Head - QUALITY

Quality Management & Strategy

• Develop and implement the overall quality management system (QMS).
• Set quality standards, KPIs, and quality objectives for the factory.
• Establish quality procedures for fabric, cutting, sewing, finishing, packing, and shipment.
• Drive continuous improvement and reduce quality-related costs.

2. Incoming Material Quality

• Ensure inspection of fabric, trims, accessories, labels, thread, buttons, zippers, etc.
• Establish inspection standards and acceptance criteria.
• Monitor fabric defects, shade variation, GSM, shrinkage, color fastness, and other parameters.
• Coordinate with Purchase and Suppliers for quality issues and corrective actions.

3. Pre-Production Quality

• Review buyer specifications, tech packs, measurement charts, construction details, and quality standards.
• Ensure PP samples and size sets meet buyer requirements.
• Conduct and approve Pre-Production Meetings (PPM).
• Identify potential quality risks before bulk production starts.

4. Production Quality Control

• Monitor quality at cutting, sewing, washing, finishing, ironing, and packing stages.
• Ensure proper implementation of inline and end-line inspection systems.
• Monitor defects, DHU, RFT, rejection, alteration, and rework.
• Take immediate corrective action for recurring defects.
• Ensure operators follow approved workmanship and quality standards.

5. Final Inspection & Shipment

• Ensure garments are inspected according to AQL/buyer inspection standards.
• Review final inspection reports before shipment.
• Ensure all critical defects are identified and corrected.
• Coordinate with Production and Merchandising teams to avoid shipment delays due to quality issues.

6. Buyer & Customer Quality Management

• Handle buyer quality requirements, audits, inspections, and quality-related communications.
• Analyze buyer inspection reports and complaints.
• Implement corrective and preventive actions (CAPA) for buyer complaints.
• Maintain strong relationships with buyers and third-party inspection agencies.

7. Quality Team Management

• Lead and develop the Quality Assurance (QA) and Quality Control (QC) teams.
• Define responsibilities for Quality Managers, Executives, Inspectors, and Auditors.
• Conduct training on garment defects, workmanship, inspection procedures, and buyer standards.
• Evaluate team performance and improve quality capability.

8. Quality Audits & Compliance

• Conduct internal quality audits and process audits.
• Ensure compliance with customer requirements and factory quality procedures.
• Prepare the factory for buyer, third-party, and certification audits.
• Track audit findings and ensure timely closure of corrective actions.

9. Root Cause Analysis & Continuous Improvement

• Analyze major and repeated defects using 5 Why, Fishbone, Pareto analysis, etc.
• Identify root causes and implement permanent corrective actions.
• Monitor effectiveness of corrective actions.
• Drive initiatives to reduce alteration, rejection, rework, DHU, and customer complaints.

10. Quality Performance & Reporting

• Prepare daily, weekly, and monthly quality reports.

• Monitor KPIs such as:

• DHU / Defect Rate

• First Pass Yield (FPY)

• Right First Time (RFT)

• Rejection %

• Alteration %

• Rework %

• Final Inspection Pass Rate

• Buyer Complaints

• Cost of Poor Quality (COPQ)

• Present quality performance and improvement plans to senior management.

11. Cross-Functional Coordination

• Work closely with Production, IE, Merchandising, PPC, Cutting, Finishing, Maintenance, Stores, Purchase, and HR.
• Participate in production planning and problem-solving meetings.
• Ensure quality requirements are considered before making process or production changes.

12. Cost Reduction & Productivity

• Reduce quality-related losses through prevention rather than correction.
• Minimize rework, alteration, rejection, wastage, and customer returns.
• Improve process capability and operator awareness.
• Support management in achieving better quality at lower cost.