Fabric inspection and QC is one of the major areas in textile and garment sector. To establish a workable system for inspecting and evaluating piece goods shipments is vital. No single accepted system for measuring the quality of fabrics, but some of the more commonly used systems are described in this section.
We recommend a minimum of 10% inspection of fabrics prior to spreading. Some are intending to inspect the goods while spreading. However this is unrealistic and the spreaders are not the QC.
1-Ten-Point System
In 1955, the Ten-Point System for piece goods evaluation was approved and adopted by the Textile Distributor's Institute and National Federation of Textiles. This system assigns penalty points to each defect, depending on its length. The Ten-Point System is somewhat complicated because points-per-length vary for warp and filling defects. Table blow shows a breakdown of the points:
Table 1 - Ten-Point System
Warp Defects Penalty Filling Defects Penalty
10-36 inches 10 points Full width 10 points
5-10 inches 5 points 5 inches - 1/2 the width of goods 5 points
1-5 inches 3 points 1-5 inches 3 points
Up to 1 inch 1 point
Under the Ten-Point System, a piece is graded a "first" if the total penalty points do not exceed the total yardage of the piece. A piece is graded a "second" if the total penalty points exceed the total yardage of the piece.
2- Four-Point System
The Four-Point System has received the widest acceptance in both the textile and needle trades because it is the most lenient. It is simple and easy to understand. Since it is the most widely used?
2.1- Amount to Inspect - Inspect at least 10% of the total rolls in the shipment.
2.2- Selection of Rolls Select at least one roll of each color. If more than one roll per color must be inspected, then select the number of additional rolls in proportion to the total rolls per color received.
2-3 Defect Classification The Four-Point System classifies defects as shown in Table 2:
Table 2 Four-Point System
Size of Defect Penalty
3 inches or less 1 point
Over 3, but not over 6 inches 2 points
Over 6, but not over 9 inches 3 points
Over 9 inches 4 points
A maximum of four points is charged to one linear yard.
The length of the defect is used to determine the penalty point. Only major defects are considered. (A major defect is any defect that, if found in a finished garment, would classify that garment as a second.) No penalty points are recorded or assigned for minor defects.
Major defects are classified as follows:
- Major woven fabric defects are slubs, hole, missing yarn, conspicuous yarn variation, end out, soiled yarn, wrong yarn.
- Major knitted fabric defects are mixed yarn, yarn variation, runner, needle line, barre, slub, hole, and press off.
- Major dye or printing defects are out of register, dye spots, machine stop, color out, color smear, or shading.
- Suppliers using the Four-Point System should obtain examples of major defects and minor defects, and make them available as visual aids for the Inspectors.
2.4- Acceptance Point - Count Most suppliers use 40 points per 100 yards as the acceptable defect rate. However, you should establish your acceptance point-count based on your product and its end use.
2.5- Acceptance Criteria - There are two methods of determining whether a shipment is acceptable. You must decide which method will fit your product. The methods available are as follows:
One method of acceptance uses a projection of total defects based on the number of defects found during inspection of a sample. Here is an example using this method:
Total yardage received: 2,400 yards
Acceptance point-count: 40 per 100 yards
Total yards inspected: 240 yards
Total penalty points found in the sample inspection: 148 points
148 / 240 X 100 = 61.7 points per 100 yards.
(Allowance is 40 points per 100 yards.)
Action: Shipment would fail.
A second method is acceptance of 10% bad rolls.
Here is an example of the method:
Total yardage received: 2,400 yards
Acceptance point count: 40 per 100 yards
Total yards inspected: 7 (10 % rolls)
Number of rolls rejected: 2
2 / 7 = 29% rolls rejected.
Action: As 29% of rolls inspected were rejected, the shipment would be held for a decision.
------------------------------------------------------------------------------------------------------------
You must decide whether to reject the entire shipment and return it to the piece goods source, or whether to 100% inspect the balance of the rolls. Management must make this decision; do not leave such decisions to the Inspector or Quality Control Supervisor. If you need production from the good rolls, it may be to your advantage to 100% inspect.
2.6- Inspection Procedure This procedure shows the steps necessary to ensure an effective piece goods quality control program:
* Determine the amount to inspect,
* Select the rolls to inspect,
* Put the rolls on the inspection machine or other viewing device,
Cut off a 6-inch piece across the width of the goods. Mark this piece so that the Inspector will know the right and left sides of the fabric. Use the strip to check for shading side-to-side and end-to-end by checking it at least once against the middle of the roll and once at the other end,
· Inspect for visual defects at a speed slow enough to find the defects,
· Check that the roll contains the yardage as stated by the piece goods source,
· Check for skewed, biased, and bowed fabric. Predetermine the tolerance you will allow; this will depend on your product.
· Example: Width of Fabric Tolerance
(In Inches) (In Inches)
45-50 1
50-60 1 1/2
Weigh the roll of fabric to determine yield: Yards/Weight = Yield
Example:
Weight of roll = 35 pounds
Yards in roll = 59.5 yards
59.5 / 35 = 1.70 yield.
If major defects are not cut out of the fabric by the Inspector, mark them on the selvage (for example with colored threads). Should you later want to review the defects with the piece goods representative, the defects can be easily located on the inspection machine. In addition, the defects can be easily noted by the Spreader so that they can be cut out.
Record the defects on a report form. (See the suggested Piece Goods Quality Control Inspection Report form on the following page. Please note that this is only a suggested report form. Since report forms can require a variety of detailed information, make sure that your report form contains all the information you need. The original version of our suggested form is enclosed at the back of this manual for duplication purposes.)
Do not require data on the form that you will not use. Recording data is a labor cost, so keep your form simple.
2.7- Possible Considerations for Rejection In addition to excessive defects, the following are common reasons for rejecting fabric rolls:
No roll with a length of less than 25 yards should be accepted as first quality. You may want to specify this on your purchase order.
No roll containing more than one splice should be accepted as first quality.
No roll containing a splice part less than XX* yards should be accepted as first quality. (You may not want to receive rolls with a splice near the beginning or end of the roll.)作者: danieltextile 时间: 2008-2-19 17:51
难道没有人验过布吗？？？可以发表一下见解。。。。。。作者: dickyhk 时间: 2008-2-23 09:56
Thanks for your sharing!!!!!作者: hgj78 时间: 2008-2-23 10:57 标题: 回复 #1 danieltextile 的帖子 这东西太普通啦,呵呵作者: danieltextile 时间: 2008-2-25 13:24
普通中透露了非常不普通的道理.... 希望各位能活用它。。作者: xuqing 时间: 2008-2-28 12:40
可惜我英语不行................
正在努力中作者: sweet4 时间: 2008-3-1 15:16
一大堆字～其实AQL就是一个盾牌而已～作者: cdphz 时间: 2008-3-1 19:52
有中文的就可以分享了！！作者: chocoxiao 时间: 2008-3-2 21:57
tks for yr files.
but that's too easy and basical for a fabrics inspector.
how to use it and how to score for different fabrics, are more important.
very glad to communicate with u. my QQ no.:20044529.作者: heibao136 时间: 2008-3-12 17:10
积分，金币，我都要！！！！作者: danieltextile 时间: 2008-4-7 13:54
好东西大家分享作者: waynelu 时间: 2011-5-23 22:06
THANKS.TAKE A LOOK TO LEARN.作者: feishifan 时间: 2011-5-27 08:41
这是一份基本的疵点扣分体系，实际上的收货标准是以买卖双方基于不同不种时再另外确订货布的收分标准。作者: rdc128 时间: 2011-7-20 11:02
中文的有无呀
希望各位能活用它。。