Mastering Quality Control in Textiles

What is Quality? Why is Quality Control Important?
Quality in textiles refers to meeting or exceeding customer expectations through consistent production standards. It involves ensuring that products are free from defects and meet the specifications set by the brand or client. Quality control ensures the reliability of garments, improves customer satisfaction, reduces the chances of returns, and strengthens the brand’s reputation in the market.
Benefits of Quality Control
The primary benefit of quality control is the reduction of defects, which directly impacts cost savings by minimizing rework and waste. Quality control helps streamline production, improves efficiency, and maintains product standards. It also enhances customer confidence in the brand, leading to fewer complaints, stronger customer loyalty, and better overall market performance.
Necessary Documents for Inspection
Quality inspections require a set of important documents. These include inspection checklists that cover key areas such as stitching, fabric quality, and measurements; technical specification sheets that outline garment standards; and quality control manuals that provide guidelines on inspection processes. These documents ensure that the inspection process is systematic and consistent.
Understanding Defects and Defect Categories (DCL)
A defect is any deviation from the specified garment quality or standard. Defects are categorized into three types:
Critical Defects: These affect product safety or usability and render the garment unsellable.
Major Defects: They are visible and affect the appearance or performance but may still allow the garment to be sold.
Minor Defects: These are slight issues that do not affect the garment’s functionality or appearance significantly.
The Defect Classification List (DCL) categorizes these defects and sets allowable limits for each, ensuring consistency in garment quality.
Clockwise Garments Inspection System
The Clockwise Garments Inspection System is a methodical approach used for garment inspections. It begins at the collar, moving clockwise around the garment to check critical areas like seams, buttons, zippers, and overall construction. This system ensures that every part of the garment is thoroughly inspected, reducing the chance of missed defects.
Follow-up Points and MMR During Inspections
After each inspection, follow-up points are critical to ensure corrective actions are taken. Inspectors will monitor the corrective actions based on the defects found. Minimum Manufacturing Requirements (MMR) are documented standards that must be met, and they play a vital role in ensuring consistent production quality. Regular follow-up and MMR tracking help prevent recurring issues and maintain high standards.
Label Knowledge and Functionality
Labels serve as more than just branding; they include vital information about the garment’s size, material composition, care instructions, and sometimes even safety standards. Proper labeling is essential for product identification, compliance with regulations, and guiding customers on garment care to extend the product’s life.
Tools and Techniques for Garment Measurement
Accurate garment measurement is essential to maintain consistency in production. Tools like measuring tapes, rulers, and calipers are used to check garment dimensions against specifications. The technique involves ensuring that the garment is laid flat and measured in key areas like the chest, waist, sleeve, and inseam to maintain accuracy.
How to Measure Garments Correctly
To measure a garment correctly, ensure it is placed on a flat surface without stretching the fabric. Key areas to measure include the shoulder width, chest circumference, waist, and hemline, as well as sleeve length and inseam. It is important to use industry-standard methods to measure these areas, as even small deviations can lead to fitting issues and dissatisfaction among customers.
Understanding 5S & Product Safety in Textiles
5S is a workplace organization method that contributes to both product safety and efficiency.
Sort: Remove unnecessary items from the workspace.
Set in Order: Organize tools and materials for easy access.
Shine: Keep the workplace clean and in good condition.
Standardize: Establish procedures for maintaining cleanliness and order.
Sustain: Ensure that the system is maintained consistently.
This system not only increases efficiency but also ensures that the environment is safe for both workers and the products being manufactured, ultimately contributing to product safety by minimizing errors and risks.