When end customers purchase a garment, they appear for the standard first. So, to possess a satisfied customer, retailers must keep the standard product in their shops. consistent with the acquisition agreement, buyers can penalize suppliers for supplying them with defective pieces. it'd cost the factory lot of cash and goodwill. So, the garment manufacturers lookout of garment quality at each stage of production. In maximum cases, the customer inspects shipment at the factory before accepting the finished garments. Whatever defects found within the final inspection, it's the cumulative figure of previous processes. So, it's vital to rectify defective pieces within the process where it occurred rather than within the finishing.
What defects come in garments?
A lot of individuals and machines are involved in producing a garment. there's a clear chance of creating a couple of faulty garments during a batch thanks to faulty machines or human intervention. The defective pieces are often corrected by repairing or changing defective parts. But repair work costs money and time. These both increase the inefficiency of the corporate . And if one defect skilled the initial process without detecting and correction and process continue then at the later stages repair cost are going to be far more than detecting it within the initial stage.
The production process starts after receiving of materials and end after dispatching of packed garments. Generally, the garment export houses place quality checkpoints at the top of every process to make sure that only quality pieces move to subsequent process.
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Quality checkpoints during a garment factory
In a garment factory, department wise quality checkpoints are explained within the following
1. Fabric Store:
In the fabric store fabric is being checked before issuing it to the cutting department. generally , not all the material rolls are checked. Usually, 10% of materials are checked permanently fabric suppliers. For loom fabric and printed fabric 100% checking is completed . Fabrics are checked on a flat table, flat table with lightbox, or on a cloth checking machine. 4 point system for cloth inspection is employed to live the standard level of the incoming fabric.
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2. Trims & Accessory:
Trims quality is additionally vital for having a top quality garment. Trims inspection is completed randomly against the given standards, like color matching. except for trims and accessories quantity checking is important .
3. Cutting Room:
It is said that cutting is that the heart of production. If cutting is completed well then the probabilities of occurring defects within the following processes come down. within the room , checkpoints are –
i) marker checking, ii) cut part audit, and iii) bundle checking.
4. Printing Checking:
Printing isn't a legal right . If printing is completed in fabric form then printing is being checked within the fabric store. For knits garment, maximum printing is completed in cut panels. So before issuing cuttings to the stitching department, each panel is being checked properly. Defects that are found here is print placement, color matching, misprint, or print overlapping or shade variation.
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5. Embroidery checking:
Like printing embroidery is also not a legal right . If there's embroidery add the garment panels then 100% inspection is completed before issuing to sewing.
6. Sewing Department: Checkpoints within the sewing departments are as follows.
Inline inspection: within the production line generally check pints are kept for the critical operations. In these checkpoints, 100% checking is completed for partially stitched garments and defect-free pieces are forwarded to subsequent process. this sort of checking is employed for the high-value garment.
Roaming inspection: during this case, checkers roam round the line and randomly check pieces at each operation.
Traffic light inspection system: Some garment manufacturers use this inspection system. during this system, each operator is given a card for measuring their quality performance. the standard checker goes to the operator and does a random check for few pieces and consistent with the inspection result, the checker marked red or green on the cardboard following rating criteria.
End of line inspection or table checking: A checker checks a totally stitched garment at the top of the road . 100% checking is completed here,
Audit of the checked pieces: some manufacturers follow this audit procedure but it's a really essential checkpoint to assure that only 100% of the inspected garment is shipped to finishing from the stitching department. and every one defective pieces are repaired before sending it to the finishing section.
7. Finishing Department:
Checkpoints within the finishing department contains the followings
Initial finishing inspection: checking done before pressing of the garment at the finishing room is understood as initial finishing.
Final finishing Inspection: After pressing, garments are again checked and passed to the folding section for tagging and packing.
Internal audit: After garments are packed up to a particular quantity, the standard control team, do an audit of packed garments. This process is administered to make sure that before delivering shipment to buyer QC
If the finished work is being checked at each process and defective pieces are corrected before handing to subsequent process then at the top of production there's little or no chance to possess a defective at the ultimate inspection stage.