Woven Garments Quality Control Procedure

WOVEN GARMENTS
QUALITY CONTROL
PROCEDURE
PRESENTATION
1
Editor
MD. Hafij Uddin
Quality Assurance Inspector
Cell (+88) 01787 713253
Dhaka | Bangladesh
Defect prevention is Better than

Rectify. Hafij
Uddin
2
QUALITY CONTROL SYSTEM CUT TO SHIP
CUTTING PROCESS DESCRIPTION
1. FABRIC INSPECTION, 2. SHADE BAND & LOT CHART, 3. SHRINKAGE TEST, 4. FABRIC
WEIGHT CHECK, 5. COLOR CONTINUTY CHART MAKE, 6. BLANKET CUT & MAKE,
7. SPREADING CHECK, 8. MARKER CHECK, 9. CUTTING QUALITY CONTROL 10. AFTER
CUTTING PATTERN CHECK, 10. CUT PANEL CHECK
SEWING PROCESS DESCRIPTION

1. SIZE SET, 2. INTERNAL PP MEETING, 3. SUPPLIER QC PP MEETING, 4. PILOT
RUN, 5. PROCESS CHECK, 6. MEASUREMENT AUDIT, 7. HOURLY AUDIT.
8. ACCESSORIES CHECK 9.PRINT / EMBRODAIRY/ WASH
FINISHING PROCESS DESCRIPTION

1. WASH CHECK, 2. TOP SIDE PROCESS CHECK, 3 INSIDE PROCESS CEHCK, 4. IN SIDE
GATE UP CHECK, 5. TOP SIDE GATE UP CHECK, 6. RE-GETUP CHECK, 7. PINCH SETTING
& PULL TESTING,
INSPECTION PROCESS DESCRIPTION

1. DAY FINAL INS: 2. 25% INSPECTION 3. 100% INSPECTION, 4. SUPPLIER QC
PRE FINAL INSPECION, 5. MANGO QA FINAL INSPECTION
3
QUALITY CONTROL PROCEDURE OF CUTTING
1. FABRIC INSPECTION REPORT (BASE ON 4 POINT SYSTEM)
2. SHADE BAND & LOT CHART 100%

3. SHRINKAGE TEST 10% IF SPENDEX 100%
4. FABRIC WEIGHT REPROT 10%
5. FABRIC RELAXING REPORT IF SPANDEX
6. COLOR CONTINUTY CHART MAKE 100%
7. SHADE LOT BEFORE & AFTER WASH MAKE
8. BLANKET CUT & MAKE
9. SPREADING QUALITY CONTROL
10. MARKER CHECK REPORT 100%
11. CUTTING QUALITY CONTROL WITH STANDARD
12. AFTER CUTTING PATTERN CHECK WITH STANDARD
13. CUT PANEL CHECK 100% INSPECTION
4
1. FABRIC INSPECTION (BASE ON 4 POINT SYSTEM)
a. Fabric inspection done based on 4 point system

b. At first should check 10% from packing list if fail then 15% if
again fail then check 100%
c. One man can check 10/12 yrd fabric per minute
d. During fabric inspection must use mockup of various kind of
fabric defect.
5
2. SHADE BAND & LOT CHART 100%
a. First collect shade band according to dye lot.

b. Must maintain100% shade band chart.
c. Shade band chart must wash as per buyer requirement.
d. During cutting must maintain the shade band chart.
6
3. SHRINKAGE TEST 10-20% IF SPENDEX 100%
a. Shrinkage test is done 10-20% for cotton/ polyester/ canvas & twill
b. If spandex fabric need to check 100% shrinkage test
c. Calculation:- shrinkage %= before wash – after wash / before wash * 10
7
4. FABRIC WEIGHT REPROT 10%
a. Check GSM at least 10% out of a lot (received fabric).

b. Before wash & after wash should check GSM & compare with requireme
8
5. FABRIC RELAXING FOR SPANDEX & LYCRA
a. Fabric relaxing need for spandex fabric only.

b. Relaxing time minimum 24 hrs before cutting.
c. Must keep records.
9
6. COLOR CONTINUTY CHART MAKE 100%
a. Color continuity chart should make according to shade wise from every rol
b. Every roll no & quantity should be write on continuity chart.
c. Keep record properly.
10
7. SHADE LOT BEFORE & AFTER WASH MAKE
Every approved shade lot before wash & after wash swatch should record
on shade lot chart.
11
8. BLANKET CUT & MAKE
a. Must collect fabric from every roll & make blanket

b. Must wash blanket & need to take approval from buyer
c. Must Follow blanket during cutting.
12
9. SPREADING QUALITY CONTROL
a. Shade band should maintain during fabric spreading.

b. Mark fabric defect during spreading.
c. Check 900 angel from lay starting point
13
10. MARKER CHECK REPORT
100% marker check with pattern
14
11. CUTTING QUALITY CONTROL WITH STANDARD
QC should check random 7 pcs if lay quantity 180 pcs,
15
12. AFTER CUTTING PATTERN CHECK WITH STANDARD
Compare Cut parts with the pattern at top / middle / bottom
16
13. CUT PANEL CHECK
a. All cut panel must be checked

b. Then sent to sewing floor.
17
QUALITY CONTROL PROCEDURE ON
SEWING SECTION
1. SIZE SET PREPARE.
2. INTERNAL P.P MEETING.
3. SUPPLIER QC P.P MEETING.
4. PILOT RUN.
5. PROCESS CHECK.
6. DAILY LINE QC COMMENTS.
7. DAILY LINE QC MEASUREMENT CHECK.
8. PROBLEM SOLVING REPORT.
9. ROOT CAUSE ANALAISIS REPORT.
10. REJECT COUNTING REPORT.
11. MEASUREMENT AUDIT.
12. HOURLY WORKMANSHIP AUDIT.
18
1. SIZE SET PREPARE
a. During size set making line qc & floor qc should follow up this process.
b. After completing line qc must compare with seal sample & measure
with correct spec
c. QM/AQM again compare with seal sample & measure for styling
review
d. Then sent to technical dept. for correction
19
2. INTERNAL P.P MEETING
a. After size set correction from technical floor qc should arrange an internal
P.P meeting with QI & production staff.
b. This meeting they will discuss bout the potential problems of a style.
20
3. BUYING QC P.P MEETING
a. PP meeting must be done with supplier QA representative.

b. Supplier representative will review the size set & will discuss about others
workmanship issues.
21
4. PILOT RUN
a. Pilot run done based on correction from size set

b. Minimum 50 pcs & maximum 250 pcs are required for pilot run
c. All kinds of corrective action is done during pilot run
d. Gmts quality & measurement both are ensured on pilot run
f. When pilot run process done successfully then need to go for bulk cutting
& production
22
5. PROCESS CHECK
2. Back part check

1. Front part check
4. Waist band join check

3. Side seam & inseam
join check
23
PROCES CHECK
5. BARTAK CHECK 6. OUT PUT CHECK
a. All process is inspected by QI

b. A line controller follow up
the total process
7. Line controller follow up QI

24
FOR RIB ITEAM
1. Rib make inspection 2. Eye let attach inspection
3. After Rib joint inspection 4. After Rib joint measurement inspection
25
THIS REPORTS SHOULD MAINTAIN
6. DAILY LINE QC COMMENTS
7. DAILY LINE QC MEASUREMENT CHECK.
8. PROBLEM SOLVING REPORT.
9. ROOT CAUSE ANALAISIS REPORT.
10. REJECT COUNTING REPORT.
26
11. MEASUREMENT AUDIT
Sewing qc should measure audit for every hour.

Min 20 pcs gmts should measure per style in a d
27
12. HOURLY WORKMANSHIP AUDIT
Sewing qc must do hourly workmanship audit

for every style, if pass then sent to wash
28
13. PRINT / EMBRODAIRY / WASH
a. All kind of value added process must inspect by nominated

b. If done other factory, Qc team will follow up the full process,
c. They must do inspection before receiving from other factory
29
14. ACCESSORIES INSPECTION
Checking with standard
a. Qc team should check all in house accessories & trims

b. All countable accessories is checked as per AQL 1.5 level- 2
c. If non countable need to check 100%
d. Must compare all accessories with approved trim card & gold seal commen
30
FINISHING
31
QUALITY CONTROL SYSTEM FOR FINISHING
1) Wash check
2) In side process check
3) Top side process check
4) Embroidery + print
5) Pull test, pinch setting, Button & rivet check
6) Final get up
7) Measurement check (key point)
8) Get up
9) Hourly audit + measurement
10) Qc comments + measurement
11) Day final + Pre- final inspection
12) Supplier QA Pre Final inspection
13) MANGO QA Final inspection
32
1. WASH CHECK
After receiving gmts from wash at first should

check shade with wash approvals
33
2. IN SIDE PROCESS CHECK
1. Waist band check 2. Hem check
3. Front part check 4. IN Seam check

34
IN SIDE CHECK
5. Back part check 6. Side seam left
In side get up
7. Side seam right
35
3. TOP SIDE CHECK
1. Waist band check 2. Front part check
4. Back part check

3. Hem check
36
TOP SIDE CHECK
5. Inseam check
6. Side seam check
1. Then send for button & others trims

attachment.
2. Must Check by QI during trims attachments
37
4. Embroidery + print
If need must check with proper system
38
5. PULL TEST, PINCH SETTING, RIVET & BUTTON
ATTACHMENT
2. Checking pull test

1. Checking pinch setting
a. At first compare pinch setting

with data sheet
b. Pull test should do every 4 working
hour
b. 100% trims attachment must check
3. Rivet & button check

39
6. FINAL GETUP
AFTER TRIMS ATTACHMENT QI WILL DO FINAL

GET UP INSPECTION & SEND FOR PRESSING
40
7. MEASUREMENT CHECK (KEY POINT )
a. Measurement should be checked separately of all key

points after pressing & kept record
b. If stretch fabric must do all key point
41
8. GET UP INSPECTION
a. After measuring key point QI will do get-up inspection

b. They see quality, wash & others abrasion of garments
42
9. HOURLY AUDIT + MEASUREMENT
a. Hourly audit is done for lot wise

b. If pass then the goods throw on metal detector machine of packing
10. QC COMMENTS REPORT

a. Per finishing qc do a QC comments report
b. QC comments report are based on overall quality progress
43
Safety Issues follow up
Qc dept must follow up all kinds of safety issues like metal detectio
needle control, sharp tools register
Qc checking needle control register Qc checking sharp tool register
Metal detection follow-up Metal check report follow-up

44
10. DAY FINAL + PRE FINAL INSPECTION
a. Day- Final inspection is should conduct every day

b. Per Style we do pre final inspection at starting 25% & end of
pack should do 100% inspection
45
11. SUPPLIER QC’S INSPECTION
Supplier QC should conduct a

inspection before final inspection
46
FINAL INSPECTION
&
SHIPMENT
Defect prevention is Better than

Rectify. Hafij
Uddin
47

Woven Garments Quality Control Procedure

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WOVEN GARMENTS

Defect prevention is Better than

SEWING PROCESS DESCRIPTION

FINISHING PROCESS DESCRIPTION

INSPECTION PROCESS DESCRIPTION

1. FABRIC INSPECTION REPORT (BASE ON 4 POINT SYSTEM)

2. SHADE BAND & LOT CHART 100%

a. Fabric inspection done based on 4 point system

a. First collect shade band according to dye lot.

a. Check GSM at least 10% out of a lot (received fabric).

a. Fabric relaxing need for spandex fabric only.

a. Must collect fabric from every roll & make blanket

a. Shade band should maintain during fabric spreading.

100% marker check with pattern

QC should check random 7 pcs if lay quantity 180 pcs,

Compare Cut parts with the pattern at top / middle / bottom

a. All cut panel must be checked

a. PP meeting must be done with supplier QA representative.

a. Pilot run done based on correction from size set

2. Back part check

4. Waist band join check

5. BARTAK CHECK 6. OUT PUT CHECK

a. All process is inspected by QI

7. Line controller follow up QI

1. Rib make inspection 2. Eye let attach inspection

3. After Rib joint inspection 4. After Rib joint measurement inspection

6. DAILY LINE QC COMMENTS

7. DAILY LINE QC MEASUREMENT CHECK.

8. PROBLEM SOLVING REPORT.

9. ROOT CAUSE ANALAISIS REPORT.

10. REJECT COUNTING REPORT.

Sewing qc should measure audit for every hour.

Sewing qc must do hourly workmanship audit

a. All kind of value added process must inspect by nominated

Checking with standard

a. Qc team should check all in house accessories & trims

After receiving gmts from wash at first should

1. Waist band check 2. Hem check

3. Front part check 4. IN Seam check

5. Back part check 6. Side seam left

1. Waist band check 2. Front part check

4. Back part check

1. Then send for button & others trims

2. Checking pull test

a. At first compare pinch setting

3. Rivet & button check

AFTER TRIMS ATTACHMENT QI WILL DO FINAL

a. Measurement should be checked separately of all key

a. After measuring key point QI will do get-up inspection

a. Hourly audit is done for lot wise

10. QC COMMENTS REPORT

Qc checking needle control register Qc checking sharp tool register

Metal detection follow-up Metal check report follow-up

a. Day- Final inspection is should conduct every day

Supplier QC should conduct a

Defect prevention is Better than

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