH 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.25 FRONT POCKET PLACEMENT FROM WAIST SEAM 0.5 -1.5 -1.0 -0.5 0.5 1.0 1.5 0.25 POCKET OPENING LENGTH ALONG SS FROM WB SEAM 0.5 -1.5 -1.0 -0.5 0.5 1.0 1.5 0.25 FRONT POCKET BAG LENGTH FROM BELOW WAIST SEAM 0.5 -1.5 -1.0 -0.5 0.5 1.0 1.5 0.25 FRONT POCKET BAG WIDTH AT WAIST SEAM 0.5 -1.5 -1.0 -0.5 0.5 1.0 1.5 0.25 BOTTOM HEM HEIGHT 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.25 BACK POCKET PLACEMENT FROM WAIST SEAM 0.5 -1.5 -1.0 -0.5 0.5 1.0 1.5 0.25 BACK POCKET OPENING 0.5 -1.5 -1.0 -0.5 0.5 1.0 1.5 0.25 Note : All measurments are half and and in cm.

BOTTOM GRADING – ALPHA SIZE POM GRADING XS S M L XL 2XL 3XL TOL(+ / -) WAIST RELAXED 3.0 -9.0 -6.0 -3.0 3.0 6.0 9.0 1.00 WAIST EXTENDED 3.0 -9.0 -6.0 -3.0 3.0 6.0 9.0 1.00 WAIST BAND HEIGHT 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.00 LOW HIP 20CM FROM TOP WAIST BAND 3.0 -9.0 -6.0 -3.0 3.0 6.0 9.0 1.00 THIGH CIRCUMFERENCE 2.5CM BELOW CROTCH 1.5 -4.5 -3.0 -1.5 1.5 3.0 4.5 0.50 KNEE 36CM FROM CROTCH POINT 1.25 -3.8 -2.5 -1.3 1.3 2.5 3.8 0.50 LEG OPENING 0.5 -1.5 -1.0 -0.5 0.5 1.0 1.5 0.50 FRONT RISE INCLU W/B 1.25 -3.8 -2.5 -1.3 1.3 2.5 3.8 0.50 BACK RISE INCLU W/B 1.75 -5.3 -3.5 -1.8 1.8 3.5 5.3 0.50 INSEAM LNEGTH 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.50 J STITCH WIDTH 0.0 0.0 0.0 0.0 0.0 0.0 b 0.00 J STITCH LENGTH 0.5 -1.5 -1.0 -0.5 0.5 1.0 1.5 0.25 FRONT POCKET PLACEMENT FROM SIDE SEAM 0.5 -1.5 -1.0 -0.5 0.5 1.0 1.5 0.25 POCKET OPENING LENGTH ALONG SS FROM WB SEAM 0.5 -1.5 -1.0 -0.5 0.5 1.0 1.5 0.25 FRONT POCKET BAG LENGTH FROM BELOW WAIST SEAM 0.5 -1.5 -1.0 -0.5 0.5 1.0 1.5 0.25 FRONT POCKET BAG WIDTH AT WAIST SEAM 0.5 -1.5 -1.0 -0.5 0.5 1.0 1.5 0.25 BOTTOM HEM HEIGHT 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.25 BACK POCKET PLACEMENT FROM WAIST SEAM 0.5 -1.5 -1.0 -0.5 0.5 1.0 1.5 0.25 BACK WELT POCKET OPENING 0.5 -1.5 -1.0 -0.5 0.5 1.0 1.5 0.25 BACK POCKET BAG LENGTH FROM WAIST SEAM 0.5 -1.5 -1.0 -0.5 0.5 1.0 1.5 0.25 BACK POCKET BAG WIDTH AT WAIST SEAM 0.5 -1.5 -1.0 -0.5 0.5 1.0 1.5 0.25 Note : All measurments are half and and in cm.

Quality Checkpoints in Garment Production Cutting Process: Fabric upside down, Fabric Skewing, Relaxation, Height of cutting pile, Numbering and bundling, Storing Sewing Process: Critical operations, Attaching label, Seam allowance, Numbering, Garments styling construction Washing Process: Washing method, Bleaching method, Special processes, Color tone, Rubbing effect, Hand-feel Finishing Process: Button attaching, Pressing, Full Garments quality check, Packing and carton.

Cutting Process Quality Check Point 1. Fabric upside down: Make sure the fabric is not upside down. 2. Fabric Skewing: A maximum skewing of 2 cm for the chest of 60 cm is acceptable, but not more. This defect can be solved by re-setting of the fabric at the fabric mill. 3. Relaxation: Before cutting, knitted, elasticized woven fabrics should be suitably relaxed for around 12~24 hours or more, depending on the type of fabric. Relaxation is mandatory for stretch fabrics. 4. The height of cutting pile: The higher the pile on the cutting table, the more chance the cut pieces are unequal in size. This can lead to size specification & fitting problems. Make sure the height is suitable for the type of fabric (usually 2~3 inches and never more than 5 inches). 5. Numbering and bundling: Make sure the different parts are properly numbered to avoid shading and that this numbering can be easily removed after sewing is complete. 6. Storing: Make sure the different parts are properly stored, for example, rolled, and not folded..

Sewing Process Quality Check Point 1. Critical operations: Check all critical operations repeatedly (like the sewing of the neck- seam, armhole, cuff, placket, etc.), so the operator gets the clear input of what is required and how to make it correctly before large quantities of garments are finished. 2. Attaching label should be correct as per the size of 100% garments 3. Checking bonding strength of interlining in the fusing process. 4. Seam allowance: check operators repeatedly on this point to make sure they use the correct seam allowance. 5. Numbering: Make sure the sewing operatives keep parts with the same number together to avoid shading. 6. Confirm Garments styling construction and measurement are correct as per the approved sample..

Washing Process Quality Check Point 1. Washing method: normal wash, stone wash, sand wash, or enzyme wash. 2. Bleaching method: stone bleach, garment bleach 3. Any special process. E.g. over-dye after the washing process 4. The color tone of the blue yarn 5. The whiteness of the white yarn 6. Resultant color tone: bluer or yellowish 7. Rubbing effect: contrast on the blue yarn and white yarn 8. Evenness on the blue and white parts 9. Hand-feel 10. Record the identification of the sealed sample, quality standards on the final inspection report to ensure QC check the bulk according to the correct standards. 11. Tick and sign all quality standards as an indication of proper QC checking. 12. QC should not release the shipment if they find the following major faults. 13. Color out of the approved shade band 14. Fabric flaws and washing marks in excess of 1″ on the garment zone above the knee 15. Fabric flaws and washing marks in excess of 3″ on any part of the garment.

Finishing Process Quality Check Point 1.Button attaching and button 2.Pressing 3.Full Garments quality check 4.Packing and carton.

Button Attaching and Button • Snap button too loose / too strong • Snap button not closing properly / broken • Missing poly washer for snap buttons • Button coming off • Fabric not strong enough to hold the button • Mark from molding • Paint damaged • Rust • Text on button not straight • Wrong position / not in line with counterpart / incorrect spacing • Button shank missing when required • Buttonhole too big or too small • Buttonhole not clean / badly stitched/ losing shape / stitched with wrong thread quality • Spare button missing or put in the wrong position.

Check Pressing • Shiny marks • Not pressed or improperly pressed • Should avoid the press and fold the pigment-dyed fabrics before garment washing entirely. It is because it will leave a clearly visible mark on the garment after washing. After sewing, put the garments on a hanger until washing starts..

Full Garments Quality Check • Checking full garments workmanship defects • Measure 100% garments to assure fittings • Heat seal peeling off • Confirmation quality check of final garments product.

Packing and Carton Quality Check • Correct ticketing and placement • Packing accuracy of quantity, assortment, and folding • Correct carton selection as per customer requirement • Packaging, sealing, binding and barcode checking.

Quality Inspection Criteria’s are of Final Audit 1.Workmanship 2.Appearance 3.Measurement/Fittings 4.Materials 5.Accessories 6.Finishing/Packing.

Quality Inspection Criteria Workmanship: Fusing, Open seam, Broken stitch, Miss/Skip Stitch, Seam grinning, SPI incorrect, Needle damage/cut/holes, Puckering/Twisting Appearance: Loose/uncut thread, Dirt mark, Oil stain, Garment damp, Crushed, Pressing, Shinning, Wrinkle Measurement/Fittings: Out of tolerance any measurement points Materials: Body fabric way, Contrast fabric, Print/Dyeing Fault, Color Shading, Bald Patches, Holes or Cuts, Yarn Runs, Slubs, Color fly/Foreign yarn Accessories: Thread/Yarn, Assortment, Main Label, Carton Marks, Care Label, Polybag printing, Zipper, Hangtag, Tapping/Capping, Price ticket, Screenprint/Embroidery, Barcode, Buttons/Snaps/Rivets, Carton Barcode, Velcro, Elastic.

Garment Quality Control Procedure 1. Checking fabrics, trims, and accessories as per buyer requirements 2. Make size set sample and review in PPM 3. Pattern correction based on size set garment measurement 4. Cut some pcs as a pilot run from all size ranges after the PP meeting 5. Keep a pattern library of a printed pattern in the CAD room 6. Ensure fabric shrinkage differs by more than 2% 7. Ensure all cut panels should be double-checked with the pattern 8. All cut panels are to be quality inspected before inputting to the sewing section 9. Checking fabrics bonding strength with interlining after fusing 10. Keep Go by sample for every running style 11. Ensure all marking instruments are invisible 12. Ensure all machine tension with feed rock is set up properly 13. 100% garment quality inspection in both sewing and finishing 14. 100% garments to be measured in finishing.

Conclusion Summary: Vendor technical training is crucial for achieving high-quality garment production, improving efficiency, and building strong partnerships. Next Steps: Implement training programs, focus on continuous improvement, and stay updated with the latest trends and technologies..