From fabric roll inspection to the final inspection before shipment, in each step, there is a need for a quality check. This department focuses on that specific process. There is minimal likelihood that any rolls will pass through production or be sold to buyers without being thoroughly checked and approved. The inspectors possess extensive experience and are fully aware of their duties and responsibilities. Regularly, all rolls are placed in front of the inspection machine and visually examined using a grey inspection machine at a predetermined speed against a light source. Any significant or minor defects such as thickness variations, barre marks, fallout, contamination, flies, holes, oil lines, needle lines, slubs, and so on are documented in the grey inspection report, which helps categorize the fabric according to the four-point system. Collars and cuffs undergo a visual inspection under a light box, and any major or minor flaws such as incorrect ply, holes, needle lines, slubs, incorrect design, or first-line issues are carefully counted and recorded.
The 4 Point System is used all over the factory in all sections to follow a certain standard of the produced garment.
- In the fabric inspection section, a 4-point system is followed as per SOP. There are 2 dedicated fabric inspection machines operated by 2 fabric inspection workers.
- Every kind of fault is marked and documented in the Fabric Inspection Report.
Following is the 4-point system’s point distribution system.
Table: Defect measurement
| Size of Defects | Penalty Points |
| Defects up to 3” inches | 1 |
| Defects from 3” to 6” inches | 2 |
| Defects from 6” to 9” inches | 3 |
| Defects of more than 9” inches | 4 |
The same can be done with Spot, Oil, and other Contamination
Table: Defect measurement for Spot, Oil, and other Contamination
| The following formula is used to calculate the fault point. | Penalty Points | |
| Up to 3” inches | 1 | |
| From 3” to 6” inches | 2 | |
| From 6” to 9” inches | 3 | |
| More than 9” inches | 4 | |
| Following formula is used to calculate the fault point. | ||
Quality Points / per 100 square meters = (Total Points * GSM) / (Roll Weight * 10)
Where:
- Quality Points: The total points obtained for the quality of the fabric.
- Total Points: The sum of points recorded for various faults and defects in the fabric.
- GSM: The weight of the fabric in grams per square meter.
- Roll Weight: The weight of the fabric roll in kilograms.
For Example, by examining a roll of fabric 48” in width and 120 yards in length, the below defects have been determined or marked:
4 defects below 3” 4 x 1 = 4 points
6 defects between 3” to 6” 6 x 2 = 12 points
2 defects between 6” to 9” 2 x 3 = 6 points
1 defect more than 9” 1 x 4 = 4 points
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Total points = 26 points
Points/100 square yards,
= 16.25 defect points/100 square yds
NOTE: Quality control unit follows the requirement of the buyer at a certain tolerance. The buyer sets the tolerance of the defects and the quality control team follows that. Usually, the common practice is to have tolerance at 18.
