1) Preventive maintenance is given top priority in the factory before starting new pattern/style, thorough checking of the machine is carried out and all defective elements are attended to.

2) Knitters check 100% of the socks for quality by mounting the same on their hand. They are segregated in three heaps i.e

      1) First quality,

      2) Mendable and

      3) Seconds.

3) Knitters check flat measurement of one pair of socks of each machine in one hour and enter the reading in prescribed printed form. Any variation observed is brought to the notice of the technician. Technicians check two pairs of socks from each machine in one shift for quality and flat measurements.

4) Any defect/deviation observed by knitters or by quality control personnel during quality rounds, are immediately reported to the technicians, who rectify the same. The machines remain stopped till the defect/deviation is rectified.

5) Each pair of sock of approved shade and design is kept hanging on the machine. Technician/knitter checks that yarn shade and design of bulk production is in conformity with the above hanging socks.

6) We have an independent quality control section, reporting to the President – Works and headed by a qualified Technician with 9 years experience. 3 assistants work under him. The outline of their job is as under:

• Monitoring sample preparation and sample checking

• 3 Quality rounds in each shift in all three shifts to check quality and specifications

• Checking flat as well as stretch measurements of finished socks from each knitting machine – once in a day and give feed back to the Department to take remedial steps

• Checking of Board fit

• AQL of unfinished socks of every knitting machine in each shift

• AQL of finished socks at pre-dispatch stage

• Checking of First piece of sock of new style, before bulk production is started.

• Checking of yarn shade in colour box.

7) Besides, all raw material suppliers are required to send yarn test report on physical properties, fastness properties and colour continuity. These results are also counter checked in International reputed Labs.

Additional process checks are carried out as follows:

Before Boarding:

- Uniformity of dyeing of yarn - visual

- Uniformity of welt

- Knitting structure from knitting defects point of view

- Colour Scheme of the motif (to compare with approved sample)

- To check the size of float of motif on the backside of socks

- Stitching/seam - no big end, no hole, no lint interwoven

- Weight per pair

- Course length and courses per inch.

After Boarding:

To check and enter data into Sample sheet:

- Flat measurements immediately after boarding and after 24 hours.

- Stretch measurements immediately after boarding and after 24 hours

- Courses per inch in leg and foot

- Course length of leg and foot

- Courses of welt (if Double Cylinder Machine)

- Weight per pair of the finished sock.

- Board fit as per clients stretch board.

The above checking systems are over and above the routinal checks of quality at various stages of manufacturing and finishing.