Quality Inspector in knitwear garments stitching flow and 5S

 Duties and Responsibilities of a inline Quality Inspector and 5S.

For what 5S stand for in knitwear garments stitching flow?.

Elaborate the tools and techniques of 5S for maximising the quality standards in knitwear garments industry.

How much important the quality skill as base on 5S in a knitwear garments industry for a inline quality inspector?.

In knitwear garments stitching and sewing industry a inline quality inspector not sit idol but wonder here and there on every one stitching and sewing machine to monitor, inspect and control the all measures of quality in a knitwear garments producing flow. During stitching and sewing process the " improved red tag sample is accept as a reference of/for standards of sewing and stitching, for styling, for attaching accessories, for screen printing and for Englishmen", yes that preimproved sample describes and denotes accessories attaching placement and displacement. A inline quality inspector not entirely relay on only preimproved sample but for further guidelines, for further satisfaction and for further improvements thoroughly study the tech pak of the relevant exporting job order for gaining more information, more knowledge and more sewing skill for improving the quality conditions of the knitwear garments as those input is running in sewing and stitching machines flow for output. Yes still the quality improvement methodology is not completely full swung, for much further improvement,a inline quality inspector study the preproduction meeting guidelines and discuss different sewing and stitching terminologies with seniors members of quality in house team. Here after reading above mention abilities and competencies of a inline quality inspector who is discharging his or her duties and responsibilities in a knitwear garments sewing and stitching industry, if someone think, it is complete list of a quality inspector, yes truly someone is completely wrong because below lines will describe the abilities and competencies of a inline quality inspector as a new comber or already working in a " knitwear garments sewing and stitching industry".

"Knowledge and skill of 5S is must for a inline quality inspector because without practical work with tools and techniques, no inline quality inspector can best understand the sewing and stitching terminologies in a knitwear garments producing machines flow. These 5S are key for unlocking the all hidden doors of improving quality skill during producing knitwear garments on stitching and sewing machines. Yes,these 5S stands for " Shade,shape,stitch per inch,specs,stitch behavior and sometimes these 5S denotes seam length, seam width, Seam integrity, seam allowances, seam strength, seam shape and seam durability. Yes without practical working skill, without practical knowledge, without proper understanding of the sewing and stitching tools and techniques, no inline quality inspector is a skillful. Yes if someone inline quality inspector or quality stitching supervisor is doing job  on suchbjob position then those are unlocking the quality locks without proper Keyes,and it is universal truth " no lock can be open without exact key" ,yes if there are no key in the hands of a inline quality inspector or quality supervisor the the lock of quality remains in close conditions and in dark state. So learning skill and regular learning practical work on 5S can better improve methodology of sewing and stitching of knitt fabric garments as producing for exporting purpose. Yes rudimentary skill of 5S provide bael for guarrenty for holding of job position and open the door of success for future the opportunities of searching job somewhere in such kind of industry but only if conditions meet with relevant situations. As for a quality inline inspector 5S understanding is must,yes same is true with quality supervisor and stitching master because without implementation of 5S in inline stitching flow no production will accept somewhere because all those knit fabric garments products produce without basic and fundamental stitching strategy may have many different kinds of defects and faults and faulty knitwear products no body want to purchase from market,but if all those knit fabric garments products that's are launch in market or produce for export purpose and manufacture with the implementation of 5S complete understanding,there are better chances for the acceptance of all those products because durability, consistency and reliability are awake in those products with the help of 5S implementing 5S strategy. Remember where as with the technical point of " risk analysis and risk evaluation" explanation can entirely explore the furthermore improvements as 5S rudimentary skill explain in details" where " Some types of defects and faults can damage the quality standards, quality levels and quality appearances",such kinds of cautions sign for improving quality conditions at the needle point or at sewing and stitching machines plate form where 5S completely holding the already active position. Yes all those knitwear garments products and all those minds set that's all involve in producing under the umbrella of 5 S implementing strategy are successful in the field of knit fabric sewing and stitching industry both at home expersing level and for exporting to others countries of the worldwide.

Again for revising purpose we return backward and deeply explore the foundation for learning, spreading, understanding, implementing, improving and developing the methodologies of 5S in a sewing and stitching knitwear garments inline production flow where need base stitching and sewing machines are arrange in a straight line and here main objective is to feed accordance with the requirements of new sample model and output must fully cover with the implementations of 5S such as shape of all parts of garment are same for all cut parts,there should be consistency and integrity in shape look. Out of shape knitwear garments parts should segregate and return to cutting department for further improving the shapes of all return garments parts. Yes out of shape knitwear garments parts are sleeves curve shape without needed shape or as mismatch with the improved red tag sample. Neck shape is very critical because even minor fault or defect in the shape of garment neck is measure as critical defect. Yes critical defect in knit fabric sew and stitch garments are not acceptable anywhere. So be conscious about the shape of neck as whether someone is manufacturing T-shirts or low standards quality or producing highest cost.highest prices polo shirts in inline stitching flow. Please no compromise with wrong, dirty,misshape and out of shape garments parts otherwise be ready to compromise on quality structure and construction ways of sewing " as results appear wrong production, wrong guidelines and as rejection ratios increase till climax point, yes humiliation everywhere. Only correct, justify and shape accordance with preimproved sample allow to travel from one stitching machine to next stitching machine. But here now a new quarry arise " how inline quality inspector will watch,observe, rectify and measure the feeding and inducting material from cutting department is free from shape out parts,all parts have integral shapes and all parts and trims shape completely match with improved red tag sample", although this question is no so difficult but with practice and with to the point brainstorming, inline quality inspector can understand the "right and wrong shape,out of measure shape and out of curve shape" differences. More so senior quality staff can provide instructions, guidelines and improvements for the inspections cut parts shape such as armhole shape,neckshape,shoulder shape,border and hem shapes and cuff shapes,if these cut parts shape is accordance with nesting shape then these knit fabric parts all to transfer in flow on stitching and sewing machines as input. A well cut shape of garment part further improve the look of garments when ready for parking. But if shape of knit fabric garment parts are not well cut and not well shaped accordance with improved sample the customer can/will raise quarries " why not these according with our demands, why not completely match with sent sample for improvel, why not exporter focus attention on our quality products demands?".

Quality inspector and stitching quality supervisor must check the shape of cut parts of inducting input in many ways when cutting materials bags arrive on induction table or reach at feeding table. The quality inspector reachc at once on cutting feeding parts table and first and foremost check the " cutting shape of the cutting cake", here word cutting cake can arise problems and some difficulties for understanding but for easiest way of information " a city cake is a many different layers of knit fabric on cutting tables for the purpose of cutting different parts of garments with  special type of hand hold cutter on with the help of LASER cutter. So a cake is a piles of different layers of knit fabric of solid colour or of many different types of shade varient. Here during spreading of different layers of knit fabric on cutting tables if some one latest " hard and harsh way" pull with more strength will appear as out of shape in cake conditions, so there are automatic spreading machinery is available in market that automatically spread knit fabric layers on cutting tables. But during cutting process only little neglegency can bring out of shape garments parts that can entirely damage the production process/quality process till to zero stage quality. Yes we are talking about the " knit fabric cut parts shapes" although this little blog post can't measure the entire circle of "shape monitoring, checking and inspecting criteria" because every part of knit fabric cut parts shapes encircl very wide range of excellent understanding, interpersonal skill, experiences of some time periods and on time well instructions set by senior quality authorities but only here highlights of rudimentary knowledge and understanding basics composites of such wast field. Further understanding and learning skill about knit fabric cut parts shapes  a special posts will deliver here on this web page. With tools and techniques of quality measures someone can best familiarise with such type of technical knowledge and contemporary skill. Furthermore learning quest can best arise with learning curve skill on the spot of job position as environment indicates to the point arrow with proper understanding of best,well suit and ugly shapes of knit fabric cut parts shapes of new models. So shapes of knit fabric cut parts indicates the maps of further all ways where right brisk pave for future building of entire quality system. For further improvement in your quality learning skill regular practice is must because without regular practice someone can't experience with first hand skill. More so conceptual skill is first stair in the learning of quality skill especially about the " shapes of knit fabric cut parts " and duties and responsibilities of a inline quality inspector in stitching and sewing industry. Yes it is impossible to learn "quality skill" without conceptual skill of quality so concepts concern stimulation for further and future practice as a support for learning possibilities. As we are dealing here with shapes of knit fabric cut parts, it will be our misunderstanding if we not thoroughly differentiate the duties and responsibilities of cutting department of any knitwear garments producing firm because all knit fabric cut parts shapes are done by cutting department experts and specialists,where garment technologists are present there in the cutting department when shaper do the duty of shape cutting with hand cutter or with automatic knives. But when such cutting material in stitching and sewing department, here it is the responsibility of a inline stitching quality supervisor and inline quality inspector to carefully watch and observe the shapes of all cut parts accordance with nesting shapes. If shapes of a knit fabric is well cut with suitable tools then ready made knit fabric garments look attractiveness increase till every buyer wish to wear it. It all depend on the enternal capastencies and abilities of inline quality control inspector " how much excellent the shapes of knit fabric cut parts during feeding in stitching flow where all cut parts joint by stitching machines operator to produce a ready made knit fabric garments.

Let's see the next and second S in the set of "5S"and try to explore the dignity of second S with a complete study of "Shade such as shade variation, minor shade variation and major shade variation, critical shade variation observation in the of bulk production, mix shade variation, thread shade variation, cuts parts shade variation due to mixing of different lots of knit fabric lots,weakness in dying process and shade variation.

Why shade variation faults or defects are critical to quality of " knitwear garments?". 

What mean the term " critical to quality?", elaborate this term with many examples.

Controlling the shade variation in  a line flow of stitching machines is the responsibility of only inline quality control inspector and inline quality control stitching supervisor or others authorities of dying department and cutting department involve in such type of neglegency.

Remember second S in the row of "5S" stand for " Shade" and it is the first and foremost duty and responsibility of a inline quality control inspector to observe carefully the shade of different cut pars as soon as those bundles arrive on feeding tables. Yes with best kind of inline quality measuring tools such special color light spreading tube lights,highest entensity bulbs and shade variation cutting edge lenses. Yes with the help of high precision quality controlling tools " the shade variation can be control on stitching floor.

Please pasue here with me for a while and think about the " shady parts of a knitwear ready made garment" I will not purchase that garment because ugly shady parts look very bad", " will you like to purchase that garment thats parts are of different colours and different shade, may you will not want to buy that knit fabric upper wear or lower wear,the cause is only one the 'shade variation' in different attach and stitch parts", yes same is true for all,yes this is true to you,true for me and true for everyone else. Why not a inline quality inspector focus attention on shady parts of knit fabric upper wear or lower wear when put induction on feeding tables where two or there feeders are already present there with duties and responsibilities of monitoring, checking and inspecting "5S" at beginning point of feeding and those feeders thoroughly perform well but as rich mean of technical skill  of " shade differentiation" feeder only check shade accordance with own prospects but inline quality inspector focus full point of attention on "cut parts shade variation" as there must not attach a shady part with garment body", yes there should be"shady trims attachment with entire output",so performing accordance with standards situations, a inline quality inspector gain support of " additional tools and techniques of quality parameters", such as " shade continuity",and " knit fabric approved shade cards"as these are " matching elements" for feeding to first stitching machine.

Cut parts shade continuity+improved knit fabric approved shade cards are attach with supply chain material one by one lot indicating and  measuring "the shade continuity" is completely prepared from layer to layer of knit fabric during spreading on cutting tables and exactly match the shade with improved customers shade will. And shade card is a witness card that denoting" this shade card is improved by merchandiser, improved by cutting manager, improved by dying department head,improved by quality manager and improved by garment technologist. This card travel from section to section till reach in the hands of  inline quality inspector for monitoring, checking and inspecting the "shade variations in different parts of already cut materials" so inline quality inspector match the shade of cut parts+shade continuity+ shade card and if under special light intensity there a little or minor shade difference among those checking layesof patches then inline quality inspector will not allow the feeding to stitching and sewing machines. But if there is shade variation in cut parts as exactly match with continuity and shade card then feeding continue to stitching machines.

It is the further duty and responsibility of inline quality inspector during sewing and stitching process the cut parts containing baskets or bundles travel from one stitching machine to next so during transference no cut parts mix with others baskets or bundles otherwise there are chances increase to attach shady parts with garment. Yes these chances increase due to the neglegency of snitching machine operators so monitor the shade mixing variations time to time and control all process with the help of " root cause analysis tools and techniques" as this analysis describes about " where,why some thing went on wrong way during process". Although a inline quality inspector is a  planner the certify different kind of strategies during inspecting shade variations in garments cut parts and these strategies include best awareness with " shade variation segregation tools and techniques", uses of different kinds of apparatus for monitoring and distinguishing shade variations among varient cut parts of a knit fabric garment.

So if there are no shady parts attach with sewing and stitching garments the quality parameters and quality standards are assume as exactly match with required quality standards, so inspection methodology and procedure provide urgent control for shade variation. Yes these criterias on the apart side with quality checking, quality standards setting and providing a long run path of success of knit fabric garment shade control policy. Here again a new question arise in front us " what is shade variation control policy in knitwear garments exporting firms?".

Yes all knit fabric sewing and stitch garments exporting firms develop " shade variation policy"that describes the shade variation acceptance/rejection, yes such as minor shade variations, major shade variation and critical shade variations. Then these guidelines, instructions set and complete technical package is handover to quality department personal. For example there are special instructions set " How to collect shade band of whshed program of some job orders?". And gathering/searching and collecting different minor shade garments pieces from mix variation after wash procedure and process.let's deeply explore these treated garments pieces because there many different types of washing programs such as silicon wash garments, enzyme wash garments, acid wash garments treatment, detergent wash garments pieces, "prepared for dying",or "PFD" program of job orders and simple hot water wash program. Although there are many process and procedures for washing the knitwear garments pieces bit all these are treated with varieties of chemicals and these chemicals can effect the original colour and shade of knit fabric garment pieces. So it is natural way ,the original colour disappear of all those washed garments pieces thats are produce with/from different lots of knit fabric. Yes that is why?,shade band is require to improve different shade garments pieces from senior authorities of quality and production department, especially from merchandising department head and job order related merchandiser because merchandising department related personal directly deal with customers and buyers and know batter way than others " what are real requirements about shad  varient acceptences of customers and buyers?" So final and last stamp by merchandiser can passe the shade band of produced knit fabric garments pieces.

Due to highest scope and standard as need a quality inspector while performing in knitwear garments producing industry only relevant skill of "5S" so above paragraphs are enough and now we leave to third S from the couples of "5S".

Yes third S stand for " stitch per inch" in simple words it mean " how many stitches require in only one inch of fabric during sewing on stitching machine", commonly such type of requirements are different on different sewing operations, for instances there need twelve spi ( spi stand for stitch per inch) on every nakedand barely stitches seams but cover seams require less than twelve spi because out seam look can cover with an other upper stitches lines such as when arm hole of a hood shirt is first attach on over lock machine then  there ten or less spi are enough because on upper sides there are twu needle or three threads chain stitch on all over the armhole so over lock stitches seams can be cover with flat lock machine stitches and spi density loose it importance. Please pause here with me for a while and brainstorm about the two centimeters width of bottom hem on chain stitch,three threads flat lock machine yes ,because out look and shape of bottom hem look very ugly if there are short spi or less spi less than twelve spi.

Stitches per inch mean  " how many stitches include in only one inch lengthy sewi seam" think about the importance of spi during stitching and sewing operations of a knitwear garments on different sewing and stitching machines in line production.

It is the first and foremost duty and responsibility of inline quality inspector to monitor, check and verify the counting of spi after every one hours and if there short spi on different sewing and stitching machines operations then at once try to recover the short spi sew operations as are already stitch by machine operator. Yes note that stitching machine number and machine operator code,then write all discrepancies about short spi and inform to quality stitching supervisor, quality assistant manager and stitching master and ask then to sign on short spi report. Yes in every round collect short spi count,write on inline quality report for future record and further document for further actions and reactions of quality and production top level authorities.

Some dishonest stitching machine operators always try to ignore the set of sewing and stitching quality instructions as are order and increasing production quantity try to sacrifice the quality of sewing and stitching, especially "running the short spi"but it is the duty and responsibility of inline quality inspector to control the requirements of spi on every on stitching machine.

Furthermore quality contents of output as produce knitwear garments pieces decrease to acceptences level, offline quality inspectors return those garments pieces for removing the short spi defects and faults, and for recovering those garments pieces faults and defects, in this way much over time will consumes, yes it will greatest loss for the firm that is producing the garments productions.

Sometimes some dishonest stitching machine operators increase or decrease sewing machine tension during stitching and sewing machine operations this bad habit and bad behavior can cause short spi during stitching different sewing and stitching machine operations. So an active inline quality inspector can check, monitor and inspect "sewing and stitching machines adjustment time to time" for controlling the neglegencies of spi count. If spi count is not match with twelve spi standard then CTQs increase at first instance then rejection ratios increase too at, at a level where quality automatically drop to zero point. Yes this will greatest loss for exporting firm.

So a inline quality inspector must measure spi of all operations as are those under the control of a inline quality inspector because in one operational stitching machines flow three or four inline quality inspector are nominate for monitoring, inspecting, checking and controlling the quality of stitching and sewing operations such as if there are forty five stitching machines are operating for producing the output of three thousands ready made knitwear garments pieces then these forty five stitching machines operations equally divide on three inline quality inspector. Yes after dividing stitching machines operations in three inline quality inspector then every inline quality inspector will held responsible for only fifteen stitching machines operations such at the start of stitching machines operations flow basic and fundamental operations are complete such as in T-shirt sewing operations start from attaching shoulder on over lock machine, where inline quality inspector will check the shape of shoulder, seam stitch length,shade variations both in  sewing thread and shade difference in back and front. If inline quality inspector found nothing in first operation set then " shoulder attach" piece transfer to next machine where again inline quality inspector make sure" there complete twelve spi on that sewing and stitching machine. Remember there must beno compromise of the quality and quantity of spi during sewing and stitching knit fabric garment operations.

Although there some variable that brings changes in spi during sewing and stitching machines operations such as"stitching machine adjustment, quality of threads,internal abilities of stitching machine operator, stitching machine tension and speed of machine, yes speed of machine is also known as rmp or round per minute. Stitching machine needle aging and time period is a fundamental risk sign for occurring discrepencies  in sewing and stitching machines operations. But there be should not a littl compromise on the quality and quantity of the spi on every stitching machine operations.

For counting the spi on every machine operation, basic tool for measuring spi is inches tap. Yes a one inch taproole consist of five feets,150 centimeters and millimeters scale. Inch tape is a tools and techniques for measuring is fundamental unit conversions and these skill,knowledge and information are Keyes for counting and measuring different POMs of knit fabric garment on different sewing operations and stitching machines operations.

Forth S from the family of "5S",stand for word " specs", although this word 'specs' further shortended for "specifications" yes specifications itself are broad way of descriptions that denotes " callouts" and sketches that completely describes" from where to measure different point of measurements of sewing garments operations on stitching machines. May be some exact and to the point example famalarize you more about specs or specification.If someone want to measure the shoulder length, it may be only one single shoulder length or across shoulders length, so a inline quality inspector will completely study the tech pak for further guidelines. Oral and verbal instructions by seniors quality authorities for improving stitching and sewing quality especially "stitch per inch" on every sewing operation is a key for quality of production successful program particulerly " more than twelve spi on every sewing operation".

Form the family of "5S" fifth S stand for the word of "stitch behavior", then what about the " stitch behavior", of a stitch seams?.

Although the term " stitch behavior" denotes clutchers of/sums of very widely used common and particular factors such as,

If some one try to run trial with some pulling force/strength with elasticity as from two ends and stitch and sew with thread the" sew and stitch seam threads can't broke then " stitch behavior is satisfactory and (may be) accordance with given standards.

If shape of stitch seam is entirely match with improved red tag sample and stitching and sewing machines adjestment is accordance with require standards, if stitching and sewing machines adjestment is matching as the demands of buyers and customers.

If seam stitches are accordance with washing standards such as " PFD" ( prepare for dye) stitches  are some  lossy behavior, why?, because during washing process of already produced knit fabric garments stitches can't broke in washing machines as higher resolution revolve in washing solutions and these washing liquids may be compose with different solvent, solute and solution. Such as some washing process start with silicon washing materials, some knitwear ready made garments are Wash with enzyme and some wash with others many different kinds of detergents and with chemicals. So during sewing and stitching knit fabric garments care are taken by quality supervisor and inline quality inspector to observe, watch, measure and regulate stitch behavior of all production, of all operations and  all seams,there is no bubbling,there is no needle cut or needle hole,there are no oil stains, there are no fabric faults and every measure is according to improved sample, yes then achievements of quality standards are satifectory and there are no chances of increasing rejection ratios,yes then stitch seam behavior is as,as match with preimproved red tag sample.

If there are no faults or defects on stitch seam such as, there is no skips,there is no shady threads,there is no seam slips,there is no open seam, there are no gathering, there are no stitching machine pressure foot marks,there is no chew stitch or uneven stitch,if there are no loose stitches, there no twists or ropping, there are no hicking ,puckering and no gathering, yes seam is without pleats and wavy turns with twist.

Yes if seam point of measurement are are accordance with  " POM sheet".

Yes seam stitch behavior is OK all around if stitches seam look and naked morphology is attractive, funny and lovely.

Yes seam stitch behavior is OK if  someone stretch with some force and seam stitch can't break with some extent of lengthy run such as if length of stitch seam is  twelve inches and someone stretch this till fourteen inches and there are no brokage of needles stitches then stitch seam behavior is well satisfactory and quality standards achieve and gains are hundred percent OK.

"Seam integrity" very wide subject for learning the quality skill of knitwear garments,for improving quality of bulk production and entirely controlling the quality of all out put from stitching machines in a stitching machines flow. But " what about the seam integrity in  stitching with quality during production process?". How inline quality inspector monitor, inspect and varify seam integrity during production process?". What kind of badly effects seems if seam integrity not follow during knitwear garments production process in inline flow during production of knitwear garments pieces on sewing and stitching machines?". What about the looks and morphology of  a seam integrity if these all deleted matters not monitor, inspect and control properly?". Always remember "Root cause analysis" completely determine the reallity of  " why 5S stand all alone behind the superiority of producing products of knitwear garments with highest quality standards?".

So next post will completely describe you much about 5S and about the " Root Cause Analysis" of 5S. Please study next future post and after reading next post write your comments details freely.

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