Quality Manual

PRIME CAP (BD) LTD.
One Prime. Best Prime. Quality Prime.

HaziRafizUddin Tower, Unique Bus Stand, Ashulia, Dhaka-1349.
Quality Manual
With the increased demand of Bangladesh caps in the whole world market outside the country, number of
caps factories is growing rapidly but QA management system cannot be developed in the same speed due to
the lack of QA management system. It is the quality of our product and service along with the efficiency of
the work force, which is the foremost objective of Prime Cap (BD) Ltd's. aims to produce products and
service of the high standard, which meets all the specifications, including environmental concern and safety
Prime Cap (BD) Ltd's commitment to its valued customer always been:
 Maintaining the highest achievable quality possible.

 The most competitive pricing in the world market.
 Shortest lead-time with on time delivery.
 The best environment for ethical standard in accordance with world compliance standards.
OBJECTIVE
Objectives of these policies are:

 To understand customer's perspective of quality.
 To provide better quality of products and service.
 To provide good and safe working environment to the workers, which includes human
value, respect, justice, cleanliness, discipline and equality between workers and others.
 To implement quality control system with the aim to achieve zero defect level through
efficient management, research, development and continuous improvement.
COST AND QUALITY

QUALITY: Quality is defined as "Totality of characteristics of an entity (product, service etc.) That bears
on its ability to satisfy stated and implied needs."
QUALITY CONTROL: Is an effective system for interchanging the quality maintenance and quality
improvement efforts of various groups in an organization so as to enable production at the most economical
levels which allow full satisfaction for the consumers.
TOTAL QUALITY MANGEMENT (T.Q.M.): Is described as an all- inclusive fully integrated

productivity technique. It helps to create new markets, expand existing markets and recapture lost markets
by utilizing the optimum capability of man, machine, material, method and produces high and uniform
quality of products with reduced costs. Total quality control starts from market i.e. from purchasing material
and machine and ends in the market are selling the finished products in the market including after-sale
service. It includes market analysis, product development, production planning, statistical quality control,
preventive maintenance, wastage control, inventory control, cost reduction and after sales service et. The
ultimate goal of T.Q.M. is to increases the quality / cost ration and continuous improvement. It may be done
by increasing the quality with same cost, decreasing the cost with same quality and increasing quality and
decreasing coast at the same time.
HaziRafizUddin Tower, Unique Bus Stand, Ashulia, Dhaka.

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The above graph shown that there is an optimum quality of a product. Above this optimum, the increased the
cost, there will be no increase of quality. But below the optimum, lower the quality lesser the cost. The basic
quality problem is to set correct balance between the cost and quality is to find out a suitable quality / cost
ration for the product which will satisfy the consumer both for cost and quality.
MANAGEMETN RESPONSIBILITY
Section: 1
PURPOSE
The organization's quality policy is documented and communicated to each person in the organization. The
organizational structure, responsibilities and authorities have been described to ensure every key personnel
know his job and the same could be crosschecked by his higher management. To check the effectiveness of
the quality system, it has been suggested to conduct a meeting after every fortnight with the responsible
officers taking care of quality system in their assigned position.
SCOPE:
This section covers the organizational structure and responsibilities of all personnel who supervises, perform
and verify works at different stages for the improvement and maintenance of quality.
ORGANIZATIONAL STRUCTURE AND RESPONSIBILITIES
The following positions held within Prime Cap (BD) Ltd. plays a managerial role in the maintenance of
product quality and the quality control system through chain of command. Quality management system
illustrated in the flow diagram.
JOB DESCRIPTION OF RESPONSIBLES PERSONS FOR QUALITY IN PRIME CAP (BD) LTD.
1. MANAGING DIRECTOR: Will ensure the absolute adherence to the quality control system by
exercising his authority through his channel of command.
2. G.M.Q.A CENTRAL:
a) Preparing quality manuals for the group.
b) Taking approval from the MANAGING DIRECTOR for implementation of the system stated in the
manual.
c) Implementation of statistical quality control system in the factories here it is applicable.
d) Training of QC personals for continuous improvement to achieve zero defect level.
e) Training of QC personals on statistical quality control system and graphical method for achieving target
quality level desired by the buyer.
f) Collections of buyers quality guide lines from buyers website or manual and convey it to Manager QA
central, Manager QA factory and Monitoring for proper implementation to achieve buyers quality level.
g) Maintain liaison with buyers QA team for technical problems for which their help is needed.
h) Monitoring the job of Manager QA central, Manager QA factory to evaluate their performance and report
it to concern authority.
i) To help authority to recruit right person for right job of QA department.
j) To inform to concern directors and chairman of the group the overall quality position of the factories by
MIS.
k) Inform the concern director if any factory is unable to perform up to the desired level of quality by
corrective action request or verbally.
l) Study quality related books, journals, manuals and research for continuous improvement.

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3. MANAGER QA CENTRAL:
a) Collection of spec sheet, shade band card, trims card, fabric test report and approval sample from the
concern merchandiser and compare production sample with the Approval samples as well as technical sheet.
b) Not to allow any deviation from the approval sample if there is no written confirmation form the buyer.
c) Collection of fabric inspection report to judge whether fabric is acceptable for production on the ground
of shade, defect and other factors.
d) In line inspection to see whether the caps quality is as per buyer’s requirement or not. In case of any
deviation, take corrective and preventive action.
e) Briefly describe the buyer requirement and quality control procedure to Manager QA factory for proper
monitoring to produce caps as per requirement of buyer.
f) Report to Manager Quality, all his findings and inspection report for taking corrective actions and
monitoring.
g) Collecting of buyer's quality guideline documents, going through these and explain these to manager QA
factory, and monitoring the same for correct implementation.
h) Conduct pre-shipment inspection before buyer's inspection to be confirmed about the lots defect level,
whether it is as per buyers desired level or not. It not, sends the lot for recheck for correction (alter) and re-
inspect the same lot after correction.
i) Allotment of his QC team to all our mother and sub contract factories (if any). Monitoring the quality of
production in all our factories and subcontract factories as well.
4. MANAGER Q.A:
a) Over All Administration of factories QA dep't and monitoring the work of Sewing QC, Finishing QC,
Line QC, QI Cutting and all inspectors as well as evaluation of their performance.
b) Conduct training and make all his sub ordinates accountable to him for their performance to achieve the
target of quality level.
c) Reporting day-to-day quality status and trend to factory GM/PM.
d) Collection of approval sample, shade band card, trim card, spec sheet and go through these to compare
first of production with the approval sample before going for bulk production.
e) In case of any change in the style or design by the buyer he will communicate the floor people for the
confirmation of change.
f) Send samples of fabric, caps, and accessories to the concern merchandiser for lab test, if it is required.
g) Conduct day final inspection on the available quantity of ferments at the end of day in finishing as per
US-MIL-STD-105E. If the lost is not accepted, go for correction. Conduct pre shipment inspection after
completion of the lot and take necessary corrective measures before buyer's final inspection.
h) Details study of test cutting, sample, wash and non-wash and consult with Manager QA Central, GM/PM
of the factory if there is any discrepancy to find out appropriate solution.
i) Keep close co-ordination with Manager and GM QA, central for continuous improvement.
5. QC MIS & MONITORING: Controlled by GM)

a) Monitoring the job of MIS Asst. / Inspector, and monthly MIS report to GMQA.
b) Process capability study of every line by calculating C.V of lines defect percentage.
c) Study of Technical sheet and approved sample of buyer. Compare first of production sample with
approved sample, with respect of technical sheet approved trim card and shade.
d) Monitoring in-process 7 pcs inspection, counter check table inspection.
e) Checking of line wise Monthly operator's performance and Monthly table defect analysis.
f) Monthly defect analysis, C.V of defects line wise and factory wise
g) Moving average line and factory wise to observe the trend of defect.
h) Defect analysis after 100% process inspection in finishing.
i) Monitoring accessories, fabric and cutting inspection.

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6. SUPERVISOR QC:
a) Carry out instruction receives from manager QA factory.
b) Monitor the job of line QC's in process 7pcs inspection, table inspectors and maintain liaison with cutting
quality inspectors.
c) Go through buyer's approval sample, shade band card, trim card, spec sheet and supervise making caps as
per style and measurement.
d) Implementations of design change approved by buyer and instructed by Manager QA Factory.
e) Management, administration, training, motivation of his stuff for of continuous improvement.
f) Conduct daily inline inspection and fit audit and report to the manager QA.
7. TWO HOURS Q.I (FINISHING):

a) Two hours’ inspection, visual and fit audit on the basis of US-MIL-STD-105E on buyers desired AQL. If
lot is not passed, correction of defects Andre inspection on same method.
b) Monitor the job of all finishing inspectors and report to Manager QA Factory.
c) Keep close co-ordination with Sewing for rectifying defects in Finishing and make defect analysis in
Finishing to take corrective and preventive action in sewing.
d) Conduct training of all finishing QC Inspectors for continuous improvements.
8. Sr. QI. CUTTING:

a) He is responsible to Manager QA Factory.
b) Monitor accessories inspection, fabric inspection, and cutting inspection.
c) Submit all inspection report to Manager QA Factory.
d) Collection of trim card and shade band card from Manager QA to compare the lot during inspection.
e) Conduct cut panel inspection and accessories inspection as per sampling inspection plan.
f) Monitor spreading quality control and cutting quality control.
9. SR. QI. SEWING: Two/Three for each line (Depending on no. Of machines in line)
a) Carry out instructions of Manager QA Factory.
b) Conduct process capability study of the Line by calculating CV (Co-Efficient of variation) of hourly
defect percentage.
c) Monitor quality performance of operators for continuous improvement and incentives to operators for
their performance.
d) Supervise the cutting bundles numbering, size and serial for proper control in the sewing.
e) Review the production sample according to approval sample and shade.
f) Check machine cleanliness, needle condition and size, proper thread count and shade.
g) Conduct process inspection having idea from table inspection report and defect analysis, about the source
of high ranking of defects.
h) Observe the trend of defects from the moving average of defects in the table inspection and take special
care in those particular processes in the line.
10. ACCESSORIES INSPECTOR:
a) Sampling of accessories as per US-MIL-STD-105E Normal Inspection Level II AQL 2.5 or specified by
buyer.
b) Inspection of accessories as per approved trim card by the buyer.
c) Segregation of non-conforming accessories and keep it separately with nonconforming tags.
d) Preparing inspection report and submit it to Manager QA, factory.

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11. FABRIC QUALITY INSPECTOR:

a) Random selection of rolls as per US-MIL-STD-105E6D-1 05E to 10% of the lot.
b) Shade grouping of all rolls, compare shades with approved shade.
c) Side center side, side-to-side, end-to-end and running shade check of individual rolls.
d) Preparing shade grouping report and submit it to Manager QA.
e) Fabric inspection by 4-point system and making fabric inspection report.
f) Segregation of non-conforming rolls with red tag and keep ii) a safe place.
12. CUTTING QUALITY INSPECTOR:

a) Spreading checking on 10 points.
b) Block and bundle check.
c) Daily summary of cutting and spreading quality control report to manager A factory.
d) Affix allotted QA numbered arrow sticker to mark all defects where applicable.
13. TARLE QI, OUTPUT: Number two/three for each line (inside and outside) 100Inspection of outside
and inside of caps.
a) Segregation of non-conforming caps and returns to line QC for taking corrective and preventive action.
b) Re inspection of non-conforming caps after correction. b) Fill up the line wise hourly inspection format.
c) Affix allotted QA numbered arrow sticker to mark all defects where applicable.
14. FINISHING QI (individual process):

a) 100% inspection of individual process inside and outside.
b) Segregate non-conforming caps in separate box and hand over to Finishing QC for correction.
c) Re inspection of non-conforming caps after correction.
d) Affix allotted QA numbered arrow sticker or mark all defects where applicable.
15. FINISHING QI (Measurement)

a) Measurements of 100% caps on specified points shown by QA Manager.
b) Segregation of non-conforming goods and hand over to QC Finishing for necessary correction.
c) Re-measurement of non-conforming goods after correction.
d) Fill up the measurement report and submit it to QC Finishing.
6. FINISHING INSPECTOR (Final)

100% inspections of caps get up (Overall appearance)
a) Segregation of non-conforming goods to QC Finishing for correction.
b) Re- inspection of non-conforming goods after correction.
c) Fill up the hourly inspection report.
QUALITY SYSTEM
(Section 2)
PURPOSE
To document and maintain a quality system as a means to ensure that product of Prime Cap (BD) Ltd.
conforms to specified requirement.

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SCOPE
The quality system operated by Prime Cap (BD) Ltd. aims to ensure compliance to specified requirements
and is defined and driven by Quality Manual, departmental procedures and work instructions, those are
defined in this section.
UALITY SYSTEM PROCEDURES
The Quality procedure of each factory will be reviewed by the concerned persons of Management of that
factory. Describing the quality systems of all factories of Meridian Fashions Ltd, this manual includes a
brief description of the functions and mode of operation of the factories management personnel with respect
to quality.
QUALITY PLANNING
Documented quality planning is stated by this manual, accompanying procedure,

work instructions and quality, all of which comprise the Prime Cap (BD) Ltd. Quality System. Thus, quality
planning is, documented and implemented by all Executives and Managers playing a role in the maintenance
of product quality and the quality management system. To achieve the goal of zero defect level following
steps has been taken".
* For massive awareness building regular discussion and meeting are conducted with the concern people.
* Regular training session is being conducted on Statistical Quality Control System
* Introduce it as a tool to achieve the goal.
* Introduce incentives for inspectors and operators for the best performing line.
* Introduce operators' quality performance chart to find out source and type of defect for taking preventive
and corrective measures.
* Reorganize process / 7pcs inspectors job allocation, work procedure to make them more accountable for
effective control on process inspection with the help I operators quality performance chart.
* Weekly defect analysis of process inspection, table inspection and final inspection to find out the
irregularities of inspection if any and to take corrective measures.
Monthly defect analysis and moving average, line and factory wise, to monitor improvement and trend of
defect.
* For graphical representation of hourly defect percentage in control chart to set upper control limit at 1.0%,
central line is 0.65% and lower control limit at 0.0% to brine down defect level towards zero by continuous
improvement
Quality planning also includes the following:
* Assignment of responsibility for conducting checks.

* Stages at which checks are to be carried out.
* Methods to be followed in conducting the checks.
* Frequency of the checks.
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* Criteria for acceptance / rejections.

* Related documents to be checked.
* Documents to maintain as evidence of the checks.
* Corrective & preventive action to be taken subsequent to the check.
RECEVING INSPECTION
(Section 3)
PURPOSE:
To establish and maintain documented procedures for receiving inspection in order to verify that the
specified requirements for the product are met.
SCOPE
This section applies to the product being produced in the cap factories of Prime Cap (BD) Ltd.
RECEIVING INSPECTION
ACCESSORIES:
Before receiving accessories all necessary tests and inspection is conducted lot wise by the accessories
inspector of the factory under the guidance of QA Manager of Factory as per US-MIL-STD-105E at buyers
desired AQL. If result found acceptable, then the lot is accepted otherwise lot is rejected and kept in marked
area with a red tag for. the safety. So that non-conforming goods are not used in process. Accessories
inspection report is illustrated in Annexure: 3.01
FABRIC INSPECTION:
Fabric roll is selected on the basis of random sampling; acceptance or rejection criteria are decided at
prescribed label on 4-Point system. 10% of rolls -are inspected in this stage by Fabric Inspector. In case of
rejection of lot on 10% of rolls, rest of the rolls of the lot is inspected thoroughly. Reject rolls are kept
separately with red lags illustrated in Annexure: 3.04
Inspection records are kept in inspection format, illustrated in Annexure: 3.02
Summary of the fabric inspection is recorded in the summary sheet, for management information, illustrated
in Annexure: 3.03
Conforming goods are kept separately with Green Sticker and kept in stack named
READY FOR CUTTING, All rejected goods are treated as "NON CONFORMING GOODS" and
marked withered sticker, illustrated in Annexure: 3.04
Checking of s-lade and shade grouping is illustrated in Annexure 3.05
FABRIC INSPECTION PROCEDURE - 4 POINT SYSTEM
OBJECTIVE
The aim of fabric inspection is to check the quality, quantity and packing by visual, measurement a color
checks confirming with the specification and general appearance of the approval sample given by buyer.
INSPECTION PROCEDURE: -
• Receive approved color and quality swatches.
• Check lot size and label against the submitted packing list.
• Randomly draw 10% of the lot.
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• Delivery of less than 1000 yds. - 100% inspection

• Delivery of 1000 yds. to 10000 yds. to inspect at least * 1000 yds.
• Shipment of more than 10000 yds. inspects 10% of the lot.
PENALTY POINT EVALUATION:

Fabric to of graded will be examined from a distance of approximately three feet while runner-Up cover the
perch of a fabric inspection machine. The inspector will run the fabric at a speed compatible with his ability
to distinguish.
POINT CALCULATION
INDIVIDUAL ROLL:
Penalty points X 36X 100Total / yards Inspected X Width of cloth in inch
= Points per 100 Sq. Yard
AVERAGE POINTS PER SHIPMENT:

Total Points per 100 Sq. yds. of all rolls Inspected / Total number of rolls Inspected
= Average points per 100 Sq. yard
PENALTY POINTS IN FOUR POINT SYSTEM:

The position of the defect in the fabric in either length or width.
ROLLS SELECTION PROCEDURES:

• These rolls shall be selected for inspection on a totally random basis.
• The knit dyeing unit is required to present the inspector with a shipment packing list when eighty (80%)
percent of the rolls are packed from which the rolls to be inspected will be chosen.
• Once the inspector has selected the rolls for inspection, no adjustment may be made to the number of rolls
to be inspected or to the rolls selected for inspection.
• At no time during the inspection may any yardage be removed from any roll other than for recording and
measuring shade tolerances.
• All rolls inspected will be graded and assigned penalty points.
ACCEPTABLE PENALTY POINTS:

If no specifies standard provided for knit fabric, the average point value per shipment not exceeds 40 points
per 100 linear yards. Individual rolls exceeding 40 points shall be rejected.
DEFECTS CONDITIONS:
• No more than 4 points will be penalized within one yd.
• Severe defects are assigned max 4 points for each yd.
• Any hole and any running defect will be penalized 4 points
• Whole roll having running defect or continuous defects in more than 10 yds. will be considered reject.
SPLICE ALLOWANCE
• It will not be allowed more than one splice
No part of a spliced roll can be shorter than 40 yds. except specified by customer.
ROLL LENGTH
• Roll found to deviate more than 2% from the roll ticket yds. shall be rejected.
• The entire shipment shall be rejected if the total measured yds. in the sample Audit deviates 1% or more
from the ticket yds.
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HAND FEEL
The hand feel will be checked between roll with a reference sample. If there is a noticeable difference, the
roll will be classified as second quality.
SHADE HATCHING
Roll to roll with head to end, side to side, side center side will be checked during visual quality inspection
for preliminary. Final checking will be taken in the light box against gray scale rating. Under light source D-
65.
COLOR SHADING RATING
1) Side to Side 4-5 or 5 (Accepted)
2) Side center Side 4-5 or 5 (Accepted)
3) End to End 4-5 or 5 (Accepted)
4) Lot to Lot 4 or 4 - 5 or 5 (Accepted)
1) Against approval sample 4 or 4 - 5 or 5 (Accepted)
ACCEPTABLE POINT COUNTS LEVEL:

Various types of textiles are divided into the following five groups. Individual rolls exceeding the specified
point count level shall be graded as second quality. A shipment shall fail the inspection if the shipment
penalty count points exceed the specified point count level
REJECTION RATE:
If total rejected inspection yardage is over 10% of total inspected yardage, then overall result is concluded as
"Rejected"
RUNNING DEFECTS:
• Any defect found to repeat and / or run in a continuous manner will constitute a running defect. All
running defects must be assigned four points to every yard in the roil when the running defect occurs.
• Any roll having a running or repeating defect through more than three continuous yards shall be rejected
regardless of point occurs.
FULL WIDTH DEFECTS:

• No roll that contains more than four full width defects per one hundred linear yards shall be accepted as
first quality.
• Any roll found to contain defects, in any increment of one hundred yards, with an average of more than
one major defect per ten linear yards will be rejected.
• No roll shall be accepted that contains a major defect in the first or last three yards of the rolls. A major
defect is considered to be any three or four-point defect
• No roll shall be accepted as first quality that exhibits a noticeable of loose or tightness along either or both
selvedges or ripples, puckers, folds or creases in the body of the fabric that would prevent the fabric form
lying flat when being spread in a conventional manner.
FABRIC WIDTH:
• Fabric width will be checked a minimum of three times during the inspection of a roll, beginning, middle
and end. The roll width will be checked more often if the fabric is close to the specified minimum width of if
the fabric width is uneven.
• Rolls `paving a measurement of less than the specified width will not be accepted.
• For knit fabric, rolls having a measurement of 1 "wider than the specified diameter will not be accepted.
But for the stretched woven fabric, it can be accepted 2" wider than the specified purchased width.
• For knit fabric, rolls having a measurement of 2 "wider than the specified purchased width will be
accepted. But for the Lycra knitted fabric, it can be accepted3" wider than the specified width.

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PROCESS INSPECTION
(Section 4)
PURPOSE:
To establish and maintain documented procedures for process inspection in order to Verify that the specified
requirements for the product are met.
SCOPE:
This section applies to the product being produced in the factories of Prime Cap (BD) Ltd.
PROCESS INSPECTION
Process inspection is conducted on following sages.
• Spreading Inspection
• Cutting Inspection.
• Sewing Inspection.
• Table Inspection.
• Two hour Inspections
SPREADING INSPECTION
Following ten points must be taken care of by the cutting quality inspector at the time of spreading.
• Table marking
• Ends
• Leaning
• Tension
• Narrow goods
• Remnants
• Counts
• Poly height
• Marker Placing
• Fabric Flaws Inspector should check following at the time of fabric spreading illustrated in
(Annexure: 4.01).
CUTTING INSPECTION
Cutting inspection should be on the basis on random sampling on desired AQL. If the lot is passed on
sampling inspection then it is send for sewing operation, if not passed the whole lot is re-inspected and
rejected parts are replaced by good parts. In cutting inspection there are two types of check.
BLOCK CHECK & BUNDLE CHECK.

Following points are inspected in block check such as Size, Parts, Pattern check, Miss cut, Ragged cutting,
Notches, Matching plies. Following points are checked in the bundle check such as Size, Parts, Total
quantity, Inspect quality, Defect quality. Cutting check is illustrated in (Annexure: 4.02). However it is
recommended to check 100% cutting parts under the light box table.
SEWING INSPECTION:
a) The SR. Line QI should audit completed finished bundles.
b) He must select 7 pcs at random from the bundle.
c) If the inspector finds defective unit, he will take following steps on operator’s duality Performance Chart
(Annexure: 4.03)
i) He will mark red in the room against date of inspection with defect code and frequency as a symbol for
warning and recheck. He will hand over remaining units of the bundle to supervisor for check and taking
corrective action.

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ii) He will inspect next three bundles as follow up audit of the same operator and mark yellow in three
rooms if no defective units are found in next three bundles.
iii) He will mark green in the room against date if no defective unit is found in the bundle.
d) The inspector will make operators monthly analysis to compare it with tables monthly defect analysis to
find out whether there is any lacking in the sewing inspection procedure. Illustrated in the (Annexure: 4.04)
e) QC Supervisor Sewing will monitor 7 pcs inspection, whether it is being done properly or not.
TABLE INSPECTION
Table inspection is conducted by two/three /four inspectors (depends on hourly output) to inspect inside and
outside of the caps. They will record hourly inspected caps, defect found, defect percentage; also calculate
average defect percentage, quality index of the day and CV of defects. This will help to represent the defects
graphically with the help of MIS Inspector and is illustrated in (Annexure: 4.05). Monthly table defect
analysis report illustrated in (Annexure 4.06) is prepared and to compare it with operator’s monthly defect
analysis.
TWO HOURLY INSPECTIONS:

i) It is the responsibility of finishing unit TWO HOUR QI.
ii) It is conducted every after two hours.
iii) Both visual and fit audit is conducted on available caps received. pp two hours on US-MIL-STD-105E at
desired AQL illustrated in Acceptance Sampling chapter.
iv) If lot is acceptable than passed for poly packing.
v) If not return back for correction,
vi) After correction it is re inspected in the same way

FINAL INSPECTION
(Section 5)
PURPOSE:
To establish and maintain documented procedures for final inspection in order to verify that the specified
requirements for the product are met.
SCOPE:
This section applies to the product being produced in the Prime Cap (BD) Ltd. Factory facilities.
ACTIVITIES:
Final inspection is the inspection which is conducted before shipment or buyer’s inspection. It is conducted
in two stages.
i) Day Final.
ii) Lot Final.
DAY FINAL:
Day final inspection is the responsibility of factory QA Manager. He conducts this inspection daily on
available caps which has passed by TWO HOURLY inspection and is conducted on the basis of US-MIL-
STD-105E on desired AQL Illustrated in Acceptance Sampling chapter. If it is passed, caps are ready for
Central QC Inspection or Buyers 0 C inspection.

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LOT FINAL:
Lot final is conducted by Central QA Manager when the lot is passed by Factory QA Manager before
shipment or in case any buyer gives the authority to the factory to conduct final inspection before shipment.
It is also conducted when buyer’s inspection is conducted before shipment. It is conducted as per US-MIL-
STD-105E on desired AQL. If lot is passes, they are ready for shipment and placed before buyer's
representative for final inspection before the shipment. Day final and lot final inspection procedures are
illustrated in Caps Inspection Procedure Chapter,
CAPS INSPECTION PROCEDURE

STEP-I
Inspector should collect the following before going for the inspection.
a. Approved sample from the proper authority
b. First of production (FOP) caps sample as per size and color from the concern person or authority.
c. Approved color swatches, shade band card, trim card from the concern person or authority.
d. Caps and Fabrics test report from the factory or agent.
STEP-II
a. Inspector should take the following items with him.
• Inspection report form
• Spec sheet.
• Calibrated flexible fiber measurement tape.
STEP-III
a. Collect packing list from the factory and check carton against the packing list.
b. Compare FOP sample with the approval sample and find out if there is any deviation.
c. Check the shipping mark with the work sheet.
d. Select the carton for inspection by square root of the total carton and select carton number with the help of
random number table illustrated in Sampling Technique chapter.
e. Put signature on both the side of carton opening.
f. Bring the carton in the inspection room which should be sufficiently lighted, tidy and clean.
d. Unseal the carton and check assortment, poly packing, hang tag, labels, color tone etc.
e. Select the caps for fit audit size and color wise with respect to prescribed. AQL of fit audit as per US-
MIL-STD-105E illustrated in Acceptance Sample chapter.
f. Conduct fit audit and identify total major and minor defects.
g. The major defects will be called if it Exceeds tolerance and touch another size in case of measurement.
k. The minor defect will be called if it Exceeds tolerance but does not touch another size in case of minor
defects measurement.
I. Major and audit criteria for Visual below.
m. If Have Been illustrated the major and minor points Total Points Exceeds prescribes as per AQL, lot will
be rejected audit.
n. Select caps fit for sample size for workmanship with the help of US-MIL-STD105E, illustrated in
Acceptance Sampling chapter.
i) Inspect pcs caps by pcs.
ii) Put arrow sticker on the defect position.
iii) Classify as major and minor defects and the overall points score accordingly.
iv) If, each major and minor = 10 = 0.5 Exceed the prescribed points as per Desired AQL reject the lot.
v) Complete data sheet of Both visual and fit, take from the factory representative signature on the sheet.
vi) Replace defective caps in the cardboard by some good-caps.
vii) Collect reference for defective caps These hand over to the Person concern for corrective and preventive
action.
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PRIME CAP (BD) LTD.
Different type of fabric defects for WOVEN, KNIT and Dyeing or as are explained FINISHING Annexure:
5.00
FECT LIST OF CLASSIFICATION (MAJOR)

FABRIC DEFECTS:
1. Holes (yarns cut), broken ends, continuous missing yarn.
2. Soil, oil spot, visible contrast at arm’s length / A-zone, adversely affecting appearance.
3. Miss weaves, miss picks (woven).
4. Slubs (Linen & Silk not included) When Viewed distinguishable earnest at length A-zone.
5. Color bleeding (A-zone) Color combination not as specified.
6. Misprint, dye knit spot.
7. Bow in '/ to 1/2inch. (A-zone).
8. Coating defect less than% inch. round (All zones).
9. Shaded parts (mismatched conspicuous).
10. Hand feel different from swatch.
11. Permanent approved fabric crease mark. Streaks.
COMPONENTS AND TRIMS:

BUTTONS & BUTTON HOLES
1. Buttons sewing thread color not as specified.
2. Missing button or button hole.
3. Broken, damaged, defective or inverted buttons.
4. Buttons do not conform to specification.
5. Britton insecurely sewn.
6. Improper button or button hole.
INTERFACING / LINING / PADS

1. Fusible interfacing must be compatible to cap without bubble or pucker.
1. in A lined cap, the liner must not extend below the hem of shell.
2. Interlining apparent from outside of caps.
3.Missing one or Both pads.
ZIPPERS
1. Insecure bottom or top stops.
2. Incorrect colored tape (shade) of zipper.
3. Faulty slider on zipper.
4. Any missing or damaged teeth.
5. Does not function without special effort.
6. Zipper size and length cap Should Be Appropriate to end use or as specified not more than + 1/2inch.
From spec. Any cut in from the zipper tape. Tape stitched tight or too loose RESULTING in excessive bulge
on tape or placket when closed.
9. Any malfunction.
10. Missing top or bottom stopper.
11.Wavy zippers.
HOOK AND YES

1. Omitted or sewn in wrong places.

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2. When Hook and misaligned eyes fastened Causing bulge or twist at the point of closure.
3. All metal parts (snap, hook and eyes, rivets etc.) must be rust proof, dry cleanable.
4. Improper washable and type.
5. Defective,
BELT AND BELT LOOPS

1. Belt Loop not fully secure.
2. Incorrect number of belt loops on caps as specified.
3. Missing belt loop.
POCKET AND FLAP

1. Missing located tack bar or miss.
2. Wrong placement,
3. Insecure opening.
4. Pocket zippers and no stress points' as specified / bar tacked.
NECK LABEL/CARE LABEL

1. Incorrect fiber content, country of origin, RN number etc.
2. Maintenance instructions do not meet all federal requirements.
3. Not caught or not completely sewn securely.
4. Missing/incorrect / illegible.
5. Incorrectly attached
COMPRESSION ATTACHMENT OF HARDWARE

1. Clasp/snap, rivet Which is defective, damaged or incorrectly Placed attached.
2. Eyelet missing or misplaced.
3. Velcro closure not placement Within 50% of the total area mates.
4. Draw cord not free to move as designed.
5. Length of drawstring not as specified,
6.Ends of drawstrings not secured (missing stopper).
EMBROIDERY (ZONE - A) APPEARANCE

1. Use of unauthorized embroidery,
2. Embroidery thread color, not as specified.
3. Pattern / placement not as specified.
4. Insecure sewing beading.
1. Conspicuous incomplete embroidery.
5. Incomplete logo.
2. Dirty or unlearned embroidery.
3. Untrimmed, hanging thread.
PRINTING DEFECTS:
1. Wrong color, missing color.
2. Miss registered obvious from 6 inch.
STITCHING
1. SPI in excess of more than 3 or less than 2 than the specified.
2. Ends of stitching (back tacked AT LEAST '/. Inch / 2 or 3 stitches).
3. Open seams more than 1/ 4 inch. On outside or '/ 2 inch on inside.
4. Any raw edges on more than Y4 inch stitch outside.
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5. Run off (conspicuous)

6. Needle holes.
7. Seams closure uneven, off more than 1/8 inch.
8. Seam twisted, puckered or pleated (conspicuous).
9. Poor mending or repairing (conspicuous).
10. Gathered/bunched stitching.
11. Skipped stitch (401), one skipped stitch in a row permitted; not more than 2 occurrences per seam (lock
stitch - 301).
12. Button hole (skipped stitch, cut Securely not caught in fabric, stitch incomplete, uncut not aligned)
Securely.
13. Button not sewn, stitched not cross tacks specified.
14. Bar When not specified as length, placement, width, stitch count or completely missing.
15. Blind stitch (103.503) excessive pick-through 3/32 inch or more, or tight voltage causing distortion
puckering.
16. Beaded or stitching (loose top of bobbin thread)
17. Button or button hole not aligned, Causing noticeable bulge.
18. Conspicuous noticeable variation in length of necklace points.
19. Conspicuous high / low pockets (A-Zone).
20. F -ant uneven legs off more than 1/4 inch on any fabric.
21. Part ^, F cap caught in any unrelated or stitching operation (unauthorized stitches) and stitching.
22. Seams and stitching not as specified type.
23. Tight/Loose stress.
24. Top stitching not uniform Greater Than -3/4 inch hole Affecting appearance.
25. Permanent needle hole (needle cut, burrs).
26. Seam allowance (All zones) - join seam <1/2 inch. / Double needle setting <inch. Zipper setting <1/4
inch.
FINISHING AND PACKAGING

1. Not pressed / folded / hang / assorted specified.
2. Over as pressing or under pressing / pressing defects Including poor-shine, color change, or any other
conspicuous scorching "Hard" pressing defect.
1. Labs, tickets, tags, logo, hanger clip size missing / incorrect, illegible or not specified.
2. Item When not dry packed.
1. Adhesive labels or adhesive residue visible from 3 inch. (?2 inch in any view).
2. Searn should be pressed open.
3. Burn or scorch mark.
4. Shine marks on the surface of the cap.
5. Sweaters pressed out of size.
PACKAGING
1. Merchandise folded or incorrectly packed, resulting in poor appearance.
2. SKU information on box not the same as item in the box.
3. Incorrect item in poly bag, box dimension.
4. Size sticker, price tags, hanger, box labeling UPC code etc. Placed incorrectly, not as specified.
5. Printed missing or incorrect or missing information.
6. Poor or improper selling.
7. Not packed assorted or as specified.
8. Wrong marking cardboard (shipping mark).
BUCKLES AND SUSPENSION LOOP

1. Broken, rough or sharp edges.
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2. Or omitted coating thickness or coating / plating less than specified.

3. Wrong Color or metal type.
4. Wrong size or type.
1. Oxidized or corroded.
2. Misplaced,
3. Not attached as specified.
DEFECT CLASSIFICATION LIST (MINOR)

FABRIC:
1. Broken yarn (one yarn) - zone B/C.
2. Mispick (low contrast) - zone C.
3. Barre (low contrast) - zone B.
4. Needle hole (Which holes do not run/enlarge).
5. Caps not within specified shade range or shade band.
6. Printing defects:
i) Incomplete coverage of color.
ii) Design and pattern direction not as specified.
7. Mismatched stripe / plaid:
i) On side seam or seat seam When Requested in construction specification over Y4 inch.
ii) 1i) On placket or pant fly – Over 1/16 inch.
iii) On center front panels or placket -over 1/8 inch.
iv) On pocket or flaps – Over 1/8 inch.
v) Skewed, bowed or biased fabric, solid or stripe over '/ 2 inch. side to side.
vi) Shaded parts / thread / or visible components.
COMPONENTS AND TRIM:
1. Any component not of specified color, dimension, or appearance,
2. Hardware misaligned trim.
3. Incorrect position of snaps in excess of 1/8 inch's-, and the specified.
3. Untied cord.
3. Velcro, placement (closure) not Within 75% of the total area mates.
INTERLINING AND PADS:

1. Type of interlining or pad not as specified.
2. Misplaced or fused interlining pad location. 0
3. Insecurely attached pad.
LABEL.
1. Label must be Positioned at specified location + Y4 inch and fully visible.
2. Crooked label.
THREADS:
1. Outside, Uncut thread over '/ 4 inch.
2. Inside Uncut thread over 1/2 inch seen hanging below a cuff or hem or visible as Presented.
STITCHING:
1. Topstitching - Single or double needle not overlapped, stitch on stitch at start and finish.
2. Poorly objectionably mended (C-zone).
1. Gathering or bunched stitching (B & C zone). 1 / 13,

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2. Sewn in pleat over Y4inch. (C zone).
CONSTRUCTION:
(FRONT, BACK AND ASSEMBLY DEFECTS)
1. Knitted only - Insecure shoulder tape.
2. Fronts are uneven at the bottom in excess of 1/4 inch.
3. Uncle- facing shows on the top side of the cap.
4. Component to component or joining seams (rib sleeve cuff seam to seam, crotch to seat, waistband seam
to side and underarm seams) -seam - alignment worse than% Inch.
5. Darts uneven in length in excess of% inch.
6. Darts poorly shaped with large bubbles at the end.
7. Darts Not Properly located.
8. Waistband irregular or not uniform in width in excess of 1/4 inch.
9. Right versus left side seam/in seam difference not exceeds 1/4 -1/2 inch.
10. Neck rib and short rib sleeve cuff rib- width variance Greater than +3/, s inch.
11. Long sleeve cuff rib, bottom rib and rib turtleneck - Greater Than variation width + X inch.
12. Fly that gaps or does not lay flat, exposed zipper tape when fly is closed.
SLEEVE AND ARMHOLE DEFECTS

1. Sleeve stay stitch head showing on outside.
2. Underarm seam not aligned with side seam in excess of X inch.
3. Cuffs uneven in size and shape.
4. Cuff facing to sleeve seam misaligned in excess of Y4 inch.
5. Sleeve to side seam misaligned in excess of Y4 inch.
6. Right versus left sleeve lengths difference over 1/2 inch.
COLLAR / NECKLACE SETTING, AND LAPEL CUFF DEFECTS

1. Excessive fullness, puckers or twisting of top collar.
2. Collar points distinctively ill-shaped or not uniform.
CONSTRUCTION
1. Corded, piped trim or other insert conspicuously uneven, lose or tight.
2. Under necklace showing outside of top necklace, topstitch seams not balanced top to bottom (rolled).
3. When noticeably necklace off center attached to cap.
4. Center back seam not covered by neck collar.
5. Cuff facing uneven, twisted or poorly sewn.
POCKET DEFECTS
1. Raw edge of pocket not square.
2. Corresponding pockets uneven or misaligned horizontally in excess of 1/4 inch.
3. Flap and pocket pattern mismatched.
4. Weight and color of materials not pocketing according to specification.
5. Dog ears at pocket corners, more than '/8 inch. above top of pocket.
6. Non-uniform shaped pockets or biased more than 1/4 inch, side to side or top to bottom, noticeable at
arm’s length.
7. Pocket bigger than flap width in excess of 1/8 inch
BELT LOOP DEFECTS

1. Belt crazy incorrectly Placed in excess of '14 inch.
1. C- Color shade of loop as not specified.
1. Thread Color matching must be crooked unless otherwise specified.
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PRIME CAP (BD) LTD.
1.Conspicuously belt loop.

2. Width of belt loop more than% inch. too wide too narrow.
HEM DEFECTS
1. Excessively puckered or twisted hem.
2. Open hem Greater Than 1/4 sleeve inch.
3. Hem uneven, twisted or poorly sewn.
4. High/lpN bottom hem Greater than Y4 inch difference. side to side, or back to Front.
5. Lining less than 1/2 inch. below top edge of the shell hem turn back.
BUTTON/BUTTON HOLE DEFECTS

1. Improper button hole size.
2. Ragged edges Caused by dull knife cut if Causing fabric pulls.
3. Thread shade That does not match specified color.
4. Incompatible density of stitching in relation to the fabric.
FINISHING
1. Draw cord length as not specified.
2. Odours - Offensive odor (Chemical odor).
3. Improper Sealing.
SAMPLING TECHNIQUE
The purpose of sampling is to draw correct about the population from finding the ‘sample, now if the
sampling is not proper, may we be misguided for taking action on the basis of wrong-sampling. Again
checker cannot check all the items produced in a factory in the whole day, it will cause more man power,
more cost, more time and more work. If proper, sampling technique is used to draw sample, it will not only
reduce These factors, will Also reduce the monotonousness of the inspector. One of the Most Important
Thing of sampling technique is the business of the inspector. Inspector Cannot Take sample as per His wish,
I must follow the probability table and random number each item to be drawn is equal. There are various
types of sampling of Which, sample random sampling, stratified random sampling, systematic sampling is
Commonly used.
SIMPLE RANDOM SAMPLING: - Is a method of selection n units out of N, such that every Cn one of
the samples you have an equal chance of Being chosen. It is the simplest type of probability sampling and is
the basis of most of it the other sampling methods. In practice a single random sample is drawn unit by unit.
I've units of the population are numbered I to NA series of random numbers Between I and N are drawn
with the help of random number table or computer Which produces Such table.
USE A RANDOM NUMBER TO SELECT A SAMPLE: - The RAND Corporation of Ushas a random
number table published in 1955 in the name "A million random digits with100000 regular Deviates" To
select a sample with This table, let us Consider we have 750 items numbered from 1 to 750 on each item and
we want to draw a sample of size 5. For These purpose we need to select three digits’ number 001 to
750.First it is Necessary to determine the starting point of the table. The random Number table contains 50
rows and 50 columns of digits. We are starting from 8 th row 39th Column from there the first number is 471,
098, 443, 3351 015 We arrange them in order in 015, 098, 335, 443, 471. Again we want to select seize 10
sample from a population of 500, for this We Have to select three-digit number i.e. from 001 to 500. Let us
start from row 30, column 11 arid Then our first number will be 732 but it is not in our serial so we will not
exclude it, by going down we will Have 752, 640, we will also exclude these. Next 268, 454, 013, 201, 017,
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PRIME CAP (BD) LTD.
194, 361, 452, 419, 312 excluding all the serial numbers which are out of. Arranging the numbers in order
013, 017, 194, 201, 268, 312.361, 419, 452, 454 These Are the sample numbers Which We want to select
randomly.
PRE-SHIPMENT SURVEY BY ACCEPTANCE SAMPLING
ACCEPTANCE SAMPLING: - Is the art or science That Deals with Procedures in which decision to
accept or reject lots or process are based on- the examination of samples. Generally, 100 percent inspection
is not justified Because of time and cost as well as for the shortage of trained manpower. Good sampling
inspection, where the items are inspected Carefully Examined May even provide. Better product quality
assurance -of than 100 percent inspection with carelessness. The purpose of acceptance sampling is to
specify course of action not to check lot quality. Acceptance Accepts Merely sampling plan C.
rejects lots. Generally, we like to ensure that lots of manufactured goods do not Contain an excessively large
portion of defective items. This is mainly Achieved Through the technique of sampling inspection.
Acceptance sampling have indirect effect on improvement of quality through ITS encouragement by high
rate of acceptance of good quality and bad quality of through discouragement by high rate of rejection. Also,
it you reduce the risk of rejection of good lots and accepting of bad lots on the basis of sample.
TERMINOLOGY ACCEPTANCE OF SAMPLING:
LOTS SIZE: - Is the number of units in the lot and is denoted by "N"
SAMPLE SIZE: - The number of units in the sample and is denoted by "N"
LOT INSPECTION: - A specific quantity of similar material, or a collection of like units, Offered for
inspection and acceptance at one time.
SAMPLING INSPECTION PLAN: - A specific plan Which states (a) the sample size (b) The criteria for
accepting, rejecting, or taking another sample, to be used inspecting a lot.
ACCEPTANCE NUMBER: - The large number of defectives (or defects) in the samples under
consideration sample or That will permit the acceptance of the inspection acceptance lot is called number,
and is denoted by "Ac".
REJECTION NUMBER: - The smallest number of defectives (or defects) in the samples under
consideration sample or That will require the rejection of inspection is called rejection lot number, and is
denoted by "Re".
PRODUCER'S RISK: - The probability of rejecting a lot under the sampling inspection plan When the
fraction defective in the lot is actually with limit is specified in called producer’s risk and is denoted by
"Pp".
CONSUMER'S RISK: - The probability of accepting a lot with higher fraction defective than the limit
specified under the sampling inspection plan is called consumer's risk. And is denoted by "Pc".
SINGLE SAMAPLING INSPECTION PLAN: - Is the sampling inspection plan in which a decision to
accept or to reject a lot is Reached after the inspection of a single sample.
PROCESS AVERAGE QUALITY: - Expected quality of products form GIVEN process, from first
sample Usually Estimated results of past inspection lots.
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ACCEPTABLE QUALITY LEVEL: - The maximum percent defective That, for purpose of sampling
inspection, can be Considered satisfactory as a process average is called anti acceptable quality level is
denoted by AQL.
PROBABILITY OF ACCEPTANCE: - Probability That a lot is or will be accepted called probability of
acceptance and is denoted by "Pa".
OPERATING CHARECTERSTIC CURVE OR O.C CURVE: - A Curve showing the relation between
the probability of acceptance, either lot or quality. process quality, whichever is applicable is called OC
CURVE. The stealer the OC CURVE, the Greater is the protector to the consumer Against accepting a bad
lot.
AVERAGE SAMPLE NUMBER: - The expected value of the sample size required for Coming to a
decision, i.e, for acceptance or rejection of a lot, under the plan is called sampling inspection average sample
number and is denoted by ASN. The ASN curve obtained by plotting against "P" is called ASN curve.
Lower the ASN curve is better the sampling inspection plan.
MAJOR DEFEC: - A major defect is a defect That is likely to result in failure, or materially to reduce the
Liability of the unit of product for ITS Intended purpose.
MINOR DEFECT: - A minor defect is a defect That is not likely to reduce materially the usability of the
unit of product for Purpose Intended STI, or from established standards a departure Having little bearing on
the effective use or operation of the unit. Minor defects May be classified into two categories, more
important minor defects Minor May be designated as "A" and less Important ones, Minor "B"
CRITERIA FOR SHIFTING TO TIGHTENED INSPECTICN: - When normal inspection is on effect,
tightened inspection to be instituted when 2 out of 5 consecutive lots or batches have been rejected on
original inspection.
CRITERIA SHIFTING TO NORMAL FOR INSPECTION FROM TIGHTENEDINSPECTICN: -

When tightened inspection is in effect, regular inspection Shall be instituted When five consecutive lots or
batches Have Been Considered acceptable on original inspection, criteria for reduced shifter to inspection: -
Normal When inspection is on effect, reduced inspection institute maybe when,
(a) The PRECEDING 10 lots or batches Have Been on regular inspection and has been accepted on the
original inspection.
b) The overall number of defects in the samples from the are equal preceding 10 lots or batches to or less
than the Desired level.
(c) Production is at a steady rate.
d) Reduced inspection is Considered desirable by the responsible authority.
CRITERIA FOR INSPECTION FROM SHIFTING TO NORMAL REDUCEDINSPECTION: -
When inspection is reduced effect on normal inspection must be reinstated Whenever a lot or batch is
rejected or production Becomes in e-regulate. or delayed or other conditions warrant regular inspection That
Shall Be Instituted.
AQL SYSTEM FOR ACCEPTANCE SAMPLING (US MIL-STD-105E)

The AQL (Acceptable Quality Level) concept was first devised in Connection with the development of
statistical acceptance sampling for the Ordinance Department of the US Army in 1942, as modified MIL-
STD-105A in 1950, MIL-STD-105B in 1958, MILSTD- 105C in1961, MIL-STD-105D in 1963. American,
British, Canadian military agencies have accepted it as common standard of acceptance sampling, that is
why it is Also called ABC, standard. This standard has later on accepted by most of it American and
European Organizations. Latest development of These series is MIL-STD-105E in 10 May 1989.

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PRIME CAP (BD) LTD.
HOW TO USE (US-MIL-STD-105E)
For the use of 'US-MIL-STD-105E We Have to choose level of AQL first, next step is to find out sample
size code letter ACCORDING TO lot size from the sample size code letter table, then: with "the help of
sample size code letter and AQL level, to find out acceptance number and rejection number form or tighten
the standard, single or double sampling table of US-MIL-STD-105E.
CONTROL OF NON CONFORMING PRODUCTS
(Section 6)
9.1 PURPOSE:
To Prevent the dispatch of nonconforming products to the customer.
9.2 SCOPE:
This section Applies to the products conform the Which do not require quality.
9.3 ACTIVITIES:
9.3.1 Non-conforming goods are Identified During the checking of receiving section. Process inspection end
or inspection.
• When a major North conformance is discovered i.e. (One That requires a managerial "{executive decision
regarding its disposition it is so Identified and segregated, "subject to the Appropriate management decision,
the defective goods are reworked, on concession accepted, rejected or re-graded.
• Appropriate where, the customer is Consulted Concerning any concession.
CONCLUTION
Quality has Always Been a primary requirement and Consider to be the life of a cap. There is no denying the
fact That Prime Cap (BD) Ltd. Had been following Quality Control System in the production process since
birth but there it might have Been Differences in Those applications in his factory. This quality manual is
Compiling a humble effort to put almost all Necessary details of Quality Control System to Ensure our
factory that all Have a written Manual / Guideline in black and white to follow. In the beginning, we will not
concentrate on the statistical Quality Control System. We will Follow this after a while when We Have
enough manpower and required to exercise that. Any positive inclusion in this manual Which will help the
factory in Improving quality is always welcome; but you have to donate with prior approval from the
Managing Director, Prime Cap (BD) Ltd. We all need to educate and train our workforce in line with This
Quality Manual and try to streamline our quality system. And sincere Our united effort can only help to
improve increase in the area of quality.

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PRIME CAP (BD) LTD.

One Prime. Best Prime. Quality Prime.

 Maintaining the highest achievable quality possible.

Objectives of these policies are:

COST AND QUALITY

TOTAL QUALITY MANGEMENT (T.Q.M.): Is described as an all- inclusive fully integrated

HaziRafizUddin Tower, Unique Bus Stand, Ashulia, Dhaka.

ORGANIZATIONAL STRUCTURE AND RESPONSIBILITIES

HaziRafizUddin Tower, Unique Bus Stand, Ashulia, Dhaka.

5. QC MIS & MONITORING: Controlled by GM)

HaziRafizUddin Tower, Unique Bus Stand, Ashulia, Dhaka.

7. TWO HOURS Q.I (FINISHING):

8. Sr. QI. CUTTING:

HaziRafizUddin Tower, Unique Bus Stand, Ashulia, Dhaka.

11. FABRIC QUALITY INSPECTOR:

12. CUTTING QUALITY INSPECTOR:

14. FINISHING QI (individual process):

15. FINISHING QI (Measurement)

6. FINISHING INSPECTOR (Final)

HaziRafizUddin Tower, Unique Bus Stand, Ashulia, Dhaka.

Documented quality planning is stated by this manual, accompanying procedure,

* Regular training session is being conducted on Statistical Quality Control System

* Introduce it as a tool to achieve the goal.

* Assignment of responsibility for conducting checks.

* Criteria for acceptance / rejections.

FABRIC INSPECTION PROCEDURE - 4 POINT SYSTEM

• Delivery of less than 1000 yds. - 100% inspection

PENALTY POINT EVALUATION:

AVERAGE POINTS PER SHIPMENT:

PENALTY POINTS IN FOUR POINT SYSTEM:

ROLLS SELECTION PROCEDURES:

ACCEPTABLE PENALTY POINTS:

ACCEPTABLE POINT COUNTS LEVEL:

FULL WIDTH DEFECTS:

HaziRafizUddin Tower, Unique Bus Stand, Ashulia, Dhaka.

BLOCK CHECK & BUNDLE CHECK.

HaziRafizUddin Tower, Unique Bus Stand, Ashulia, Dhaka.

TWO HOURLY INSPECTIONS:

HaziRafizUddin Tower, Unique Bus Stand, Ashulia, Dhaka.

CAPS INSPECTION PROCEDURE

FECT LIST OF CLASSIFICATION (MAJOR)

COMPONENTS AND TRIMS:

INTERFACING / LINING / PADS

HOOK AND YES

HaziRafizUddin Tower, Unique Bus Stand, Ashulia, Dhaka.

BELT AND BELT LOOPS

POCKET AND FLAP

NECK LABEL/CARE LABEL

COMPRESSION ATTACHMENT OF HARDWARE

EMBROIDERY (ZONE - A) APPEARANCE

5. Run off (conspicuous)

FINISHING AND PACKAGING

BUCKLES AND SUSPENSION LOOP

2. Or omitted coating thickness or coating / plating less than specified.

DEFECT CLASSIFICATION LIST (MINOR)

INTERLINING AND PADS:

HaziRafizUddin Tower, Unique Bus Stand, Ashulia, Dhaka.

2. Sewn in pleat over Y4inch. (C zone).

SLEEVE AND ARMHOLE DEFECTS