PROCEDURES, METHODS, REQUIREMENTS, FORMS & REPORTS

DGL Pre Production activities

• Process development department analysits issues a file to Quality and Production.
• Suggests batch layout/folders/guides and egronomic as per GSD to be used for bulk production
• Changes in design / construction suggested to the buyer for improved quality / productivity

DGL Fabrics

• 4 Point system for fabric inspection by professionally trained manpower.
• In house lab for testing various fabric parameters like shrinkage, spirality, wet and dry rub, colour fastness to washing etc.

DGL Cutting

• State of the art cutting room equipped with latest CAD/CAMS to provide precision cutting consistently.
• Fabric is relaxed to control shrinkage
• In majority of cases panel wash is done to arrest shrinkage, and spirality (in knits).
• On line inspection to address issues related to laying, spreading, cutting.
• Lot wise GSM / Shade continuity cards maintained in cutting section.

DGL Sewing

• Stress on process standardization to enhance quality
• Deskilling Operation by using folders / guides / patterns to get consistent quality.
• SPF concept enables minimum wip in the lines thereby making it easier to control quality.
• In line inspection points to weed out issues as close as possible to the needle.
• An independent audit team audits pcs after end line inspection @ 1.5 AQL.
• Pcs are moved to fng only after their certification.
• Feedback from Audit on daily basis for further improvement.

DGL Finishing

• Clear SOP for processing of a style in finishing.
• Strong independent internal audit to certify quality before final shipment.

Quality we follow as per our Clients terms and condition as below

• QUALITY STATEMENT
• QUALITY STAGES
• DEFECTS AND CLASSIFICATION
• CLASSIFICATION EXAMPLE AS PER M&S
• COUNTER / CONTRACT SEAL SAMPLE
• RAW MATERIAL
• REQUIREMENTS PRIOR TO INSPECTION
• FABRIC INSPECTION
• FOUR POINTS SYSTEM
• FABRIC INSPECTION PROCEDURES
• ACCESSORIES INSPECTION PROCEDURES
• LABORATORY TESTING PROCEDURES
• CUTTING ROOM PROCEDURES
• REQUIREMENT PRIOR TO CUTTING ACTIVITIES
• INSPECTION SYSTEMS
• PRE PRODUCTION MEETING
• SUPERVISOR’S FIRST SAMPLE
• SEWING AREA
• REQUIREMENT PRIOR TO SEWING
• SEWING CONTROL PROCESSES
• FINAL APPEARANCE & MEASUREMENT AUDIT
• PACKAGING AUDIT
• ACCEPTANCE QUALITY LEVEL
• SAMPLE PLAN – NORMAL LEVEL II
• CORRECTIVE ACTION PLAN
• QUALITY CONTROL RECORD FORMS

QUALITY STATEMENT

It is the main objective of the corporate to produce garments to the highest possible standard & to adopt the best practices in order to achieve this objective.

The purpose of this manual is to outline the various stages & control systems within each stage of the manufacturing process.

The Quality Control Systems designed to help maintain control over the quality of the garment through the manufacturing process.

The QC Department has the quality responsibility along with the staffs and management of manufacturing and finished goods. This includes controlling the in coming raw materials, the work in process and auditing the finished lots to ensure product's quality is at an acceptable AQL level and correspond to the client requirement.

QUALITY CONTROL STAGES

Quality Control is present al the following stages:

RAW MATERIAL

• Material Inspection
• Trims Inspection

Laboratory Procedure

• Lab Testing

Cutting Room

• Marker Checking
• Laying Checking
• Cutting checking
• Printing & Embroidery Quality Audit
• Fusing Checking
• Bundling Checking

Sewing Department

• In Line Inspection
• In Process Station Checking
• End Line Inspection
• Final appearance and measurements audit

Packing Department

• Packaging Inspection

AQL acceptance sampling of completed lots prior to shipment

DEFECTS AND CLASSIFICATION

To control quality conformity and problem seriousness, the quality department must put in a place a list of possible defects related to safety, appearance, and measurement based on the garment types produced in the factory. In some cases the list could be obtained from the buyer. The QC staffs, checkers, and auditors use the defects list to identify the problem.

Each type of defect should be related to a classification such as: critical, major or minor.

Critical	:	A fault that is likely to cause injury. A legal requirement such as labeling. Evidence of infestation. Chemical odors. Safety fault, especially children’s wear.
Major	:	A fault that is likely to result a return to buyer from the consumer or which you would not purchase as a customer.
Minor	:	A fault that is likely to result a return to buyer from the consumer or as a customer you reject in favor of another item.

To make it much easier on the corrective action plan, QC could develop series of reasons causing such a defect with possible solutions related to each reason.

CLASSIFICATION EXAMPLE AS PER Norms

Critical – AQL 0%

• Incorrect country of origin / Fiber composition
• Inconsistent labeling between UPC and outer box
• Needle / Pin in product
• Rough sharp edges metal / plastic trims and components
• Missing safety warning
• 6Missing sewn – in label
• Chemical odors

Major defects – AQL 1% - 2,5%

• Fabric flaws on presentation area and visible at arms levels
• Snags, pulls in fabric, embroidery, lace
• Shade variation
• Soiling, dirty marks
• Non-inclusion
• Needle damage marks
• Broken stitches
• Cracking stitches
• Buttons missing
• Unraveling buttonhole
• Fit measurement
• Differential between 2 sides
• Bar tack out of range
• Zip broken

Minor defects – AQL 4%

• Poor thread matching
• Poor thread join
• Thread not trimmed properly
• Missing trim
• Measurement outside tolerance
• Stepped seams / hems
• Tension on elastic
• Poorly Pressed
• 9Creased legs lining not even with front pleat/dart