Submission to

Ms. Nanika Kaushal

Assistant Professor,
NIFT
By: -
AQE FINAL K. Vidya Sagar
M.F.TECH

ASSIGNMENT
AQE FINAL ASSIGNMENT

(1Q). Inspection Loop

(A).

(2Q). Explain what the holding of a Quality Assurance Manual will tell
potential customers.

(A).

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(2Q). List down the fabric testing machines which should be considered by
Purest Manufacturers.

(A).

 Air permeability machine: -

The air permeability specific surface of powder material is a single-parameter

measurement of the fineness of the powder. The specific surface is derived from the
resistance to the flow of air (or some other gas) through a porous bed of the powder.
 Crease recovery machine: -
This is a fabric defect evidenced by a broken line or mark or folds in a fabric
generally caused by a sharp fold. Crease appears when the fabric is distorted in such a
manner that part of it is stretched beyond its elastic recovery. 
 Water repellent machine: -
Durable water repellent is a coating added to fabrics at the factory to make them
water-resistant. Most factory-applied treatments are fluoropolymer based; these
applications are quite thin and not always effective.
 Tear strength machine: -
Tear strength is the tensile force required to rupture a pre-slit woven fabric sample
under controlled conditions and is determined by measuring the work done in tearing
the fabric through a fixed distance. The tearing strength is measured in newton(N) or
centinewton (CN). The apparatus consists of a pendulum carrying a clamp and is
aligned with a fixed clamp. The procedure starts with raising the pendulum. Upon
raising the sample fabric is placed between both the clamps. On releasing the
pendulum, the fabric tears from the already slit point as the moving clamp move away
from the fixed clamp. There is a pointer attached to the pendulum which is graduated
to read the tearing force directly.
 Tensile strength machine: -
Tensile testing, also known as tension testing, is a fundamental material
science and engineering test in which a sample is subjected to a
controlled tension until failure. Properties that are directly-measured via a tensile test
are ultimate tensile strength, breaking strength, maximum elongation, and reduction in
area. From these measurements, the following properties can also be
determined: Young's modulus, Poisson's ratio, yield strength, and strain-
hardening characteristics. Uniaxial tensile testing is the most commonly used for
obtaining the mechanical characteristics of isotropic materials. Some materials
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use biaxial tensile testing. The main difference between these testing machines being
how the load is applied to the materials.
 Pilling machine: -
A pill, colloquially known as a bobble, fuzzball, or lint ball is a small ball of fibers
that forms on a piece of cloth. 'Pill' is also a verb for the formation of such balls.
Pilling is a surface defect of textiles caused by wear and is generally considered an
undesirable trait. It happens when washing and the wearing of fabrics cause loose
fibers to begin to push out from the surface of the cloth, and, over time, abrasion
causes the fibers to develop into small spherical bundles, anchored to the surface of
the fabric by protruding fibers that haven't broken. The textile industry divides pilling
into four stages: fuzz formation, entanglement, growth, and wear-off.
 Bursting strength machine: -
This test is used as a general guide to determine the strength of any fabric. It is done
by putting the sample in a mould through which pressure is applied from the bottom
of the fabric after its threshold point explodes. Parameters such as speed, duration,
severity are recorded when the sample explodes. Bursting strength is usually quoted
in kPa.
 Launder meter machine: -
It is a laboratory instrument used for conducting accelerated laundering and or dyeing
tests. It can be used for performing washing, dry cleaning, dyeing, detergency, and
other laboratory tests. Inside the container parameters like temperature, mechanical
agitation can be controlled and recorded for optimal testing and grading. This is most
useful because it can depict various washing conditions required for different types of
fabric.
 Rubbing machine: -
In the textile industry, a rub test determines the colorfastness of the color or dye in the
fabric. It is an essential test. Fastness to rubbing also determines how well
a fabric will resist stains. A test for fastness to rubbing can be performed on dry or
wet fabric.
 Spray test machine: -
Namely to determine the behavior of a fabric to absorb water that gets in contact with
the same, in form of rain. Spray tester 36 is especially suitable to measure the water
repellence of fabrics. The exact definition of the Spray test method is "resistance to
wetting."
 Gsm cutter machine: -
The GSM Cutter is a textile testing instrument that is used for measuring
fabric GSM with the aid of a weighing scale and GSM pad. The GSM cutter is a
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circular fabric sample cutter. With this instrument, a uniform circular fabric is cut
without measuring. Area of the fabric specimen cut by GSM cutter is 100 square
centimeter areas
 Dimensional stability machine: -
Dimensional stability is the change of dimensions in textile products when they are
washed or relaxed. The change is always expressed relative to the dimensions before
the exposure of washing or relaxing. Shrinkage is also called residual shrinkage and
measured in percentage
 Abrasion resentences machine: -
Abrasion resistance is the ability of a fabric to resist surface wear caused by flat
rubbing contact with another material. There are two different test methods commonly
used by the textile industry to assess abrasion resistance: Wyzenbeek and Martindale
(described in detail below).
 Drape machine: -
Fabric drapability is a morphological characteristic occurring when the fabric is
hanging down for its gravity. It is one of the important indicators to measure clothes
close-fitting. Some fabrics like dresses, curtains, table cloths are required to a good
drapability. Whether fabric drapability is good is closely related to fiber
classification, fiber stiffness, yarn twist, fabric density, organizational structure, etc.
 Stiffness & Bending machine: -
The Shirley stiffness tester fabric testing instrument is used to determine
the stiffness of fabrics. Description of Shirley stiffness tester the stiffness tester is
consists of a platform, having smooth low friction, flat surfaces such as polished
metal or plastic
 Crease recovery machine: -
This is a fabric defect evidenced by a break line or mark or folds in a fabric generally
caused by a sharp fold. Crease appears when the fabric is distorted in such a manner
that part of it is stretched beyond its elastic recovery.
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(3Q). Analyse the advantages and disadvantages to Purest Manufacturers

adopting Statistical tools.

(A). TOOLS:
 Quality is always the key to determining the standard of a product. And to maintain
such standards there are universal tools that are being used throughout the industries.
These are known as the Seven basic tools of quality.
 These are a fixed set of graphical techniques that are used to identify all the issues
related to quality and assist in solving those issues. These tools can be implemented in
garment manufacturing to improve the process and product quality. These tools are
very effective for apparel or any other type of factory to solve almost every type of
problem in a factory operation.
 These are the tools for troubleshooting quality issues, based on the numeric value. If
you can use these fundamental tools, then definitely quality control will be effective
for your company.

WORKING:
The working involves several steps: -
 Choose control – What is to be measured
 Establish Measurement
Eg: Whether 100% inspection (or) 5/6 stitches (or) several processes Calibrated or not
 Establish standard of performance – like length has to be stated in a tech pack
 Measure actual performance
Eg: Measure length of garment for comparison
 Compare to standards – Compare & interpret the difference
 Take actions on the difference

ADVANTAGES:
 Collect, present, identify, and analyze data Proper analysis of data is as important as
anything here, since improper data takes to several other problems.
 Data-driven – Removes Ambiguity
Eg: Blaming each other is reduced. The complete information on data provides
knowledge.
 Eliminates errors Since enough clarity can be noticed people can use several methods
to rectify it
 Establishes relation with all the most probable root causes Enables to find the root
causes
 Gives a direction of Improvement, Since root causes are identified, the several small
links which are associated with the target one with problems tend to get eliminated
too through correction
 When done correctly, eases the process of Implementation.
Eg: A team sits together and does the analysis, hence the result would be a minimum
number of errors.
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 Improves Management decision-making skills

Eg: Appropriate decisions can be made, which is not one time and for improving
futuristic performances as well
 Reduce variations and improve quality
 It directs us towards an even path thus resulting in enhancement of quality.
 Reduce defects and improve production
 Reduce cycle time and improve efficiency
 Continuous quality improvement
 Encourages teamwork and confidence
 Enhances customer satisfaction through improved quality product
 Most effective utilization of resources
 Reduction in inspection cost.
 Brings about economies in inspection and considerably reduces the cost of the
inspection.
 Increased goodwill, by producing better quality products and satisfying customer’s
needs, raises the goodwill of the concern in the minds of people. A reputed concern
can easily raise finances from the market.
 High morale of employees, Proper tool utilization methods are greatly helpful in
increasing the morale of employees, and they feel that they are working in the concern
producing better and higher quality products.
 Improved employer-employee relations
 Develops to a better industrial atmosphere by increasing morale of employees which
ensures cordial employer-employee relations leading to better understanding and
closeness between them.
 Improved technique and methods of production, by supplying technical and
engineering data for the product and manufacturing processes, improved methods, and
designs of production are ensured very well.
 Effective advertisement, Proper correction of defects leads the industry to produce
quality products which thus leads to the effective advertisement. They win public
confidence by supplying those better-quality products.
 Facilitates price fixation, by introducing appropriate measures, uniform products of
the same quality are produced. This greatly facilitates the problem of price fixation.
One price of standard products becomes prevalent in the market.
 Increased sales, these tools ensure production of quality products which is immensely
helpful in attracting more customers for the product thereby increasing sales. It is
greatly helpful in maintaining existing demand and creating new demand for the
product. It has been rightly pointed out that these tools act as a powerful instrument
with the help of which markets both at home and abroad can be expanded.
DISADVANTAGES:
 The tools involved for Quality control in manufacturing significantly contributes to a
manufacturer's brand and bottom line. However, persistent challenges to continue to
trouble small and medium-sized manufacturing companies alike. The issues, of
course, vary depending on the existing management culture of the company. Here are
some issues in manufacturing that are getting in the way of increasing effectiveness:
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 Managing by departments:
The usage of these highly effective tools finds itself in a tighter position in
factories/manufacturing units since managing these stuff could become slightly
impractical at times.
 Resistance to Innovation:
Innovation is not merely a shift in daily practices but the creation and adoption of new
technologies to improve quality. In manufacturing, the implications of innovations are
endless, often leading to radical changes in systems, processes, machinery
requirements, and skillsets. Resistance to these changes creates barriers up to some
extent
 Upper Management's Unwillingness to Provide Additional Resources and Time
From several case study references, it is highly evident that the managers (for
example) in a manufacturing unit generally agreed that they were more concerned
with daily operations than they were with quality management, even though they
recognized its importance. They contended that fixing errors and flaws take time and
they would rather delegate quality responsibilities to other people so they could better
focus on their assigned tasks. As a result, upper management didn't see the urgency to
allocate the resources and time needed.
 Increasing Complexity of the Supply Chain
Evolving trends in manufacturing have forced companies to expand into new regions
where they can leverage lower production costs and higher availability of raw
materials and qualified manpower. Globalization has also created more complex
supply chains that require supply chain management throughout the world, thus
further complicating the quality-related prospects in manufacturing.
 Limited people availability
The presence of fewer people is of another great concern to a manufacturing unit
 Data – accurate/not
Usage of accurate data should be addressed as a mandatory one. However, tools use
the data only which we are providing and even slight variation could result in
changing the entire course of action.

(4Q). Evaluate the proposed move from traditional quality control methods
to new quality control tools.

(A). INTRODUCTION:
Quality control techniques apply statistical principles and techniques at all stages of the
life-cycle of a product, i.e., "from cradle to grave". Statistical quality control methods are
quite different from traditional methods and they have made a great contribution to
improvements in companies dealing with mass production. 

TRADITIONAL QC METHODS TO NEW QC TOOLS:

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In traditional methods, the product is manufactured first and then it is checked to

determine whether it meets the quality requirements. The product that does not meet the
quality requirements is rejected and sent back to the machines for machining or correction
otherwise it is thrown away as scrap. If faulty products are too much, to eliminate the
assignable causes or the problem necessary corrections are made by examining the
production period.

Traditional method

Thus, statistical quality control is a vital part of the production. Instead of checking the
finished product after production, it is applied at every period of production. If this period
is under control, the next period is considered; otherwise, the assignable causes are
discovered and corrected.

STATISTICAL QC WAYS
QC TOOLS ELABORATION:
The QC tools work on the data(numerical) collected during the processing/production of the
products. The traditional/basic tools do not greatly help in that to form plans or ideas.

HISTOGRAM:
The histogram is also a bar chart. It is a graphical chart based on a numeric value for showing
the frequency distribution of the database. People become confused about Histograms and
Bar Charts. A histogram is used for continuous data, where the bins represent ranges of data,
while a bar chart is a plot of categorical variables.
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CHECK SHEET:
The Check/Tally sheet is a simple document that is used for collecting data in real-time and at
the location where the data is generated. A document is typically a blank form that is
designed for the quick, easy, and efficient recording of the desired information, which can be
either quantitative or qualitative. When the information is quantitative, the check sheet is
sometimes called a tally sheet. A tally sheet to collect data on the frequency of occurrences
custom-designed by the user.

CAUSE AND EFFECT DIAGRAM:

A cause-and-effect diagram looks like a fish that’s why it’s called Fishbone Diagram, also
called Ishikawa diagram, herringbone diagrams, or Ishikawa diagrams, a visualization tool
for categorizing the potential causes of a problem to identify its root causes.

USE:
In process improvement methods to identify all of the contributing root causes likely to be
causing a problem.

PARETO CHART:
A Pareto chart is a bar graph. The lengths of the bars represent frequency or cost (time or
money) and are arranged with the longest bars on the left and the shortest to the right. In this
way, the chart visually depicts which situations are more significant.

PRINCIPLE:
The Pareto principle (also known as the 80–20 rule) states that, for many events, roughly
80% of the effects come from 20% of the causes.

SCATTER DIAGRAM:
The scatter diagram graphs pairs of numerical data, with one variable on each axis, to look
for a relationship between them. If the variables are correlated, the points will fall along a line
or curve. The better the correlation, the tighter the points will hug the line. The scatter
diagram Collect pairs of data where a relationship is suspected.

CONTROL CHART:
Control charts, also known as Shewhart charts or process-behavior charts, are a statistical
process control tool used to determine if a manufacturing process is in a state of control. A
control chart shows how data frequency changes, defects trends and compares with a
previous time record. Control chart monitor process and hypothetical prediction. The apparel
industry needs to reduce defect frequency to get quality improvement

STRATIFICATION:
It is a method of dividing data into subcategories and classify data based on a group, division,
class, or level that helps in deriving meaningful information to understand an existing
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problem. The main purpose of Stratification is to divide the data and conquer the meaningful
information to solve a problem. The visual nature of the chart makes patterns jump out.

FOR IMPLEMENTATION:
To implement these tools in the manufacturing industry/factory, you must have to do Pareto,
Fishbone for every section. Result publishes visibly in each line or area inboard. People will
be conscious to reduce defects. There improvement tracking on the control chart also visible
for each line/area. You have to find the root cause from the root level for the cause-and-effect
diagram. Data and data collection must be accurate. Every section has to be taken corrective
action based on quality data. Every section must do a quality meeting to take a new decision
for quality control at least once per month.

NEW QC TOOLS:
With continuous improvement and Quality control becoming increasingly important to
world-class brands, companies, and industries, there's an urgent need to build quality into the
decision. Unlike the seven traditional QC tools, which measure quality problems that already
exist and are used by quality circles, these seven new QC tools make it possible for managers
to plan wide-ranging and detailed TQC objectives throughout the entire organization. These
tools include the relations diagram, the KJ method (affinity diagram), the systematic diagram,
the matrix diagram, matrix data analysis, the process decision program chart (PDPC), and the
arrow diagram. Together they will help you to:
 Expand the scope of quality efforts company-wide.
 Set up and manage the systems necessary to resolve major quality problems.
 Anticipate potential quality problems and eliminate defects before they happen.

RELATIONS DIAGRAM:
Relations diagram is used for Finding Solutions Strategies by understanding relationships
with Complex Interrelated Causes.
To allow a team to systematically identify, analyze, and classify the cause-and-effect
relationships that exist among all critical issues.

AFFINITY DIAGRAM:
This is highly useful for gathering large amounts of data that involves ideas, opinions, and
issues & organizes the data into groups based on natural relationships thus making it feasible
for further analysis and to find a solution to the problem.

TREE DIAGRAM:
Used when dealing with complex problems. For pursuing the best strategies to combat a
problem and to reach the target.

MATRIX DIAGRAM:
This is another planning tool used for analyzing and displaying the relationship between data
sets. The matrix diagram shows the relationship between two, three, or four groups of
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information. It also can give information about the relationship, such as its strength, of the
roles played by various individuals or measurements.

ARROW DIAGRAM:
It is a tool used to detect the sequence of events and their links. It is used for scheduling and
to determine the critical path through nodes. Helps to understand the schedule.

PROCESS DECISIONS PROGRAM CHART:

This chart is used for planning the activities when the information is incomplete. The goal is
to depict the events. Used for taking big steps

PRIORITIZATION MATRIX:
A prioritization matrix is a 2×2 matrix designed to help you discern which tasks/projects are
“Critical and Urgent,” so you can focus on what matters most.

CONCLUSION:
On a whole, starting from traditional tools which were introduced in Japan, several changes
were made sure to be processed which could have created huge troubles to showing
innovation by introducing new QC tools to minimize the risk of errors or weaknesses in
procedures or the source material, turned/proved to be of great use. The continuous use of
these tools upgrades the personnel characteristics of the people involved. It enhances their
ability to think to generate ideas, solve the problem, and do proper planning.