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Apparel Quality control

in Garments Manufacturing, Quality

Quality Control in Apparel industry

The apparel industry is all about garments manufacturing, a manufacturing industry about making a
garment. Quality control in garments manufacturing is the biggest deal for management, Satisfaction on the
bulk production, sample quality /workmanship what observed in garments manufacturing floor matching
buyer expectation. Garments Quality requirements meet with correct quality, workmanship and accepted
measurement tolerance. Any chaos in quality issue garments manufacturer suffers most. Reporting is the first
work of quality controlling then work for a solution. Follow SOP in every work is the key quality control.

Importance of Quality control

Quality is the key to successful garments manufacturing. Nowadays Quality demand is very and everyone is
very much fashion trend. If a garments factory cannot meet the expected quality level they will lose order
straightaway and effect in business. Garments factory survive on Quality. Every time the Garments industry
penalize a big amount of money for failing in final quality inspection. And then the buyer asks the factory to
recheck all packed goods. Rechecking a complete lot and re-final audit process is very much costly. Shipped
garments have another quality audit process in of buyer overseas warehouse. If the buyer found bad quality
products in their audit, claim full FOB cost as their compensation. Quality is the first thing that garments
manufacturers have to maintain.
Quality control of Apparel Industry

Fabrics Quality control

There are many steps of fabric quality control in the garments industry. Fabrics shrinkage,
distortion, shade, fabrics visual defects, etc. It has to do inspections for all rolls as per customer
standards & segregate the rolls & properly distribute to cutting as per Shrinkage & shade wise.

Fabrics Quality control Flow:

Roll wise Blanket making

↓
Blanket washing

↓
Shade checking of every blanket

↓
Blanket shade grouping
 ↓
Making shade chart by A, B, C....

↓
Selecting master Roll of every shade

↓
Making shade Band

↓
Submit shade band to buying a house

↓
Color continuity/Run card making

↓
Shrinkage, Skew and Distortion test

Pattern Quality Control
The pattern is a very sensitive and unauthorized person not allowed to edit the pattern. It is better to
keep plus tendency in all patterns. It also requires making separate patterns by considering shrinkage
differences. There must a pattern library with all set of a pattern of every style. Every stage pattern from
sampling to bulk should keep separately and follow the changelog as best practices of the garments
pattern section.

Cutting Quality Control

Cutting is not all about cut, bundling and input to the sewing section. Cutting quality
effects on end products like measurement, shape, fabrics defects on garments, etc.
1.      Cutting is an important part of garments to keep standard qualities.
2.      It must require to keep fabrics relaxation for at least 24 hours. It must roll out all rolls by using fabric
relaxation machines.
3.      If fabrics are stretch fabrics, it has to handle separately by using smooth steel or plastic Pipe & need to
pull the fabrics over that pipe to keep fabrics perfect.
4.      After laying fabrics, it has to put a marker over the fabrics.
5.      Then, it requires cutting the edge of laying fabrics. Also, divide laying fabrics in various big parts & keep
at least two hours & then, cut fabrics. It will help to keep garments measurement unique.
6.      Check fabric quality against approvals (construction /colors/weight/ etc….)
7.      Maintain shade lots (ensure to match related components eg-collar/cuff)
8.      Ensure fabric relaxing procedures
9.      Ensure layering, panel inspection & replacement SOP
10.  Ensure numbering and bundling, proper storage and transportation procedures.
11.  Ensure outsourcing (print, EMB, etc….) procedures / SOP is following
12.  Ensure outsourcing panels been checked 100% and removed/replace defective panels before input.
13.  Ensure SOP follow-up at heat sealing/fusing pasting, etc…..
14.  Follow up & update cutting control chart.

Sewing Quality control

Through the received book, the Sewing distributor will collect the entire wash garments from the washing
section according to buyer, style, lot, color and size. There will be a signature of the designated person in the
wash distribution department. In the Sewing section, a counter sample with buyer comments, size set
comments, factory’s P.P- meeting sheet, measurement sheet and pass size set report will be hanging. All
garments collected from the wash section should be separated according to the buyer, style, color, size .‍
Then marking the size label, care label, the main label to be applied. Following the sample after applying the
label to the garments, the buyer's label will be approved by the QA Department.
1.         Follow key quality controlling points & check at regular intervals /check process & maintain records.
2.         Provide pattern measurement to sewing QC to make sure before wash measurement and keep a
record,

3.         It has to sew perfectly at the time of sewing garments & train operators & inform them about
tolerance.
4.         Strictly control not to cut by overlock machine. 
5.         Make sure no fraying out due to more handling in the sewing line, and set machine layout accordingly.
6.         Make sure a separate pattern set create based on shrinkage as per SOP.
7.         Make sure wash QC measuring after wash goods batch to batch and keeping record out of tolerance
quantity.
8.         Ensure AQL 1.5 quality standards+ measurements at sewing section (maintain daily records)
9.         Traffic light system will increase operator quality and productivity
10.       Make sure keeping record treatment recipe of out of tolerance garments and re-measuring report,

11.       Send goods to washing shade wise bundle by bundle.

12. Follow the sample to determine the position of the care label.
13. According to the sample, the hanger loop grading will have to be approved from the QA section.
14. The main label and size label will be put in the middle. The side should not be curved.
15. The main label's backstitch contrast will not work.
16. Remove the size mistake and always work on updating information for the label.
17. If there is a problem during production, you will have to work on writing and tell the QA department.

Washing Quality Control

Washing has a big role to keep control measurement, garments hand feel and appearance. If washing
can not meet the standard, garments put away as reject.
1.      To keep measurement within tolerance, the washing plant has important roles.
2.      It has to train all washing related personnel & create awareness regarding buyer required wash &
measurement tolerance standards.
3.      They have to work by heart & honestly maintain the recipe & timing. It has to check batch by batch
after wash measurement.
4.      It has to follow the buyer wash team given instructions perfectly to maintain wash shade &
measurement within tolerance.
5.      It has to create a team that will measure the garments in key points & then deliver goods.
6.      The washing plant does not deliver any goods which are out of tolerance. They have to keep goods
separately whose are out of tolerance.
7.      Later, they have to rework with the garments which are out of tolerance & then deliver goods.
8.      Make sure not to pass out of tolerance garments into the finishing section by washing QC.
9.      Make sure after wash measurement is correct before attaching finishing items.

Finishing Quality control

Finishing is finish everything before the final finished goods. Here the QC department has to check whole
garments quality though there is an inspection system in cutting, sewing too.
All products, buyer, style, color, size, grading will be sent to the gate-up table passed by Iron QI. After the
gate-up will use the QI number pass sticker in the ok garments.

1.      All loose thread will be trimmed

2.      Ironing/Pressing should be smooth, no crease mark is acceptable
3.      Right ticketing and proper placement must be ensured
4.       Check & update packing /packaging accessories inventories in advance
5.      Ensure measurement accuracy
6.      Ensure packing method, trims accuracy
7.      Ensure packaging accuracy/ctn audit
8.      Maintain AQL 2.5 quality standard at packing section (conduct daily inspections & advise reports) 
9.  All defects checked by the gate-up QI will be corrected and checked. 
10. All types of mending defects must be corrected by the operator.
11. Spot defects should be fixed by sending them to spot remover. 
12. If there is a big problem or damages, then it should be informed to the section supervisor, in-charge, FQC,
QCI, and Manager, and the right solution is also to be done. 
13. Reject garments should be kept in separate boxes with proofs. 
14. Setting quality goal every day save the data of problems and discuss with the responsible person for the
problems and solve it 
15. All submitted products checked by QI should be stored and sent to the packing section.

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