Quality control
Quality control (QC) is crucial to ensuring that garments meet client specifications and international standards. The QC process is carried out at multiple stages during production to catch and resolve defects early. Here are the key stages of quality control in a readymade garment export order:
- Pre-Production Quality Control
- Fabric Inspection: Before production starts, the fabric received from suppliers is checked for defects like uneven dyeing, holes, stains, or other inconsistencies.
- Trims & Accessories Inspection: All trims, buttons, zippers, labels, and other accessories are inspected to ensure they meet quality and durability standards.
- Pre-Production Sample Check: The pre-production sample (PPS) is checked for approval based on design, fit, construction, and material before bulk production starts.
- In-Line Quality Control (During Production)
- Initial Production Inspection: This is conducted on the first batch of garments produced to ensure they are being made to the approved specifications and standards.
- Sewing Quality Inspection: During stitching, checks are performed for issues like uneven seams, incorrect thread tension, or skipped stitches. Inspectors ensure that garments are sewn as per client specifications.
- Component Quality Check: Each garment part (sleeves, collars, etc.) is inspected individually before being attached to the main body to ensure correct assembly.
- Random Inspection During Sewing: Random pieces from the production line are checked throughout the process to ensure consistency in quality and catch any defects early.
- Post-Production Quality Control
- 100% Visual Inspection: After production, every garment undergoes a thorough inspection for defects such as:
- Incorrect stitching or loose threads
- Measurement inaccuracies
- Color shading differences
- Fabric defects like holes or stains
- Missing or incorrect trims
- Fit and Measurement Check: Garments are measured to confirm they match the approved size chart and fit specifications.
- Functionality Testing: For garments with special features (like zippers or buttons), functionality is tested to ensure they work as intended.
- Final Inspection (Before Packaging)
- AQL (Acceptance Quality Level) Inspection: Before packaging, garments are inspected using AQL standards, which involve checking a sample of garments from the batch to determine the overall quality. Based on the results, the batch is either approved or rejected for shipping.
- Packaging Inspection: Inspectors check that each garment is folded properly, packed in the correct polybag, and labeled accurately (size, style, and barcode).
- Carton Check: The final packaging in cartons is inspected to ensure that each carton contains the correct number of garments and is properly sealed.
Readyment Garment Tests parameters:
Here’s a comprehensive chart of various test parameters for ready-made garments, including methods, acceptable limits, and brief descriptions for each test:
Test Parameter | Method | Acceptable Limit | Description |
1. Fabric Weight | ISO 3801: Measuring the weight of fabric over a specific area (e.g., 1 m²). | Varies by fabric type (typically 150-300 g/m²) | Determines the heaviness and quality of the fabric. |
2. Color Fastness to Washing | AATCC 61: Wash test under specified conditions and rating scale. | Grade 3-5 (on a scale of 1-5) | Assesses how well the color withstands laundering. |
3. Color Fastness to Rubbing | AATCC 8: Rubbing with dry and wet test fabrics. | Grade 3-5 (on a scale of 1-5) | Evaluates color transfer from the fabric to other surfaces during friction. |
4. Shrinkage | ISO 6330: Wash and dry fabric samples, then measure dimensions before and after. | ≤ 3% (woven); ≤ 5% (knit) | Measures the reduction in size after laundering. |
5. Tensile Strength | ASTM D5034: Strip method for measuring fabric tensile strength. | ≥ 30 N for lightweight fabrics | Determines how much force the fabric can withstand before breaking. |
6. Tear Strength | ASTM D2261: Measure the force required to tear the fabric. | ≥ 5 N for lightweight fabrics | Assesses the resistance of the fabric to tearing. |
7. Seam Strength | ASTM D1683: Measure the strength of the seam under tension. | ≥ 20 N | Evaluates the durability of seams in the fabric. |
8. Pilling Resistance | ASTM 4970: Evaluate the fabric’s tendency to pill after abrasion. | Grade 3-5 (on a scale of 1-5) | Measures how well the fabric resists the formation of small balls of fibers on the surface. |
9. Flammability | ASTM D6413: Testing fabric for flammability by measuring the rate of burning. | Pass (no flaming or melting) | Assesses how quickly the fabric ignites and burns. |
10. Water Repellency | AATCC 22: Spray test for water resistance. | 80% or higher water resistance | Measures the fabric’s ability to repel water. |
11. Dimensional Stability | ISO 3759: Measure dimensional changes after washing. | ≤ 3% for woven fabrics; ≤ 5% for knits | Evaluates how well the fabric maintains its shape and size after laundering. |
12. Crease Recovery | AATCC 66: Measure the ability of the fabric to recover from creasing. | ≥ 75% recovery for dress fabrics | Assesses how well the fabric returns to its original shape after being creased. |
13. Iodine Absorption | Measure how much iodine is absorbed by the fabric to assess for residual chlorine. | ≤ 5% iodine absorption | Evaluates potential chlorine residue from bleaching processes. |
14. Light Fastness | ISO 105-B02: Expose the fabric to light for a specified time and assess color change. | Grade 3-5 (on a scale of 1-5) | Measures the resistance of the fabric color to fading under light exposure. |
15. Wash Fastness | ISO 105-C06: Evaluate color change and staining on white fabric after washing. | Grade 3-5 for both color change and staining | Assesses the fabric’s ability to maintain color and not stain other items during washing. |
16. Abrasion Resistance | ASTM D4157: Determine the wear resistance of the fabric through abrasion tests. | 20,000 cycles or higher | Evaluates how well the fabric withstands surface wear and tear. |
17. Stretch and Recovery | ASTM D2594: Measure the stretch and recovery properties of the fabric. | 25% stretch with at least 90% recovery | Assesses how much the fabric can stretch and return to its original shape. |
18. Chemical Resistance | AATCC 42: Evaluate the fabric’s resistance to specific chemicals (e.g., bleach, solvents). | No visible damage or discoloration | Determines how the fabric reacts to chemicals during use or laundering. |
19. Thermal Properties | ISO 11092: Measure thermal insulation and breathability of the fabric. | Varies by fabric type (check specific norms) | Assesses the fabric’s ability to retain heat and allow moisture to escape. |
20. Fiber Content Analysis | AATCC 20: Identify and quantify the fiber composition of the fabric. | Accurate to within ±3% | Determines the exact materials used in the fabric for compliance and marketing purposes. |
21. Dimensional Changes to Fabrics | ISO 13934-1: Measure any dimensional changes due to laundering or exposure to moisture. | ≤ 3% for woven fabrics; ≤ 5% for knits | Evaluates how the fabric dimensions are affected during regular use and care. |
22. Odor Resistance | Evaluate the fabric’s ability to resist odors, especially in activewear. | No detectable odor after testing | Assesses how well the fabric prevents odor buildup during wear. |
23. Softness | Use a subjective test or objective instruments to assess the softness of the fabric. | Varies by fabric type (subjective ratings) | Evaluates the feel of the fabric against the skin. |
24. Moisture Management | AATCC 200: Test the fabric’s ability to wick moisture away from the skin. | Higher wicking rate preferred | Assesses how well the fabric transfers moisture to the outer surface for evaporation. |
Fabric Test Parameters and Passing Limits
Test Parameter | Description | Passing Limit |
Weight | Weight per square meter (gsm) | Typically 180-220 gsm for garments |
Tensile Strength | Resistance to tension | Min. 400 N |
Tear Strength | Resistance to tearing | Varies by fabric type, generally > 20 N |
Washing Fastness | Color retention after washing | Min. Grade 3 (on a scale of 5) |
Rubbing Fastness | Color retention when rubbed (dry/wet) | Min. Grade 3 (dry), Grade 2 (wet) |
Light Fastness | Resistance to fading from light exposure | Min. Grade 4 |
Shrinkage | Fabric shrinkage after washing | Max. 5% |
Crease Recovery | Ability to recover from creasing | Acceptable recovery rate (specific to fabric) |
Flammability | Safety against fire | Must meet safety standards (e.g., NFPA 701) |
Water Repellency | Resistance to water penetration | Water should bead on the surface |