Fabric Inspection

Fabric Inspection
PURPOSE
To establish and maintain documented procedures for receiving inspection in order
to verify that
the specified requirements for the product are met.
Fabric roll is selected on the basis of random sampling;

acceptance or rejection criteria are decided at prescribed label
on 4-Point system. 10% of rolls -are inspected in this stage by
Fabric Inspector. Incase of rejection of lot on 10% of rolls, rest
of the rollsof the lot is inspected thoroughly. Reject rolls are
kept separately with red flags.
Inspection records are kept in inspection format.
Summary of the fabric inspection is recorded in the summary
sheet, formanagement information.
Conforming goods are kept separately with Green
Sticker and kept in stack named.
READY FOR CUTTING
All rejected goods are treated as "NON-CONFORMING GOODS" and marked with red
sticker.
Checking of s-lade and shade grouping.
INSPECTION PROCEDURE
1. Receive approved colour and quality swatches.
2. Check lot size and label against the submitted packing list.
3. Randomly draw 10% of the lot.
4. Delivery of less than 1000 yds – 100% inspection
5. Delivery of 1000 yds to 10000 yds to inspect at least* 1000 yds.
6. Shipment of more than 10000 yds inspects 10% of the lot.
PENALTY POINT EVALUATION

Fabric to of graded will be examined from a distance of approximately three feet
while runner-Up
cover the perch of a fabric inspection machine. The inspector will run the fabric at a
speed
compatible with his ability to distinguish.
Process Inspection
PURPOSE
To establish and maintain documented procedures for process inspection in order to
verify that
the specified requirements for the product are met.
Process inspection is conducted on following sages.
1. Spreading Inspection
2. Cutting Inspection
3. Sewing Inspection
SPREADING INSPECTION
Following eight points must be taken care of by the cutting quality inspector at the time of
spreading.
Table marking
Ends
Tension
Remnants
Counts
Ply height
Marker Placing
Fabric Flaws
CUTTING INSPECTION
Cutting inspection should be on the basis on random sampling on desired AQL. If the lot is
passed on
sampling inspection then it is send for sewing operation, if not passed the whole lot isre-
inspected and
rejected parts are replaced by good parts. In cutting inspection there are two types of check
BLOCK CHECK
& BUNDLE CHECK. Following points are inspected in blockcheck such as Size, Parts, Pattern
check, Mis cut,
Ragged cutting, Notches, Matching plies.
SEWING INSPECTION
a) The SR. Line Q.I should audit completed finished bundles
b) He must select 7 pcs at random from the bundle.
c) If the inspector finds defective unit, he will take following steps on operator’s duality
Performance Chart.
d) He will mark red in the room against date of inspection with defect code and frequency
as a symbol for
warning and recheck. He will hand over remaining units of the bundle to supervisor for
check and taking
corrective action.
e) He will inspect next three bundles as follow up audit of the same operator and mark
yellow in three
rooms if no defective units are found in next three bundles.
f) He will mark green in the room against date if no defective unit is found in the bundle.
g) The inspector will make operators monthly analysis to compare it with tables monthly
defect analysis to
find out whether there is any lacking in the sewing inspection procedure.
h) QC Supervisor Sewing will monitor 7 pcs inspection, whether it is being done properlyor
not.
Final Inspection
PURPOSE
To establish and maintain documented procedures for final inspection in order to verify that
the specified
requirements for the product are met.
ACTIVITIES
Final inspection is the inspection which is conducted before shipment or buyer’sinspection.
It is conducted
in two stages.
i) Day Final.
ii) Lot Final
DAY FINAL
Day final inspection is the responsibility of factory QA Manager. He conducts this inspection
daily on
available garments which has passed by TWO HOURLY inspection and isconducted
ondesired AQL. If it is
passed, garments are ready for Central Q C Inspection orBuyers 0 C inspection
LOT FINAL
Lot final is conducted by Central QA Manager when the lot is passed by Factory QA Manager
before
shipment or in case any buyer gives the authority to the factory to conduct final inspection
before
shipment. It is also conducted when buyer’s inspection is conductedbefore shipment. It is
conducted on
desired AQL. If lot is passes, they are ready for shipment and placed before buyer's
representative for final
inspection before the shipment.
Garments Inspection Procedure

STEP-I
Inspector should collect the following before going for the inspection.
a. Approved sample from the proper authority.
b. First of production (FOP) garments sample as per size and color from the concern person
or authority.
c. Approved colour swatches, shade band card, trim card from the concern person or
authority.
d. Garments and Fabrics test report from the factory or agent.
STEP-II
a. Inspector should take the following items with him.
Inspection report form
Spec sheet
Calibrated flexible fibre measurement tape
STEP-III
a. Collect packing list from the factory and check carton against the packing list.
b. Compare FOP sample with the approval sample and find out if there is any deviation.
c. Check the shipping mark with the work sheet.
e. Select the garments for fit audit size and colorwise with respect to prescribed AQL of fit
audit. Conduct fit audit and identify total major and minor defects.
g. The defects will be called major if it exceeds tolerance and touch another size incase of
measurement.
k. The defect will be called minor if it exceeds tolerance but does not touch another size in-
case of measurement.
Defect Classification List (Major)

FABRIC DEFECTS
1. Holes (yarns cut), broken ends, continuous missing yarn
2. Soil, oil spot, contrast visible at arm’s length / A-zone, adversely affecting appearance.
3. Misweaves, mispicks (woven)
4. Slubs (Linen & Silk not included) distinguishable when viewed at arras length A-zone
5. Colour bleeding (A-zone) colour combination not as specified
COMPONENTS AND TRIMS

BUTTONS & BUTTON HOLES
1. Buttons sewing thread colour not as specified
2. Missing button or button hole
3. Broken, damaged, defective or inverted buttons
4. Buttons do not conform to specification
INTERFACING / LINING / PADS

1. Fusible interfacing must be compatible to garment without bubble or pucker.
2. In a lined garment, the liner must not extend below hem of the shell.
ZIPPERS
1. Insecure bottom or top stops
2. Incorrect colour or tape (shade) of zipper
3. Faulty slider on zipper
4. Any missing or damaged teeth
BELT AND BELT LOOPS

1. Belt Loop not fully secure
2. Incorrect number of belt loops on garments as specified
3. Missing belt loop
POCKET AND FLAP
1. Missing or miss located bar tack
2. Wrong placement
CARE LABEL
1. Incorrect fibre content, country of origin, RN number etc.
2. Maintenance instructions do not meet all federal requirements
3. Not caught completely or not sewn securely
4. Missing/incorrect / illegible
5. Incorrectly attached
PRINTING DEFECTS
1. Wrong colour, missing colour
2. Miss registered obvious from 6 inch
STITCHING
1. SPI in excess of more than 3 or less than 2 than the specified
2. Ends of stitching (back tacked at least'/. inch/2 or 3 stitches)
3. Seam allowance (All zones) - join seam < 1/2 inch. / Double needle setting <inch. Zipper
setting < ¼ inch
4. Any raw edges more than 1/4 inch on outside
5. Seams and stitching not as specified type
6. Needle holes.
7. Seam twisted, puckered or pleated (conspicuous)
FINISHING AND PACKAGING

1. Not pressed / folded / hang / assorted as specified
2. Over pressing or under pressing/poor pressing defects including-shine, colour change,
scorching or any
other conspicuous "Hard" pressing defect
3.Labs, tickets, tags, logo, hanger size clip missing/incorrect, illegible or not specified.
PACKAGING
1. Merchandise folded or packed incorrectly, resulting in poor appearance
2. SKU information on box not same as item in the box
3. Incorrect poly bag, box dimension
4. Size sticker, price tag, hanger, box labelling UPC code etc. incorrectly placed, missing or
not as specified
5. Printed information incorrect or missing
Defect Classification List (Minor)

FABRIC
1. Broken yarn (one yarn) – zone B/C.
2. Mispick (low contrast) – zone C.
3. Barre (low contrast) – zone B.
4. Needle hole (which holes do not run / enlarge).
5. Garment s not within specified shade range or shade band.
6. Printing defects:
i) Incomplete coverage of colour.
ii) Design and pattern direction not as specified.
7. Mismatched stripe/ plaid
COMPONENTS AND TRIM

1. Any component not of specified colour, dimension or appearance
2. Hardware trim misaligned
3. Incorrect position of snaps in excess of 1/8 inch and the specified
3. Untied cord
3. Velcro, placement (closure) not within 75% of total area mates
COMPONENTS AND TRIM

1. Any component not of specified colour, dimension or appearance
2. Hardware trim misaligned
3. Incorrect position of snaps in excess of 1/8 inch and the specified
3. Untied cord
3. Velcro, placement (closure) not within 75% of total area mates
LABEL
1 Label must be positioned at specified location + 1/4 inch and fully visible
2. Crooked label
THREADS
1. Outside, Uncut thread over 1/4 inch
2. Inside Uncut thread over 1/2 inch seen hanging below a hem or visible as presented
STITCHING
1. Topstitching — Single or double needle not overlapped, stitch on stitch at start and finish.
2. Poorly objectionably mended (C-zone).
3. Gathering or bunched stitching (B & C zone)
4. Sewn in pleat over 1/4inch. (C-Zone)

Fabric Inspection

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Fabric Inspection

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Fabric Inspection

Fabric roll is selected on the basis of random sampling;

PENALTY POINT EVALUATION

Garments Inspection Procedure

Defect Classification List (Major)

COMPONENTS AND TRIMS

INTERFACING / LINING / PADS

BELT AND BELT LOOPS

FINISHING AND PACKAGING

Defect Classification List (Minor)

COMPONENTS AND TRIM

COMPONENTS AND TRIM

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