Quality Control Process
Multi-stage quality assurance from raw material inspection to final audit. Transparent QC protocols aligned with international AQL standards.
Quality Control Stages
Fabric, trims, and accessories inspected before cutting. 4-point system for fabric defects. Color, GSM, and shrinkage testing.
QC checkpoints during production. Measurements, stitch quality, construction verification. Immediate corrective action.
AQL 2.5/4.0 inspection of finished garments. Detailed defect reporting. Third-party audit coordination.
Raw Material Inspection
All materials inspected and tested before cutting authorization
| Inspection Type | Method | Frequency |
|---|---|---|
| Fabric Inspection | 4-point system on inspection table | 100% of rolls |
| Color Matching | Under D65 light source | Every lot |
| GSM/Weight Check | Electronic GSM cutter | Random sampling |
| Shrinkage Test | AATCC/ISO standards | Per lot |
| Dimensional Stability | After washing simulation | Per style |
| Color Fastness | Wash, rub, light, perspiration | Per lot |
Defect Scoring:
- • 0-3 inches defect = 1 point
- • 3-6 inches defect = 2 points
- • 6-9 inches defect = 3 points
- • Over 9 inches defect = 4 points
Acceptance Criteria:
Total points should not exceed 40 per 100 square yards of fabric. Rolls exceeding this limit are rejected or negotiated for downgrade.
Inline Quality Checks
Quality verification at critical operations during manufacturing
| Checkpoint | Verification | Timing |
|---|---|---|
| Pattern & Marking | Marker efficiency, grain line | Before cutting |
| Cutting Accuracy | Panel measurements | Random 10% |
| First Garment Approval | Complete assembly check | Every style |
| Sewing Operations | Stitch quality, seam strength | Every 1 hour |
| Measurements | Spec sheet compliance | Every 50 pcs |
| Finishing | Pressing, trimming, stain check | 100% |
Garment measurements checked against buyer spec sheet at multiple stages:
- Stage 1Cut panels before sewing
- Stage 2First garment approval
- Stage 3Every 50 pieces during production
- Stage 4After washing/finishing
- FinalPre-shipment inspection
Immediate response to quality issues:
- • Production line halt if critical defect found
- • Root cause analysis by supervisor
- • Operator retraining if skill-related
- • Machine adjustment if mechanical issue
- • Rework of affected pieces
- • Increased check frequency for next 2 hours
Final Inspection & AQL Standards
Standard acceptance quality limits applied to finished garments
| Defect Category | AQL Level | Description |
|---|---|---|
| Critical Defects | 0 | Safety issues, unwearable |
| Major Defects | 2.5 | Significant quality issues |
| Minor Defects | 4.0 | Cosmetic/aesthetic issues |
Zero acceptance for defects that render garment unsafe or unusable:
- • Needle or metal contamination
- • Broken or unsafe fasteners
- • Chemical stains or odor
- • Holes or tears
- • Wrong size or style shipped
Significant quality issues affecting functionality or aesthetics:
- • Measurement deviation beyond tolerance (±5%)
- • Seam puckering or open seams
- • Visible color shading between panels
- • Skip stitches or irregular stitching
- • Missing or defective trims
Cosmetic issues that do not affect garment functionality:
- • Loose threads
- • Minor stitch irregularity
- • Slight puckering (non-critical areas)
- • Small fabric slubs or neps
- • Minor shade variation (within tolerance)
- • Slight label misalignment
- • Light pencil marks (removable)
- • Minor packaging issues
Defect Handling & Rework Policy
Systematic approach to handle detected defects:
Stage 1: Segregation
Defective garments immediately separated and tagged with defect description.
Stage 2: Assessment
QC supervisor evaluates if rework is possible or garment must be rejected.
Stage 3: Rework
Skilled operators perform corrections. Re-inspection mandatory after rework.
Stage 4: Documentation
All defects and rework logged for trend analysis and process improvement.
Transparent communication on quality issues:
- ImmediateCritical defects found in bulk production
- Within 24hMajor defects exceeding AQL limits
- WeeklyQuality report with defect rates and trends
- Pre-shipmentFull inspection report with photos
Buyers may appoint third-party inspection agencies at any stage. We provide full cooperation and documentation.