100% Inspection:

100% inspection, also known as full inspection, is a quality control process where every item in a
batch or lot is inspected for defects with specified criteria. This method is typically used in
manufacturing and production environments to ensure that all products meet quality standards before
they reach customers.
A number of factors can be required to be checked during 100% inspections such as:
● Product quality, sewing and visual appearance inspections
● Functionality inspections
● Quantity reviews
● Labeling and packaging inspections, etc.

Here is a T-shirt manufacturing process to understand how 100% inspection would be applied:
● Appearance: Create digital designs focusing on aesthetics, including graphics, colors, and style.
● Functionality: Choose fabrics based on comfort, durability, and intended use.
● Fit and Size: Develop and test patterns to ensure proper fit across different sizes.
● Precision: Cut fabric accurately using patterns to maintain design integrity.
● Application of Design: Apply designs using reliable methods (screen printing, embroidery) to
ensure durability and visual quality.
● Assembly and Security: Sew pieces together securely, ensuring strong seams and overall
construction.
● Conventional Tests: Inspect for visible defects like loose threads, alignment issues, and fabric
flaws.
● Professional Tests: Conduct specialized tests (e.g., tensile strength, color fastness) to ensure
material quality and durability.
● Final Inspection: Ensure each T-shirt meets visual and functional standards without defects.
● Ironing and Labeling: Iron T-shirts, attach labels and tags, ensuring they are presentable and
ready for sale.
● Packaging: Fold and pack T-shirts neatly in secure packaging, including necessary labels and
barcodes.
● Shipping: Transport the packaged T-shirts safely to retailers or customers.

Advantages:
100% inspection offers several advantages, particularly in ensuring high-quality standards and
preventing defective products from reaching customers.Such as:
Ensures Quality: Every product is checked, ensuring all items meet quality standards.
Customer Satisfaction: Reduces defects reaching customers, leading to happier customers and
fewer returns.
Brand Reputation: Consistently high-quality products strengthen the brand’s reputation.
Safety and Compliance: Essential for industries with strict safety standards, ensuring compliance
and avoiding legal issues.
Detects Systematic Defects: Identifies recurring defects, helping improve the production process.
Risk Mitigation: Reduces the risk of costly recalls and negative impacts on reputation.
Immediate Feedback: Provides quick feedback on product quality, allowing for immediate corrective
actions.
Customer Assurance: Shows a commitment to quality, reassuring customers about the product's
reliability.
Disadvantages:
High Costs: Significant investment in personnel, equipment, and maintenance.
Time-Consuming: Slows down production and can delay product delivery.
Intensive Resource: Requires a large workforce and advanced inspection technologies.
Human Error: Inspectors may miss defects due to fatigue or oversight.
Complex Implementation: Difficult to integrate into existing processes and requires extensive
training.
Overall, 100% inspection is a rigorous quality control measure used to ensure that every product
leaving the production line meets the required standards.

Sampling Plan:
Sample: Sample is a prototype or model of a garment, used to help buyers decide if they want to
place an order. It is created from a design to evaluate its fit, quality, and overall appearance before
mass production begins.
Sampling: In the garments industry, sampling refers to the process of producing a sample garment to
evaluate and perfect a design before it goes into mass production. This process involves several key
steps and types of samples. Each type of sample has a specific role to ensure the final product meets
the desired standards for quality, fit, and design.
The objectives of sampling are:
➢ Quality Assurance: Ensure the garment meets the brand's quality standards.
➢ Fit and Sizing: Verify that the garment fits well and matches the intended size specifications.
➢ Design Validation: Confirm that the design looks and functions as intended.
➢ Material Testing: Assess the suitability and performance of fabrics and materials.
➢ Cost Estimation: Determine the cost of producing the garment.
➢ Customer Approval: Provide samples for buyers or clients to review and approve.
➢ Problem Identification: Detects and resolves any issues before mass production.

Types of sample: In the garments industry, there are several types of samples, each type of sample
plays a crucial role in the overall process. Here are the common types:
● Prototype Sample: Initial sample to test basic design and pattern adjustments.
● Counter sample: refers to a sample produced in response to an initial sample, often provided by
a customer or a supplier.
● Fit Sample: Used to check the fit, sizing, and comfort of the garment on a model or dress form.
Adjustments are made based on the feedback.
● Size Set Sample: A set of samples made in various sizes to ensure consistent sizing and fit
across the size range.
● Salesman Sample: High-quality samples used by sales representatives to showcase new
designs to buyers and secure orders.
● Pre-Production Sample (PPS): The final sample made just before mass production. It is used
to confirm that all aspects, including materials and construction, meet the required standards.
● Production Sample: A small batch of garments produced as a test run to identify and address
any issues before full-scale production begins.
● Photo Sample: Created specifically for marketing and promotional purposes, such as
photoshoots for catalogs or online stores.
● Top of Production (TOP) Sample: A sample taken from the first batch of mass production to
ensure that the production is consistent with approved pre-production samples.

Steps in the sampling process in the garments industry

1. The Tech Pack, or Technical Pack, is received from the buyer via the merchandiser. It contains
all the specifications necessary for garment production.
2. Designers create sketches and patterns based on initial concepts.
3. Fabric is cut and sewn to create the first sample, testing basic design and construction, which is
then sent to the buyer.
4. Based on buyer feedback, adjustments may be made to the design or materials.
5. Fit samples are created and tested on models or mannequins for fit and comfort.
6. Samples are reviewed by buyers to ensure they meet market expectations.
7. Once the fit sample is accepted by the buyer, a Pre-Production Sample (PPS) is created to
confirm that all aspects, including materials and construction, meet required standards.
8. After the buyer inspects the sample, a pre-production meeting is held. In attendance are the
buyer or their agent, merchandiser, and sample manager. They decide on how and when to start
production.
9. A small batch is produced (Production Sample), to test production processes and quality control.
10. Production samples are finalized before mass production, representing approved designs, fits,
and quality standards.
11. Specifications, patterns, and instructions are documented for the production team.
12. Clear guidelines ensure consistency during mass production.
13. Continuous quality checks are performed to maintain standards throughout mass production.
Product Quality Audit:
Quality Audit: Quality audit is the process of systematic examination of a quality system. Which is
carried out by an internal or external quality auditor or an audit team. It is an important part of an
organization's quality management system and is a key element in the ISO quality system standard.
The goal of a quality audit is to identify areas for improvement, ensure compliance with quality
standards and regulations, and enhance overall quality performance within an organization.
Importance: Quality audits are crucial because they -
● Ensure compliance with standards and regulations.
● Evaluate the performance of the quality management system.
● Find and fix errors efficiently.
● Give an unbiased review of processes and routines.
● Check processes directly where they happen.
● Drive continuous improvement in processes and products.
● Track if these actions are working well.
● Recommend ways to make the quality management system better for the organization.

Types of Audits:
● Process Audit: Evaluates the manufacturing or production processes to ensure they are efficient
and effective in producing quality products.
● Product Audit: Focuses on the final product to check conformity to specifications, functionality,
durability, safety, and other relevant criteria.
● Supplier Audit: Assesses the quality management systems of suppliers to ensure they can
consistently deliver materials or components that meet quality requirements.

Product Quality Audit: A product quality audit focuses specifically on the quality of a product or a
batch of products rather than the entire quality management system. In the garments industry,
product quality audits are essential to ensure that clothing and apparel items meet the required
standards of quality and safety.

➢ It focuses on parameters such as fabric quality, stitching quality, color consistency, sizing
accuracy, seam strength, and overall durability.
➢ Product quality audits are typically conducted at various stages of production, such as during
initial sampling, pre-production, in-process production, and post-production, to ensure that quality
standards are consistently met.
➢ The audit may involve physical inspection, testing, and documentation review to verify that
products meet customer requirements and are fit for intended use or sale.
Key Elements:
Documentation Review: Examines quality control documents, procedures, specifications, and
records to ensure compliance with standards.
Physical Inspection: Involves examining samples of products or components to verify dimensions,
appearance, functionality, and other critical attributes.
Process Observation: Observing production processes to identify potential sources of quality issues
and opportunities for improvement.
Overall, product quality audits in the garments industry are vital for maintaining brand reputation,
meeting customer expectations, and minimizing risks associated with poor quality products.

AQL:
In the fashion industry, especially in apparel exports, AQL stands for Acceptable Quality Level. It
defines the maximum percentage of defective pieces that a buyer will tolerate from a manufacturer.
Essentially, it’s the quality level that is least tolerable.
AQL is expressed as a percentage of average defective items and can be calculated using the
following formula:
Average defective item = (No. of defective item found during inspection / Total no. of item
inspection) x 100

Here’s a basic outline of how AQL works:

AQL Levels:
● Critical Defects (0.1% to 0.5%): Defects that could harm the user or render the product unusable.
● Major Defects (0.65% to 1.5%): Defects that could cause the product to fail or reduce its usability.
● Minor Defects (2.5% to 4.0%): Defects that do not significantly affect the product's performance or
usability
Sampling Plans:
● The sample size is determined based on the size of the production lot using standardized tables
(e.g., ISO 2859, MIL-STD-105E).
● The sample is inspected, and the number of defects is recorded.
Acceptance and Rejection Criteria:
● Each AQL level corresponds to specific acceptance and rejection numbers in the sampling tables.
● If the number of defects found in the sample is below or equal to the acceptance number, the lot is
accepted.
● If the number of defects exceeds the rejection number, the lot is rejected.

A standard acceptance quality level for a garment factory is 2.5% for major defects and 4.0 for minor
defects. Additionally, critical defects normally require a zero tolerance acceptance level and any
products that fail to meet the set acceptance quality level will undergo 100% inspection.
Example:
● Batch Size: 1,000 garments
● AQL for Minor Defects: 2.5%
● Sample Size (based on table): 80 items
● Acceptance Number: 5 defects
● Rejection Number: 6 defects
If 80 items are inspected:
● Accept the batch if 5 or fewer defects are found.
● Reject the batch if 6 or more defects are found.

Precautions which should be taken by Textile Industry:

The textile industry should take several precautions to ensure product quality, worker safety, and
environmental sustainability. Here are some key precautions:

Quality Control:
● Implement strict quality checks during production.
● Regularly inspect and audit products.
● Test and sample products before shipment.
Worker Safety:
● Provide comprehensive training on safety protocols and use of equipment.
● Ensure proper ventilation and protective gear for workers handling chemicals or operating
machinery.
● Regularly inspect and maintain machinery to prevent accidents.
Environmental Protection:
● Follow environmental regulations for waste and emissions.
● Use sustainable practices like recycling and reducing resource consumption.
● Educate employees on environmental responsibilities.
Supply Chain Management:
● Monitor and audit suppliers for compliance.
● Establish guidelines to avoid unethical sourcing.
Ethical Labor Practices:
● Ensure fair wages and working conditions.
● Prohibit child labor, forced labor, and discrimination.
Continuous Improvement:
● Encourage feedback and employee involvement.
● Implement lean manufacturing to optimize processes and reduce waste.

By following these precautions, the textile industry can ensure high product quality, safe working
conditions, and sustainable, ethical practices.
Eco-friendly Textiles:
Eco-friendly textiles refer to fabrics and materials that are produced and used in a way that minimizes
environmental impact throughout their lifecycle. These textiles focus on environmentally responsible
production processes, sustainable raw materials, and the overall lifecycle of the fabric.
Key Characteristics of Eco-Friendly Textiles includes:

1. Sustainable Materials: They are often made from natural fibers such as organic cotton, hemp,
linen, bamboo, or wool, which are grown without synthetic pesticides or fertilizers, or from
recycled materials like PET bottles or old clothing.
2. Low Impact Dyes and Chemicals: Eco-friendly textiles are dyed and treated with non-toxic,
low-impact dyes and chemicals that minimize water pollution and harm to ecosystems.
3. Energy and Water Efficiency: Production processes are designed to conserve energy and
water, reducing overall resource consumption and carbon emissions.
4. Biodegradability and Durability: Biodegradable or designed to have a longer lifespan, reducing
waste generation and promoting a circular economy.
5. Certifications: Many eco-friendly textiles carry certifications such as Global Organic Textile
Standard (GOTS), OEKO-TEX Standard 100, or others that verify their environmental and social
sustainability credentials.

Benefits of Eco-Friendly Textiles:

● Lower water and energy consumption, reduced chemical use, and less waste.
● Non-toxic and chemical-free textiles are safer for consumers and workers.
● Promotes responsible consumerism and supports the circular economy by encouraging recycling
and reuse.

Eco-friendly Textiles in BD
In Bangladesh, the textile and garment industry is a major part of the economy. As global demand for
sustainable products grows, eco-friendly textiles are becoming increasingly significant in this sector.
Bangladesh is moving towards eco-friendly textiles by:
● Using more sustainable materials such as organic cotton, jute, recycled fibers.
● Recycling materials like PET bottles for making fabrics.
● Manufacturers are adopting technologies to reduce water and energy consumption during
production processes
● Focus on producing textiles that decompose naturally, helping to reduce waste and pollution.
● Increasing use of renewable energy sources, such as solar power, in textile production.
● Improving worker conditions and fairness.
Examples of Eco-Friendly Practices:
● DBL Group: One of the largest knit garment manufacturers in Bangladesh, DBL Group has
invested heavily in sustainable practices, including water and energy-efficient technologies.
● Envoy Textiles: A pioneer in green textile manufacturing in Bangladesh, Envoy Textiles has a
LEED-certified factory focusing on sustainability.
● Beximco: One of the largest conglomerates in Bangladesh, Beximco is involved in producing
sustainable textiles, including organic cotton and recycled polyester fabrics.

As Bangladesh continues to evolve as a major player in the global textile industry, the adoption of
eco-friendly practices presents both challenges and opportunities. By investing in sustainable
technologies, promoting ethical standards, and meeting international certifications, Bangladesh can
position itself as a leader in eco-friendly textiles.

CAD & CAM:

CAD (Computer-Aided Design) and CAM (Computer-Aided Manufacturing) are both critical
technologies used in various industries, including the garments industry.

CAD (Computer-Aided Design): CAD software is used by designers to create detailed designs and
technical drawings of products. In the garments industry, CAD allows designers to create digital
representations of clothing, including patterns, textures, and colors. This helps in visualizing the final
product and making adjustments before manufacturing.
CAM (Computer-Aided Manufacturing): CAM software, on the other hand, is used to control
manufacturing processes through computer automation. It translates CAD designs into instructions
for automated machinery, such as cutting machines and sewing machines. CAM ensures precision
and efficiency in manufacturing, reducing errors and optimizing production processes.

CAD/CAM systems offer several advantages across various industries, including the garments
industry:-
1. Ensures precise and error-free designs.
2. Allows quick adjustments and updates.
3. Reduces material wastage and production costs.
4. Speeds up manufacturing processes.
5. Maintains uniform product quality.
6. Facilitates complex designs and customization.

Together, CAD and CAM technologies are essential in modern garment manufacturing, particularly for
ensuring consistency in pattern making, sizing, and overall product quality.
CAD/CAM software: In the garments industry, several CAD/CAM software solutions are widely used
for pattern making, grading, marker making, and overall production automation. Some popular
CAD/CAM software name includes:
1. AccuMark Pattern Design Software by Gerber Technology, which is widely used for pattern
design, grading, and marker making.
2. TUKACAD by TukaTech Inc., provides pattern-making, grading, marker making, and virtual
prototyping features.
3. Modaris by Lectra system, focusing on pattern making, 3D prototyping, and fabric optimization.
4. Optitex: Owned by EFI (Electronics for Imaging), Optitex offers advanced 2D and 3D CAD/CAM
solutions tailored specifically for the fashion industry.
5. EFI Optitex, another offering from EFI, provides a range of software solutions for pattern design,
grading, marker making, and visualization in apparel manufacturing.

Application of CAD in textile industry:

CAD (Computer-Aided Design) has numerous applications in the textile industry, revolutionizing
various aspects of textile design, production, and manufacturing processes. Such as,

1. Textile Design
➢ Pattern Design: CAD software allows designers to create detailed patterns for textiles,
including prints, weaves, and knits. Designers can manipulate colors, textures, and repeats
digitally, enabling faster prototyping and visualization.
➢ Surface Design: Enables creation of textures and designs (like embroidery pattern, digital
prints) directly applicable to fabrics.

2. Product Development:
➢ Virtual Prototyping: CAD enables the creation of virtual prototypes of garments and textile
products. Designers can simulate how fabrics drape, fit, and interact with body movements,
before physical samples are produced.
➢ Fit and Sizing: CAD systems assist in creating and adjusting patterns to achieve accurate fit
and sizing specifications.

3. Textile Manufacturing:
➢ Pattern Making: CAD systems automate pattern making processes for accuracy. Patterns can
be adjusted digitally based on design changes or size variations.
➢ Marker Making: CAD software optimizes fabric usage by generating efficient cutting layouts,
reducing material wastage.
➢ Grading: CAD systems automate grading, which involves creating size variations of a pattern.
4. Quality Control:
➢ Color Matching: CAD tools help to manage and match colors across batches for consistency.
➢ Fabric Simulation: Simulates fabric behavior under different conditions (washing, wearing) for
quality assurance.

5. Collaboration and Communication:

➢ Digital Libraries: Stores designs, patterns, and specifications digitally for easy access and
collaboration.
➢ Documentation: Generates detailed technical specifications and documents for clear
communication in production.

Overall, CAD has transformed the textile industry by enhancing design creativity, improving
manufacturing efficiency, reducing lead times, and ensuring product quality and consistency. It has
become an indispensable tool for textile designers, manufacturers, and brands looking to innovate
and compete in the global market.

CAD/CAM Systems vs. Manual Systems in the Garments Industry

CAD/CAM Systems
Advantages:
● Reduces time for design, pattern making, and manufacturing.
● High accuracy in measurements and patterns.
● Handles intricate and complex designs easily.
● Ensures consistent quality in large-scale production.
● Streamlines production with other automated processes.
● Provides 3D visualizations and virtual prototypes.
Usage:
● Large Manufacturers: Widely used for managing large-scale operations.
● Fast Fashion: Essential for rapid design turnaround.
● Sustainability: Optimizes fabric usage and reduces waste.

Manual Systems
Advantages:
● Ideal for small-scale production.
● More intuitive for custom and haute couture garments.
● Requires less technical training.
● Cost effective
Disadvantages:
● Labor-intensive and slower.
● Higher risk of human error.
● Harder to create complex designs.
● Challenging for large production runs.
Usage:
● High-End Fashion: Used by luxury brands and bespoke tailors.
● Small-Scale Producers: Favored by independent designers and small garment makers.

CAD/CAM systems are more widely used due to their efficiency, precision, and scalability, especially
in large-scale and fast fashion production. Manual systems remain valuable in niches like high-end
fashion and small-scale production. Overall, CAD's ability to enhance accuracy, efficiency, and
scalability makes it a preferred choice over manual methods in the RMG industry.