Garments Quality Checkig in Production | Check list of Garments Quality

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Quality means customer demands to be met. Any failure to maintain an adequate quality standard can be therefore be unsuccessful. Cost is involved to maintain an required standard of quality. In the garment industry quality control is practiced just right after in house fabric and all other materials in a production facility. It also can define as quality control that starts from the initial stage of sourcing raw materials to the stage of final finished goods. For whole textile industry quality of the product is calculated in terms of quality and standard of fiber, yarns, fabric construction, color or shade matching, color fastness, design and the appearance or look of final finished garments. Also the quality standards depend on the type of the customer segments and the retail outlets.

The ultimate customer of a garment look at the quality and appearance of the product at first place. Thus, to satisfy customer needs quality standard must be followed. Supplier can't produce and ship out garments according to their own wish as according to the purchase agreement, buyer can penalize supplier for delivering any defective garments.Buyer lost their faith on supplier if they do the things. Therefore it's suppliers responsibility to take care of whole production and ensure quality goods.Most of the cases, respective buying QC conducts the final inspection before delivering the goods. Whatever defects found in the final inspection, it is the result and cumulative figure of previous processes. Thus, it is very important to rectify defective garments before offering any final inspection.

Reason of producing defective garments:
There are lot of people and machines are involved in producing any garment. So there is an absolute scope of producing defective garments because of incorrect machine operation or handling of human. But, still the manufacturers have opportunity to rectify the faulty pieces though it is costly and time consuming. To make the garment production efficient maintaining good quality the checking points and methods must be followed.

The Major quality measuring points:

Fabric Store:
Fabrics are inspected fully or partially according to the international fabric inspection methods. Before issuing fabric to the cutting unit inspection is completed. Since it is the main raw material of a garment, no manufacturer compromise to check and ensure the quality.In most of the cases 10% fabrics are checked whereas for power loom and printed fabric almost 100% fabrics are checked.Among all the methods 4 point system is popular and mostly used.

Common check list of this section-

• Fabric roll to roll shade check.
• Fabric GSM check.
• Fabric color mistake check.
• Yarn contamination or foreign yarn Check.
• Selvedge or running shade check for solid dyed fabric
• Fabric blanket check after washing in case of woven and denim garments.
• Fabric width check with the PI
• Make shade range and get confirmation from buyer agents

Cutting Section:
Commonly cutting is the heart of bulk production. To avoid defects fabric needs to be cut precisely.

Quality check list of this section-

• Double check the pattern and the marker
• Check the knife of the cutter before starting cutting
• Fabric lay check
• Cut panel check
• Size mistake check
• Mixed shade check at cut panel and replace it

Trims and Accessories check:

It is very important to check the quality of trims as well because for a small item whole garment might be rejected. If there is any incorrect items and missing items found in checking then corrective steps can be taken immediately.

The check list for this section -

• Approved trims card check and confirm.
• Main, Size & Care Label Check.
• Care symbol check based on tech pack
• Thread color, count and quality check.
• All kinds of hang tag & price ticket heck. 

Sewing Section:
Quality checking in sewing section starts through size set sample making. With correct size set manufacturers and buying QC together conduct the PP meeting before starting bulk production. During PPM, samples are checked with buyer approved PP sample or counter sample. Major mistakes and quality concern are highlighted in the meeting so that bulk goods satisfy the buyer standard. PP meeting is so important as before sewing whatever corrective action plan can be taken otherwise whole production will be rejected or subjected to have rectification.

Then quality is checked in pilot run garments or trial cut garments to ensure whatever findings were in size set that are corrected now. Then inline inspection is done based on buyers AQL (Acceptable Quality Limit). Each sewing line one quality check point is present where assembled garments are taken for checking by factory quality checker or GPQ (Guideline for Production and Quality). Also in assembly line check points are kept for the critical operations. In these checkpoints, 100% checking is done for partially or fully stitched garments and defect free pieces are forwarded to the subsequent process.

The major check points of this section are:

• Approved PP/counter sample & measurement sheet check, also check the final comments from buyer.
• Sample wise input check.
• Approved trims card check.
• Styling check based on approved sample
• All machine thread tension check.
• Print & Embroidery placement check.
• All process measurement check.
• All machine oil spot check.
• All process SPI (Stitch Per Inch) check as per customer demand
• Part shading, bundle mistake & size mistake check.
• Need to balance the sewing tension precisely 
• Front part, back part, sleeve & thread shading check.
• SPI check for all process.
• Main, size and care label check.
• All process alter check.

Print/Embroidery Check:
These are not compulsory process for all styles but where it is required must be checked before forwarding them to next process. If printing is done in fabric mill then it is checked by store and if printing is done on cut panel then it is checked before sewing. For knit garments, mostly printing is done on cut panels. So before issuing cutting to sewing department each panel should be checked properly. If any defect is found on cut panel then it must be replaced by new one but it must be kept in mind that replaced cut panels shade should be identical to the other portion of that garment.

Like printing, embroidery is also checked and ensure 100% correct panels are being forwarded to next process.

The Check lists are-

• Approved sample or artwork wise bulk garment print & embroidery design check.
• Size wise approved pattern and placement check.
• Print design, color & quality check.
• Bundle & size wise print/embroidery check.

Finishing Section:

At finished garments quality is checked before packing. If all the previous check point works properly then quality goods will come in finishing section. Some processes are involed in finishing like button attachment, Hang Tag, Waist Card or other accessories attachemnt so the quality check point in this section should be strong. Before forwarding the garments for packing they go through ironing.

Here, initial finishing inspection, pre-final inspection and final inspection are conducted after finishing and packing the goods. All inspections are conducted by buying QC or assigned designated person of respective factory.

Below are the check lists of this section-

• Full styling check once again based on approved sample
• All garments shade check before starting finishing
• Print/Embroider and other sewing trims check
• All process stitching quality check
• Keep separately if there is any dirty or oil spotted garment
• All label and finishing accessories attachment and quality check
• Reject the pieces containing too much frying at inside of garments because of faulty over lock machine operation
• Remove flying dust, hairiness and uncut threads from the surface of the garment
• All points measurement check properly
• Check the manual before attaching hang tags and fold the garments
• Pack the garments based on customer demand as it may be single or blister pack
• Do cartooning carefully and keep them for final inspection

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