PRODUCT MANAGEMENT

AND

QUALITY CONTROL

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 INDEX

SR. NO. PARTICULARS PAGE NO. SIGNATURE

Apparel Production

Product and Design

Unit 1 Introduction to Quality

control

Unit 2 Inspection

Inspection- Quality
Control

Inspection-In process
inspection

Inspection- Final
Inspection

Unit 3 Textile Testing

Textile Testing-I

Textile Testing-II

Textile Testing-III

Shade sorting

Unit 4 Total quality

management

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 Meaning

How to achieve it

Various theories

Quality culture

Need for quality culture

Steps to develop quality

culture
Unit 5 Quality Audit & Garment
Testing

Practical Demonstration
of Garment Testing

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 Apparel Production
The apparel production business has long been out of the hand – needle or foot
– power stage. It has been an “engineered” industry in present time. The
properties and characteristics of the following three physical elements which are
present in every apparel production process:
The raw materials being processed – Materials
The processing equipment – Machines
The man executing the process – Men.
Awareness in the fourth area must also be added to the three areas: The
geometric principles of apparel design many types of material are sewed into the
variety of products of the apparel manufacturing and allied manufacturing
industries. A knowledge of the working properties and characteristics of these
materials is therefore of prime importance for the formulation of efficient
qualitative and quantitative production. It is therefore necessary first to be able
to identify the physical properties of fabrics and to understand the nature of the
characteristics of these fabric physical properties.
Apparel production
Fig: Apparel production
Present time apparel industry was known as “Needle – Trade” industries
originally, this encompassed in any industry producing products:
Which were made from fabric (or)
Which are produced largely with sewing machines
Basic types of Apparel production processes.
The following three major types of production phases of apparel (allied)
manufacturing.
Cutting
Sewing
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Pressing.
1. Cutting: Serving the raw material into shapes for assembly and or finishing
sewing and or pressing operation.

2. Sewing: Assembling and or finishing the cut or pre-made pieces with stitches
for cutting, pressing, packing or shipping operations.

3. Pressing: Shaping cut or sewn material with pressure, with or without heat and
or moisture, for further processing or marketing.

There are three other types of production used for assembling, decorating or
finishing purposes; they are riveting, cementing, and fusing. Riveting is used for
closures, decorative and reinforcement functions; riveting operations are
executed with punch presses. Cementing consists of joining two (or more)
sections with the use of cement, glue, paste, or any other adhesion medium.
The exact combination of production steps is determined by the following items.
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1. Product style
2. Raw materials used
3. Available production equipment
4. Available production space
5. Available labour supply.
The following are only a few of the general production sequence used:
1. Cut – sew – press – pack, store, or ship
2. Cut – sew – press – sew – pack, store, or ship
S-C-P-S-C-S- pack, Store, then ship
S-C-S-P-C-C-P- pack, or store, then ship.
P-C-S-P-S-P-, etc.
The term cut, sew, presses C or the symbols C.S.P mean that one or more such
operation take place on the production phase. The construction characteristics
and the physical properties of the materials control the manner in which these
materials react during, and to, the individual production operations. This situation
also varies with the type and degree of mechanical action and human effort
(mental and physical) necessary to perform the production operation.
Now-a-days sophisticated sewing and allied machineries are being made to fulfill
the requirement of globally oriented apparel manufacturing industries; therefore
more productivity expectation to meet the timely requirement of the global
oriented buyers will become the latest trend.
India, Bangladesh, China, Indonesia, Vietnam producing more volume of apparel
for indigenous / domestic and Export purpose. Mostly, USA, UK countries
expecting apparel product from the above mentioned countries.
The development of Apparel production sectors will be yielding better job
positions to men and women. Countries economic condition will also be
flourished. Foreign exchange gained considerably and the under developed
countries wealth rate also be increased tremendously.
In apparel manufacturing industry, sewing machines are being used for joining
the fabric parts which is supplied from the cutting section. Various types of
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stitching are done in sewing production plant by the unique help of sewing needle
and also different accessories are sewing by this machine.
The most and important sewing machines are used in Apparel manufacturing industry
are mentioned as follows.
 Lock stitch / Plain / Regular sewing machine: This machine is basically
used to stitch / sew all types of garments.

 Twin needle lock stitch machine: Normally used for decorative stitching /
seaming purpose. Suitable for woven fabric.

 Chain stitch machine: Used to stitch as well as woven and knitted

garments.

 Double chain stitch machine: Used stitch as well as woven and knitted
garments.

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 Over lock machine (3- Thread): Used for knit and woven fabric sewing.
Normally used in side seam, armhole, sleeve portion to prevent raw edges
of fabric.

 Safety Stitch over lock machine (5 – Thread): This m/c is used for knit
and woven fabric for sewing a plain seam with over lock application on side
seam, arm hole portion.

 Flat lock machine: Used for covering chain stitch. Mostly used for
producing knit wear.

 FOA m/c with cylinder Bed: Specially used for the sleeve portion, trousers
in seam joining and front risebackrise attaching purpose for pyjamas
/Bermuda’s / Boxer shorts.
 Button -hole machine: Used for sewn the button hole in the garment.

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 Button sewing machine: Used to sew the button is the garment.

 Bar lock machine: Used in trousers Belt loop joining, pocket corner and
zipper fly portion.

 Blind stitch Machine: Is used for bottom ham of the pant, skirt, shorts, and
pyjamas.

 Kansai Special Machine: This machine is used for front placket and waist
band or ----- sewing purpose. Also this m/c has a ---- needle with 0.5 to 2.5
inch distance and very much used for special attaching purpose with
required seam distance.
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 Pocket sewer Machine: Specially used for sew pockets of the coats and
overcoat with heavy weight fabric.

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 PRODUCT AND DESIGN

What is meant by product design?

Product design as a verb is to create a new product to be sold by a business
to its customers. A very broad coefficient and effective generation and
development of ideas through a process that leads to new products. Thus,
it is a major aspect of new product development.
Due to the absence of a consensually accepted definition that reflects the
breadth of the topic sufficiently, two discrete, yet interdependent,
definitions are needed: one that explicitly defines product design in
reference to the artifact, the other that defines the product design process
in relation to this artifact.
Product design as a noun: the set of properties of an artifact, consisting of
the discrete properties of the form (i.e., the aesthetics of the tangible good
or service) and the function (i.e. its capabilities) together with the holistic
properties of the integrated form and function.
Product design process: the set of strategic and tactical activities, from idea
generation to commercialization, used to create a product design. In a
systematic approach, product designers conceptualize and evaluate ideas,
turning them into tangible inventions and products. The product designer's
role is to combine art, science, and technology to create new products that
people can use. Their evolving role has been facilitated by digital tools that
now allow designers to do things that include communicate, visualize,
analyze, 3D modeling and actually produce tangible ideas in a way that
would have taken greater manpower in the past.
Product design is sometimes confused with (and certainly overlaps
with) industrial design, and has recently become a broad term inclusive of
service, software, and physical product design. Industrial design is
concerned with bringing artistic form and usability, usually associated with
craft design and ergonomics, together in order to mass-produce
goods. Other aspects of product design and industrial design
include engineering design, particularly when matters of functionality or
utility (e.g. problem-solving) are at issue, though such boundaries are not
always clear.
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Essential Requirements of a Good Product Design
Main or essential requirements of a good product design are depicted
below.

The essential requirements of a good product design are listed as follows:

1. Product must optimally perform its main function (task).
2. It must be easy to repair at a low repair cost.
3. It must be very reliable to use.
4. It must follow principles of aesthetics.
5. It must be a durable one.
6. It can be easily produced in large numbers at minimum production cost.
7. It must be simple to produce and use (handle).
8. It must also be compact.
Now let's discuss each essential requirement of a good product design.

1. Function
The product must be designed in such a way that it optimally performs the
main task or function for which it is purchased by a buyer. In other words,
the product must satisfy the needs and wants of the consumer.
For e.g. The main function of an Air Conditioner (AC) is to provide quick
cooling of a room. So, AC must be designed in such a way that it can cool a
room as fast as technologically possible. If it doesn't meet basic
expectations, the consumers won't buy it.

2. Repairability

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The product must be designed in such a way that it can be easily repaired
whenever necessary during a malfunction. The product repairs must be
done quickly that too at a low repair cost. Consumers usually don't buy
those costly products, which are either very expensive to repair / maintain
or those who take a longer time and more money for repairing.
3. Reliability
Reliability means dependability on a product. Consumers prefer to purchase
and use often those products which perform their main function or task
optimally for a longer period without any annoying malfunctions,
breakdowns or failures. In short, a product must perform quite well and give
trouble-free service for a decent amount of time. It must not need constant
repairs and/or frequent maintenances. It is so, since repairs often turn costly
and are very time consuming. Reliability is crucial for consumer durables and
office equipments. A reliable product gains consumers' trust, loyalty and this
creates its goodwill in the competitive market. Therefore, reliability is an
important factor to be kept in mind while designing a product.

4. Aesthetics
Aesthetics must be kept in mind while designing a product. It refers to, how
the product looks, feels, sounds, tastes or smells. That is, the product must
look, feel, sound, taste or smell very good. It must be attractive, compact
and convenient to use. Its packaging must also be made graphically
appealing and colorful. If this aspect is not considered, product will fail in
the market. This factor is very important, especially in case a product is
designed for and targeted to the young generation that is emerging with a
modern mindset and current trends.

5. Durability
Durability refers to the life of a product. A durable product performs
flawlessly for a longer period. It is a sign of a good-quality product.
Consumers want their products to have a longer life. They do not want to
replace their products repeatedly. This factor is very crucial for durable and
costly products like televisions, refrigerators, cars, so on. Therefore,

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durability is another important requirement that must be kept in mind while
designing a product.

6. Producibility
The product must be designed in such a way that it can be produced in large
quantities with ease at a minimum production cost. The production
department must be able to produce the product easily, quickly, in ample
quantities and at a low production cost. The production process must not
be very complex, and it must not require costly machines to produce the
product.

7. Simplicity
The design of the product must be very simple. The simpler a design, the
easier, it is to produce and use (handle). Simple products are also
economical and reliable. The product must have the least number of
operations without affecting its functionality.

8. Compact
The product must be small; it must occupy less space, and must have lower
weight. In other words, it must be very compact. The company must try to
make its products as small as possible. Today, everything is turning smaller.
Big sized cell phones are now out of fashion. In the 1950s, computers were
as huge as spacious rooms. However, today we have laptops and palmtop
computers. Most products can be made compact. Still, this cannot be done
for all products. In case of televisions, it is just the opposite. Today people
want bigger televisions. Similarly, there is a limit on small size. We cannot
have a phone which is so tiny that it requires a microscope to see its keypad.

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 INTRODUCTION TO QUALITY CONTROL

Importance of Quality Control

Quality is an important factor when it comes to any product or service. With the
high market competition, quality has become the market differentiator for almost
all products and services. Quality control is essential to building a successful
business that delivers products that meet or exceed customers’ expectations. It
also forms the basis of an efficient business that minimizes waste and operates at
high levels of productivity. A quality control system based on a recognized
standard, such as ISO 9001 published by the International Organization for
Standardization, provides a strong foundation for achieving a wide range of
marketing and operational benefits.
Therefore, all manufacturers and service providers out there constantly look for
enhancing their product or the service quality. In order to maintain or enhance
the quality of the offerings, manufacturers use two techniques, quality control
and quality assurance. These two practices make sure that the end product or the
service meets the quality requirements and standards defined for the product or
the service.
There are many methods followed by organizations to achieve and maintain
required level of quality. Some organizations believe in the concepts of Total
Quality Management (TQM) and some others believe in internal and external
standards. The standards usually define the processes and procedure for
organizational activities and assist to maintain the quality in every aspect of
organizational functioning.
When it comes to standards for quality, there are many. ISO (International
Standards Organization) is one of the prominent bodies for defining quality
standards for different industries. Therefore, many organizations try to adhere to
the quality requirements of ISO. In addition to that, there are many other
standards that are specific to various industries.
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Since standards have become a symbol for products and service quality, the
customers are now keen on buying their product or the service from a certified
manufacturer or a service provider. Therefore, complying with standards such as
ISO has become a necessity when it comes to attracting the customers.
Every organization that practices QC needs to have a Quality Manual. The quality
manual outlines the quality focus and the objectives in the organization. The
quality manual gives the quality guidance to different departments and functions.
Therefore, everyone in the organization needs to be aware of his or her
responsibilities mentioned in the quality manual.
Quality Assurance is a broad practice used for assuring the quality of products or
services. There are many differences between quality control and quality
assurance. In quality assurance, a constant effort is made to enhance the quality
practices in the organization. Therefore, continuous improvements are expected
in quality functions in the company.
When it comes to our focus, we understand that quality control is a product-
oriented process. When it comes to quality assurance, it is a process-oriented
practice. When quality control makes sure the end product meets the quality
requirements, quality assurance makes sure that the process of manufacturing
the product does adhere to standards. Therefore, quality assurance can be
identified as a proactive process, while quality control can be noted as a reactive
process.
Quality control (QC) is a procedure or set of procedures intended to ensure that
a manufactured product or performed service adheres to a defined set of quality
criteria or meets the requirements of the client or customer.

Role of Quality Control

1. Read blue prints & specifications, monitor operations to ensure that they meet
production standard.
2. Requirement adjustment to the assembly or production process.
3. Inspect, test, measure materials or products being produced.

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Quality Control in Depth
Quality control helps a company reduce errors and produce products
efficiently that are of great quality; but how does a company implement
this? For Super Sports Warehouse, it offers training courses for managers
and employees. This helps keep them updated on ways to do things better.
The company also makes goals and objectives for its employees and
products to meet. This ensures that each employee knows what they are
working for and what is expected from them.

Types of Quality Control

You may be wondering how quality control works. Well, there are four types
of quality control, and each of them has unique characteristics. In this
section we will break each of them down so that we can understand how
they might be used.
The first type is process control. When creating any type of product there is
a process, meaning all products start with pieces and end with a finished
good. Process control is the type of quality control that makes sure the
processes within a company are functioning correctly. This means that all of
the activities included in each process are operating at a nice stable pace
with little variation.
An example might be making sure the machines are operating correctly and
producing products that do not have flaws. Process control also makes sure
that a company is performing at its target level. For example, when Super
Sports Warehouse makes basketballs, the company makes sure that each
ball goes through the same process at a time frame that produces enough
basketballs to fulfill orders. When the basketballs are completed, process
control helps Super Sports Warehouse make sure there are little to no flaws
and variations so that the company can ship quality basketballs to all its
customer stores.
Another type of quality control is acceptance sampling, which is the process
of determining an inspection plan that works to meet the needs of the
company. You see, sometimes inspecting and testing every single product is
too costly for a company, or even destructive for the product. While the
company needs to inspect at least some of its products, testing all of them
may not be an effective solution for every company. Acceptance sampling
lets a company find somewhere in the middle of testing every product and
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not inspecting any of them. For example, Super Sports Warehouse inspects
1 out of every 50 basketballs. Inspecting just a few basketballs allows Super
Sports Warehouse to save time and money while being able to determine if
the entire order should be rejected or kept.

Inspection – Quality Control

Quality inspection are measures aimed at checking, measuring, or testing

of one or more product characteristics and to relate the results to the
requirements to confirm compliance. This task is usually performed by
specialized personnel and does not fall within the responsibility
of production workers. Products that don't comply with the specifications
are rejected or returned to improve.
Origins of quality inspection
Quality inspection is the first stage of evolution of quality approach. The
origins of the quality inspection back to the late nineteenth and early
twentieth century. In days of fast-growing industry, Frederick Winslow
Taylor developed the rules of scientific management. Quality wasn't up to
speed with rapidly increasing labour productivity. Often, the customer had
to reckon with defective products. To alleviate customer frustration, this
problem was solved by replacing the defective product with a new one.
Conducting this type of procedure entailed generating considerable cost. To
reduce the excessive cost
escalation manufacturers introduced controller position, unknown to craft.
The designated employee, through carried out inspections, made sure that
the greatest possible number of good products leave the gate of the factory.
This initial form of quality inspection based on the principle of quality by
sorting.

The scope of quality inspection

Organization which uses quality inspection, treats inspector as if he was a
customer. The optimum form of quality inspection is the man who's aim is
the best customer satisfaction. Quality inspection serves three main
purposes:
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 1. Identification of the quality problem
2. Provision of information to managers
3. Elimination of the problem by managers

Quality inspection can be performed at the end of production process (final

inspection) or at several stages of the production (intermediate inspection).
Quality inspection vs. quality control
Quality inspection is concerned on postoperative or post-production check
of products. It doesn't have direct impact on production process. Quality
inspector only sorts products, and he doesn't let poor quality products to
leave the factory. Quality inspection has no feedback loop. That means that
information about failures and their causes is not passed to workers or
managers. Therefore, this system cannot improve itself.
Inspection- Inprocess inspection
Inprocess Inspection is a step by step inspection.
Inprocess inspection
Pattern related information
Pattern Making Master making defects
Pattern cutting defects
Spreading (Fabric)

Cutting

Sewing Defects

Pattern making is a first step to get into the inprocess of apparel

manufacturing. Pattern making is a base of a building like apparel. Pattern
making is very important step to construct and stand with a structure of a
garment which is portrait on the paper as fashion illustration process it is
actual practical approach to develop garment structure on to the paper or
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brown paper with the help of formulas, guidelines and pattern making tools
if this basic structure would be made defectively then whole apparel or
garment can be destroyed.
Common pattern defects:
1. Some parts of pattern are missing.
2. Land mark comes grain line style number and other important are not
mention on pattern.
3. Seam allowances are wrong and unevenly given.
4. Mix parts on components of garments of other garments are group
separately. Like in garment of size 10 bodice is of size 8.
5. Pattern cutting is uneven.
6. Cutting line and stitching line are not given.
7. Notches are missing on the pattern.
Fabric Spreading Defects:
1. While spreading the fabric the table size should be according to the
fabric size either for close marker planning or for open marker
Planning. Open marker is that marker when pattern pieces are traced
onto the fully spreader fabric. close marker is that marker when the
fabric is half folded and pattern pieces are placed onto it according to
the grain line.
2. The fabric tension needs to be at correct position and tension.
3. Always check that the number of layers or plies are in correct numbers
as garment needs to be cut.
4. If the plies or layers of fabric are uneven at the size, it needs to be
aligned and cut the unevenness from the sides.
5. Fabric should always layered wrong side up and face side down.
Sometimes it happenes when fabric required as spread face up or face
to face. (Lay mode)
6. Unexpectable damages in the garment parts due to unevenness in the
layers.
7. Plies are not spread accurately one above another for cutting.

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Sewing Defects
1. While doing stitching defects occurs

1. Weavy Seam.
2. Open Seam.
3. Skipped Seam.
4. Puckering.
5. Seam Grin
6. Broken stitch/Seam.
7. Looped and entangled stitch
8. Loose thread
9. Seam slippage
10. Needle Mark.
11. Missing Back Tack

2. While attaching components to the main garment.

1. Pocket upside loose.

2. Misalignment of checks.
3. Missed alignment of striped fabric.
4. Dart alignment at waist is missing.
5. Centre Front is not at correct position.
6. Piping width is not correct.
7. Hem is weaved off.
8. Collar width & shape is incorrect.

Inspection- Final Inspection

The inspection process which is done after garment stitching & finishing.
Final inspection is the last step of garment inspection system. In this stage
complete garment are inspected by buyer different parts of garment are
inspected in this stage. Such as Garment Fabric, Trims, accessories, stitching

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etc. Final inspection is very important for an export order shipment points
to be inspected for final inspection:-
1. Size measurement checking: In this process final garment needs to be
checked specially for measurement as garment was stitched as per
measurement given by the buyer. Final measurement sheet after
amendments or changing comments should be followed for this
process.
2. Form fitting checking:
(A) Placement of Pockets, Buttons and labels.
(B) Stitching defects like puckering, fullness in seam, fly.
(C) Uneven hem.
(D) Hiking front and back.
3. Garment fitting checking on dress form (if possible on live modals).
4. After packing checking size of poly bags & garment folds.
5. Aesthetic appeal.
6. Placement of hand tags (Price, brand name).
Criteria of checking:-
1. Appearance
2. Size and measurement.
3. Fitting.
Equipment used for final inspection:-
1. Measuring Tape.
2. Dress form as per the size required.
3. Final approved measurement sheet.
4. Checklist with sheets for other defects.
Final Inspection methodologies (Types of Final Inspection
):-
1. No Inspection: Generally no inspection concept is not followed in
apparel industry, but it depends on what type of buyer is buying
apparel from manufacturer or distributor like wholesaler retailer who
used to buy goods directly or through channel from apparel
manufacturer road side selling.
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 2. 100% inspection: This type of Inspection is usually followed in apparel
industry when critical defects are occurred during raw material
Inspection as well as Inprocess inspection. In this type of inspection
total order quantity is checked completely even after packing. For high
Fashion garments which are used to make in rich fabric (Rich fabric
does not mean only shiny fabric, it can be technically structured wise
and according to texture having richness).Trims and accessories can
also be inspected 100% as they are costly than other casual garments.
3. Arbitrary / Random Inspection: In this type of final inspection process
10% of samples from total order quantity are used to be inspected. In
this process that 10% sample quantity can be taken of selected
randomly from whole ready shipment.
4. Statistical Inspection: In this type of inspection there is a statistical
system which is made for basic three types of defects that are minor
defects, major defects, critical defects. It can also be classified as types
of garment defects.

What is textile testing?

The quality of a product or process is checked before it is put into large-scale
usage. The quality of the product, its performance, and its reliability are the
key factors while testing is performed. Testing can be defined as the
methods or protocols adopted to verify/determine the properties of a
product. It can be divided primarily into two types: regular process testing
and quality assurance testing. Routine testing helps to streamline the daily
process.

Quality assurance testing helps the process or product in the long run to
establish credibility. Testing can also be defined as the procedures adopted
to determine a product’s suitability and quality.

Textile testing is a key in gauging product quality, ensuring regulatory

compliance and assessing the performance of textile materials. It is a vital
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basic tool during the processing of a textile raw material into the product. It
also helps the distributors and consumer to determine the end product’s
quality. It can include the analysis of the property of a known or an unknown
material. So, textile testing refers to the procedures adopted to determine
quality throughout the textile product chain (textile fibers, yarns and
materials etc). It can be summarized as the application of engineering facts
and science to determine the quality and properties of a textile product.
Mainly it involves the use of techniques, tools, instruments and machines in
the lab for the evaluation of the properties of these different forms of
textiles.

Objectives of textile testing:

The main objective of textile testing are:
1. To check the quality and suitability of raw material
2. To monitor the production (process control)
3. To assess the quality of final product
4. To investigate the faulty materials
5. To set standards or benchmarks
6. For R&D (research and development) purpose
7. For new product development
We can elaborate objectives of textile testing in the following ways:
1. For researchers, testing results aid the development of new products
or new processes, which can save money and resources before
production starts on an industrial scale. They also help in the choosing
of the best possible route to achieve the end product.
Testing helps in the selection of the best possible raw materials. “Raw
material” is a relative term; for example, fiber is the raw material for
spinning, and yarn is the raw material for weaving.
2. Testing helps in the process control through the use of advanced
textile process-control techniques.
3. Testing ensures the right product is shipped to the consumer or
customer and that the product meets the customer specifications.
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Testing in general, and textile testing in particular, is affected by the
following factors: Atmospheric conditions affect test results as textile
products are greatly influenced by moisture and humidity. The test method
adopted will also cause variation in test results. The testing instrument is
also a vital part and, if not properly calibrated, can cause serious variation.
Human error is another source of variation.

Textile testing starts with textile fibers and goes all the way through to the
final product. The fiber test includes the length, strength, elongation,
fineness, and maturity. The yarn test includes linear density, single yarn
strength, yarn evenness, and yarn hairiness. The fabric test includes aerial
density, weave type, and air permeability

Types of textile testing:

Textile testing can be classified according to the basic technique used and
on the basis of the data obtained. The former can be divided into destructive
and nondestructive testing, the latter being defined as the application of
noninvasive methods to reach a conclusion as to the quality of a material,
process, or product. In other words, it is inspection or measurement without
doing damage to the test specimen. Examples include drape testing and
assessment based on the Kawabata evaluation system. Destructive testing
is performed to test for failure of the sample. This type of test is much easier
to perform and yield precise information and is more simple to understand
than nondestructive testing. Examples of destructive testing are tensile
testing and tear testing.

On the basis of data obtained, testing can be classified into objective and
subjective. The former can be defined as the testing that gives us
quantitative data, which can be easily further processed and interpreted.
Subjective testing can be defined as that which gives us qualitative data,
which is difficult to interpret and is greatly influenced by operator.

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Importance of textile testing:
Principle importance of textile testing are;
1. To ensure the product quality
2. To control the manufacturing process
3. For customer satisfaction and retention
4. Good reputation (brand image) among consumers
Testing importantly supports the personnel involved in the textile supply
chain, from the textile fiber to the end product. The testing of textile
products aids persons involved in the running of the production line.

During testing, the discrepancy of the product, for example, its strength,
maturity, waste percentage (for fibers), aerial density, and weave design (for
fabrics), is properly measured. Thus the selection of the proper raw material
is an important factor. Standards of control should be maintained to reduce
waste, minimize price, and so on. Faulty machine parts or improper
maintenance of the machines can be easily detected with the help of textile
testing. Improved, less costly, and faster protocols can be developed by
researchers with the aid of testing. The efficiency and quality of the product
can also be enhanced with the help of regular and periodic testing.

Customer satisfaction and loyalty can also be won by producing according

to customer specification in good time. In short, testing is an essential pivot
to the whole textile product supply chain.

The cycle of testing starts with the arrival of raw material and continues up
to delivery of the final product. The production of the required end quality
is impossible if the raw material is incorrect. The textile product supply chain
comprises different processes, which include the raw material (natural or
man-made fiber), yarn manufacturing, fabric manufacturing, textile
processing, and apparel and home furnishing manufacturing. It also includes
some industrial products, like ropes, cords, and conveyer belts. All the
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aforementioned processes are performed in separate units or in a single unit
if the establishment is a vertical production unit.

So the raw material for a spinning unit is fiber, for a weaving unit is yarn, for
a textile processing unit is greige fabric, and so on. “Raw material” is a
relative term that depends upon the further process for which it is used. Its
testing is an important step, as improper raw material or low grade raw
material will not yield the required quality of the end product. The testing
of raw material is also performed to verify whether the incoming material
accords with the trade agreement. Its consignment is therefore accepted or
rejected on the basis of test results. The agreed specifications should be
realistic so that the incoming raw material properties can meet the required
level easily.

Production monitoring involves the testing of production line samples,

which is termed “quality control.” Its purpose is to sustain certain definite
properties of the end product within acceptable tolerance limits as per the
agreement between the producer and the consumer. A product that does
not meet the already agreed specification or the required quality will be
termed a “fail.”

The proper testing protocol as well as proper monitoring are also required.
The sampling techniques in use should also be selected properly, since the
wrong selection could lead to serious problems. At the same time, the
statistical tool employed is also an important factor. The collection of data
is one thing, but its proper evaluation and interpretation, and the action
taken on the basis of it, is an important factor in quality control.

Textile testing is vital to identify the particular cause of that fault so that it
can be avoided in future consignments. It will also help to rectify the running
process and enable it to run more smoothly so that the final product accords
with the customer’s requirement. It also helps to isolate the faulty part or
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machine so as to resolve any dispute between the supplier and the
producer.

SHADE SORTING

The shade sorting feature calculates a shade number for each sample based
on how close its color is to the standard, but ALSO has the ability to sort all
samples into shade groups and provide data on which samples belong to
each shade number. Shade numbering, sorting, and tapering are used in
many industries, but particularly the textile industry.
The shade numbering feature performs calculations on the sample data and
assigns each sample a shade number based on how close its color is to the
standard.

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