Quality Checker in Garment Industry

SOP-QA-GAR-001: Garment Quality Assurance & Inspection Protocol

1. Document Control Block

• Document ID: SOP-QA-GAR-001
• Effective Date: 2023-10-27
• Version: 2.1.0
• Review Cadence: Quarterly (Q1, Q2, Q3, Q4)
• Target Audience: QA Inspectors, Production Line Leads, Floor Supervisors, Supply Chain Compliance Officers

2. Executive Summary & Scope

This document defines the systematic inspection methodology for finished garments at Template Registry facilities. It establishes the operational framework for detecting non-conformities, ensuring compliance with AQL (Acceptable Quality Level) 2.5 standards, and maintaining integrity throughout the post-assembly phase. This scope covers raw material integrity, dimensional accuracy, stitch durability, and aesthetic finish.

3. Prerequisites & Tool Requirements

• Equipment: Calibrated digital calipers, AATCC standard gray scale for color change, illuminated inspection table (min 1000 lux), tension testing device.
• Software Access: ERP/QMS Dashboard (read/write access required).
• Certifications: Level 2 Textiles Certification (or internal equivalent).
• Safety PPE: Anti-static footwear, protective apron, needle-guard gloves (when handling sharp finishing tools).

4. Roles & Responsibilities (RACI Matrix)

5. Step-by-Step Operational Procedure

Phase I: Pre-Inspection Setup

• Verify AQL sampling plan based on total batch size (MIL-STD-105E).
• Calibrate inspection tools against master reference gauges.
• Retrieve approved "Golden Sample" and technical specification sheet (Tech Pack).

Phase II: Dimensional & Physical Inspection

• Validate garment dimensions against tolerance specs using digital calipers.
• Perform "stretch test" on critical seams to ensure thread elasticity.
• Conduct pull test on buttons, snaps, and hardware to ensure attachment security.

Phase III: Visual & Aesthetic Examination

• Inspect fabric for shading variations, weave defects, or contamination.
• Verify stitch density (SPI - Stitches Per Inch) matches Tech Pack requirements.
• Confirm alignment of patterns, labels, and care instructions.

Phase IV: Documentation & Disposition

• Log pass/fail status in the QMS portal.
• Attach digital photo evidence for all identified "Minor" or "Major" defects.
• Label rejected batches with red "NON-CONFORMING" status markers.

6. Quality Assurance & Verification Criteria

7. Practical Troubleshooting Scenarios

Scenario A: Batch-Wide Pattern Misalignment

• Detection: Multiple samples exhibit sleeve cuff misalignment exceeding 5mm.
• Corrective Action: Immediate "Stop Work" order on the sewing line. Initiate Root Cause Analysis (RCA) on the pattern-cutting template. Segregate remaining inventory and notify the Production Lead for recalibration of the CNC cutter.

Scenario B: Intermittent Needle Cutting (Micro-Holes)

• Detection: Small punctures found along seam lines during the physical integrity check.
• Corrective Action: Immediate replacement of all needles on the affected line. Re-check the last 50 processed units. Escalate to Maintenance to verify needle plate and feed dog timing.

Scenario C: Unconfirmed Color Deviation

• Detection: Garment tone appears inconsistent under varying light sources (Metamerism).
• Corrective Action: Move the affected batch to a controlled Lightbox (D65 illumination). If failure persists, quarantine the lot and notify the Dye House for material batch verification against the lab dip.