Introduction: In the textile industry, production efficiency is the most common word and every section mostly IE, Planning, and Production team work very hard for increasing production efficiency. But most of the time they complain that their production efficiency is reduced for the quality team.
Yes!!! today I will explain that point and give a positive explanation that how the quality team impacts on improving the production efficiency in the textile industry.
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| Quality Control Plan |
In general, most of the modern & compliance industry creating two quality teams. One call Quality assurance team & other is the Quality control team. The Quality Assurance (QA) team works about process development and technical side, The Quality Control (QC) team follows and controlling the process that developing by the Quality Assurance team. This developed process call Control Plan.
Control plan development and application:
A control plan is a type of document that makes with the requirement of the buyer for ensuring smooth and best quality production. In the Control Plan, There has each and every step of a product and how to control that process to meet the buyer requirement is described. This three stages are;
1. Incoming Control Plan
2. On-line Control Plan
3. Final Control Plan
1. In-Coming Control Plan: The very first step of the control plan is to ensure raw materials in-house like Fabric, Yarn, Trims & Accessories, everything that required for the product is ok as per the BOM sheet. Here the control plan has what to control, How to control, and if there any discrepancies then how to categorize and the required action should have written.
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| Zipper Control |
For Fabric and yarn, the color of fabric and yarn compared to the approved swatch card. Ensure the fabric GSM, Yarn Count, hand feel.
For Trims and Accessories, they follow the BOM sheet references or booking. Here, They check the functionality of the trims and accessories as also the color, information & measurement, etc. All of the work is done before production for the fast and right raw material supply to the production.
2. On-Line Control Plan: The next or second step is related to direct production. On-line control plan have all the required information about sewing that ensure the best quality of the product with smooth production. Here described the types of machine used and their setup, also has how to handling the garments during sewing for avoiding defect.
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| Process Control |
For machine setup, the controller work with mechanic team. He commanded the mechanic team to setup every machine to the buyer production requirements like SPI, SPCM, seam width, and attachment of some other special part that requires for easy production.
For production process development, a product has some step or precess to complete it. Here how to handle the product like how to feed to the machine, how to join one part with other part, etc are clearly mentioned and everything is going as per the buyer requirements is ensured.
3. Final Control Plan: The next and final section is the folding and packaging section. Here how the T-shirt fold and packs into the carton, the size ratio of the T-shirt for a carton, size of the carton, etc are described. This step calls final control.
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| Final Control |
How this control plan improve the production efficiency!
Actually, a control plan is the planning of production with the best quality. It requires for every style. The Quality Assurance team makes this control plan by following the buyer requirement.
When the raw material in-house they applied In-Coming Control Plan to avoid wrong material supply to the production. Any kind of wrong material distribution to sewing line can stop the production which is reduced hourly production as well production efficiency.
When the first production starts they applied On-line control plan for avoiding reworking or detect. Any type of reworking in the line reduce the production target that decrease production efficiency.
Finally after finishing a product it goes to the folding and packaging area. Here which accessories are used to pack, how to fold, which size of carton used, information of shipping address etc are described. Any kind of mistakes in this stage will do repackaging which increase shipping time and also possiblity to get GTD (General Terms of Delivery) claim from the buyer. Delay of shipment can be air shipment that is costly than sea shipment.
So, The Quality Assurance team ensure that everything is doing right way before production, during production and after production.
Reviewed by Mustaqim-Ul-Alam
on
September 27, 2020
Rating:
