Quality Control
Reports to factory management.
During product manufacturing we monitor the quality of raw material and of the final product through inspections, with a focus on process improvement. QC sits on the floor, at every stage, in real time.
Quality monitoring procedures
We define quality as the ultimate fulfilment of the customer’s requirements.
In the product, the service and the timeline — checked at every stage.
Structure
Two divisions monitor quality
The people who check the work do not report to the people who do the work. That separation is the single most important thing about our quality system.
Quality Assurance
Reports to factory ownership.
QA carries out independent audits and conveys a true reflection of the quality being produced by factory management. All internal QA audits are conducted at AQL 1.50, Level II.
Quality control
Inspection at every stage
01
Fabric inspection
Incoming fabrics are inspected on the 4-point system, and 100% of fabric is inspected by fabric QCs. Each fault is given points, keeping in view the nature and intensity of the fault. Forty points are allowed in 100 inspected yards. If the number of faults or points exceeds 40 points per 100 yards, the fabric roll is rejected.
- Lab test reports are taken from fabric suppliers
- Reports are verified through internal and third-party labs as per requirement
02
Accessories inspection
Accessories are randomly inspected by QCs and concerned persons at the time of receipt in store, covering at least 10% of the received quantity.
03
Cut parts inspection
100% of cut parts are inspected before input to the sewing section. Rejected components are replaced from remnants or removed.
- Cut parts are inspected 100% before being sent for printing, embroidery or appliqué work
- They are inspected 100% again on receipt back from those processes
04
Sewing inline inspection — the 7-0 system
During stitching operations, inspections are done on the 7-0 system. The inline QC inspects seven pieces at random for each machine operator, twice a day.
- If any fault is found among those seven pieces, the sewing operator must inspect the whole bundle themselves and offer it for inspection again
- If that inspection is fault free, the operator undergoes follow-up inspection of three consecutive bundles
- If all three follow-up inspections are clear, the inline QC moves on to the next operator
- If a fault is found during the first follow-up, a second follow-up inspection is required
- If the second follow-up also fails, work stops while one of two decisions is made — the machine goes for maintenance, or the operator goes for training or replacement
05
Sewing end-line inspection
100% of garments are checked for sewing-related faults after sewing is complete. Both the inside and the outside of every garment are inspected.
06
Auto trimmers & thread sucking machines
We use auto trimmers for clipping, which avoids the unnecessary clipping cuts that hand trimming can cause. We also use thread sucker machines to ensure that packed garments are free from loose threads.
07
Final QC inspection
After pressing, garments are checked 100% on quality for fabrication, finishing, appearance, sewing, shading and labelling — to make sure that only quality garments are packed into cartons.
08
Measurement specification control
Before packing, garments are checked 100% on measurements at all critical measuring points.
Quality assurance
Audited again, by a team that answers to ownership.
QA runs a second, independent line of defence over the whole process — and its findings go straight to the owners, not to the managers being audited.
AQL 1.50
Level II — applied to every internal QA audit.
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Daily cut-part auditsRandom audits of cut parts during the cutting process, every day.
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Inline audits during sewingConducted alongside — and independently of — the inline QC team.
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Batch audits before polybaggingOnly QA-passed garments are packed into cartons.
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Finished goods audits at shipmentA final audit is conducted once the shipment is ready to leave.
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Barcode traceabilityEvery garment carries a bar-coded sticker recording the history of each operation, so any reported problem can be traced to its root and prevented from recurring.
At a glance
The standards we work to
| Fabric inspection | 4-point system · 100% inspected · max 40 points per 100 yards |
|---|---|
| Accessories inspection | Random, minimum 10% of received quantity |
| Cut parts | 100% before sewing input, and 100% before and after decoration |
| Inline sewing | 7-0 system · 7 random pieces per operator, twice daily |
| End-line sewing | 100% of garments, inside and outside |
| Final QC | 100% after pressing — fabrication, finishing, appearance, sewing, shading, labelling |
| Measurements | 100% at critical measuring points before packing |
| QA audits | AQL 1.50, Level II |
| Traceability | Bar-coded operation history on each garment |
Bring your own inspector.
We host buyers, agents and third-party inspection agencies at any stage of production, and we will share our own audit records alongside theirs.