Amber Denim Quality Assurance:

Quality assurance refers to the engineering activities implemented in a quality system so that
requirements for Denim fabrics will be fulfilled. It is the systematic measurement, comparison with
a standard, monitoring of processes and an associated feedback loop that confers error prevention.
This can be contrasted with quality control, which is focused on process outputs.

Quality assurance system can be divided into following steps:

1. On line Quality assurance system and

2. off line Quality assurance system.

Again on line Quality assurance system can be divided into the following steps:

(a) Raw material control.

(b) Process control.

On Line Quality Control System:

This type of quality control is carried out without stopping the production process. During the
running of production process a set up is automatically performs and detects the fault and also takes
corrective action. Quality control comprises with the raw material quality control and the process
control.

Preparatory Department:

1. Production Planning: Before planning preparatory person collect approved sample from
sample or R&D department and maintain same total Ends , yarn lot, ratio
2.

Yarn (Raw Material) Control:

Amber Denim Ltd. always very concern about the quality of the product. As the quality of denim
fabrics depends on the yarn quality so we must be provided with the best quality yarn with an
economical consideration. The yarn must be proper elongation % ( 6 to 7%), CSP, Twist, whiteness
as per requirement, of the subsequent process.

So, they grey fabric from the best quality yarn & utilizes technical evaluation in every stage of the
production, as we know the quality product depends on the raw material quality.
Sizing Process Control:

Tests are done at those stages here-

-Size test.

Pick- up %

Machine speed

Squeegee pressure

Temperature

The method chosen for the process must be provided with the necessary accurate parameters. Here
the specific gravity, water level, residual hydrogen per oxide etc. at each stage is checked.

Laboratory :
Lab is the head of the textile industries. Higher precision lab can aid easily to achieve the goal of
the organization. Before bulk production a sample for the approval from industry is sent to the
buyer. As per the requirement of the buyer the shade is prepared in a lab considering the economical
aspects.

Dyeing lab:
3. Standard sample: The buyer to the industry gives the standard sample. The sample is
measured by the CCM to get the recipe.

4. Lab trial: Checked the recipe the lab officer machine will be ready same as and match
with standard according to buyer requirement

Tests are done at those stages here-

 -PH test

Shade %

-.

Pick- up %

-Shade checking.

Off Line Quality Control System:

Performed in the laboratory and other production area by stopping the production process consisting
of fabric inspection and laboratory and other test. Correction steps are taken according to the test
result.

Off-Line Tests: All the Off-Line tests for finished fabrics can be grouped as follows:

A. Physical tests
B. Chemical tests

A. Physical Tests:
1. GSM test
2. Shrinkage test
3. Spirality test
4. Tensile strength
5. Abrasion resistance
6. Pilling resistance
7. Button Strength Testing
8. Crease resistance
9. Dimentional stability
10. Brusting strength test

B. Chemical Tests:
1. Color Fastness to washing.
2. Color Fastness to lighting.
3. Color Fastness to heat.
4. Color Fastness to Chlorinated water.
5. Color Fastness to water spotting.
6. Color Fastness to perspiration.
7. Color Fastness to Seawater.
8. Fibre analysis.
9. PH test.
 10. Repellency.

Quality Parameters of Woven Fabrics:

There are some quality parameters of denim fabric.....................

1. Dimensional characteristics:
Length
Width
Thickness.

2. Weight of fabric:
Weight per unit area.
Weight per unit length.

3. Fabric strength and extensibility:

Tensile strength.
Tearing strength.

4. Threads per inch of fabric:

Ends per inch.
Picks per inch.

5. Yarn count:
Warp count
Weft count.

6. Crimp:
Warp crimp
Weft crimp.

7. Handle:.
Stiffness
Drape.

8. Crease resistance and crease recovery.

9. Air permeability.
10. Abrasion resistance.
11. Water resistance.
12. Shrinkages.
13.Different fastness properties:
Fastness to light.
Fastness to wash.
Fastness to perspiration.
Fastness to Rubbing.

Online Quality control:

Raw material control:

Process control:

The method chosen for process must be provided with the necessary accurate parameters. In the
every stage pH should be maintained sincerely.

Lab:

Lab is the heart of a dyeing industry. An efficient lab can increase the efficiency of dyeing. So lab
in-charge is sometimes called Pilot. Before bulk production a sample for approval from buyer is
sent to buyer. Lab supplies the recipes to the floor.

Purpose of Lab:

1. Get color approval from buyer.

2. Recipe supply to the floor.
3. Shade correction.
4. Minimize the deviation between bulk & lab.

Machineries in Lab:

1.Dryer m/c:

Brand Name: Whirpool

Capacity: 6kg

Origin: USA
2.Washing m/c:

Brand Name: Wascator

Company Name: ATLAS

Origin: USA

3.Color fastness to wash:

Brand Name: ATLAS

Model no: M-228

Origin: USA

4. D-65 For Illumination:

Off line quality control:

After dyeing the material is received by the finishing section. Before receiving the following
things are checked:

1. Shade condition.
2. Wash fastness.
3. Condition of softening.
4. Condition of enzyme wash.

Before delivery the finished fabric to the customer it should be pass against the requirements.

The following tests are done-

GSM check.

Shrinkage test.

Shade check.

Rubbing test.

Wash fastness test.

1. GSM check

The procedure for fabric weight test of finished fabric:

M/C used: G.S.M. cutter.

Frequency: Every order.

Procedure: 3 sample pieces are cut with G.S.M. cutter. Find their average wt.

Gram per square meter (GSM)= Average wt*100

Ounce per square meter (oz/yd2)=G.S.M.*0.0296

Performance std: According to buyers given std.

In case of non-conformity:

To increase G.S.M.: Reduce width mechanically.

To decrease G.S.M.: Increase width mechanically

2. Shrinkage test:

Testing time: After dryer or before compacting.

Equipment used: Shrinkage board, shrinkage scale, measurement tape, scissor, washing machine,
detergent.

Lengthwise shrinkage = (-ve) %.

Lengthwise extension = (+ve) %.

Test method: ISO 6330:2000.

Shrinkage tolerance: 5%.

The fabric is cut according to the shrinkage board. Then the fabric is washed by washing m/c with
PCLF for 60 min. at 40. Then the shrinkage% is determined by the shrinkage scale.

3. Shade check :

Testing time: During in the process & after finishing.

Equipment used: Verivide light box.

Country of origin: U.K.

Light sources: D-65,TL-83,TL-84,F,UV.

4. Rubbing fastness test:

Fastness to rubbing is the resistance of dyed fabric to color loss by friction or rubbing.

Crocking cloth: This is a white unbleached, undyed cotton fabric. For wet rub, crocking cloth will
be wetted with water and squeeze to 100% take up.

Procedure :

1. Cut the sample as long as that can cover the metallic mounting plate

2. Two specimens are required for dry rub and two for wet rub testing.

3. For both dry and wet test one specimen will be placed to warp direction and other weft direction.

4. Place the sample with tape under the metallic mountain plate

5. Then 10 x 10s (to and fro 1 rub/sec) rub is done by turning the handle.

6. Remove the crocking cloth form peg. In wet rub the crocking cloth is dried at room temperature.

Assessment:

Compare the contrast between the treated and untreated white crocking cloth with the staining grey
scale and color changing with changing grey scale in a color matching cabinet.

5. Wash Fastness test:

Fastness to wash is the resistance of dyed fabric to bleed under the action of washing chemicals.

For this test the following reagents are used-

1. ECE reference detergent

2. Sodium Carbonate
3. Distilled water

Testing Procedure:

1. The specimen measuring 10 cm x 4 cm of material is cut out.

2. Avoid specimen within 5 cm of the selvedge.

3. Cut a piece of multi-fibre 4 cm wide

4. The multi-fibre has selvedge of 10 cm long.

5. Align test specimens and multi-fibre and sew together to form a composite specimen.
There are 5 ISO standard washing fastness tests-

Test Temp (0C) Time (min) Steel balls Reagents

ISO 105 CO1 40 30 0 Soap (5 g/l)
ISO 2 50 30 0 Soap (5 g/l)
ISO 3 60 30 0 Soap (5 g/l)+ Soda (2 g/l)
ISO 4 95 30 10 Soap (5 g/l)+ Soda (2 g/l)
ISO 5 95 240 10 Soap (5 g/l)+ Soda (2 g/l)

Assessments :

Compare the contrast between the treated and untreated sample with the changing grey scale and
staining of multi-fibre fabric with the staining grey scale in color matching cabinet.

6. Color Fastness to Perspiration:

Equipment used: Rota-Wash.

Test Method: ISO 105E04.

The below Quality Parameters must be checked before

delivery:

1. Customer name
2. Sample #
3. Order quantity
4. GSM for every roll
 5. Shrinkage for every roll
6. Width for every roll
7. Shade grade
8. Matched with buyer approved
9. Over all test report
10. Delivery destination
11. S.S.V & S.C.V checked
12.Print fabric base color, tone, print color, size,
distance, repeat, etc.
13.

1.PI And booking issuing by one person

2. Delivery schedule would be as per raw materials availability, production capacity, OCs, BCI, CIMA ,etc.

4. yarn, dyes and auxiliaries chemicals to be procured minimum 15 before of production

5. 4. bulk confirmation need minimum 10 days before of production.
6. to improve the productivity and quality, at first priority dyeing, secondly weaving, then others.
7.