Defect does not occur but are caused by the process or our selves.

So we need to
understand what the causes of these defects are and how they are caused, so we can
correct the production process. First reaction to a bad work should be to adjust the
process back to what it should be. However, in the longer term, we need to re access the
process and improve it and also remove the possible causes of defects, the poka-yoke or
fool proofing approach. To redesign the process and the complete product would be time
consuming and expensive but the taguchi process can reduce both the time and the cost
by permitting more than one variable to be changed. the reader must have knowledge of
the mening of both taguchi and poka yoke techniques even if they don’t want to adopt the
total quality management approach fully.
It is not possible to examine every imtem in every aspect and some tests, lke those test
for flammability, as it will definitely defect the product. So we do the inspection of a
specific proportion of the total output and we try to analyse the result by the inspection of
that specific proportion. In other circustance taking arbitrary approach look more
sensible. As it is easily understood by people who use it and it will also give the accurate
results.
It is also important for get zero defect approach that the machinery should work properly
and maintained regularly.
It is not possible that we achieve a zero defect record, because of human error and also
the product and process to make that product changes with time, yet for company to be
competitive, we can come very close to zero defects.

The pattern of defects occurrence is a good guideline to the cause, yet when the cause of
the defect is determined it is easy to remove that cause of defect so the defect can be
completely eliminated or minimized.
If the sewing machine used is of good quality and also well maintained it will give a
stitch length that is well with the required limits, unless the fabric is not suitable for the
drive. Like paper nylon in a drop feed machine. Nevertheless, the stitch length will vary
by a small amount over the length of the seam. These variation may be due because of
different causes as the type of the fabric may be change, in the gear teeth of the machine
or in the way that the operative handles the work and so on. If there are enough that they
are of the same degree of importance then the variation in the stitch length be random.
That is, it does not appear to follow any pattern. Most defects which cause quality
problems occurs in a pattern. The nature of the defect yet varies with the cause.

Variation in seam margin

Lets suppose the seam margin for the side seam on a man’s jacket , below the armhole.
The variable limit is plus or minus 1mm and the specification is 10mm. so the seam is
acceptable between 9 and 11mm. above that is a cause of concern. Normally the work is
of the required standard. Twenty seam margins in every thousand are less than 9mm or
more than 11mm. The operator judges the width of the seam with the help of a graduate
needle plate.
Sampling.

The limitation and advantages of sampling

The distribution, the proportion of defects in a lot and their extent will often vary with
time, according to the nature of the cause. To understand the cause of that defect is first
step to make a system to detect them speedily and solve them. For example is is
necessary to know the difference between the random and systematic errors. Minor defect
can be used as as a ultimatum of serious or major defect to occur.

Limitations
1 the sample may not correspond with the ‘lot’ from which it comes.
2 we can not know that how many defect are there for feature of the garment which had
not judged or examined.

However the best size of the sample and the probability that it truly represents the lot can
be calculated by means of statistics and this forms the basis for statistically quality
control. It is important to realize that this is restricted to the distributions which are
represented by the model chosen. If the distribution differs widely from this, then the
SQC approach will be in accurate
Advantages
1. Reduced examination cost.
2. Reduced handling may reduce creasing and soiling.
3. Tge sanokubg method and rate can be varied, according to the prevailing quality
level, the rate of throughput and the attencance of examiners, although with
reduced accuracy in the latter two cases.

The terms in use and their meaning

This is an area where technical terms abound and to understand these terms are necessary
in order to use the system properly. The more important terms that are used are as below

Acceptance Sampling
This term is mostly used to for the procedure by which a lot is rejected or accepted
according to the number of defects in a sample. It is general term for the procedures
described above.
Random sampling
This term is usually used for sample on a random basis. This is, units are usually chosen
from a bundle, batch or lot, and this is done in a pattern that is continuously changing or
have a chance of changing. For the sample in true sense it is necessary to select the
product from the bundle according to a table or random numbers. Which may be installed
in a computer or seen from a book