SOP of Fabric Inspection 10:04 AM
Fabric inspection: - After getting fabric receiving status from material department, QC people will make plan for sampling inspection Inspection method: - M!""- #$% # $% 10&%, 'eneral inspection level !!, AQ" (& )!f t*ere is no bu+ers ot*er specification .ollow 4 point s+stem, if random inspection fail t*e+ conduct /0 inspection of specific consignment !f /0 fail t*en need to inspect 100, !n case of 100 inspection, QC personnel ma+ claim to supplier t*roug* sales division for 100 inspection c*arge b+ a specific format called claim s*eet Pass Point: 'enerall+ garments Manufacturers standard (& points per 100 linear +ards 4 point System: Attac*ed wit* details Inspection tools: - Measuring tape, scissors, defect sticker or c*alk, fabric defect displa+ board, reference sample blank inspection form, work s*eet23M s*eet 5 C*eck ticket information, item number "ot 6o Log Book (Register) :- QC s*ould maintain a "og book to see receiving situation and inspection situation at a glance also maintain a 7ed $ag "og book idth: 8enalt+ 4 points to eac* linear +ard of fabric w*ere t*e cut able widt* is less t*an t*e minimum specification and inspector will measure 4-& +ards continuousl+ at t*e 3eginning, Middle and 9nd of roll and record in inspection report !nitial disposition s*ould be taken as base on penalt+ point Lab !est: - Material department will send fabric for f or lab test as soon as a s receive fabric and QC will follow up its done or not As per fabric criteria and care label instructions "abs personnel are responsible for doing necessar+ test as per bu+er guide line "olor "ontrol : alidated alidated and updated 1st consignment sample b+ %ecat*lon are available in inspection mac*ine !nitial disposition s*ould be taken as base on color comparison
"olor Shading "heck : - !nspector will c*eck #ide- Center- #ide #ide to #ide s*ading c*eck randoml+ after completion of report; it will be dispatc*ed to concerned section and keep master cop+ for record #on "onformity : 6on conformit+ materials; material department *as to kept designated place as red tag and +ellow tag $o use red tag, it must be approved along wit* sufficient documents from 3u+er2supplier or factor+ management approval
hy Fo$r Point System preferable for Fabric Inspection% 10:1( AM
$*e word of !nspection in garments engineering mainl+ identifies to t*e visual e=amination or review2scrutini>e of raw materials )like fabric, accessories, trims etc !t is an imperative process in an+ apparel industr+ to keep awa+ from re?ects due to low fabric or accessories @ualit+ and precautions to remove une=pected loss2defects of finished goods $*e @ualit+ of a finis*ed item in apparel industr+ is mostl+ controlled on t*e @ualit+ of fabric w*en it is collected as a roll from mills 9ven it occupies /020 percent of total garments cost Apparel industr+ s*ould take some defensive actions to ensure @ualit+ full fabric is being used in t*eir items and set up fabric inspection department wit* modern e@uipment and skilled manpower &I': .abric mills and garments industr+, bot* parties @ualit+ team s*ould give t*eir *ig*est effort to erase an+ une=pected circumstances 9ven t*e most e=ceptional2e=cellence manufacturing met*ods cannot compensate for defective materials B 'arments producer: ave to inspect minimum 10 per color or more of an+ consignment w*en t*e+ got and assess t*em based on a four-point s+stem 3+ t*is process, t*e+ can minimi>e fabric related @ualit+ troubles before it moved to production B .abric mill: ave to inspect 100 of finis*ed goods; defects must be recorded for eac* roll
Dsuall+ four met*ods ma+ be followed for fabric inspection process 1 'raniteville EFE s+stem ( %allas s+stem G 4 point s+stem 4 10 point s+stem 3ut, above all 4 point system is most popular and broadl+ used as it is ver+ simple to applicable, educate and learn "etHs find a tin+ description of 4 point inspection s+stem below
$o use t*is s+stem someone *as to know following procedure: 1 ast idea on nature of fabric defects )*ow a defect looks and its appearance ( Fabric inspection method or preparation G Criteria of giving penalt+ points based on defects and defect lengt* 4 Calculation met*od of total penalt+ points for total defects found in a fabric roll or consignment & A C*eck s*eet or format for keeping data Fo$r Point System Most of t*e apparel industr+ prefers .our 8oint rating s+stem for determining fabric @ualit+ and it is certified b+ t*e American #ociet+ of Qualit+ Control )A#QC as well as t*e American Apparel Manufacturers )AAMA $*e 4-8oint #+stem assigns 1, (, G and 4 penalt+ points according to t*e si>e, @ualit+ and significance of the defect 6o more t*an 4 penalt+ points is assigned for an+ single defect %efect can be measured eit*er lengt* or widt* direction, t*e s+stem remains t*e same nl+ ma?or defects are considered 6o penalt+ points are assigned to minor defects
efect "lassification I*enever defects are recogni>ed during fabric inspection under 4 points s+stem and defect must be assigned b+ a number of points depending on t*e severit+2lengt* Inches ( ) (mm) Points
.rom * + ,- lengt*2widt*
Dp to &mm
1 point
.rom ,./- + 0- lengt*2widt* .rom 0./- + 1- lengt*2widt*
&mm 5 1&0mm 1&0mm 5 (G0mm
( points G points
More t*an 1- lengt*2widt*
More t*an (G0mm
4 points
nl+ ma?or defects are taking into account A serious defect is an+ defect t*at would cause a final garment to be considered a second B Dpon t*e number and t*e si>e of t*e imperfections in t*e given +ard, a ma=imum of 4 points can be given to one linear +ard B .our points can be given for eac* linear +ard, w*en a defect running continuousl+ along t*e lengt* of t*e fabric B ole point ma+ be evaluated b+ si>e oles and openings )t*e largest dimension 1- or less ( ver 14 &cceptability of Roll 2 Shipment .abric s*ipments can be considered to be second @ualit+ and not acceptable upon t*e following total points .abric supplier is responsible for t*eir fabric defect and to compensate for defects, 1 +ard for ever+ F points .or below items classified for a point fabric, fabric supplier s*ould compensate for all defective garment cutting panels or pieces
#+nt*etic woven
average of 1& points per 100 linear +ards
$will, cotton, linen
average of (0 points per 100 linear +ards
Iarp knits
average of 1& points per 100 linear +ards
.lat knit rib
average of 0 point per piece
8rints
average of 0 point per 100 repeat
#+nt*etic2#+nt*etic blends weft knits 3od+ mapping, 9ngineering
average of 1& points per 100 linear +ards average of 0 point per 100 repeat
Defect calculation: total liner yards + total defect points x 100
!f total point is greater t*an G0 per 100 liner +ards, no particular roll s*ould be considered first @ualit+ $otal defect points per 100 s@ +ards of clot* are computed and t*erefore t*e acceptance criteria are usuall+ no more t*an 40 penalt+ points .abric rolls containing over 40 points are considered seconds $*e formula to compute penalt+ points per 100 s@ yards is given by: J )$otal points scored in t*e roll B G/00 2 .abric widt* in inc*es B $otal +ards inspected 3ample5 A fabric roll 1&0 +ards long and &/ - wide contains following defects / defects up to G - lengt* /=1 / points 4 defects from G - to /- lengt* 4 L ( F points ( defects from / - to K- lengt* ( L G / points 1 defect over K - lengt* 1L4 4 points 1 *ole over 1 1L4 4 points
$otal defect points $*erefore, 8oints 2 s@ +ards
(F 8oints J )(F L G/00 2 )&/ L 1&0 J 1( points
6otable points of t*is s+stem are describing below: $*e process *as no stipulation for t*e probabilit+ of minor defects $*e fabric is grade regardless of t*e end-product 6o more t*an 4 penalt+ points is appointed for an+ single defect !nspection 8rocedure under 4 points s+stems: B %ecide t*e @uantit+ to inspect at least 10 of an+ consignment
B 9ven small consignment *as to be sure to c*oose at least one roll of eac* color wa+ !f more t*an one role must be c*osen, t*en select t*e additional roles in proportion to t*e total number of roles per color received B 8ick up t*e rolls to inspect B #et t*e rolls on t*e inspection device B .abric inspector s*ould *ave an approved fabric submission form to compare wit* bulk lot B Measure t*e fabric widt* and cut off a / inc* piece across t*e widt* of t*e end of t*e roll Mark t*e rig*t and left side of t*e strip After inspect ever+ &0 +ards please slow down t*e inspection process and use t*e strip to c*eck for an+ s*ading problems Also ensure to c*eck t*e end of t*e role B !nspect for visual flaws under clear lig*ting source wit* slow speed to find out t*e imperfections B C*eck for biased, bowed and skewed fabric B Mark an+ imperfections b+ t*e colored sticker or c*alk so t*at t*e+ can be easil+ found w*enever needed B Make sure t*e roll e=ist t*e accurate +ardage as declared b+ t*e supplier B .abric item, lengt*, widt*, roll no, defect t+pes and ot*er ticket information must be recorded properl+ 8lease refer to below link for inspection format w*at are vastl+ using during fabric inspection #lide s*are link: *ttp:22wwwslides*arenet2monir>2four-point-(&GG(01K !f +ou become satisfied b+ reading t*is post; +ou can s*ow +our regards b+ spreading it in social media suc* as Facebook , $witter or 6oogle7, stumble it in stumble-upon b+ *itting like button #ta+ tuned wit* us for more updates
