AQL Sampling chart for apparels industry is nothing different it remains the same, so here we will understand its usage in apparel industry. Inspecting 100 % of the garments is time taking and practically impossible for manufacturers or buyers as the order quantities are higher in the clothing sector.so there is a need to mathematically find out the optimum number of products (garments in this case) which can be inspected to judge the quality of the whole order.
To solve this problem Random sampling is used AQL is a random Sampling technique . Acceptable Quality Level sampling chart(AQL chart) tells us two things:
Inspection level: Product quality requirement may vary from one product to another. Therefore the severity of the inspection needs to be adjusted as well. The most common inspection level is “General inspection level 2” so if it’s explicitly mentioned it means it is general inspection level 2.
AQL Level: The required quality level for that lot. if the buyer’s quality requirement is higher the AQL will be set to lower. the AQL for the garment industry is set to 2.5
Reading the AQL table to find the Sample size and Acceptable Quality level is a two-step process through two charts
Step 1: Sample Size Code letter Chart:
Select the inspection level in the columns and the Lot size in the row . The intersection of row and column gives us the code letter. For example if the Lot size is 5000 pieces and Inspection level is ‘General Inspection Level 2’ then the sample size code letter will be ‘L’. Refer to the image below:
Step 2. Sampling & Acceptable Limit:
Now that we have the Sample size code letter, in the similar approach select the intersection of AQL level and Sample size code letter. For our example with code letter “L” if AQL level desired is 1.5 then the lot will be rejected if the rejected pieces are more than 7 see the image below
Whenever there is a need to find the average SAM, It becomes quite clear that simple average doesn’t give us the right picture. This is because simple average divides the SAM equally between all the styles. This division is wrong because there will be some styles with bigger order Quantity and some styles with lesser order quantity and the effect of order quantity will not be reflected in the averaged SAM. Therefore we need to calculate weighted average SAM whenever there is need to find average. Continue reading “How to calculate Weighted average SAM or weighted average SMV ?”
Fabric consumption depends greatly on the number of garments on a marker because the more the number of garment patterns on a marker the better is the marker efficiency. So a 6 way marker will have better marker efficiency than a 4 way marker which means that fabric consumption will be lesser for higher way markers. Therefore, standardizing the number of ways is very important because only then we will be able to control the fabric consumption. Continue reading “Deciding factors for number of garments on a marker”
Production planning and control in apparel industry is a department which fixes production start date(cutting start date) ,allocates the style to a sewing line and controls the processes such that the deliveries are met on time. As the name suggests there are two functions of this department
The question “Difference Between Standard & Standardised work?” has been a confusion for quite a few people and I have seen people particularly pressing on the point that “Do not confuse Standard work with Standardised work”. I googled the difference and what I could understand from many blog posts was that Standard work means the work will not change whereas Standardized work means there is a scope of improvement. Continue reading “Difference Between Standard & Standardised work ?”
“Where there is no standard, there is no Kaizen” . Effective lean strategy should be made by keeping Standardisation as the focus point. This is because Standardised work forms the foundation for Kaizens & is also one of the 5S .
Process Standardisation is a simple technique but with high impact. It is more underestimated than misunderstood. Lean strategy in Garment industry is mainly centered around 5S & Kaizen but an effective lean strategy should be made by keeping Standardisation as the focus point. This is because Standardised work forms the foundation for Kaizens & is also one of the 5S . Taichi Ohno, The father of Toyota Production System himself has famously quoted :
“Where there is no standard, there is no Kaizen”
What is Process Standardisation in garment industry?
In this post I am going to tell you a useful excel formula for merchandisers, planners and buyers ( or every garment professional) which is going to save you a lot of time and will let your boss wondering about your speed and efficiency.