How defects and faults damage the internal and external appearance, shapte and look of a knitwear garments especially during sewing and stitching in flow?.
How someone can control these defects and faults during sewing and stitching process of knitwear garments inline flow with the help of Root Cause Analysis?.
What about Root Cause Analysis?, how quality of knitwear garments can improve with the help of this analysis?, and there are " how many different stages for analysing the cause of faults and defects during the production of knitwear garments in sewing and stitching flow?".
"Nothing need to monitoring, inspecting and checking every operation of knitwear garments for improving quality standards on every sewing and stitching machine" other than learning of tools,techniques and Implementations of", " Root Cause Analysis".
What about the tools and techniques of "Root Cause Analysis"and how can a inline quality inspector can implement these tools and techniques during inspection of quality on every sewing and stitching machine of every operation of knitwear garments during production in inline flow?.
How can a new learner of inline quality standards of knitwear garments can make best practical practice of self development with the help of this famous analysis" Root Cause Analysis"?.
Some about " Quality procedures",and buyers behavior for buying knitwear garments from producers and manufacturers of such kinds of all products. Some buyers publish " Quality manual Guidelines" and that quality manual hand over to knitwear garments producers to make ready made knitwear garments accordance with the written instructions such as "how to measure the different points of measurement", from " where to measures those points of measurements" and all others instructions set as demanded by sub customers and buyers. Yes these " quality manuals" provide all kinds of instructions about sewing and stitching of knitwear garments. Because every knitwear garments importer want to buy quality products for consumers and gain satisfaction for future retention of consumers. All quality control related personals must aware of with the tools and techniques of root cause analysis because without such type and best kind of analyzing quality inspection procedure and development of quality controlling procedural methodologies are impossible withe out acceptation and implementation of this world wide famous analysis. In knitwear garments manufacturing especially when different sewing and stitching processes are in progress and procedural quality inspection, monitoring of every stitch standard and evolution of benchmarking of quality progress this analysis provide all key for unlocking the closed locks of hidden and unknown issues, problems and low performance of quality levels standards.
In very large at industrial scale production process especially in the industry where knit fabric garments are produced for exporting purpose, all these export nature industries developed indoor methodologies for improving quality measurement techniques where root cause analysis tools and techniques are first and foremost run in trial for reaching the exact point of problems solving activity.
But what about inline of flow where knit fabric garments are under process and every one sewing operation is under consideration,where quality team members are checking, inspecting ,monitoring and controlling all quality related activities such as measurement points of knit fabric garments, controlling different kinds of faults and struggling hard to run smooth the flow of garment especially determining all aspects accordance with gold seal sample standards or matching with red tag preimproved sample.
Root cause analysis is a technical way " how to improve quality of knitwear garments operations at spot on needle point from where defects and faults root causes are developing", and this methodology provide technical assumption " how to remove permonantly the causes of faults and defects occurring regularly?". So knowledge, skill and analysing techniques must learn and try to understand if you are discharging your duties and responsibilities in knitwear garments producing industry. Although these graphical representations are very easy to understand and then act upon them but for new learner and unskilled or new enter quality controlling field feel troubles at first stage but with regular practice when someone become familiar with these tools and technique's them implementations of this methodology become much easier.
Quality controlling, quality monitoring and quality inspecting procedures are varies frm one firm to an other firm but quality demands and quality are same for everyone so be careful about quality policy and job orders strategies because during process of knit fabric garments operations sewing and stitching stage many different kinds of stitching and sewing faults or defects arise and for controlling those irregularities inline quality controlling inspector and inline quality controlling supervisor trial run on different procedures, methodologies,tools and techniques for improving the quality of every one operations on stitching and sewing machines in line flow.
While monitoring and inspecting quality controlling processing inline sewing machines flow there are many weak point of hard and difficult stitching operations where chances rise to appearances of stitching faults. Here for lowering the quantity of these regular occurring faults and defects inline quality supervisor and inline quality controlling inspector monitor the "defective operation point" and at once try to note the cause of faults accordance with the assumption " where, why,how,what and situations of others related fectors such as handling problems of a stitching machine operator, sewing thread quality, stitching machine adjestment accordance with knit fabric grammage meter square, aging of needle, sewing machine operator skill level,cleanliness of stitching machine moving parts, stitching machine electronic panals performance, level of lubricent and information about reparing of stitching machines,yes all these above mention cause the fundamental irregularities while performing the relevant stitching machine operations. Another reason as arise from monitoring the defects of faults conditions are environmental factors and these factors must understand controllable situations bearing in mind " quality control performance free from defects" and there are minimum chances remain hidden and dark side for the occurances in near future time. Yes all these reasons sumsup to implement all techniques of "root cause analysis" and these techniques completely provides guidelines for securing the quality monitoring procedure, quality controlling methodology and inspections techniques.
Inline quality supervisor and inline quality inspector because of directly involve with all quality relate matters so root cause analysis directly measure and point out the real cause of arising faults at needle point. Some fundamental type of assumption such as why ships appear of flat lock operation during stitching of top of arm hole of a sweat shirt. Here real cause of occurances of faults are search with root cause analysis by line quality supervisor and inline quality inspector by rectifying and analysing techniques of root cause analysis in sch a way,as under,
- What about the nature ,look and appearance of the fault?.
- Determining the real cause of fault occourincing.
- Informing senior quality personals about the faults position on arm hole.
- Filling the already provided form for regulating the quality and maintaining quality procedure up-to-date status.
- If during inspection inline quality inspector come across with a fault or faults the " relevant quality controlling procedure" provide guidelines about root cause analysis implications such as how to implementation of tools and techniques of determining real cause of faults occurencing of irregularities again and again on stitching machine.
- Environmental awareness and at once observation of the defective parts and direct study of the relevant variable such as the " quality of the sewing thread"," age of the sewing needle", " machine stitching operator technical skill level"," handling problems and handling issues of the stitching machine operator","quality and basics properties of knit fabric", "the shape of cutting parts of stitching knitwear garments parts", and machine overhauling time period duration. Again here inline quality inspector ponder on different problems, issues and factors thats are causing skips in top stitching of arm hole at flat lock machine.
- So eridication of skip from stitching machine that is performing the top stitch operation on arm hole of sweat shirt,the inline quality inspector first and foremost monitor the quality of sewing thread and if the quality of sewing thread is poor or of very low level such as carded thread then inline quality inspector stop the stitching machine operation of arm hole top stitch and at first instance changes the sewing thread and again monitor the chain top stitching of arm hole,if skip that is a major fault, if stop by changing the sewing thread the "no matter how good= satisfaction",inline quality inspector allow the stitching machine operator to continue the performance on this stitching machine operation.
- Inline quality inspector observer the needles status of sewing with naked eyes whether the holing point of meede is sharp or not , or needle position is correct an at right angle. In short inline quality inspector will watch every one probability of possible causing of damaging the knitwear garments on stitching machine such as quality of needles,aging of needlesand time duration of working hours of needles and needle adjestment with the stitching machine loppers especially"timing adjestment of needles with timing movement of machine loopers and if still faults appear again and again then inline quality inspector call to stitching machines mechanic who come on point and rectify the faulty stitching machine adjestment .
- Some times there are hidden cause of machine adjestment such as" stitching machine tension" that cause damage and irregularities during stitching of different operations on sewing machines even low level of oil can cause big problems during stitching process.
- Inline quality inspector will check every possible cause of occurring faults such as stitching machine operator handling skill whether the machine operator is properly trained and he or she passed the skillfull test by industrial engineering department. If all these factors are accordance with relevant conditions and facing situation then inline quality inspector will note these all facing are arising issues and problems on hourly report and transfer to quality department head for further and future actions and reactions of quality department authorities.
- Yes at same time when red flag hang on stitching machine for stopping the sewing operations the stitching master and quality supervisor will attend the point where " faulty stitching machine" is working in stitching machine flow and quality supervisor will guide the inline quality inspector about all possible cause of controlling, rectifying and improving the quality of sewing machine operations.
- Yes inline quality inspector will note on hourly and on daily quality progress report of special report paper formate for future facilities of monitoring, controlling and inspecting every hours faulty stitching machine performance.
Root cause analysis as completed by inline quality inspector I'd a proper document such ad why fault appear on sewing machine operation?,what was the real cause of that fault?,ad chooses from some possible alternative and real,to the point and exact damaging cause is highlighted by inline quality inspector, but not only remove the real root of occurances of faults but these actions determined future quality controlling strategy for entire stitching flow.Because here our main heading was,
"Root cause analysis and five S"
So here our focus of attention should be to the point of real limit but sometimes background provide history for real cut to understanding the real cause of fundamental facts and figures so some possibilities raise the quarries "why lengthy study is suitable for gaining knowledge, skill and information about such technical topics. Yes leaving this long discussion here we shall try to focus our attention on our regular field for this day study and this heading is,
"Root Cause Analysis" of
Shape,shade,stitch per inch, specs and stitch behavior.
Seam strength, seam length and seam width.
Again remember here the" Root Cause Analysis" is a fundamental tools for reaching on the exact point from where the faults are arising and that points are real root cause of faults. So controlling the real AMD exact point of occurances of faults root cause analysis is must to complete during the quality controlling and the inspection of sewing operations on relevant stitching machines in line stitching flow.
With the help of this famous analysing tools and techniques inline quality controlling inspector reach at exact and final point from where wrong and ugly shapes of cut parts are mixed during cutting process or adjusting wrong pattern position on knit fabric layers as those layers of knit fabric stretch on long cutting tables, even sometimes wrong bundles are cover during bundling process but in five S family, the shapes of cut parts of sewing garments are must to verify with nesting and after making insurance and satisfaction with these process then cut parts are induct and feed in to machines stitching flow for sewing garments operations. Here root cause analysis provide guidelines tools for monitoring the shapes and if OK sign is "yes"but during stitching machines process again some types of unshapey appearance is arising then on stitching machines needle point is causing the faulty production such as " out of shape knit fabric garment seams"so inline quality controlling inspector will complete and analyze the wrong process for controlling quality process, for controlling the shapes regularities and for fulfilling the daily and routine work about producing all output of knit fabric garments with exact level of quality standards. Yes in simple words all output is match with exactly as the " preimproved red tag sample", or " gold seal improved sample",.
In the family of "five S" second S stands for shade variations. Yes shade variations mean different colour mixed during cutting process of knit fabric for sewing purpose. But its mean very different in stitching processing such as during stitching and sewing stage different cut pieces mixed while it may be due to the neglegency of stitching machine operators or by mistake feeding people can mixed during feeding at first sewing stage because bundles or baskets containing cut parts of knit fabric may be mix while weak handling or neglegency and hurriness. But it is the first and foremost duty and responsibility of inline quality inspector closely monitor and carefully watch such misleading and wrong handling. But sometimes such issues and problems raise much difficulties for quality processing and proceduring at sewing and stitching stage and this case increasing in higher level of defects ratios benchmark so root cause analysis determine right path for controlling the" wrong events occurances of mix variations during stitching and sewing of knit fabric garments out pit in line production machine flow.
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