Konfeksiyonda kalite kontrol programının önemi ve oluşturulması

Abstract

Kaliteyi kısaca kullanıma uygunluk olarak tanımlayabiliriz. Firmalar müşterilerini memnun edebilmek için bir kalite sistemi kurmak ve işletmek durumundadırlar. Böylece bir sistemde kalite planlanmalı kontrol edilmeli ve geliştirilmeli ve bu konularda gerekli eğitim tüm kuruluş çalışanlarına fonksiyonel düzeylerine göre verilmelidir. Kalite kontrol imalatın bir bölümü olmaktan çıkmış kendi başına kesim, planlama, satış gibi bir bölüm olmuştur. Kalite kontrol elemanları sadece kendi müdürlerine ve yöneticilerine bağlı bir duruma gelmişlerdir. Kalite kontrol müdürlüğü imalattan bağımsız denetim müdürlüğü haline gelmiştir. Bu kişilerin görevi çalışanları hatalarından dolayı cezalandırmak veya sadece hataların tespiti değildir. Hazırlanan raporlar sonucu yapılan hatalar kayıt edilir ve tekrar etmemesi için gerekli düzenlemelerin yapılması sağlanır. Kaliteli mal üretimi için gereken kalite kontrol birimlerinin oluşturulması gerekli programın belirlenmesi, uygulanması ve geliştirilmesi için yöneticilere büyük görev düşmektedir. Bu tez çalışmasında konfeksiyon firmalarında uygulanmak üzere tavsiye edilen Kalite Kontrol Programı ve bu programın uygulanışında izlenebilecek yol incelenmiştir. Bu programın temeli bir Amerikan firması olan J.C. Penney firmasının imalatçıları için derlediği notlardır. Ayrıca tez çalışmasında tavsiye edilen K.K. Programının benzeri bir programı uygulayan X firmasının (firma adının açıklanması istenmediğinden X firması olarak bahsedilecektir.) K.K. sistemi ve uygulamaları incelenmiştir Yapılan araştırmalar sonucu yeni bir Kalite Kontrol sistemi oturtmaya çalışan X firmasının karşılaştığı zorluklar, izlenen yol, şu andaki durumu ve bundan sonraki hedefleri Kalite Kontrol sistemi oluşturmak isteyen firmalara örnek olmak üzere özetlenmiştir.

Quality is defined as the weighted characterises of a product (or service) which in their totality add up to the consumer's satisfaction. The higher the degree of satisfaction the higher quality Definition could be represented by the simple equation; ZWjC; 1=1 where w the weight (importance), c;a particular characteristic, and n number of the relevant characteristics of the product (or service). This definition of quality shows that the quality is measured. Based on the above definition, quality has been given the short and most popular definition of "fitness for use". Control of the quality is the measurement of the characteristics of an item or process to determine its conformance to specified requirements and, the taking of action when non conformance exists. Experience has proven that the key of effective quality control is management's leadership in the program. If top management wants good quality and displays leadership in quality concerns, middle management and production supervisors will follow through. Without leadership from the top, there is often little or no improvement in quality no matter what system is used. A company wide quality standard manual defining all major and minor defects should be developed. This should be written and/or illustrated in such a way that it is easily understood by all who participate in the manufacturing process. This provides a reference tool for direct labor as well as the supervisors and inspection staff. It eliminates the possibility of misunderstanding your company's standards of what is or is not acceptable. Copies should be distributed throughout the work place. Periodic review of the manual employees is recommended. A final statistical based quality audit should be installed. This audit should be performed by designated quality auditors who are not involved with production responsibilities. This audit should be performed on every lot/cut or production run that is produced. To perform a successful audit, the following needs to occur: * A random sample of merchandise should be pulled from finished inventory. * A precise inspection of the samples must include both the outside and inside of the products on a flat, well lit surface when looking for major defects. * Critical measurements should be taken on 3 products per size, a minimum of 12 units. * Lots/cuts should be rejected for %100 inspection if the number of defective units exceeds the parameters noted in table. After the % 100 inspection, a re-audit should be performed. * Document and analyze records of all audit results. These audits should be maintained and utilized to improve overall quality. An in-process inspection should be installed. The inspection should be performed by a designated quality inspector with no production responsibilities. This inspection should be based on a 2.5 A.Q.L.(Table 1) where pieces are pulled randomly from the bundle. An inspection should be performed, away from the operator, on a finished bundle. For bundle sizes up to 180 pieces, seven pieces should be inspected. The bundle should be rejected back to the operator on 1 defect, for % 100 re-inspection and repair. After the operator has performed the repair and inspection of the rejected bundle, immediate, subsequent inspections should take place on the operator's work. This monitoring should continue until three consecutive bundles have passed. Specific records should be kept on all in- process inspections by operator. Each operator should be checked a minimum of two times per day. Inspections by production supervisors should not replace inspections by dedicated quality control personnel. A quality control program in the cutting room with a designated quality control inspector performing spread and cut checks throughout the day should be installed. The inspection should be performed on a statistical 2.5 A.Q.L. basis. There should be written standards and tolerances which include items such as tension, count and leaning, as well as checking top and bottom plies against hard pattern. Detailed records for spreading and cutting should be kept. Additional training for individuals in inspection is needed. This training should include, but not be limited to * Classification of major/minor defects * Methodology of performing the inspection. * How to examine the product. * How to measure the product. * How to keep good records. * Stressing consistency in the inspection. * Understanding the need for quality control. * Being aware of quality goals and improvement measures. Product performance testing should be formalized and should include testing for shrinkage, color fastness, wet and dry crocking as well as verification of weight and/or count of piece goods. Test results should be compared to written standards. Documented records need to be kept. In addition, cleaning of finished products to verify correct care labeling and seam performance should be performed. IX l'-fNco.nt-SS^^^^ < Of o u rr\e->r^esa>r>'r>>r>v~> a."'>°0-İNS8oo2222 c l^^^c^^^O^;--- < V-l vo" g |oooo£Op,00;qS88 cu ~ bO . F^ "E s. S 3 §0--r.cn^^02-- £ g 3 fr S ° g >J -*" C H «- cx 2 «c^cncno