Fabric Inspection Using Four-Point System

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Briana Dalton
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1 Fabric Inspectin Using Fur-Pint System Hw t draw the samples? If there are 10 rlls and each ne is a different type f fabric r a different design, all the rlls have t be checked. Hwever, in mst cases there are several identical rlls, and statistical sampling helps us reduce the amunt f wrk. But mst f the times clients impse their wn methds: fr example take 10% f the rlls at randm, r check the square rt f the ttal number f rlls. All are usually wrkable. Selectin f Rlls: At least ne rll f each clr / quality is selected. If mre than ne rll per clr / quality must be inspected, then the number f additinal rlls in prprtin t the ttal rlls per clr / quality is inspected. What can be checked? The number f presented rlls, and the length & width f each inspected rll, is verified. Sme tlerance is necessary because the factry s machine (see abve image) is ften imprecise. Usually the client sends sme fabric swatches fr reference. It is great t check the cnfrmity f prductin. Lastly, packing and labeling. Tti-Inspectins (Pvt.) Ltd 347-S, Quaid-e-Azam Industrial Estate, Kt Lakhpat. Lahre-54770, Pakistan

But mst f the times clients impse their wn methds: fr example take 10% f the rlls at randm, r check the square rt f the ttal number f rlls. All are usually wrkable.

2 Inspectin: Using 4-Pint System r any ther agreed upn system as defined by the custmer, inspectin is carried ut n a fabric inspectin machine. Defect Classificatin Using Fur-Pint System: Size f Defect Penalty 3 inches r less 1 Pint Over 3, but nt ver 6 inches 2 Pints Over 6, but nt ver 9 inches 3 Pints Over 9 inches 4 Pints A maximum f fur pints is charged t ne linear yard The length f the defect is used t determine the penalty pint. N mre than fur penalty pints may be given fr any single defect. General Inspectin Prcedures 1. Fabric inspectin is dne in suitable and safe envirnment with enugh ventilatin and prper lighting. 2. Fabric passing thrugh the frame must be between degree angles t inspectr and must be dne n apprpriate Cl White light 2 F96 flurescent bulbs abve viewing area. Back light can be used as and when needed. 3. Fabric speed n inspectin machine must nt be mre than 15 yards per minute. 5. Standard apprved bulk dye lt standards fr all apprved lts must be available prir t inspectin (if pssible) 6. Apprved standard f bulk dye lt must be available befre starting inspectin fr assessing clr, cnstructin, finish and visual appearance. Tti-Inspectins (Pvt.) Ltd 347-S, Quaid-e-Azam Industrial Estate, Kt Lakhpat. Lahre-54770, Pakistan

pints is charged t ne linear yard The length f the defect is used t determine the penalty pint. N mre than fur penalty pints may be given fr any single defect. General Inspectin Prcedures 1.

3 7. Shade cntinuity within a rll by checking shade variatin between centre and selvage and the beginning, middle and end f each rll must be evaluated and dcumented. 8. Textiles like knits must be evaluated fr weight against standard apprved weight. 9. Fabric width must be checked frm selvage t selvage against standard. 10. All defects must be flagged during inspectin 11. The length f each rll inspected must be cmpared t length as mentined n supplier ticketed tag and any deviatin must be dcumented and reprted t mill fr additinal replacement t avid shrtage. 12. If yarn dyed r printed fabrics are being inspected the repeat measurement must be dne frm beginning, middle and end f selected rlls. N penalty pints are recrded r assigned fr minr defects. Only majr defects are cnsidered. A majr defect is any defect that, if fund in a finished fabric /garment, wuld classify that fabric / garment as a secnd- rated. Majr wven fabric defects are slubs, hle, missing yarn, cnspicuus yarn variatin, end ut, siled yarn, wrng yarn. Majr knitted fabric defects are mixed yarn, yarn variatin, runner, needle line, barre, slub, hle, and press ff. Majr dye r printing defects are ut f register, dye spts, machine stp, clr ut, clr smear, r shading. The Quality Inspectr may include any ther defect which he feels are f a majr categry and may frward such defect details t the custmer fr feed back as and when required. Tti-Inspectins (Pvt.) Ltd 347-S, Quaid-e-Azam Industrial Estate, Kt Lakhpat. Lahre-54770, Pakistan

All defects must be flagged during inspectin 11.

4 Minimum acceptable width This width is excluding selvedge. Fabric width will be checked minimum f three times during the inspectin f a piece (beginning, middle and end f a piece). Pieces having a width f measurement f less than the specified purchased width shall be graded as secnd quality. Defects Rules: A cntinuus f defect shall be assigned fur pints fr each linear meter r yard in which it ccurs. Any piece having a running defect thrugh mre than three cntinuus linear meters r yards shall be rejected. Regardless f pint cunt. Any piece with a full width defect ver six inches in length shall be rejected. Any piece that cntains mre than three full width defects per ne hundred linear meters r yards shall rejected. N piece shall be accepted that cntains a full width defect in the first and last three meters r yards. A hle r trn is cnsidered t be a majr defect and shall be penalized fur pints. Fabric cnstructin and weight, N tlerance will be allwed. The distance between majr defects shuld be mre than 20 meters. All majr and full width defects shuld be seemed a plyester thread at the selvedge. Waviness, tightness, ripples, puckering in bdy f fabric which wuld prevent the fabric frm lying flat when spread in a cnventinal manner is nt acceptable. Tti-Inspectins (Pvt.) Ltd 347-S, Quaid-e-Azam Industrial Estate, Kt Lakhpat. Lahre-54770, Pakistan

Defects Rules: A cntinuus f defect shall be assigned fur pints fr each linear meter r yard in which it ccurs.

5 Fllwing defects will be penalized penalty pints as per rules; Kinks, Knts, slub, cntaminatin, spt, and half/duble pick, cckled yarn, carse pick. Heavy weft bar belw 6 in length, set mark, rapping, brken pick, ut mark, hles & flat up t ¼ Fllwing defects are cuttable and will be rejected: Frequent kinks, knts, slub, cntaminatin, spts etc Any cntinuus defect Mre than ne meters brken end, duble end, wrng draw reed mark Hles trn and flat abve ¼ Irregular selvedge, light weft bar, cunt variatin, Lecc, shade variatin Heavy weft bar abve 6: in length The mst cmmnly used system is the American 4 pint system. The ASTM D5430 standard explains hw t assign pints t each defect mstly based n its size. The verall result cnsists f tw numbers (and they are all mst buyers want t knw regarding defects): The average number f pints (n a 100 meters basis) f all inspected rlls, The prprtin f rlls abve acceptance limit. Hw can we measure pints n a 100 meters basis? Maximum Acceptable Pints = 20 pints per 100 sq. yards OR 22 pints per 100 sq. meters. Tti-Inspectins (Pvt.) Ltd 347-S, Quaid-e-Azam Industrial Estate, Kt Lakhpat. Lahre-54770, Pakistan

cntinuus defect Mre than ne meters brken end, duble end, wrng draw reed mark Hles trn and flat abve ¼ Irregular selvedge, light weft bar, cunt variatin, Lecc, shade variatin Heavy weft bar abve 6: in

6 Calculatins: Pints/ 100 sq. yard = 3600 Ttal pints assigned Fabric Length in yards Fabric Width in inches Pints/100 sq. mtrs. = Ttal pints assigned Fabric Length in mtrs Fabric Width in mm Fr example- Ttal Linear pints = 13 Ttal Length f the rll = 31 meters Width f the rll = 166 cm = 1.66 meters Area Area = Length x Width = m m2 has ttal linear pints = 13 1 m2 has ttal linear pints = 13/51.46 Pints per 100 m2 = (13/51.46) x 100 = pints / m2 Results: Unsatisfactry Rll Tti-Inspectins (Pvt.) Ltd 347-S, Quaid-e-Azam Industrial Estate, Kt Lakhpat. Lahre-54770, Pakistan

= 166 cm = 1.66 meters Area Area = Length x Width = 51.46 m2 51.46 m2 has ttal linear pints = 13 1 m2 has ttal linear pints = 13/51.

Quality Assurance to ISO 9000 series. Normal Route With No QA System. Categor y. Serial Production. A Internal production control

Quality Assurance to ISO 9000 series. Normal Route With No QA System. Categor y. Serial Production. A Internal production control The directive lists 13 different mdules that define the inspectin requirements f bth the manufacturer and ntified bdy. Tw mdules, & 1, cver design nly and have t be used in cnjunctin with anther mdule