CASE STUDY

IMPLEMENTING QUALITY MANAGEMENT IN THE TEXTILE

INDUSTRY IN PAKISTANN
BY
ASIF HUSSAIN
GROUP GENERAL MANAGER
QUALITY ASSRANCE & HR DEVELOPMENT
SAPPHIRE
 PAKISTAN INSTITUTE OF QUALITY CONTROL

Presented by:
Ambreen Zafar
Areeba
Fatima
Mehar
Sehar
Presented to:
Mr. Kamran Moosa
 CASE STUDY MAIN FOCUS
• Case study is about the implementation of TQM in textile
industry.
• Authers' main focus is on implementation of ISO 9000
and ISO 9002 in Sapphire Textile for quality management
purpose.
• Development of Independent department to improve
quality.
 INTRODUCTION

Setup of Textile Manufacturing Plan

Composite Textile

Individual Textile
 FOCUS ON SAPPHIRE TEXTILE

• Purpose to produce quality yarn of different counts

• Vertical integration policy
– Own Power Plant
• Projects: producing woven, knitted fabrics, yarn cons,
dyeing and dyed fabrics.
 Well Begun in half done

• ISO 9000 Quality Management System is good for

starting TQM in less developed countries.
– Ensure customers to deliver consistent products and services
in global market
• Other Standards also join the race
 APPROACHES

Approach # 1 Sapphire Adaptation

• Initially selected
Draw Back
System development by a • Hard for single person to
selected employee
provide assistance
• Poor judgement
Conti...

Approach # 2 Sapphire Adaptation

• After 1st approach adopt 2nd
approach
System development Draw Back:
through consultant • Expensive and not beneficial
• very few have technical
knowledge and background.
Conti...
Approach # 3 Sapphire Adaptation

• Infrastructure for
independent department was
System Development brainstormed.
• Harmonize communication
through HRD • Highlights operational strength and
weaknesses
• Cost effective
• Establish consistent system
Road map to quality management system
development at sapphire
 Quality Assurance and HR Department
 Training Setup
 Training Syllabus Development
 Training of Trainers
 Documentation to each plant
 Set up ISO 9000 Offices
 Calibration setup
 ISO 9000 Certification Cost
TANGIBLE AND INTANGIBLE ACHIEVEMENTS
• Intangible benefits of ISO 9002:
• Greater clarity in operational roles
• Higher Higher sense of Responsibility of what to do or what not do
• Better house keeping
• Higher Self Discipline
• Customer focused approach
• Greater employee satisfaction due to improved work environment
• Tangible Benefits:
• Tangible benefits are difficult to observe
• For this purpose Sapphire a model plan name Diamond Fabric
Ltd.
 GOOD POINTS OF CASE STUDY
• Main focus on ISO 9000
• Training Focused
– Set-up
– Syllabus
– Trainers Training
– Documentation
• Intangible Benefits (ISO 9002)
 DRAW BACK
• Not proper sequence
• Incomplete End
• Implementation Missed
• TQM Process Missed
• Incomplete Information
 HOW TO IMPROVE
• Complete process of TQM (QC, QA, TQM)
• Define Tangible benefits in result of TQM implementation
• Monitoring Procedure
 QUALITY CONTROL FLOW CHART
Check
Received
Finished Marker Spreading Cutting Numbering
finished fabric
Fabric

Cutting Measurement Table

Checking Bounding Quality Audit Input Checking Inspection

Basic
Alter/ Sewing Checking for Quality Audit
Iron Measurement
Rectification Quality Audit Finishing for Workshop
Check

Metal
Carton Internal Final
Folding Poly/ Hangar Detector Carton Quality Audit Inspection
Checking
 QUALITY ASSURANCE FLOW CHART
Accessories Check Fabric Inspection Shade Segregation Shrinkage Test

Spreading Quality Cutting Quality

Size Set Check Marker Check
Assurance Assurance

Pre-Production
Hard Pattern Check General Inspection In Process Audit
Meeting

Two Time Process Two Time Machine Two Time Weekly in process
Check Check Accessories CHeck Summary

100% Inline Hourly Final Audit Finishing 100% Buttton Pulls

Process Check with Measurement Checking Check

Brooken Needle Accessories Pre Final

Hourly Final Audit
Check Compliance Inspection