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Quality Control

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.


Establishing the Quality Requirements:

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


Various Steps of Inspection & Quality Control:

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.


Pre-production Inspection

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.


During Production Inspection

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


Final Inspection

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.


AQL (Acceptable Quality Level)

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.

Eco-friendly Clothing
1001, #2BLDG, NO.519 AOMEN RD., SHANGHAI
sales@peonybuyoh.com
+86-2132557631