PRELIMINARY VISION,

TO

GARMENT INSPECTION
BY

TALHA MALIK
&

NORAIZ NADEEM KHAN LECTURER : Mr. BABAR RAMZAN

 PROLOGUE  AQL  INSPECTION METHODS  GARMENT DEFECTS  AQL CHARTS  INSPECTION LEVELS  EXAMPLE

Today, most of the customer demand for high quality products in low prices. So we should maintain the quality from the beginning stage of the production then only the final product with reach the consumer with right quality and we can get the order continuously from our customers. The garment manufacturers inspect their products continuously by designated responsible inspectors then only the right quality product will reach the consumers.

 AQL stands for Acceptable Quality level. The AQL

determines the maximum amount of admitted defective units in a sample. AQL, for purposes of sampling inspection, can be considered satisfactory as a process average. The most commonly used AQL is a major 2.5 minor 4.0.
 This method constitutes taking random sample,

inspecting them and depending on the quality of the sample inspected determining whether the entire lot is acceptable or not.

 STAGES OF GARMENT INSPECTION  AQL RANDOM SAMPLING INSPECTION  INSPECTION SAMPLING PLAN

 Pre-production Check

Final check on the raw material used, style, cut.  Initial Production Check First batch of garments is inspected, make correction before bulk production.  During Production Check  Final Random Inspection Checking the total production quality by selecting the samples from the order. AQL sampling inspection may be applied.

 The AQL inspection takes the samples from a goods, inspect

them and depends on the quality of samples inspected and decide to accept or reject them.  The standard is based on Military Standard 105D (MIL-STD105D)  It provides with the sampling plans, the number of samples to be inspected and the acceptable quality level (AQL)  AQL 1.5 is applied to very severe inspection on high-class expensive item.  AQL 2.5 is applied when textiles of normal/good quality are involved.

Single sampling plan - Normal inspection

Assurance as AQL 2.5% and a lot of 1,200 garments and the sample size is 80 garments. If the number of defective garments found are 5 the total lot is "Acceptable" suppose if the garments found is 6, the total lot is "Reject/Re-Check".

Double Sampling Plan - Normal inspection

Assurance an AQL 4.0% and lot size is 1,200 garments and the sample size is 80 garments. If the number of defective garments found is 7, the total lot is "Acceptable" suppose if the defective garments found are 8, the total lot is "Reject/Re-check".

Once the samples are selected, each article is to be individually inspected. Defects detected during an inspection are buyer specific so therefore vary from one buyer to another. Defects are classified within the following categories:
 Critical Defects

A serious defect that can cause harm or injury to the user and/or result in a hazardous condition.

 Major Defects

A defect that falls to meet the mandatory regulations directly affecting the usability, salability, safety and value of the merchandise or as specified by customer are considered as major defects and are generally non repairable for example fabric hole, shading among panel, wrong measurement, foreign yarn, dye patches etc. The measurement tolerate level may vary from customer to customer.

 Minor Defects

A defect that does not adversely affect the usability of the product but does consists of a deviation from the original sample, and may affect the sale of the product. Some of these defects are due to workmanship and some can be repairable but still can deteriorate the serviceability of the merchandise for example stain, skip stitch, wavy bottom hem etc.

SAMPLE NUMBER SIZE CODE OF LETTER SAMPLES A A

1.5 AQL

2.5 AQL

4.0 AQL

6.5 AQL

R A

R A

R A

2
3

0 0 0 0 1 1 1 1 2 2 1

13

SAMPLE NUMBER SIZE CODE OF LETTER SAMPLES A F

1.5 AQL

2.5 AQL

4.0 AQL

6.5 AQL

R A

R A

R A

20 32 50
80

1 1 2
3
5

2 2
3 4 3
5

3 4
6

3 5
7

4 6
8

2 2
3 4
6

3
5

6 7

8 10

11 15

125

10

11 14

SAMPLE NUMBER SIZE CODE OF LETTER SAMPLES A L

1.5 AQL

2.5 AQL

4.0 AQL

6.5 AQL

R A 8 10

R A 11 14

R A 15

200
315

21 22

10

11

14

15

21

22

500

14

15

21

22

800

21

22

1250

Lot or Batch size 2 to 8 9 to 15 16 to 25 26 to 50 51 to 90 91 to 150 151 to 280

S-1

S-2

S-3

S-4

II

III

A A A A B B B

A A A B B B C

A A B B C C D

A A B C C D E

A A B C C D E

A B C D E F G

B C D E F G H

Lot or Batch Size 281 to 500 501 to 1,200 1,201 to 3,200 3,201 to 10,000 10,001 to 35,000 35,001 to 150,000 150,001 to 500,000 500,001 & over

S-1 B C C C C D D D

S-2 C C D D D E E E

S-3 D E E F F G G H

S-4 E F G G H J J K

I F G H J K L M N

II H J K L M N P Q

III J K L M N P Q R

If an order is 10,500 units. When using General Inspection Level II, the factory learns from the second chart that this quantity order equates to "M". The factory then goes to the first chart and sees that for "M" they should inspect 315 garments. If they want a 2.5 AQL they can have 14 defective units or less from the 315 that they inspect. If they have 15 defective units or more they are rejected. If they want a 4.0 AQL they can have 21 defect units or less to pass and they have 22 defects they will be rejection.

 Textile school.  Fashion industry.  Ellis developments limited.  AVS Technical Research, Development & Training.