Factory Quality Control process

Below are the factory process for best Quality garments, Connor QA can review during their line visits …

Fabrics Stores:
Relaxation :
First fabric has to be relaxed so that there is no tension or strain during rolling or unrolling while layering
or cutting. This will ensure that there is minimum shrinkage in garments.
Shrinkage adjusting
Shrinkage adjustments should not distort the original shape and balance of the patterns. When
shrinkage is applied to a panel in garment all corresponding patterns must also be applied with
shrinkage adjustments.
The picture on the left shows how a
garment panel looks like after it has been
scanned and graded.

Fabric Shrinkage is a very important factor for any physical inspection

According to the above picture, a fabric piece of the above-mentioned specification is cut

Color Fastness or Crocking: In order to check color fastness, 2 fabric swatches are taken.
On 1 of the swatch, a white seam is put on all the four sides of the fabric. Both of the them
are washed and the results are compared. If it is stained or slotted then it’s rejected.
C.S or Centre Selvedge test: This test is used to check the color variation in the fabric.
Full width of the fabric is taken (length can vary according to requirement say 10”).
TRIMS STORES
This store is responsible for storing and neatly maintaining the trims received from the
suppliers, approved by H/O. Trims card to be readily available for each of the PO/style being processed
that is duly approved by the nominated quality assurance person.
➢ WORKFLOW OF TRIMS STORE
Department wise quality system in factory
1) FABRIC STORES:
o Neatly arrange the fabric rolls received and maintaining the department cleanliness to
avoid spotting and contamination of the fabrics. Packing the fabrics in plastic sheets can
be useful.
o Fabric inspection is done on 4 point system.
o Shade cards/fabric quality swatches for each style approved by the PO are maintained.
2) TRIMS STORES:
o Trims stores have racking system to store the trims in a proper order.
o Trims card for each PO/style being processed should be maintained.
3) CUTTING SECTION:
o Making CSV ( centre to selvedge variation) sample for each of the roll to analyze
the shade variation.
o Maintaining shade samples and providing shade details to presentation checkers
in finishing dept for shade reference.
o Proper pattern checking report.
o Proper lay check, marking check, sorting/bundling check report.
o Cutting projection tallies updated.
4) SEWING SECTION
o Effective maintenance for each of the machine.
o Proper updated broken needle log (should have needle issuing record from
stores and properly pasted broken needle book).
o Keyhole, bartack, overlock, label attach operation internal approvals and display
of mockups.
o Effective mockup system on all operational areas.
o All scissors and trimmers should be secured properly.
o Clearance of WIP at all levels.
o Display of trim card at required areas.
o Checking garments before wash and after wash for both quality and
measurement.
o Random in-line checking at each chain stitch operation like feed of arm machine.
o Each supervisor is advised to check randomly the operation in their own working
limits.
o Each operator is advised to clean their machine and area before start of work in
the morning and after lunch- waste fabric is issued to the operator for the same.
o In-line and end-line checking report.
o Before wet processing in-line audit report is also maintained.
o Washing facility is not available in-house. It’s done on jobber basis.
5) FINISHING SECTION
o Fabric defect identification by stickering and alteration piece identified by
knotting at place of alter by the checker.
o Dusting is done by dust pads wherever sucking machine is not used.
o Cartoons are properly stacked.
o Presentation checker to have ready reference of shade cards of fabric and trims
cards as well.
o Daily checking report is maintained.
o Measurement audit report is maintained.
o Pre-final auditing is also gone on garments.
o Defective cartoons are replaced by good cartoons.
6) PACKING AND DESPATCH SECTION
o Separate departments are maintained for topwear and bottom wear.
o The fully packed garments are racked in sequential manner and each rack is
given a number for identification.
o Garments are stored brand wise, sizewise, and garment wise.
o Barcode stickering is done and checked.
o Packing in inners and outer cartoons is done according to the size ratio or
packing specifications as specified.
o Goods to be shipped are packed readily with proper covering and sealing and
kept near the main gate to be loaded in the cargo.
o Proper recording of dispatch, packing and stock stored in-house pending for
shipment are maintained along with Chelan entries of cargo and transportation
services.
o Good relations with distributors are held.
7) ENTIRE WORKING AREA
o Properly certified fire extinguisher to be free from all obstacles.
o Each operator to wear mask to avoid inhalation of dust inside the factory.
o Dust collection bags for each work station/machine.
o Separate area for storing rejected garments.
o Proper covering of stored pieces.
o Properly maintained QC reports and files maintained by QA.
➢ Department wise quality check points
Fabric Store - 100% fabric inspection
Trim & accessories- Trims inspection
Cutting Room - Marker checking
- Cut parts checking or audit
- Bundle inspection
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 wash) and alterations
- Final finishing inspection (After Pressing)
- Internal
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. 100 % fabric 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. Embroidery checking: It is also not a compulsory process. If there is embroidery work in
the garment panels then 100% inspection is done before issuing to sewing.
5. 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.
- Roaming inspection: In this case checkers roam around the line and randomly check pieces at
each operation.
- 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: 100% inspected garment are sent to finishing from sewing
department. And all defective pieces are repaired before sending to finishing.
6. Finishing Department: Check points in finishing department consists
- Initial finishing inspection: checking done prior to pressing of the garment at finishing room is
known as initial finishing.
- Final finishing Inspection: After pressing garments are again checked and passed for tagging
and packing.
- Internal final audit: After garments are packed up to certain quantity, quality control team,
does audit of packed garments. This process is carried out to ensure that before handing over
shipment.
If the completed work is being checked at each process and defective pieces are corrected
before handing to the next process than at the end of production there is very little chance to
have a defective at final inspection stage.