QUALITY ASSURANCE

RAJBY TEXTILES
(GARMENT FACTORY)

Presented By:
Saba Zafar
Fizza Asad
Rubina Khan
 INTRODUCTION
 Established in 1989
 vertically integrated garment manufacturing
organization.
 A pioneer and market leader in manufacturing of
woven bottoms
 Especially making Denim Jeans and Casual
Bottoms.
 Export garments to some of the top and
distinguished garment houses in North America
and Europe.
 MAIN DEPARTMENTS IN
RAJBY
 Sampling
 CAD/CAM
 Cutting
 Stitching
 Washing
 Finishing/Packaging
 Quality Assurance In Rajby
Textiles
When we visited Rajby Textiles we noticed that
they are applying quality assurance by:
 Planning
 Checking
 Acting
Rajby Textiles have:
 9 stitching lines
 2 stitching line are under 1 QA in charge
 2 QC’s will check 1 stitching line for basic styles
 3 QC’s will check 1 stitching line for fancy items.
 1 stitching line is having 90-95 machines
 Under QC there will be 12 checkers for each line.

 
Rajby has the following AQL standards:
 Finishing and washing: 2.5
 Stitching: 1.5
 Cutting: 0.5
 Following are the steps which were carried out in
Rajby Textiles:

 Sampling is done using the same parameters as

required by the buyer. Quality is assured in this very
first step as all orders will be depended on this.
 After the sample being accepted by the buyers the
files goes to unit.
 Then it goes to lectra department. In this department
they design the whole size set of the product.
 After designing the patterns they will do the cutting
of one size set.
 That one size set will go to production line, so
that cutting and stitching operators will know the
exact specification before starting bulk
production.
 QA will assure the quality before and after wash.
 After assuring the quality which has been
demanded by the buyers then the bulk cutting
will start.
 Cutting report will be formed to assure quality.
 Every piece of garment must be numbered.
 QC will form trim card of the garment.
 Meetings will be arranged before inducting any
new product into stitching line.
 CHECKING: For the defects checking QC will
go to each operator and will check 7 pieces, if
one major defect comes then operator will check
the whole bundle (1 bundle =30 pieces)
 Then all pieces will be moved from operator to
100% checking.
 ANALYSIS OF DEFECT
 RAJBY introduced a new product names IRMA DENIM which was a skirt and
the buyer was H&M. The skirt was made by using lock and chain stitches.

 The skirt was having the following parts:

Point pocket, Facing, Back and front pocket, Pocket Lining (Pocket bag), Zip,
Button takes +fly, Back yoke, Back panel, Front panel, Waist band, Loops
(reinforcement)

 Time duration for making 1 piece of skirt:

Cutting =1min
Enzyme Stone=1:50mins enzymes Stone
Bleaching= 20-25mins
Spray =10mins
Dryer= 40-45mins

 Company was facing problem regarding this product.

 FACAP ANALYSIS

FAULT:
The waist band of the skirt gets unstitched while
washing. This was the defect which was coming
in Production of that specific garment.
 AFFECT:
This fault have affected the whole production.
First order of this product by H&M included
100,000 pieces from which 6000 pieces were
defected.
In second order, 1500 pieces were defected.
 CAUSE:
Following can be the causes of defect:
 No product needed that much washing time.
They must be using less quantity of enzymes to
reduce the enzyme cost.
 Or they must be overloading machine, because of
that garments get rub with each other and stitches
got broke.
 Or having less elasticity in stitches, machine
setting is not accurate.
 Or the scrapper is affecting strength of stitches.
 ACTION
 They should use more and high quality
enzymes in washing to reduce washing time.
 Maintain lot size according to machine capacity
so that machine will not be overloaded.
 And they should monitor elasticity of stitches
also so that stitches will be having room to
move little bit in washing and not get stiff.
 They should monitor the scrapping procedure more
efficiently because one scrapper is use for hundred
pieces. When operator changes a scrapper, in
beginning it’s very sharp so it cuts many threads. It
could be the reason behind unstitching of waist band
because yarn looses its strength at scrapping
procedure and later on it gets break in washing
procedure.
 PRECAUTIONS
As a precaution Quality managers should
monitor all the processes so that there will be less
defects and more productivity. By doing this time
will be saved and there will be less cost regarding
removing defects.