Itru E- Learning by Teaching Series

Application of Knowledge Based QCC for Textile Mills

Version 1.1 with Itru QCCv1 Software




Course content

Teaching & Training


Methods of Evaluation and Certification

Course Enrollment Fees and Registration for Entrance


A very rapid development of science and technology also brings many changes along with it. At this point the mills that implement these changes have much higher chances to compete than others. Today Optimum / Quality / Minimum Manufacturing Cost has become the most important key to success for competitiveness in the international market. Accomplishing this goal with the classic management control systems is no longer possible. Mills who are aware of this fact started the restructuring their process and established Knowledge-Based Mills Control Systems in some ways.

This quality assurance system requires four-control level of communication. These are Quality Planning, Quality Management, Quality Control and Quality Circles units. The main difference of this new system from the classical system is the presences of Quality Management unit.

This unit prepares Quality Reports by evaluating the reports and test results submitted from quality control / process control. Quality Management provides the rearrangement of Quality objectives according to changing conditions. Thus, Quality Assurance Department for companies as a priority to be established. Quality Planning, Quality Management and Quality / Process Control sections are created in connection with the Quality Assurance Department. Quality Management is a very important role in this new system. Running of Quality Management necessitates very knowledgeable and educated people.

Knowledge-Based System must include these four elements of the control level. All four of these are in a cycle of control levels. Therefore, the essence of the system is continuous improvement.

Quality Planning organizes all the quality assurance system all quality criteria and practices should be rearranged in accordance with the changing conditions.

Quality Management is a junction point of the quality loop. There is a linking communication from here to Process/Quality Control and Quality Planning. The test results submitted to Quality Management are condensed here and each process control entity is provided.

Quality Control Section includes Production Planning and Quality Control Systems and QCC The tests results carried out in Quality Control also provides direct communication between production and maintenance units. Therefore, Quality Control has the possibility to intervene directly to the process, operation and machine maintenance.

Computer-aided system simplifies these operations and results in a short time and ensures an effective and efficient manner.

DPEA (Defect Probability and Effect Analysis), Knowledge Based PC-Programs are also available in Quality Management Department . SPC techniques play an important role in the preparation of test reports and the condensation of the data.

A job that is directly related to the quality circle team work, based on the principle of voluntary participation, gather once a week on average, and to determine the actual or potential business problems, discuss, offer solutions to management in order to improve or create their own cluster solution.

What's New in Knowledge-Based QCC ?

Main intention of QCC is to define the problem or goal and solve it with team members. With the Knowledge-Based System the problem is classified according to four main factors :_

· Status

· Variable

· Control

· Interference

This classification makes it simpler to solve the problem in statistical ways and also helps you which techniques to use to analyze and solve the problem .

Secondly , Knowledge-Based PC-Programs assist solving and identifying most of the problems that exist in textile mills.

Thirdly, Knowledge-Based QCC includes Knowledge-Based Problem-Analysis and Problem Solving Algorithms which make simpler and shorter in solving the problems .

Fourthly , QCC is a part of Knowledge-Based Quality Management System which already include Process Optimization works itself. Hence all of these lead to better performance of QCC in textile mills. Knowledge-Based QCC ver1.1 software makes it simpler to control all QCC activities.

Fifthly, QCC activities are classified in accordance with Knowledge Based SPC techniques .

Sixthly, QCC activities carried out along with Process Optimization works of Quality Management Team. (QM)

Seventh, QCC activities give suggesting to QM for new Process Improvement Works .

Trainees are also supported with Itru QCC- ver 1.1 PC-Program. Examples to make their knowledge enhanced and practical. After a completing the course a trainee could establish and or improve QCC- System in their field. Support will be given for those who enroll the course and as well as in actual mill practices.

Read More QCC ver 1.1 Software Click Here

QCC is also closely related to Quality/Process Control procedures in spinning, weaving and finishing mills as well as a part of Knowledge Based Quality Management System.

QCC software makes it simple to adapt QCC systems in textile industry. After completing this course the candidates will make use of QCC software more effectively.

Requirements: In order to enroll this course the candidate should have a minimum of BSC in Science or Engineering in order to get Facilitator Certification For Group Leader Certification no document is required.

1-2 General Overview of the Course

This training course has main 5 chapters

Chapter 1 is related to Knowledge Based Quality Management (KBQM) and place of QCC in KBQM

Chapter 2 . Quality Circle Techniques in Relation to Knowledge Based Quality Management

Chapter 3. Implementation Knowledge Based QCC in Textile Mills

Chapter 4. Application of Knowledge Based QCC ver 1.1 Software in Textile Mills

Chapter 5. Learning by Teaching to Implement QCC in Textile Mills.

2- Qualifications and Goals

This course as instructed in the course book and knowledge Based QCC ver 1.1 Software intended for the better use and installation of QCC in textile mills for

-Quality Planning ( QCC activities control )

-Quality Management ( QCC Reviewer and Facilitator)

-QCC Circles ( Group Leaders and Members)

The candidate will be able to control quality level in fibers, yarns and fabrics as well as spinning and weaving and knitting mill performance. Itru QCC ver 1.1 software could also be used for process improvement in spinning, weaving and knitting and processing mills.

Any candidate who completes and passes the main exam will be able to take over the tasks of QCC Facilitator and Group Leader for Spinning, Weaving and Knitting Mills and will have a certification signed and approved by Itru Group Ltd

The aims of this e-learning QCC ver.1.1 for textiles could be

- Fees paid during the reduction in lost time

- Reduction in complaints

- Reduction in occupational accidents

- Reduction in incidents related to occupational safety

- Reduction in failures in using the best equipment for workers

-More effectively using the existing textile testing equipment and machinery

-Applying QCC systems to quality control and process control

-Revising existing QCC-Systems and developing further

-Improving quality, productivity and machine and material performance and reducing waste and optimization test total.

3- Course content

The main course is written in PDF file format which covers main subject,exercises and examples. The course is divided into 5 chapters .

Table of Contents

1.1 Introduction 4

1.2.1 Quality Assurance System Design 4

1.3 .1 Definition of Quality Circle 7

1.4.1 Objectives of Quality Circles 7

1.5.1 Requirements for the Establishment of Quality Circles 8

1.6.1 Benefits of Quality Circle Activities 9

1.7 .1 Functional Work Flow Knowledge-Based QCC 9

1. 7.2 Establishment of Quality Circles 10

1.8.1 Basic Knowledge Based Quality Circle Techniques 12

1.8.2 Internal Structure and Functioning of Quality Circles 12

1.8.3 Some Common Features of Quality Circles 14

1. 9.1 Quality Circle Success Evaluation with QCC ver 1.1 Software 15

1.10 Implementation of Quality Circle Watch-points 16

1.11 Understanding the Purposes of Quality Circles 16

2.Quality Circle Techniques in Relation to Knowledge Based Quality Management 17

2.1.2 Pareto Analysis 17

2.2 Control Charts and Flow Diagrams 21

2.3 Knowledge Based Problem Analysis Problem Solving Algorithms 24

2.4 Cause-and-Effect or Fishbone Diagram (Ishikawa diagram) 28

2.5 Brainstorming 29

2.5.1 Process and Study Tips for Brainstorming 29

2.6 Histograms, Cumulative Frequency , Box Plot and Hi-Low Charts 30

2.7 FTA (Fault Tree Analyses) and DPEA(Defect Probability and Effect Analyses) in Relation to Flow Chart and Control Plan 33

2.8 Scatter Diagrams ,Spline Charts and Regression Analysis 34

3-Implementation Knowledge Based QCC in Textile Mills 35

4 Application of Knowledge Based QCC ver 1.1 Software 36

5- Learning by Teaching to Implement QCC in Textile Mills. 41

6. References 42

Appendix 1 Deming's 14 Quality Articles and Assignment 43

Appendix 2 Quality Circles Milliken Example 44

7- Questions and Exercises 45

The course period is total of 8 weeks . At least after one week of the course Facilitator starts to establish QCC in his/her mill as instructed in Chapter 5 in accordance with QCC ver 1.1 software.

Read More QCC ver 1.1 Software Click Here


Total Period :8 weeks

4-Teaching-training activities

The core of the system is Learning Path, which covers

a) Reading Chapters

b) Understanding examples

c) Solving exercises

d) Passing the test at the end of the course.

e) Submitting assignments to course administrator and further reading related documents from Wiki and prepare Home Works

f) Submitting questions and answers to Forum

g) Suggestions new subjects to main course to be included or excluded

5 -Support

Training course has self-supporting system. Each candidate will submit their questions to Forum and will be answered by the forum or course Administrator

6 - Human and Physical Resources

QCC ver 1.1 Software , Spread Sheet Examples and practical mill samples applications.

7- Methods of Evaluation and Certification

This course has been intended to give training for

QCC Group Leader

QCC Facilitator

QCC Members

A certification will be given as QCC Facilitator and also QCC Group Leader that can apply this system in practical application.

The evaluation is a total of

a) Exercises solving ( % 20)

b) Home work written documents (%20)

c) Final Exams performance for the candidate (%45)

d) Deriving Questions , answers and mill practical samples for the related topics ( %15)

Any candidate who can not complete the course for a given period of time automatically deleted from the course without any refunding . Any misuse of the system resources may lead to canceling of enrollment without any refunding and notification .

Itru E-Learning Site -Textile Mill Training Service

8- Course Enrollment Fees and Registration for Entrance

Requirements :Internet connection and familiarity with spread sheet software.

Ms-windows Operating System XP,Vista or Windows 7 , Open office ver 3.4.0 English version and Adobe Reader

Course Fee :

For individuals = 220 USD per person

For companies = 220 USD per group ( Each group has 1 to maximum 2 members )

Registration : Click here for registration to QCC

Validation of Registration : An e-mail will be send to you for validation of your registration including information about payment . Course Fee includes QCC ver 1.1 software.

Read More QCC ver 1.1 Software Click Here

Read before enrollment

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