Quality Monitoring Procedures
We define Quality as ultimate fulfillment of customer’s requirements in the product, services and timeline. We have two divisions to monitor quality: Quality Control Department which is reporting to factory management and Quality Assurance Department reporting to the factory ownership for independent audits and to convey true reflection of quality being produced by factory management.
Quality Control
During product manufacturing, we monitor quality of raw material and final product through inspections with focus on process improvement.
Fabric Inspection and QC Procedures:
Incoming fabrics are inspected at 4 Point system. 100% fabric is inspected by fabric QC’s. Each fault is given points keeping in view the nature and intensity of the faults. 40 Points are allowed in 100 inspected yards. If number of faults/points exceeded than 40 points per 100 yard, the fabric roll is rejected. Lab test reports are also taken from fabric suppliers and verified through internal and third party labs as per requirement.
Accessories Inspection
Accessories at the time of receipt in store are randomly inspected by QC’s/concerned persons at least up to 10% of the received quantity.
Cut Parts Inspection
100% cut parts are inspected before input to sewing section. The rejected components are replaced from remnants or removed. Cut parts are also inspected 100% before sending and after receipt from printing , embroidery, applique work etc.
Sewing Inline Inspection
During stitching operations, the inspections are done on 7-0 System. Inline QC inspects 7 pieces randomly for each machine operator twice a day. If he finds any fault among these 7 inspected pcs, the Sewing operator has to inspect the whole bundle himself and offer inspection again to Inline QC. If the inspection is fault free, then this sewing operator will undergo follow up inspection of 03 consecutive bundles. If 03 Follow Up Inspections are ok, the Inline QC moves to next machine operator. If during 1st follow up inspection, the Inline QC finds any fault, then the said sewing operator has to go under 2nd follow up inspection. If the 2nd follw up fails then operator has to stop the work for two decisions to be made depending on the nature of the faults (either machine to go under maintenance or sewing operator to go for training or replacement).
Sewing End Line Inspection
100 % garments are checked on sewing related faults after sewing completion. Both in and out sides of the garments are inspected.
Use of Auto Trimmer & Thread Sucking Machines
We are using Auto Trimmers for clipping to avoid un-necessary clipping cuts during this process. We are also using thread sucker machines to ensure that packed garments are free from loose threads.
Final QC Inspection
Garments are checked 100% on quality after pressing for fabrication, finishing, appearance, sewing, shading, labeling etc to make sure that quality garments are packed into cartons. We are also using thread sucker machines to ensure that packed garments are free from loose threads.
Measurement Specs Control:
Before packing, garments are 100% checked on measurements for critical measuring points
Quality Assurance:
QA conduct daily random audits of cut parts during cutting process, inline audits during sewing. They also do Batch audits before garments are packed into polybags. Only QA passed garments are packed into cartons. Finished goods audits are also conducted when shipment is ready. All internal QA audits are done at AQL 1.50 Level II of military std. III. Quality Assurance Department is reporting to factory ownership for independent audits and to convey true reflection of quality being produced.