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Quality Control | AQL (Acceptance Quality Level)

Quality Control | AQL (Acceptance Quality Level)

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Mustafizur Rahman Shanto
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Former Intern at Esquire knit composite ltd | Studied Apparel Engineering at Bangladesh University of Textiles | Went to Shahid Syed Nazrul Islam College - SSNIC,Mymensingh,Bangladesh
Mustafizur Rahman Shanto
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Quality Control | AQL (Acceptance Quality Level)


Quality Control

American Society for Quality Control ( ASQC ) defines quality as “A systematic approach to the search for excellence”. According to International Standard Organization ( ISO ), “Quality is the fulfillment of the specified requirements for a product or service”.

However, quality also means much more, they include:

  1. The degree of excellence that an item possesses.
  2. The best money can buy.
  3. Meeting a specification
  4. Not more than 1% defective a lot.
  5. Not more than 1% defective a lot.
  6. Quality is when the customers come back not the goods.

Quality of a garment refers to the product free from staining faults, sewing defects, fabric faults, size measurement faults, matching of color and stripe faults, cutting faults, etc.

Synonyms: Productivity , Cost reduction , Scheduled performance , sales , Customer satisfaction , Teamwork, and manymore.

Dimensions of quality:

  1. Over dimensioned quality
  2. Under dimensioned quality
  3. Dimensioned quality

To achieve dimensioned quality, the organization’s staffs should have exact knowledge of the requirement profile of the products. This part can only be fulfilled if the information regarding the quality is freely exchanged between the various interfaces of the process.

AQL (Acceptance Quality Level) :

The (AQL) standard is based on Military Standard 105D (MIL-STD-105D). 

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Example of AQL defects:

Critical-AQL (0) %:

  1. Incorrect country or origin /fiber composition.
  2. Inconsistent labeling between UPC and outer box.
  3. Needle/pin in product.
  4. Rough sharp edges metal/plastic trim and composition.
  5. Missing safely warning
  6. Missing sewing label.
  7. Chemical orders.

Major defect AQL (1—2) %:

  1. Fabric flaw on presentation area and visible at area level
  2. Snags at arm level
  3. Shade variation
  4. Soiling, dirty marks
  5. Non-inclusion
  6. Needle damage mark
  7. Broken stitch
  8. Cracking stitch
  9. Button missing
  10. Unraveling buttonhole
  11. Fit measurement
  12. Different between two side (shade variation)
  13. Bar—tack out of range
  14. Zip broken
  15. Printing defect
  16. Washing defect

Minor defect AQL (4%):

  1. Poor thread matching
  2. Poor thread join and bar tack
  3. Thread not trimmed properly (poor trimming)
  4. Missing trimming
  5. Measurement outside tolerance (out of tolerance)
  6. Stepped seams/hem
  7. Tension on elastic
  8. Poorly pressed
  9. Creased by lining not even with foot pleat/dust

Uses of AQL:

In this system, sample is selected by random sampling technique from a lot. After proper inspection, the decision is taken whether the lot will be accepted or rejected. This is applicable for raw materials to finished products inspection as well as garments. This system is popular and used widely in the world trade. Acceptable sampling system consists of 5 parts:

  1. Lot size
  2. Sample size
  3. AQL
  4. Accept number
  5. Reject number

Customer’s choice is given priority in this system. It is the customer who decides whether the goods will be inspected at AQL of 1.5%, 2.5% or soon. They generally give preference to the major defects ( such as oil mark, holes, torn, etc) i.e. which a tag lance seems to be odd for use. They also give the direction on sampling technique.

Garment Inspection system (AQL):

Lot Size

 

 

Acceptable Quality levels

 

 

Being Audited

Inspect

1.5

2.5

4

6.5

 

 

 Ace

 Ace

 Ace

    Ace

Less than 151

8

0

0

1

1

151–280

8

0

1

1

2

281–500

32

1

1

2

3

501–1200

32

1

2

3

5

1201–3200

50

2

3

7

7

3201–10000

80

3

5

7

10

10001–35000

125

5

7

10

14

35001–150000

200

7

10

17

21

For AQL system which points are to inspect is given below:

Model descriptions

Fabrics:

Construction

ok

 

Printings cracks

 

 

Color

Needle marks

Yarn dyed

 

Solid

ok

Sport/stain/Oil

Cylinder marks

Naps/Dead yarn

 

Bobbling/Pilling

 

Crease marks

Hand feel

Shell color

 

Lining color/Fishing

x

Wash effect

 

 

Sewing (General description’s)

Styling

Open seam

 

Poor Pressing

 

Loose thread

 

Broken/Skips

Measurements

 

GSM

 

Tensions Thread

 

Color/Zippers

Appearance/over all

 

Shadings

 

Button/Snap/Etc

 

Seam Twisted

Color

 

Interlining

 

Hanging yarn

 

 

Accessories/Trims

Main Label

 

Size Label

 

Button /Buckle/Stopper

 

Loops with rings

Rivals /Button /Holes

 

Velcro tape

 

Technical Label.

 

 

washing Label

 

Flasher Lbl.

 

Print/Embroidery

 

 

 

Packing Division                                                                    

Solid

 

BD. Striker

 

Striker

 

Price tag

Assort

 

Ratio Striker

 

Card Board

 

ORMS#

Recycle Symbol

 

Folding Size

 

Shipping Mark

 

Size of carton

Top Bottom

 

Hang tag

 

Carton ploys

 

Bar code

Poly Bag/Tissue

 

Net wet.

 

Gross. Wt./Net wt

 

 

(156)

Mustafizur Rahman Shanto
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Former Intern at Esquire knit composite ltd | Studied Apparel Engineering at Bangladesh University of Textiles | Went to Shahid Syed Nazrul Islam College - SSNIC,Mymensingh,Bangladesh
Mustafizur Rahman Shanto
  • Save
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