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Quality control is practiced right from the initial stage of sourcing raw materials to the stage of final finished garment. For apparel quality is calculated in terms of quality and standard of fibers, yarns, fabric construction, color fastness, surface designs and the final finished garment products. However quality expectations for export are related to the type of customer segments and the retail outlets.
How to make sure the good quality of our products, Let's do below jobs:
1. Understanding the customers' quality requirements.
2. Organizing & training quality control department.
3. Ensuring proper flow of quality requirements to the QC department.
4. Ensuring proper flow of quality requirements to the Production Department.
5. Establishing quality plans, parameters, inspection systems, frequency, sampling techniques, etc.
6. Inspection, testing, measurements as per plan.
7. Record deviations
8. Feedback to Production Department.
9. Plan for further improvement.
The first step for quality control is to understand, establish & accept the customers' quality requirements. This involves the following steps.
1. Getting customers specifications regarding the quality
2. Referring our past performance
3. Discussing with the Quality Control Department
4. Discussing with the Production Department
5. Giving the Feed Back to the customers
6. Receiving the revised quality requirements from the customers
7. Accepting the quality parameters
The following levels are discussed at the Garment Making Department assuming that this department is receiving the ready to cut dyed & finished fabrics from the Dyeing & Finishing Department.
The following parameters & defects are checked prior to cutting.
1. Shade Matching
2. Fabric Construction
3. GSM (grams per square meter)
4. Whales & courses if required)
5. Diameter
6. Dyeing Levelness
7. Ecological parameters if required
8. Softness
9. Shrinkage
10. Matching of Rib, Collars & Cuffs
11. Fabric Holes
12. Vertical & Horizontal Stripes
13. Knitting defects such as missing loops, sinker lines, etc.
14. Bowing
15. Skewing
16. Yarn defects such as thick & thin places
17. Dirt & Stains
18. All accessories, we have to check if the quality of all accessories meet buyer's requests.
1. Verify cutting patterns
2. Cut components measurements
3. Cutting shapes
4. Fabric defects
5. Other specific parameters as required by the customers Rib, Collars & Cuffs matching
6. Stitching defects
7. Sewing threads matching
8. Dirt & Stains
9. Measurements
10. Labels
11. Trims & Accessories
A. PACKING & ASSORTMENT
1. Wrong Model
2. Wrong Quantity
3. Missing labels & tags
4. Wrong Size & Color assortment
5. Wrong Folding
B. FABRIC DEFECTS
1. Wrong Shade
2. Uneven dyeing
3. Holes
4. Knitting stripes
5. Thick & Thin places
6. Dirt & Stains
7. Oil stains
8. Sinker line
9. Poor softness
10. Higher Shrinkage
11. Crease Marks
C. WORKMANSHIP DEFECTS
1. Open seam
2. Puckering
3. Needle holes & marks
4. Unbalanced sleeve edge
5. Unbalanced placket
6. Insecure shoulder stitch
7. Incorrect side shape
8. Bottom hem bowing
9. Uneven neck shape
10. Cross labels
11. Broken & Missing stitch
12. Insecure buttons
13. Untrimmed threads & fabrics
14. Poor Ironing
15. Double stitch
D. GENERAL DEFECTS
1. Shade variation within the garment parts
2. Shade variation between the garments
3. Defective printing
4. Defective embroidery
5. Defective buttons
E. MEASUREMENT DEVIATIONS
Compare the garment measurements against the Customers' Measurement Charts.
Following are the some of the important garments' measurement aspects to be considered.
1. Garment length
2. Body width
3. Shoulder length
4. Arm hole
5. Arm Opening
6. Sleeve length
7. Placket length
8. Placket width
9. Neck width
10. Neck opening
11. Hemming width
12. Rib or Collar width
13. Waist Width
14. Front rise
15. Back rise
16. Hip
17. Thigh
18. Inseam
19. Leg opening
Many of the important parameters of Pre-productions, During productions & Final inspection parameters. This is to ensure that wrong or major defective garments are not packed.
A certain proportion of defective will always occur in any manufacturing process. If the percentage does not exceed a certain limit, it will be economical to allow the defective to go through instead of screening the entire lot. This limit is called the "Acceptable Quality Level" ( AQL )
Considering the practical & economic aspects, Sampling Techniques are adopted to Accept or Reject a Lot on the basis of the Samples drawn at Random from the lot. It has been found and accepted that a scientifically designed sampling & inspection plan protects a Manufacturer as well as the Buyer economically.
Our acceptable Quality Levels 2.5
SAMPLING PLAN
1.5 | 2.5 | 4.0 | ||||
LOT SIZE | Inspect | Accept | Inspect | Accept | Inspect | Accept |
0-151 | 8 | 0 | 5 | 0 | 13 | 1 |
152 - 280 | 8 | 0 | 20 | 1 | 13 | 1 |
281 - 500 | 32 | 1 | 20 | 1 | 20 | 2 |
501 - 1200 | 32 | 1 | 32 | 2 | 32 | 3 |
1201 - 3200 | 50 | 2 | 50 | 3 | 50 | 5 |
3201 - 10,000 | 80 | 3 | 80 | 5 | 80 | 7 |
10,001 - 35,000 | 125 | 5 | 125 | 7 | 125 | 10 |
35,001 - 150,000 | 200 | 7 | 200 | 10 | 200 | 14 |
150,001 - 500,000 | 315 | 10 | 315 | 14 | 315 | 21 |
500,001 - over | 500 | 14 | 500 | 21 | 315 | 21 |
Peony & Buyoh－Procedures and Guidelines for Auditing by ourselves | ||||||
--------Procedure: | ||||||
* Select the specified lot or the lot being audited. The lot size is the total units in the specification | ||||||
** According to the sampling plan under the 2.5 AQL, determine the number of units to inspect. These units will be your | ||||||
sample size. Example: if your lot size is 2500; then your sample size would be 50 units accepting 3 defects. | ||||||
*** The sample size will be thoroughly inspected for: packaging, labeling, size, color and workmanship. | ||||||
-------Pass / Fail Guidelines: | ||||||
* An audit is considered passing if the sample size meets or is lower than the 2.5 AQL chart for a specified lot size. | ||||||
** If the initial sample size exceeds the 2.5 AQL chart for a specified lot; an additional sample size must be pulled from that | ||||||
same lot. If the second sample size meets or is lower than the 2.5 AQL chart, the audit results in a pass. | ||||||
*** If the first and second sample size exceed the 2.5 AQL chart for a specified lot; the audit results in a fail and must | ||||||
go through a 100% re-inspection for that specified lot. Products that fail cannot be shipped until it receives a passing status . | ||||||
Remark: LOT SIZE = Order qty; Inspect (qty); Accept (qty)
Click here to check the Garment Defect Codes.
