Quality Control Plan:

A quality control plan is a formal document with supporting information that shows a
process owner and local work team the important variables, that impact a process
workflow relative to its outputs. In this article I will discuss about quality control, quality
assurance and quality control pan in garment industry.

Quality control and quality assurance are complex areas of the apparel industry. First
off, quality assurance is not quality control, but quality control is an aspect of quality
assurance. Quality assurance is the process of designing, producing, evaluating, and
assessing products to determine that they meet the desired quality level for a company’s
target market. Quality control is the day-to-day implementation of quality assurance, and
to succeed you have to be very proactive at all levels.

Quality control, is different from quality assurance. The objective of quality control is to
check if the products being produced are according to the given specifications. Their entire
job is during the production process. Quality control department has quality inspectors /
auditors who check the product specifications at different stages of production. In most of
the industries, the quality control teams are divided into two parts. First team is
responsible for inline quality inspection. Inline quality inspection means that the quality
inspectors check the products at different machines randomly. The second team is
responsible for final inspection. Final inspection means that the inspection of goods at
the end of production line. The amount of inspection varies from industry to industry.

Quality assurance looks at a product from the first design concept until it is sold to the
consumer. Quality control is generally understood as assessing for quality after products
have already been manufactured and sorted into acceptable and unacceptable categories. It
is costly for companies that do not take a quality assurance method, but only look at quality
in terms of quality control. Quality is a multifaceted concept that describes how well a
service, process, material, or product possesses desired intangible or physical attributes.
Garment manufacturing companies always strive to produce garments that meet their
customer requirements. A wide range of quality processes, are used in the apparel industry
to ensure that these quality standards are met. The examination and measurement of
garments are common ways of ensuring that the garments produced meet customer
specifications. Quality control consists of a 100% inspection process, to ensure that
garments not satisfying customer requirements are removed. A strong quality control plan
or QC plan helps to set quality targets for apparel manufacturing to ensure that the
deliverables produced, meet the needs of customer requirements.

Quality Control Plan in Garment Industry:

A Quality Control Plan, or QC Plan, is a critically important document for apparel business.
It is the basis for assessing and maintaining of the quality of continuous emission
monitoring data. In this article I have discussed a quality control plan or QC plan with
template. In quality control plan template I have given a readymade garment factory as an
example.

MAHBUB FASHIONS LTD.

QUALITY CONTROL PLAN

The under mentioned generic quality plan for Day-to-Day production activities of factories /
production unit has been developed based on the regular activities of MAHBUB FASHIONS
LTD.

SL EXPERIMENT
SECTION SOP Procedure
no. POINT

Yarn General Check

Bag, carton no., lot no., Weight, etc
receiving (10%)

Select cones for below testing

Cone to Cone variation

1 Yarn
Yarn
Visual Check Shade variation in one cone
inspection

Lot to Lot variation

Count and twist variation

 Frequency of knot

Spirality

Foreign fiber and slub yarn

Oil and dirty mark

Knitting performance

Odor

Shrinkage

Moisture

Mildew

Yarn Approve by QAM to see overall

Manual
Approval Quality in all stage of yarn

SL SECTION SOP Procedure

2 Winding Have to 1. It is Prohibited to issue several lots, colors & Styles at

follow in the same time & same Machine.
winding
Section
2. Pay attention to the color shading during winding.

3. Prohibited to wind more than one lot in the same

bobbin.

4. Ensure tracing number attaching in the yarn cone of

the machine operator.
 5. Pay Attention regarding bobbin color mixing after
wound,keep it separately.

6. Ensure the yarn name,lot,quantity & color

Machine
Winding Speed,Tension,Wax,Lubrication etc
inspection

Online
Order requirement,Winding formula & winding control
activity
report.
Inspection

SL SECTION SOP

1. Make Size set sample based on production approval.

2. Attend PP Meeting and decided how to start knitting.

3. Pick first bundle or Pilot run from knitting production.

A) The QA have to check tension, same part up down of same size, yarn
lot number, Shading, number of panel in a bundle, spot, needle drop, etc

Auto
3 B) Write the report.
Knitting

4. Roving QA Must make sure the products are produces according to

buyer requirement if any problem found, take corrective action as below.

A. Identify the problem,

B. Find out the source,

C. Stop the process (if necessary),

 D. Solve the problem,

E. Prevent it from recurring.

F. Write the report

5. Panel checker: Check the panel quantity, color & size wise of knitting
completed goods.

6. 100 % check the knitting panels and mark the defect area for rectify &
write the report.

7. If meet the quality than pass & sign on the issue card with individual
checker ID number .

8. AQL: 1.00 must be conducted for knitting panel inspection. If pass,

than it will proceed for linking.

Section SOP

1. All types of linking process Should be Performed according to

Technical Sheet.

2. Linking complete than sign on swatch paper with individual checker

ID number.

4.a
3. Inline QA always follow & check overall quality like, Shoulder join,
Linking overlock, Sleeve stitch, Sleeve join, Side join, neck join, size yarn & lot
yarn etc

4. If any mistake found between operation than Line QA Applied Traffic

light Systems.Traffic light colors are defined as below.
 * Green Card: This card show to operator at primary stage when any
problems found & Give Suggestion for improve operation.

*Yellow card: This card show if problem found again & further suggest
the operator.

*Red Card: This card show when problem found again & again and apply
the bellow process.

A. Stop the process .

B. Solve the problem,

C. Prevent it from recurring.

D. Write the report

5. After Linking AQL: Must be

conducted 7-0 systems for
linking complete garments. The
QA have to check 7 pcs
garments from a basket ,if he
get any problems then recheck
all garments of the basket.if
goods pass will be than consider
for next process

1. The line QA check Trimming portion such that its will be well trimmed
Trimming
& Mending completed garments must be accurate such that no mending
4.b and
fault shown. The mending operator must keep mending indication sign
Mending
such that Qa understood the garments is correct mended.

6. After Trimming & Mending AQL : Must be conducted 7-0 systems for
trimmed & Mending complete garments .The QA have to check 7 pcs
garments from a basket, if he get any problems then recheck all garments
of the basket. If goods pass will be than consider for next process

Light Here pcs to pcs garments should be check by light and make report by
Check operator. The QA see the report and take necessary action if problems
 (B/W) found.

SL SECTION

SOP

1. Firstly Washing QA have to take care such that washing load,cycle

5 Washing time, Chemical Mixture ratio will be accurate.

2. After complete washing, the QA have to check about the following side
like spot, Stain, Color variation, Hand feel, Pilling, Shrinkage etc.

Light Here pcs to pcs garments should be check by light and make report by
Check operator. The QA see the report and take necessary action against the
(A/W) finding problems.

SOP

1. Trim and accessories: QA make trim card & take approval from related
merchandiser.

2. Line QA Have to follow label instruction according to buyer

requirement.
Sewing
6
and FQC
3. Here QA have to follow different attaching measurement, sewing
stitch, density of stitch, approve sewing thread, Count. of sewing thread
etc

4. FQC operator have to check main label,care label,side seam, uncut

thread , hanger loop and those attaching measurement according to SOP,
etc and make report.than the QA check report and take corrective action
against finding problems. Also The QA must randomly check after FQC
operator checked garments.

7 Ironing SOP
 A) Board marking and marking approval (Approved By QA manager)

B) Have to follow the system of ironing & proper utilization of steam

based on garments construction.

C) Line QA strongly follow up about ironing like following problems, iron

shape, shinning mark, correct measurement etc.

D) 100% measurement by measurement QI.

SOP

1. Line QA follow up & instruct to operator such that good quality goods
Finishing proceed
8 and Get
Up
2. Here AQL done, following topics, getup, hole ,mending, shading, main
label, care label, hang tag, uncut thread overall total appearance and
instruct the operator how to improvement task. If AQL pass will be goods
proceed to packing. If fail recheck all goods for rectification.

SL Section SOP

1. Garments Scanned through needle detecting machine to find out any

broken needle, or any other metal which may go with garments. If any
problems can detect the machine than alarm will be ringing.
Metal
9
Detection
2. M/C Calibration:The machine operator should be completed every 1
hours test the machine by using 1.2 mm by sphere ferrous test card.

SOP
10 Packing
1. Checking accessories as per approved trim card.
 2. The QA have to check Size wise folding, Size wise poly, no. of garments
in carton, carton number, Shipping mark,Assortment

3. Hourly audit have to do from completed carton. If report is pass than

seal on the carton & handover to packing responsible person . If fail than
arrange to recheck .

4. Inspect rectified goods again

Section SOP

1. AQL 2.5 must be conducted for pre final inspection

2. Sample to inspect must be select randomly from the finished product

packed in cartons

3. The selected goods must contain all sizes, color & countries
11
Pre final
4. Before final inspection must need to go through with tech pack and
seal sample, based on this need to check the garments

5. The inspection result will show whether the entire lot is acceptable or
not

6. Use the inspection report to compare with previous inspection report

SOP

Final 1. Before final inspection by Customer following procedure.

12
Inspection

Correct Packing list (Invoice) & Shipping mark on carton, carton serial
number, assortment all are make sure to correct.
We have sent some completed garments for testing purpose