Quality Control

A group of licensed technicians and a multiple diversified lineup of quality inspectors are to examine and scrutinize the processed merchandises. The groups are equipped with state-of-the-art apparatus and they abide strict inspection methods. They even have regulated quality standards to examine the products in order to ensure that these products meet the standards of the clients prior to any market release. The company has formed its own set of quality control system based on the clear knowledge of what their clients’ preferences of their goods. This quality control system is a result of the company’s of years of experience of exporting their merchandise to the United States, Canada, Germany, and the United Kingdom.

Excellent workmanship is important in designing high quality fabrics and garments. This can only be attained through training, oversight, and management to achieve the company’s goal and that is to come up with ideas and concepts at the Design Workshop that are suitable for production and delivery.

Quality Policy:

Based on Management – to keep the business continually growing

Focused on the Clients – always make improvements to satisfy client’s requirements.

Quality Objective:

Our company owned quality assures and control team that is composed of well trained and experienced members capable of examining the fabrics and garments produced in the manufacturing line. This is to ensure that the quality of our final products will not be compromised.

Our garments inspection process is composed of 8 steps and these are:

  1. Piece by piece examination – 100%
  2. Random in line spreading inspection
  3. Cut piece inspection
  4. In line sewing inspection and examination – 100%
  5. Trimming and examination – 100%
  6. Inspection during press fold – 100%
  7. Finishing and packing final audit – 100%
  8. Employment of metal detectors for broken needle management system – 100%

These in line inspection show that we are committed to the quality of our products and that we ensure that the highest standards of quality are met. We do not allow any compromise when it comes to the quality of our products. From the procurement of our raw materials to the last part of the shipment, we ensure that the quality of our products is maintained. It is also given that our suppliers comply with the same standards of quality control. We made it sure that Quality Assurance is a focal point of our services and that our goal is that no client will complain pertaining to the quality of our products.

Inspection Procedure:

  1. During Cutting

The products from the cutting section should undergo inspection for any type of visual imperfection. Included are the following:

  1. Holes, bare, needle line, variation of the yarn shade, and repeated differences. These are called as knitting defects and the defects are not limited to the ones mentioned above.
  2. Water marks, component shading, compactor shoe marks, and dead cotton slabs. These are called as processing defects.
  3. Inappropriate notching and incorrect cuts.
  4. Unmatched front and back panel based on the customer’s requests and specifications.
  5. Unmatched designs.
  6. Sampling quantity example:
Visual Inspection 100%
Measurement Check 2 out of 10 pieces

If a particular product did not qualify to the standards above, that product will be returned to the cutting section for restoration and adjustment, or replacement.

Acceptance Standard:

Bundle Size Defects allowed
Up to 4 Pieces 0
7 to 12 pieces 2
13 to 19 pieces 3
19 to 25 pieces 4
More than 20 pieces 4

If there are products that are required to be replaced, the quality control officer will see to it that the shade and measurements of the new products will match to the replaced ones. This is to ensure that the numbers of the batch will also match.

Rate of Defects Calculation:

Calculation of Reports Generated for all Procures that are Archived:

  • Cutting Quality Assurance Report – Exhibit 3A

 

  1. During Sewing

For a particular sample to be accepted, the quality assurance officer relies on the following parameters:

  1. Pattern of the fabric, design, and weight
  2. Details of the stitches
  3. Placement of the accessories and trims
  4. Details of folding and packing

 

The following are treated as primary errors:

  1. Any holes in the surface or even minute defects that will eventually lead to a hole.
  2. Any type of detectable blemishes.
  3. Incorrect shading within the garment itself.
  4. Dye stains and misprints.
  5. Conspicuous cuts and tears.
  6. Unmatched checks and stripes.
  7. Unfolding of the fabric that can affect the overall display of the garment.
  8. Conspicuous marks, or stains.
  9. Changes in measurements or specifications that surpassed the standard tolerance.
  10. Crooked or wrinkled seam.
  11. Susceptible seam or damaged stitches.
  12. Seams that are not bar fastened unless concealed by another seam.
  13. Uneven and erratic top stitching and contrast stitching.
  14. Top stitching that splits in distinguishable regions of the garments.
  15. Inaccurate stitch numbers or counts.
  16. Wrong allowance of the seam.
  17. Crooked hems and irregular hems.
  18. The bar track is missing.
  19. The fronts, sleeves and other symmetric components are uneven or irregular.
  20. Mending is poorly done or unacceptable according to standards.

The following are considered as potential secondary or minor errors:

  1. Stains or marks that can still be removed.
  2. Other defects that can be considered temporary and not listed above.

In line Quality Audit

It is part of the job of the quality control officer to conduct an in-line quality audit based on the procedures given below:

  • After any operation, the officer will pick up a random bundle.
  • The quality of that operation is examined through that random bundle as a representative sample.
  1. The procedure will be repeated at least 3 times in a day.

If a discernible trend of repeated errors is observed, the entire production will be stopped. It will only be resumed when a corrective action is employed to address the problem and that corrective action must be approved by the quality control officer.

End of Line Quality Control

It is also part of the job of the quality control officer to wait at the end of the sewing operation to examine the following:

  1. Formation of the stitches
  2. Variation of the component shades
  3. Variations and sewing changes
  4. Damaged or destroyed parts
  5. Jumping of the side label
  6. Sewing operation that is possibly missed
  7. Specification of the broad measurements

Pilot Run

A pilot run may be carried out depending on the order size. This is to address the problems that may arise in the full production mode. In this run, all the products are examined visually for any defects. The sample sizes for pilot runs are given below:

Order Quantity Pilot Strike Off
Up to 4, 000pcs 5 pcs
5,000 to 10,000 pcs 20 pcs
10,000 to 25,000 pcs 50 pcs
26,000 to 50,000 pcs 75 pcs
Above 5,0000 pcs 100 pcs

If there discernible deviations in the measurement or style during the pilot run, these are incorporated in the sewing line before the full production starts. All the reports are presented and archived.

  • Embroidery

Approved Sample

The quality assurance team ensures that quality of the embroidery is not compromised. A sample embroidery sew-out is done and the sample of the garment together with the details is constructed to ensure the quality of the embroidery. This is done before the mass production and the control parameters are strictly adhered.

Control Parameters

  1. Correct shade of threads
  2. Layout of the embroidery
  3. Coverage or stitch density based on the order
  4. Alignment of the embroidery
  5. Tattering of the thread
  6. Clarity of the design based on the original sample
  7. Appropriate tension of the threads
  8. Holes made of the threads originality by the needles
  9. Skipped or broken threads
  10. Variation of the shades within a box of threads

Quantity of the Pilot Strike Off:

Order Quantity Pilot Strike Off
Up to 2000pcs 15pcs
  1. Printing

Approved Sample

Any approved strike off product is ensured by the quality assurance team to be of the same color tone as its reference number or standard color. The sample garment together with its position details must exist at the department. The strike off should be done with the use of the actual garment and that garment should be examined before the bulk production. In any case, the quality should be examined according to the following standards:

  1. Correct shades of the colors used
  2. Placement of the prints
  3. Accurate registration
  4. Alignment of the prints
  5. Clarity of the design based on the original sample
  6. The surface must be correctly cured
  7. Presence of spots and stains
  8. Skewness of the print
  1. Pilot run quality audit report for printing (Exhibit 5A)
  2. Daily quality report for printing (Exhibit 5B)
  1. Finishing and Packaging

To eradicate wrinkles, the knitted or woven fabric products are pressed. The following are key points to be ensured by the quality control officer while pressing of the fabric is in progression:

  1. A proper temperature should be maintained for the knit product iron process.
  2. A Teflon shoe should be provided by the system and a periodic cleaning is required.
  3. It is necessary not to hard iron the areas like collar, embroidery, or printing for it might destroy that particular area.
  4. The surface of the garment should be free from mall wrinkles, defective luster, and iron-pressed marks.
  5. The iron finished product volume should conform to the specification of the order.
  6. There should be an allowance of 1 hour before the products are loaded in a poly bag in order for the products to be cooled.
  7. The horizontal and vertical markings of the ironing table top should match to the outline size of the garment.

Packing is also an integral part of the garment production. The characteristic details are to be examined by the inspector:

  1. The hangtag, price ticket, and bar code stickers.
  2. The appropriate size of the poly bag should be utilized for a specific garment to be packed.
  3. The insertion of the garment into the bag should not be too tight or too sloppy. There should be a correct tightness of the packing.
  4. The proportion of the pre-packs and the quantities in each carton should be verified at random interval.
  5. Visual symmetry should be observed from the garment through the poly bag.
  6. The markings of all the cartons should be appropriate according to the requirements of the order.
  1. Final Audit

Before any of the garments exit the manufacturing area and delivered to the clients, a final audit should be performed in order to establish the quality level of the product. This is very critical in the factory for any defect that was not detected earlier will be observed, thus preventing any customer complaint.

It is now the quality assurance manager who will perform the final quality audit of the packed goods and is usually done in two stages:

  1. Once half of the delivery is packed.
  2. The other is when all of the delivery has been packed.

If in case a problem pertaining to quality arises, the goods have to be screened for the specific type of problem. Once the correction has been implemented, the steps above should be repeated. The reports are then presented and archived