MANUFACTURING QUALITY SYSTEM

ARRIVAL OF
MATERIALS

MERCHANDISER/
INSPECTION / LABTEST
PURCHASER/ SUPPLIER
(FBC &ACCS)

INSPECTION OF
PATTERN

INSPECTION OF PANEL REPLACEMENT

/ RE-CUTTING
MARKER & CUTTING
(CUT PANEL)

MERCHANDISER/
SEWING INLINE INSPECTION OF PRINTER /EMB.
INSPECTION PRINTING / EMB.

FINAL INSPECTION / SEWING SUPV. , LINE

ENDLINE / TABLE
MEASUREMENT LEADER, OPERATOR -
INSPECTION
CHECKING REPAIR / ALTERATION

PRE-FINAL / FINAL AUDIT & PACKING SUPV. ,

PACKING ACCURACY AUDIT IRONING, FOLDING,
POLYBAGGING,
ASSORTING & PACKING)

SHIPMENT
OF GOODS
Production process starts after receiving of fabrics and end after dispatching of packed garments.
Generally export house put quality check points at the end of each process to ensure that only quality
pieces move to the next process. Department wise quality check points have been explained in the
following.

Fabric - 100% fabric inspection - 4 point system

Trim & accessories - Random inspection - AQL 1.5
Cutting Room - Marker checking
- Cut parts checking or audit
- Bundle inspection

Printing and - 100 % inspection of printing panels

Embroidery - 100% inspection of embroidery

Sewing Department - Inline check point (at critical operation)

- Roaming checking (Random checking)
- End of Line checking (100%)
- Audit of checked pieces

Finishing Department- Initial finishing inspection (After Pressing,

Tagging, Poly bagging, Assorting)
- Internal shipment audit (After Packing)
-

1. Fabric Store: In the fabric store fabric is being checked before issuing it to cutting department. In
general not all the fabric is checked. Usually 10% of fabrics are checked for good fabric suppliers.
For power loom fabric and printed fabric 100% checking is done. Fabrics are checked in flat table,
flat table with light box or on fabric checking machine. 4 point system for fabric inspection is used
to measure the quality level of the incoming fabric.
2. Trims & Accessory: Trims quality is also very important for having a quality garment. Trims
inspection is done randomly against the given standards, like color matching. But for trims and
accessories quantity checking is essential.
3. Cutting Room: It is said that cutting is the heart of production. If cutting is done well then chances
of occurring defects in the following processes comes down.

In cutting room, check points are – i) marker checking, ii) cut part audit and iii) bundle checking.

4. Printing Checking: Printing is not a compulsory process. If printing is done in fabric form then
printing is being checked in fabric store. For knits garment, maximum printing is done in cut
panels. So before issuing cuttings to sewing department, each panel is being checked properly.
Defects that are found here is print placement, color matching, misprint or print overlapping or
shade variation.
5. Embroidery checking: Like printing embroidery also is not a compulsory process. If there is
embroidery work in the garment panels then 100% inspection is done before issuing to sewing.
6. Sewing Department: Checkpoints in the sewing departments are as following.
 Inline inspection: In assembly line generally check pints are kept for the critical operations. In
these checkpoints, 100% checking is done for partially stitched garments and defect free pieces
are forwarded to the next process. This type of checking is used for high value garment.
 Roaming inspection: In this case checkers roam around the line and randomly check pieces at
each operation.

Traffic light inspection system: Very few garment manufacturer use this inspection system. In this
system each operator is given a card for measuring their quality performance. Quality checker
goes to the operator and do random check for few pieces and according to the inspection result,
checker marked red or green on the card following rating criteria.

 End of line inspection or table checking: A checker checks completely stitched garment at the
end of the line. 100% checking is done here,
 Audit of the checked pieces: Very few manufacturers follow this audit procedure but it is very
essential checkpoint to assure that only 100% inspected garment are sent to finishing from sewing
department. And all defective pieces are repaired before sending to finishing.

7. Finishing Department: Check points in finishing department consists

 Initial Finishing Inspection: After pressing garments are again checked and passed for tagging,
poly bagging, assorting and packing.
 Internal final audit: After garments are packed up to certain quantity, quality control team, do
audit of packed garments. This process is carried out to ensure that before handing over shipment
to buyer QC.