3 Quality Assurance Manual

Shin Shin Group
QUALITY ASSURANCE (QA) MANUAL
Key Contents:
1. Introduction to Quality Management System (QMS) ………………………………………. 3-6
1.1. Quality Management System (QMS) ……………………………………………………………… 3
1.1.1. What is Quality Management System (QMS)? ……………………………………………………….... 3
1.1.2. Scope of Quality Management System (QMS)..………………………………………………………… 3
1.1.3. Principles of Quality Management System (ISO-9001)..……………………………………………. 3
1.1.4. Main Components of Quality Management System (QMS)…………………………………….... 3
1.1.5. What is Quality Assurance (QA)? ……………….…………………………………..………………………… 3
1.1.6. What is Quality Control (QC)? …………………………………………………………..……………………… 3
1.1.7. Distinction between Quality Assurance (QA) & Quality Control (QC)…………………....….. 4
1.2. Quality Policy...……………………………………………………………………………..…………........ 4
1.3. Quality Goals……...………………………………………………………………………..………………… 5
1.4. Quality Department Structure ……………………………………………………………………….. 6
2. Product Development Process..……………………………………………………………………..... 7-11

2.1. Materials Requirement for Product Development …………………………………………………… 7
2.2. Responsibilities of Different Department in Product Development …………………………. 7
2.3. Different Stages of Product Development Process …………………………………………………… 8-11
3. Manufacturing Process…………………....……………………………………………………………... 12-44

3.1. Store (Purchased Materials Inventory, Testing and Inspection Process).……….. 12-25
3.1.1. Fabrics & Accessories Receiving Procedure……………………………………………………………... 12
3.1.2. Fabrics & Accessories Inventory Procedure……………………………………………………………... 13-14
3.1.3. Fabrics & Accessories Storing Procedure …..…………………………………………………………….. 14
3.1.4. Fabrics & Accessories Inspection Procedure………..……………………..……………………………. 14-21
3.1.4.1. Fabrics Inspection Procedure.…………………………………………………………………………….. 14-17
3.1.4.2. Fabrics Accept & Reject Procedure……………………………………………………………………… 17
3.1.4.3. Shade Band & Blanket Preparation……………………………………………………………………... 17
3.1.4.4. Shade Band for Approval of Wash Shades by the Buyer………………………………………. 17
3.1.4.5. Bulk Fabric Approval………………………………………………………………………………………….… 17
3.1.4.6. Shade Segregation & Country/Delivery/PO Wise Planning……………………..…………... 17-18
3.1.4.7. Accessories Inspection Procedure..……………………………………………………………………... 18-21
3.1.5. Fabrics & Accessories Test Procedure……………………………………………………………………….. 21-24
3.1.6. Fabrics & Accessories and Reject & Left-over Garments Reconciliation Procedure……. 25
3.2. Pre-production Meeting ……………………………………………………………………….……….. 26
3.3. Pilot Run/Size Set/Initial..……………………………………………………………………………….. 27
3.4. Cutting Section..……………………………………………………………………………………………... 28-31
3.4.1. Quality Control Process & Procedure in Cutting..…………………………………………………….... 28-31
3.4.2. Cut panel Storage Procedure ….…………………………………………..………………………………..….. 31
3.5. Sewing Section……..…………………………………………………………………………………………. 32-36
3.5.1. Quality Control Process & Procedure in Sewing ……………………………………………………….. 32-34
3.5.2. Zero Defect Thread Control Procedure.…………..……………………………………………………….. 35
3.5.3. Inspection Procedure for Wash Received Garments……………………………..………………..... 35-36
3.5.4. Moisture Control Procedure for Washing…………………………………………………………………. 36
3.6. Washing Section……………………………………………………………………………………………… 37-39
**NB: This is a controlled document. Page: 1 of 59
Written & Developed by: Md. Mostafizur Rahman - Head of QMS, Shin Shin Group
3.6.1. Quality Control Process & Procedure in Washing..………………………………………………….... 37-39
3.7. Finishing Section..…………………………………………………………………………….…………….. 40-44
3.7.1. Quality Control Process & Procedure in Finishing..…………………………………………………... 40-44
4. Product Integrity and Safety……………….….………………………………………………………... 45-48

4.1. Needle Control Procedure ……………………………………………………………………………… 45-46
4.2. Sharp Tools And Others Metal Control Procedure………………………………………….. 46-47
4.3. Disposal Procedure of Needle, Sharp Tools and Others Metal………………………… 47
4.4. Pest Control Procedure……………………….………………………………………………………….. 47
4.5. Mold Prevention Procedure……………………………………….…………………………………… 47
4.6. Rejected/Non-conforming Garments/Products Control Procedure.……..………… 48
5. Measuring Tools & Equipment Calibration……………….…………………….……………….. 49-50

5.1. Needle Detector Machine Calibration Procedure…………………………………………… 49
5.2. Fusing Machine Calibration Procedure…………………………………………………………… 49
5.3. Pull Test Machine Calibration Procedure………………………………………………………… 50
5.4. Weighing Scale Calibration Procedure……………………………………………………………. 50
5.5. Measuring Tape Calibration Procedure…………………………………………………………… 50
6. Inspection/Audit And Others Procedure………………………………………………………..… 51-59

6.1. Pre-final/Final Inspection Procedure…….………………………………………………………… 51-52
6.2. Root Cause Analysis (RCA) Procedure.…………………………………..……………….………. 52
6.3. Internal Quality Audit Procedure……………………………………………………………………. 53-55
6.4. Preparatory Works for External Quality Audit ………………..……………………………… 55
6.5. Customer Complaints Handling Procedure……………………………………………………… 55
6.6. Product Recall Process & Procedure……………………………………………………………….. 56-59
Annexure:
1. Flow-chart-
- Fabric Inspection
- Accessories Store Quality
- Cutting Section
- Embroidery & Printing
- Sewing Section
- Metal/Needle Detection Process
- Finishing Section
- Pull Test
- Metal Detector
- Packing Section
Changes/Improvement:
1. Re-arranged Content
2. Inspection Procedure Updates
3. Add Customer Complaints Handling Procedure
4. Add Product Recall Procedure
5. Buyer Procedure
**********

1. Introduction to Quality Management System (QMS)
1.1. Quality Management System (QMS)
1.1.1. What is Quality Management System (QMS)?
Quality Management System is a collection of business processes focused on achieving quality
policy & quality objectives to meet the customer requirements.
It is expressed as the organizational structure, polices, procedures, processes and resources needed
to implement the quality management system.
1.1.2. Scope of Quality Management System (QMS)

The Quality Management System (QMS) is applicable for Shin Shin Group which covers all the
clauses of ISO 9001:2008 standard such as:
- Policy & Procedure
- Supporting Documents
- Operational Procedure & Control
- Enabling Agreements
- Compliance & Improvement.
1.1.3. Principles of Quality Management System (ISO-9001)

ISO 9001 is based on EIGHT core principles which define the standard and direction for Quality
Management.
Company is committed to execute Quality Management following the below principles in
accordance with ISO-9001.
▪ Customer Focus
▪ Leadership
▪ Involvement of People
▪ Process Approach
▪ System Approach to Management
▪ Continual Improvement
▪ Factual Approach to Decision Making
▪ Mutually Beneficial Supplier relationships
1.1.4. Main Components of Quality Management System (QMS)

The main components of Quality Management System are:
- Quality Planning (QP)
- Quality Assurance (QA)
- Quality Control (QC)
- Quality Implementation (QI)
1.1.5. What is Quality Assurance (QA)?

Quality Assurance is a set of planned and systematic actions necessary to ensure require quality
standards of a product.
Or, Quality assurance refers to the processes and procedures that systematically monitor different
aspects of a facility to detect & correct and ensure that require quality standards are being met.
1.1.6. What is Quality Control (QC)?

Quality Control is the operational techniques and activities that are used to fulfill requirements for
quality of a product.
The key tasks of quality control include:
- Testing
- Monitoring
- Auditing
- Reporting
1.1.7. Distinction between Quality Assurance (QA) & Quality Control (QC)
Although QA and QC are closely related concepts and both aspects of quality management, they are
fundamentally different in their focus.
QA QC
QA is a set of planned and systematic actions QC is the operational techniques and activities
necessary to ensure require quality standards of that are used to fulfill requirements for quality
a product. of a product.
It is process oriented and focuses on defects It is product oriented and focuses on defects
prevention. identification & correction.
QA aims to preventive defects to make a QC aims to identify & correct defects in the
product. So, it is a proactive quality process. finished product. So, it is a reactive quality
process.
Prevention of quality problems through planned The operational techniques and activities are
& systematic actions including documentation. used to achieve and maintain the quality &
process.
Everyone on the team involved in developing a A specific team involved in testing or
product is responsible for Quality Assurance. identifying a product defects are responsible
for Quality Control.
It is a managerial tool. It is a corrective tool.
QA is the process of managing for quality. QC is used to verify the quality of the output.
1.2. Quality Policy

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cÖbq‡b cÖwZkÖæwZe×|
We are committed to formulate measurable quality policy & objective based on our capabilities and
customer’s expectations.
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The quality policy of the company is as followed:
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Manufacture world class products for global market.
2. c‡b¨i m‡e©v”P ¸bMZgvb I wbivcËvi gva¨‡g evqv‡ii mš‘wó AR©b Kiv|
Achieve customer’s satisfaction by ensuring highest quality & safety of products.

1.3. Quality Goals (2017 - 2018)
Materials:
Store (Materials):
1. Ensure minimum 95% materials storage on time.
2. Ensure 98% materials inspection pass.
Cutting (Materials):
1. Ensure 100% fabrics cutting finished as per plan.
2. Keep rejection (%) below 1%.
Sample:
1. Deliver 100% sample on time.
2. Keep rejection (%) in 0%
Production:
Sewing:
1. Keep defects (%) below 5%.
2. Keep rejection (%) in 0%.
Finishing:
1. Keep defects (%) below 5%.
2. Keep rejection (%) in 0%.
IE & Planning:
1. Ensure Production efficiency above 60% at both sewing & finishing area.
2. Keep NPT (Non-Productive Time) (%) below 15% at both sewing & finishing area.
3. Ensure 100% shipment on time.
Customer Focus:
RQS, NQC & GPQ:
1. No claim & stop order from Customer.
2. Ensure 100% styles Pre-final & Final inspection finish on time for both Internal & buyer.
3. Ensure above 98% styles Pre-final & Final inspection pass and fail (%) below 2% for both Internal
& buyer.

1.4. Quality Department Structure
Chairman
Sohel Sadat
GM - Quality
DGM/AGM - Quality
Sr. Manager - Quality
Cutting Sewing GPQ Finishing

Quality Manager Quality Manager 06 Persons Quality Manager
D/Asst. Manager- Asst. Manager- D/Asst. Manager-

Quality Quality Quality
Vacant 02 Persons Vacant
Finishing QC
Cutting QC Fabric QC Washing QC Sewing QC Needle Man QA 05 Persons
01 Person 01 Person 02 Persons 17 Persons 02 Persons 03 Persons
Finishing QI
Cutting QI Fabric QI Sewing QI 78 Persons
10 Persons 11 Persons 59 Persons
Embroidery
QI
01 Person
**********

2. Product Development Process
Product development is the first phase of manufacturing process which deals with the development
of sample product to be used in the bulk production. The objectives of product development are:
- Understanding the man, machine & materials requirement
- Understanding the production process
- Calculation of cost
- Understanding the quality standard
2.1. Materials Requirement for Product Development

- Specification Sheet
- Sketches or Photos
- Size Details
- Sample (if available)
- Style Details
2.2. Responsibilities of Different Department in Product Development

The following departments are responsible for Product Development:
- Sample / Technical Department
- Merchandising Department
- CAD Department
Things to be considered to Product Development

To develop any product, Merchant & Sample department should be considered the following
matters:
a) Master files
Sample department must keep master file with all relevant documents as per buyer
requirements. The master file should contain PO Sheet, Sketch or Photos, Size details, PP
Comments, Approved lab dip, BOM list, Trim card, Spec Sheet, Test Report of Fabric &
Accessories, Approved Shade Band, Shrinkage & GSM test report, Inspection report etc.
b) Dummy Sample
Merchandisers have to ensure to make a dummy sample using alternative similar fabric if the
receiving of actual fabrics become late. In this case, the construction & GSM of the alternative
fabric must be same as required by the buyer.
c) Collection of P.O. Sheet
Merchandiser will collect purchase order from buyer and compare the sample with P.O. Sheet
as well as buyer’s comments. If any discrepancy is found then he must communicate with buyer
in order to rectify P.O. Sheet & Sample.
d) Required Materials
As per confirmed order quantity, fabrics and accessories are needed to resource from the
suppliers. Merchandiser will communicate to several suppliers & collect price lists and also
ensure the receiving date. He ensures on time receiving of fabric & accessories at minimum
price with proper quality for better interest of the company.
e) Approved Dress Forms (Dummy)
Factory should be kept approved dress forms (dummy) as per buyer requirements. They check
the fitting of sample & production as per buyer requirements. Also, factory QA team checks the
minimum neck stretch of kid’s items.

2.3. Different Stages of Product Development Process
The process may be broken down into following stages:
- Pre-sampling meeting
- Development/Quotation sample
- Fit sample
- Photo Sample
- Size set Sample
- Pre-production/Counter Sample
- Gold Seal/Production Sample
- Test Sample
- Shipment Sample
Each of the stages is displayed in chart below:
Development/
Pre-sampling Photo Shoot
Quotation Fit Sample
Meeting Sample
Sample
Pre-
Gold
Size Set production /
Test Sample Seal/Production
Sample Sample Counter
Sample
Shipment
Sample
Details Process of the above Activities

✓ Pre-sampling Meeting
Pre-Sampling Meeting is a way to facilitate communication and understanding between the
various departments involved in the preparation of the development sample.
Pre-sampling meeting is carried out for development sample in presence of following department:
- Merchandising Team/Department
- Sample Department
- Quality Department
- Industrial Engineering Department
- Production Department
- Maintenance Department
The following matters are discussed in Pre-sampling meeting:

- Required machines & raw materials.
- Pattern, Marker, Ratio & Consumption.
- Fabric Shrinkage, GSM & Composition/Construction.
- Design & Specification
- Critical Operation or Process.
- Delivery Schedule of Sample
✓ Development/Quotation Sample
The development/Quotation sample is prepared before the actual order is confirmed by the
buyer, so that the buyer can understand the product design & cost, which up to this point might
simply be a CAD Drawing physically, represents.
The following personnel are responsible for development sample:
- Merchandiser
- Sample Room In-charge
- CAD In-charge
The below steps are needed to be followed to prepare the development sample.
- Merchandiser provides requisition for samples to the Sample & Technical department.
- Merchandiser also provides the Supplier Specification Sheet, Sketch/Photo/Sample (if available)
& tech pack to the sample department.
- Development/Quotation Sample is prepared by Sample Department as per requirements.
- Merchandising department submits the Development/Quotation Sample & the price quotation
to the buyer for approval.
- Ensure one-piece sample is kept in the factory for reference.
- After receiving the approved sample with comments, we can commence on preparation of Fit
Sample.
✓ Fit Sample
Fit Sample is prepared with similar fabrics and all available trims. The below steps are followed to
prepare Fit Sample:
- If sketch/photo/sample from the customer is available, we compare the Technical Pack to it. If
any discrepancies are found, Merchandiser follows up with the customer accordingly.
- A one-piece sample is made based on the Technical Pack; the sample/Technical Department
prepares CAD Pattern with all comments which the buyer might have on the development
sample.
- The sample is checked for required quality and measurements. All details are documented in
Fit Sample Report.
- The sample is submitted to the buyer by the Merchandiser.
- Ensure one-piece sample is kept in the factory for reference.
- Merchandiser awaits buyer’s comments and feedbacks.
- The sample/ Technical team adjusts the patterns based on further comments from the buyer’s.
- Merchandiser creates a Fit Sample report and highlighting all the facts & changes.
✓ Photo Shoot Sample

- On receipt of the Fit Sample, the photo shoot sample is prepared with using required original
fabrics and trims.
- On completion of preparing photo shoot sample, Merchandiser will send to the buyer within
due date & wait for the next comments (if available).
- Photo Shoot Sample is prepared to check with the live model and advertisement for market.

✓ Pre-production/Counter Sample
Pre-production/Counter Sample is made due to ensure/get clearance for bulk production &
washing by submitting to the buyer. The following steps are taken to make Pre-
production/Counter Sample:
- Ensure that all comments and corrections from previous Sample by the buyer are incorporated
in the making of the Pre-production/Counter Sample.
- Wash the sample by following the same instruction or requirements by the buyer.
- On completion the above process, submit the sample to the buyer for approval and comments.
- Ensure one/two pieces sample is kept in the factory for further reference.
✓ Size set Sample

Size Set Samples are covered for all the sizes of a particular style. The purpose of the Size Set
Sample is that buyer will make no changes in cutting details and carry out extensive laboratory
tests on it.
The following groups are responsible:
- Merchandising Team/Department
- Sample Department
- Industrial Engineering Department
The following steps are taken to make Size Set Samples:

- Ensure that the size requirements are discussed with the buyer before the Pre-production
Meeting.
- Grade and issue of patterns based on the size set requirements.
- Ensure that the size set samples have one size for every color.
- Ensure that correct materials and trims are used for the development of Size Set sample.
- Ensure that the correct machineries, work aid and manufacturing methods are used.
- The Quality team needs to ensure in-process quality during production of Size Set Sample.
✓ Gold seal/Production Sample

Gold Seal Sample is made in bulk production stage before offering any pre-final/final inspection.
Actual raw materials are used to make the Gold Seal/Production Sample.
The following departments are responsible:
- Merchandising Department
The below steps are followed to prepare Gold Seal/Production Sample:

- Samples are made in bulk production stage according to the requirements / methods finalized
during the PP Meeting and approved by the buyer.
- On completion, the samples are checked again for quality and measurements and
documented.
- Samples which require washing are washed as per buyer requirements.
- Washing of samples are co-ordinate by the merchandiser.
- Samples are ironed, finished and packed according to the requirements outlined in the Tech
Pack approved for production by the buyer.
- Samples are submitted to the buyer for approval of inspection and one sample is retained in the
factory for reference.

✓ Test Sample
- The Test Sample is the final sample made for testing in the laboratory whether it fulfilled
required standard of buyer.
- It is also used to get buyer’s approval as per test result for clearance of shipment.
✓ Shipment Sample
Shipment sample is ensured that which is required by the buyer after final inspection is passed
and the goods are ready for shipment.
- Shipment Sample is collected from the running production floor.
- Concern Merchandiser will ensure the required quantity with all required quality & measurement
by the Quality department and send to the buyer and also kept one/two piece for in the factory
for further reference.
**********

3. Manufacturing Process
3.1. Store (Purchased Materials Inventory, Testing and Inspection Process)
Raw materials Inventory & Test is very important in export-oriented garments industry which is
mandatory prior to starting any production. Raw materials Inventory & Test may happen in both in-
house lab and outside lab depends on the decision of concern buyer. But for the in-house process
quality department will ensure the procedures are maintained below.
3.1.1. Fabrics & Accessories Receiving Procedure

Fabrics:
1. During fabric receiving ensure the fabric challan & gate pass, fabric packing list, inspection
report, test report & guaranty letter as per fabric booking sheet otherwise inform concern
merchandiser.
2. During fabric receiving if any missing of inspection report, test report & guaranty letter then
instantly inform concern merchandiser and no receive any fabrics until received above report.
3. After received of fabrics must be inventory with check the supplier name, buyer, style, P.O
number, color, role quantity, weight etc. as per booking sheet/packing list in presence of
supplier representative.
4. Send fabrics sample/swatch and packing list to concern merchandiser and get chop, sign & date
of him for confirmation of fabrics & consignment accuracy.
5. Notification has to be made all concern merchandiser through Viber & Text Massage and by
mail, if any shortage/problem.
6. The list of shortage/problem has to be notified to the management with immediate effect for
next initiatives.
7. Ensure exact time & date of balance quantity fabrics from concern merchandiser with written
approval to receive.
8. All information of daily receiving fabrics must be entry into the software.
Accessories:
1. During accessories/trims receiving ensure the accessories/trims challan & gate pass, packing
list, inspection report, test report (only for trims) & guaranty letter as per booking sheet.
Specially, for receiving of fusing must be ensure fusing data sheet with all above report. Without
fusing data sheet no fusing cannot be received.
2. During accessories/trims receiving if any missing of inspection report, test report & guaranty
letter then instantly inform concern merchandiser and no receive any accessories/trims until
received above report.
3. After received of accessories/trims must be inventory with check the supplier name, buyer,
style, P.O number, quantity, weight etc. as per booking sheet/packing list in presence of
supplier representative.
4. Send accessories/trims sample/swatch and packing list to concern merchandiser and get chop,
sign & date of him for confirmation of accessories/trims & consignment accuracy.
5. Notification has to be made all concern merchandiser through Viber & Text Massage and by
mail, if any shortage/problem.
6. The list of shortage/problem has to be notified to the management with immediate effect for
next initiatives.
7. Ensure exact time & date of balance quantity accessories/trims from concern merchandiser
with written approval to receive.
8. All information of daily receiving accessories/trims must be entry into the software.
9. For receiving of accessories/trims must be mentioned lot/batch number in the report.

3.1.2. Fabrics & Accessories Inventory Procedure
Fabrics & accessories inventory is the pre-condition for starting any production. Production
process may face disruption due to lack of proper inventory. Fabric and accessories inventory is
necessary to know the actual quality & quantity of received materials in the store, based on
reference PO Sheet provided by the merchandiser. If any shortage of materials is found, it must be
collected on due time in order to ensure product shipment with right quantity and at the right
time.
In case of inventory control we have to remember some features which is given below:
- Buyer, Style, Order quantity etc.
- When to place order.
- Record keeping.
- Size of inventory (how much quantity).
- Duration of ordering for quantity.
- Types of items.
Fabric Inventory Procedure

The following steps need to be carried out properly to conduct fabric inventory:
Challan & Packing List Check
1. After receiving fabric in store, Store In-charge will inform to quality team to perform inventory of
receiving fabric along with them. In this regard, quality team will use the specific format for
preparing report.
2. During inventory will use tally method otherwise individual stick.
3. Store In-charge & quality team will go to the fabric’s receiving area with the specific format and
verify sticker no, manufacturer sl. no, packing list sticker & sl. no, quantity of rolls, weight &
quantity, color, dye lot etc. of each fabric rolls.
Fabrics Roll Inventory

1. Count 100% fabric roll to compare with the challan & Packing list and check the fabric rolls are
separated as per color & dye lot.
2. At least 10% of total fabric rolls are weighted & checked randomly and calculate other rolls based
on the 10% result to verify with same as packing list.
3. Once all above steps are completed, quality team will prepare report and record for further
reference.
4. If found any discrepancy, inform to concern merchant, CEO, Sr. GM and supplier to take necessary
action immediately.
Accessories Inventory Procedure

The following steps need to be carried out properly to conduct accessories inventory:
Challan & Packing List Check
1. After receiving accessories in store, Store In-charge will inform to quality team to perform
inventory of receiving accessories along with them. In this regard, quality team will use the
specific format for preparing report.
2. Store In-charge & quality team will go to the accessories carton’s area with the specific format and
verify sticker no, manufacturer sl. no, packing list sticker & sl. no, quantity, weight, color etc. of
each carton/Lot.
Accessories & Trims Lot Inventory

1. Collect the approved bill of materials (BOM) list first.
2. Count 100% lot of accessories to compare with the challan & Packing list.

3. Once all above steps are completed, quality team will prepare report and record for further
reference.
4. If found any discrepancy, inform to concern merchant, CEO, Sr. GM and supplier to take necessary
action immediately.
3.1.3. Fabrics & Accessories Storing Procedure

▪ Before storing fabrics & accessories, the storing area must be cleaned.
▪ Fabrics & Accessories should be kept separately in rack (if possible) with proper marking
of tag.
▪ Maintain Bin card for identification easily.
▪ The Bin card is contented the following information- buyer’s name, Style, PO, Color,
quantity, shade and Lot no.
▪ Regarding fabric issues - Confirm the shade of fabric before issuing in the production
line.
▪ For reject fabric & accessories – keep separately with proper information & red marking
in designated area.
▪ Maintain report for further references.
3.1.4. Fabrics & Accessories Inspection Procedure

3.1.4.1. Fabric Inspection Procedure
There are three types of Fabric Inspection System available in Garments Industry.
1. Ten points systems.
2. Dallas system.
3. Four (4) points system.
Out of three systems, four (4) Points System is the most popular inspection method and easy to
understand & accept by all. More than 90%-95% apparels industries are adopting this system.
Four (4) Points System
Sampling plan
Sample plan provides a guideline to determine the inspection sample size. But every apparels
company suggests that minimum 10% should be inspected covering all color & dye lot of fabric.
Fabrics Qty. Inspection %

0 – 1000 yards 100 %
Over 1000 – 10000 yards Minimum 1000 yards
Over 10000 yards ……….. 10% of Total Qty. (including all color & Dye lot)
Tools for fabric inspection

The person who is responsible for fabric inspection must have the following facilities / equipment in
good working condition.
▪ Inspection frame with counter, Measuring tape & pair of scissors.
▪ Stickers or masking tape to identify the faults.
▪ Pick glass.
▪ Digital Camera for taking reference snaps.
▪ Master fabric sample or customer’s reference sample.
▪ Fabric inspection format.

Light sources
For fabric inspection a standard light source should have available in every apparels industry. But
sometimes it is according to the customer’s requirement. A standard light box equipped with:
Light sources Light types

Primary light sources D-65 (6500k, near to daylight)
CWF (4150k, a bit with red) or TL-84 (4000k) and
Secondary light sources
TL 83 (3000k, For H&M)
UV light, P-15 and “A” Light (40W - 2856k, For H&M) and
Additional light sources
U35 for K-mart
Inspection Procedure
▪ Fabric inspection will be performed by a fabric inspection machine.
▪ At least 10 % of fabric should be checked covering all color & dye lot. If the lot is rejected at 1st
time, then perform 15% inspection for 2nd time. If the lot is rejected at 2nd time, then perform 100
% inspection of the lot.
▪ If quantity is only 10 rolls or within 1000yds than perform 100% inspection.
▪ Keep defective samples swatch board in inspection area. Inspector can easily review & remember
the defects which occur in fabric.
▪ Fabric roll set in the machine and run the machine slowly.
▪ Start the frame & inspect for defects of rolls. Run maximum the frame at 10-12 meters per
minutes.
▪ If defects are observed, classify the defects & assign the appropriate points based on the severity
of the defects. The severity is determined by the type & length of the defects.
▪ Identify the defects & mark with sticker and also check the width of fabric in three different
places –
- Top Edge
- Middle Edge
- Bottom/End Edge
▪ Defects of the fabric are marked properly in a format.
▪ The roll length is count by yards/meter.
▪ Finally count all the defects and find out the result of defect % of the roll to confirm acceptance &
rejection.
Note: If there is any other requirement/specification of buyer then we are used to adhere that.
The grading standard

▪ No matter how many defects in one linear yard, the maximum penalty point is 4.
▪ As to single defect, the maximum penalty point is 4 for each yard.
▪ Hole means, there are two broken yarn or more than two yarns or no matters how big the hole
sizes, the penalty point is 4.
▪ If any sewing is present in the roll, the penalty point is 4 for each roll.
Defect Length Points

0 – 3 inches 1 point
Over 3 – 6 inches 2 points
Over 6 – 9 inches 3 points
Over 9 inches 4 points
Any size of hole 4 points

Inspection Result
Complete the work sheet (defect record form) & calculate the total Defective points of inspected
rolls & also the length of the inspected rolls.
Total penalty points x 36
Defective points = ---------------------------------------------------------- x 100 = Result
Total inspected fabric length x Fabric width
Acceptance Point Range

Different fabric has different acceptance point range for fabric inspection, which is as follows:
Acceptance point Acceptance point
Fabrics Type
(Individual Roll) (Average Roll)
Polyester, Viscose, Fine copy, silk, Jeans, Twill Cotton, Canvas, 20 points/100 sq. 14 or 16 points/100 sq.
Plain, Poplin, Oxford, Rowling etc. yards yards
Indigo Chambray, Printing, Jacquard, Corduroy, Velveteen, 28 points/100 sq.
20 points/100 sq. yards
Bengaline, Mixture Cotton etc. yards
Acceptance point Acceptance point

Fabrics Type
(Individual Roll) (Average Roll)
13 points/100 sq.
Worsted Wool 10 points/100 sq. yards
yards
Synthetic (Polyester/Polyinide/Acrylic/Spandex/ 24 points/100 sq.
18 points/100 sq. yards
Viscose/Lycoll) yards
30 points/100 sq.
Corduroy 25 points/100 sq. yards
yards
24 points/100 sq.
Other Natural 18 points/100 sq. yards
yards
If an individual roll or a lot exceeds the above points range then the roll or lot is considered as
rejected. Otherwise should be inspected 100% roll of fabric lot or followed as per guideline of
buyer.
Defect Range
▪ Less than 25/30 yards (22.86/27.5 m) of fabric roll is rejected for inspection.
▪ Any fabric defect in warp more than 6 inches than the fabric roll is rejected.
▪ 3 yards of top and bottom of fabric roll with full weft/width defect should be rejected.
▪ Unfolding, loosing of width, tightening of width, wrinkles & crease mark of fabric roll should be
rejected.
▪ The continuity defect spot of fabric roll is penalized 4 points per yard.
▪ If the continuity defect spot of fabric roll exceeds more than 3 yards, then the fabric roll will be
rejected.
▪ Any color shading of top and bottom will not be noticed as continuity defect but off shade in the
whole roll of fabric will be rejected.
▪ Mismatch dye lot of fabric roll will be rejected.
▪ Printing Mistake in fabric will be rejected.
▪ More than 5% bias of fabric roll will be rejected for inspection.
Defective Rolls Separation

All defective rolls keep separately which exceed the required points or any other mentionable
problems (which is not accepted by Buyer). Put a red tag mentioning buyer name, style no, PO no,
color, and quantity, type of defects and % of defects. Replace the defective rolls discussing with the
fabric supplier through concern merchandiser.

Types of Fabric Defect
- Yarn: Slub, Uneven yarn (thick thin yarn), Yarn contamination (foreign yarn), Dead cotton.
- Construction: Hole, Missing yarn, broken end, Stop mark. / Barrie mark, Knot, Miss Pick, Reed
mark, Miss-weavy / Miss-knit pattern, Fabric damage.
- Dyeing: Dye spot, Color tone, Color bleed.
- Finishing: Bowing, Skewing, Wrinkle, Fold mark, Pin hole, Narrow, Abrasion mark.
- Cleanliness: Stain, Oil, Dirty / soil, Water mark.
3.1.4.2. Fabrics Accept & Reject Procedure

▪ Inspector performs inspection a whole lot of fabric in case of acceptance & rejection.
▪ Proper judgment is needed about a lot i.e. lot is Accept or Reject.
▪ Inform Quality Manager, Merchandiser & related persons about the lot status.
▪ If lot is rejected in first time then ensure second time inspection as 100% of fabric roll or guidance
as per buyer.
▪ Merchandiser will inform Supplier / Vendor & take decision about rejected lot and how much
excess fabric is needed for required of shipment.
▪ Merchandiser should be ensured that factory will receive excess fabric with proper quality on
time.
▪ To cut fabric need proper decision from Quality Head/Senior Management.
3.1.4.3. Shade band & Blanket Preparation

▪ A small piece of fabric (8”x 8” or 12”x 12”) is cut from every role
▪ The cut piece is placed on swatch board one after another or stitch together to make blanket to
see the color variation of fabric within the same color & dye lot.
▪ The blanket will be prepared 3 pcs, one for before wash reference and another two for washing
as per following the recipe of buyer.
▪ In this regard, follow the fabric shade from darker portion to light portion.
▪ Prepare report & record for further reference and one pcs send to the buyer for approval.
3.1.4.4. Shade band for approval of wash shades by the Buyer

▪ After receipt of the approved fabric rolls in the factory warehouse and before washing of the bulk
garments, a shade blanket is produced. The blanket is then treated at the wash house in
production conditions to produce the shade which has been approved by the buyer. This will
show any shade variation between the rolls.
▪ A shade band hanger will be produced from the washed blanket and submitted for final approval
to buyer. 3 copies must be submitted to ensure the Buyer, Factory and the wash house have a
copy. The shade bands submitted, should include a range of 3 to 5 shades which match to the
approved Base hanger.
▪ All wash recipes must be recorded for each shade and a record of the quantity in each lot.
3.1.4.5. Bulk Fabric Approval

▪ Only when the shade band range from the shade hanger has been approved should the factory
proceed to wash full production.
3.1.4.6. Shade Segregation & Country/Delivery/PO wise Planning

▪ On completion of shade band identify all roll based on founded shade & mark all roll with proper
information of tag such as; shade, lot no, roll no, fabric quantity of roll.
▪ Segregate all roll as per individual shade & store on pallet with maintaining maximum heights 6’
and attached the bin card with necessary information.
▪ Before delivery to the cutting, define country/Delivery/PO wise plan for cutting based on the total
quantity of individual fabric shade as per individual Country/Delivery/PO shipment quantity.
▪ Prepare report & record for further reference.
3.1.4.7. Accessories Inspection Procedure

Garments accessories means all the items used in the garment except the main raw material
(fabric). There are hundreds of items used to manufacture the garments, which are used as trims
and accessories. A list of few important trims and accessories mentioned below:
- Sewing thread - Metal and plastic clip
- Button - Tissue paper
- Label - Al-pin
- Interlining - Price tag, Hang tag
- Padding - Tag pin
- Collar bone - Poly Bags
- Zipper - Hanger
- Lace - Scotch tape
- Solder tape - Gum Tape
Accessories/Trims Card Verification Procedure

▪ Quality Controller/Inspector should be aware of Bill of Material (BOM) list.
▪ He should be checked the trim card as per approved bill of materials (BOM) list & also
merchandiser will give approval swatch card.
▪ Quality manager also verify the trim cards.
▪ If found any discrepancy must inform senior management & merchandiser.
The standard of accessories inspection system is mentioned below:

Required Documents
▪ Packing list of trims & accessories and
▪ Approved swatch card.
Sampling plan
Sample plan provides a guideline to determine the inspection sample size.
Accessories Qty. Inspection %
0 – 1000 pcs 100 %
Over 1000 – 10000 pcs Minimum 1000 pcs
Over 10000 pcs ……….. 10% of Total Qty.
Or,
As per AQL Table (Level – I, AQL – 1.5).
Inspection Procedure
▪ Identify the accessories/trims to be used for a specific style.
▪ Prior to start inspection you must have style wise approved accessories/trims card by the concern
merchandiser.
▪ Select the accessories/trims at random basis.
▪ For Countable accessories/trims; at least 10% of the total quantity or Level – I, AQL – 1.5 wise
accessories/trims have to be taken for inspection. The following table is stated below with
acceptance & rejection range:

If % wise then maximum 1% rejection will be allowed out of total lot qty. and Level – I, AQL – 1.5
wise then the lot will be Passed/Failed as per AQL acceptance/reject qty. But critical defect is
zero% (0%) allowed.
▪ For Non-countable accessories/trims; at least 10% of the total quantity of accessories/trims have
to be taken for inspection and maximum 1% rejection will be allowed out of total lot qty. And
critical defect is zero% (0%) allowed.
▪ Compare the accessories/trims with approved specimen to justify the quality parameters.
▪ During inspection the following parameter should be checked:
- Shade matching - Number & size
- Shrinkage - Fiber content
- Color bleeding - Text content in label & tag
- Width & thickness - Printing & Embroidery (If required)
- Strength
▪ If the lot is failed by inspection in first time, then 100% accessories should be inspected.
▪ Damage or reject accessories should be segregated and keep separate with proper identification.
▪ Have to make counter trims card for each line as per approved trims card.
▪ After completion of inspection, prepare report and record for further reference.
Thread Inspection
- To identify any discrepancy, check different parameters like - Construction, Color & shade,
Number or Count, Quantity, Plies, Strength, Hand feel of the thread.
- Based on the findings prepare a report and take decision whether the thread are accepted or
rejected.
Brand Label
- To identify any discrepancy, check different parameters like - Construction, brand name, logo,
weaving quality, hand feel, Printing (if required), color & size of brand label.
- Based on the findings prepare a report and take decision whether the label is accepted or
rejected.

Company: Shin Shin Group Doc’s Name: Quality Assurance (QA) Manual Doc’s No: SS/QAM/M-04 Dept.: QMS
Issue No: 1.0 Issue Date: Rev. No: 1.4 Rev. Dt: 15/06/2017
Care & Size Label

- To identify any discrepancy, check different parameters like - construction, instruction of care
symbol, warning instruction, printing quality, and country of origin, color & size of the label.
- Based on the findings prepare a report and take decision whether the care label are accepted or
rejected.
Zipper
- To identify any discrepancy, check different parameters like - construction, color, size, tape &
teeth width, strength, slider, stopper & puller of the zipper. Also check the functional test of the
zipper.
- Based on the findings prepare a report and take decision whether the zipper are accepted or
rejected.
Button or Rivet
- To identify any discrepancy, check different parameters like - construction, color, size, broken,
sharpness, number, color bleed, functional test & pull test of the button or rivet.
- Based on the findings prepare a report and take decision whether the button or rivet are
accepted or rejected.
Hangtag, Price tag

- To identify any discrepancy, check different parameters like - brand name or symbol, color,
number, barcode, printing quality, price, thickness & size of the hang tag & price tag.
- Based on the findings prepare a report and take decision whether it is accepted or rejected.
UPC Sticker
- To identify any discrepancy, check different parameters like - barcode number, scan the number,
color, printing quality, hand rub, thickness & size of the sticker.
- Based on the findings prepare a report and take decision whether the UPC sticker are accepted or
rejected.
Poly Bags
- To identify any discrepancy, check different parameters like – Poly types, warning instruction,
printing quality, size (Length-with flap & without flap, width) & thickness, adhesiveness, aeration
hole quantity & placement, dust of poly bag etc.
- Based on the findings prepare a report and take decision whether the poly bags are accepted or
rejected.
Carton
- To identify any discrepancy, check different parameters like – color, ply, size (length, width &
height), NW, GW, shipping mark & printing quality of carton.
- Based on the findings prepare a report and take decision whether the cartons are accepted or
rejected.
Hanger
- To identify any discrepancy, check different parameters like – color, design, size (length & width),
hook (curvedness, thickness & length) of hanger.
- Based on the findings prepare a report and take decision whether the hangers are accepted or
rejected.
Gum Tape
- To identify any discrepancy, check different parameters like – Adhesiveness, strength, width &
Thickness of Gum Tape Roll.
- Based on the findings prepare a report and take decision whether the Gum Tapes are accepted or
rejected.
3.1.5. Fabrics & Accessories Test Procedure

Fabrics Test Procedure:
Fabric GSM Test Procedure
GSM test is very important part to ensure fabric quality before manufacturing product. GSM testing
procedure of different stage is stated below:
Sample
▪ All type of sample (Development, QA, PP, Size Set sample etc.) fabric from supplier, 100% of fabric
challan/lot must be tested for GSM both non-wash fabric and washed gmts.
▪ GSM weight should be followed based on buyer requirements.
▪ Non-wash Stage:
- Take 1 yds of fabric from every sample stage fabric.
- Cut the fabric by GSM cutter.
- Formula:
With GSM Cutter:
(Weight of the cut fabric in gm. with the digital/electric balance &
multiplied by 100)
Without GSM Cutter:
(Avg. Weight of the cut fabric in gm. Х 10000/Cut fabric area CM2)
- In this regard, +5% is acceptable.
- Prepare non-wash fabric GSM test report & keep records with all concern signature for further
reference.
▪ Washing and After Washed Stage:
- During wash development, the wash development recipe must record and follow the same in
every stage of sample wash development.
- After receiving development sample from wash, take 2 pcs garments from every sample stage
for GSM test and test in following the above fabric GSM test procedure.
- Prepare respective after washed sample garments GSM test report & keep records with all
concern signature for further reference.
▪ The test will be performed by LAB department and the report submitted to the concern
merchandiser.
▪ If garments GSM test result is failed, then it should be approved by concern merchandiser/buyer
with written document.
▪ The procedure should be followed-up by Quality GM/Head of Quality and signed report time to
time in every sample stage of fabric & garments GSM test report too & updated to the
management.
Bulk Production
Non-wash Fabric (Received from Supplier)
▪ 100% of fabric rolls received from supplier, fabric GSM must test covering all color & batch/lot &
shade no.
▪ Fabric Batch/lot & shade no from supplier must include to the fabric GSM test report.
▪ Prepare non-wash fabric GSM test report & keep records with all concern signature for further
reference.
▪ If fabric GSM test result is failed, the report submits to the concern merchandiser along with
management.
▪ Only merchandiser/buyer written approval will be accepted in this regard to go for the next
process or bulk production.
▪ Fabric cutting for initial must on hold until approval is granted.
Washing and After Washed

▪ Initial:
- Initial garments must be identified by batch/lot & shade no. before sending to wash as per
factory inhouse wash blanket/shade report.
- Washing method will be followed as same as sample development washed recipe.
- During initial washing, if any change in washing recipe the changes should be recorded too.
- After receiving initial garments from washing, GSM test report of initial garments must ensure
covering all batch/lot & shade no. (min. 2pcs from each batch/lot & shade no.).
- Prepare after washed initial garments GSM test report & keep records with all concern
signature for further reference.
- If initial garments GSM test result is failed, the report submits to the concern merchandiser
along with management.
- Only merchandiser/buyer written approval will be accepted in this regard to go for the next
process or bulk production.
- Fabric cutting for bulk must on hold until approval is granted.
▪ Bulk Production:
- Each cutting must maintain fabric batch/lot & shade wise.
- During sewing, the respecting batch/lot & shade must identify by separate batch/lot & shade
label.
- The garments send to wash batch/lot & shade wise.
- Instruct wash factory to return all reject garments on daily basis with OK garments.
- Washing method will be followed as same as initial garments washed recipe.
- During bulk washing, if any change in washing recipe the changes should be recorded for
further reference.
- After receiving washed garments from washing, take 2pcs reject garments from each batch/lot
& shade for GSM test report.
- Prepare after washed garments GSM test report & keep records with all concern signature for
further reference.
- If any lot garments GSM test result is failed, the report submits to the concern merchandiser
along with management.
- Only merchandiser/buyer written approval will be accepted in this regard to continue bulk
production.
Fabric Shrinkage Test

▪ At first take a piece of fabric from every roll and a specific length & width (30cm X 30cm or, 60cm
X 60cm) mark on the cut piece of fabric (25cm X 25cm or, 50cm X 50cm) except 5 or 10cm from
both sides.
▪ Then the piece of fabric is washed & dried by washing machine.
▪ After the length & width of fabric is measured again and find out the percentage of shrinkage
comparing with previous length & width of the fabric.
▪ Formula:
(Before Wash – After Wash Measurement/ Before Wash Measurement Х 100)
▪ The shrinkage acceptance range is 2-2.5% in the fabric also +/- 5% is acceptable also it can be
changed as per buyer requirements. If shrinkage % more than the acceptance range then the rolls
should be separated and separate pattern will be made for cutting or take decision by informing
the concern head.
▪ Preparing report & keep record for further reference.
Torque/Twisting Test
▪ A piece of fabric length & width (30cm X 30cm or, 60cm X 60cm) mark in square and take the
measurement (25cm X 25cm or, 50cm X 50cm) from opposite corner to corner.
▪ Measures the deviations after wash how much displaced from the actual position of straight line
and find out the percentage of torque/twisting of the fabric.
▪ Formula:
(After Wash Measurement of Twisting / Total Length or Width of fabric Х 100)
▪ The acceptance range of twisting is 3-3.5% in the fabric also +/- 5% is acceptable also it can be
changed as per buyer requirements. If twisting % more than the acceptance range then take
decision by informing the concern head.
Color Fastness Test

In order to check color fastness –
▪ 2 fabric swatches (6”x 6” or More/Less) are taken together.
▪ On 1 of the swatch, a white seam is put on all the four sides of the fabric. Both of them are
washed and the results are compared.
▪ If it is stained or bleeding, then it’s rejected otherwise accepted.
▪ Prepare report & record as ready reference.
Crocking Test
▪ Take 1 base fabric swatch and stick with the Crock Testing Machine.
▪ Take 4 white fabric swatches (5cm x 5cm), separate 2 swatches for dry & 2 swatches for wet.
▪ Set the swatches with the Crock Test Machine one by one and rub the machine manually on base
fabric swatch for crocking test.
▪ The rubbing duration for each swatch is 10 times.
▪ On completion of rubbing test, check the white fabric swatches. The acceptable range of crocking
value is for dry fabric 3-4 and wet fabric 2-3.
▪ If the result is more or less than the range, then the fabric is rejected.
▪ Prepare report & record for further reference.
PH Test
▪ Take 3 fabric swatches 2gm per swatch.
▪ Make a solution by using following chemical –
333ml Distill Water and 2.49gm KCL mix together.
▪ Two methods are maintained for PH test; one is in normal case and another is in emergency case.
▪ Sink each fabric swatch one by one in the solution (100ml solution for each swatch) for 15hrs in
normal case.
▪ For emergency case, after sinking fabric swatch in the solution shake 2hrs continuously & rest for
5 mints and check result by PH meter.
▪ If the PH value is within 4-8.5 then the fabric is passed.
▪ Prepare report and record for further reference.
Test Report Collection

▪ Collect all the test report on time from fabrics & accessories supplier & also laboratory which are
required by the buyer.
▪ If fabrics & accessories found fails in testing, then don’t receive the items & collect it again with
consulting or informing senior management.
▪ If any item not submit for testing, then merchandiser will arrange testing before issuing for
production floor.
Accessories Test Procedure

Generally, the accessories which are directly attached with product those are tested internally.
Shrinkage Test (Label, Drawstring, Elastic etc.)

▪ At first take few pieces/quantities of trims from received lot and take before wash measurement.
▪ Then the pieces/quantities of trims are washed & dried and take after wash measurement.
▪ After that both measurement of trims is calculated and find out the percentage of shrinkage %
comparing with before wash & after wash measurement of trims.
▪ Formula:
(Before Wash – After Wash Measurement/ Before Wash Measurement Х 100)
▪ In this regard, +5% is acceptable otherwise rejected.
Color Fastness Test (Label, Drawstring, Elastic etc.)

▪ 1 white fabric or required base fabric swatches & the trims are taken together.
▪ Both of them are washed and the results are compared.
▪ If it is stained or bleeding, then it’s rejected otherwise accepted.
Wash & Print Duribility Test (Label)

▪ Collect required pcs of label for test.
▪ Wash the label as per given instruction by the buyer.
▪ If label print is scratched or pulled out, then it’s rejected otherwise accepted.
Nickel Test (Metal Button, Zipper etc.)

▪ The required materials for nickel test are –
- Cotton bud
- Two types chemical – Di-methyl-glyoxime and Ammonia
▪ Mix the both chemical together & two drops use in cotton bud and rub for 30 times.
▪ If the color is changed to pink or red, then it’s ensured the presence of nickel & rejected.

3.1.6. Fabric, Accessories and Reject & Left-Over Garments Reconciliation Procedure
Fabric:
1. On completion of any order/style, concern fabric responsible will hand-over the balanced
fabrics to concern Left-over responsible with authentic records.
2. Concern Left-over responsible will keep the balanced fabrics in well-organized and separately by
using BIN card in containing with Closed Date, Buyer, Style, PO, Color and Qty.
3. A separate register should be maintained for balanced fabrics stock for further records and this
stock should tally with ERP and physical balance.
Accessories:
4. On completion of any order/style, concern accessories responsible will hand-over the balanced
& rejected accessories to concern Left-over responsible with authentic records.
5. Concern Left-over responsible will keep the balanced & rejected accessories in well-organized
and separately by using Tag/BIN card in containing with Closed Date, Buyer, Style, PO, Item, Size
and Qty.
6. A separate register should be maintained for balanced & rejected accessories stock for further
records and this stock should tally with ERP and physical balance.
Reject & Left-Over Garments:

7. Concern Left-over responsible will collect whole orders/styles information from Planning
Executive/Manager.
8. Rejection responsible will hand-over all rejected garments on daily basis at 6.30 PM of every day
to concern Left-over responsible.
 Before handover rejected garments, all label attached with rejected garments are carrying
buyer information must be removed and permanently marked with a stamp as per buyer
name such as “Rejected for Buyer”.
 All rejected garments must be contained with proper information Rejected Date, Buyer,
Style, PO, Color, Size, Qty, Item.
 A copy of daily rejection report should be submitted to Planning Executive/Manager and
Factory Management/CEO.
9. Concern Left-over responsible will prepare month wise summary report by extracting data from
daily received rejection qty.
 Rejected garments must be kept of minimum 6/12 months.
 Finally, all rejected garments will be disposed by top management (Chairman) decision.
 A disposal report must be prepared with mentioned all information such as; Disposal Date,
Buyer, Style, PO, Color, Size, Qty, Item, Disposal method, Disposed by and pictorial evidence.
 All disposal report must be kept at the relevant master file and need to review by the top
management monthly basis.
Monthly audit will be conducted by factory internal audit team to verify the physical and
register/records balance.
**********

3.2. Pre-production Meeting

Pre-production Meeting (P.P. Meeting) is mandatory against every order in presence of the entire
related person i.e. merchandiser, production, quality, CHO QA, store, maintenance, IE, & sample
man. Merchandiser or CHO QA team will arrange the meeting & will discuss the requirements of
buyer using format (CHO-01) & record for further reference. Concern personnel will provide the
size set sample with all the related paper and confirm swatch as per order sheet to follow
production properly.
Who to attend the Meeting?

✓ Concerned Merchant
✓ Buyer’s Representatives
✓ Factory GPQ/RQS
✓ Planning Concern
✓ Sample and CAD Concern
✓ Production Concern
✓ Quality Concern
✓ IE Team
✓ Section In-charge (Store, Cutting, Sewing, Finishing & Washing)
✓ Maintenance Concern
What Issues should be discussed in the Meeting?

The following issues must be discussed in PP meeting:
1. Quality standard of buyer.
2. Approved sample comments from customer.
3. Inventory Report.
4. List of fabric & accessories including shortage or excess quantity.
5. Approved trims card.
6. Production planning.
7. Fabric & Accessories Testing & Inspection report.
8. Pattern, Marker, Ratio & Consumption.
9. Fabric Shrinkage, GSM & Composition/Construction.
10. Approved print, Embroidery & Wash.
11. Line lay out and required machine, tools & folder.
12. Critical operation or process.
13. Packing procedure & Safety issue.
14. AQL Standard.
15. Required condition & elements for inspection.
16. Delivery date.
***********

3.3. Pilot Run/Size Set/Initial

The goals of the Pilot Run, line is ready for performing the product or style with required quality &
specification. The following team is required:
- Technician
- IE
- Quality
- Manager/Supervisor from respective line
- Operators as required for the respective line
- Maintenance
The following steps are taken for each of the different processes:
Cutting Section
1. Maintain standard procedure of first cutting for any new style.
2. The first cutting should be performed by same staff and workers who are going to handle bulk
cutting.
3. Maintain all require quality parameters in each stage of cutting.
4. Perform same fusing standard recommended by customer.
5. Maximum 200/300pcs should be cut covering all sizes and colors.
6. Cutting lot should be performed in one shade.
Sewing Section
1. All the machines operators and quality checkers should be instructed on styles in every particular
operation’s they are working.
2. Technician, quality controller and supervisor along with respective machine operators should be
made correct mock ups and signed by quality controller and hang on the respective machine.
3. Technical review should be continued in every stage of production.
4. After completing the garments should be checked properly & measured as approved spec sheet
and sent for washing (if available).
Washing Section
All the pieces should be washed as per approved sample of washing for:
- Hand feel & appearance
- Shade variation
- Streak/Crease marks
- Washing defects
- Sewing defects
- Measurements variation
Finishing & Packing Section

1. Finishing should be done as per the approved sample.
2. The actual finishing and packaging trims should be used as per approved trims card.
3. Pack one carton as per approved standard for technical review.
4. After technical review pilot run report should be submitted to quality and merchandising
department.
**********

3.4. Cutting Section

Cutting section receives the Fabrics & other materials from warehouse as per requirements. They
cut the fabrics as per PO Sheet or Style and maintain dye lot to overcome shading and compare all
fabrics with the fabric swatch provided by the merchants in accordance with the PO Sheet. If any
discrepancy is identified, then inform the factory management as well as merchants.
The following documents are required before start fabric cutting:
▪ PO sheet, Fabric Booking Records, Fabric Inventory & Inspection Reports etc.
▪ Approved Fabric /Trims Swatch
▪ Shade segregation report
▪ Approved shade band
▪ PP Meeting Report with comments
▪ PP Sample/Counter Sample
▪ Production Planning
▪ Fabric Test Reports
3.4.1. Quality Control Process & Procedure in Cutting

The following points must be considered in Cutting Section:
- Fabric Relaxation check
- Marker check
- Spreading check
- Lay Chart check
- Cutting Quality check
- Numbering, Bundling & Cut Panel Inspection
- Pocketing Inspection
- Embroidery Parts Check
- Wash Test of Embroidery parts
- Embroidery parts check by Metal Detector Machine
- Defective parts replacement check
- Fusing Procedure & Bond Test
Fabric Relaxation Check

▪ Fabric relaxation is given to control the excess shrinkage level.
▪ Check the minimum relaxation time is maintained twenty-four (24) hours for any fabric.
▪ This time is varied from fabric to fabric. Also, it may vary according to the buyer’s
recommendation.
▪ Prepare fabric relaxation report & keep record for future reference.
Marker Check
▪ Check available size grading of pattern.
▪ Check the shape, sewing allowance & measurement of pattern.
▪ Check the marker is made as fabric width.
▪ Check that no crease marks, damages & overlapping in the markers.
▪ Check the marking code no is available in the marker.
▪ Check available sizes, ratio & measurement of pattern in the marker.
▪ Check that the marker is placed on the spreading fabric with the edge parallel to the selvage of the
fabric.
▪ Check for table marks as the “table” is marked. Allow no minus tolerance for the splices.
▪ Prepare report & keep record for future reference.
Spreading Check
▪ Fabric spreads on a long wide table and lays them in superimposed plies of specified length.
▪ Spreading fabric keeps flat & smooth surface.
▪ The number of lays depends upon the fabric lay heights.
▪ The lay heights of fabric should be followed as given instructions:
▪ Maximum 2.5-3.0 inch for all Denim & Twill Fabrics
▪ Also, any other requirement/specification of buyer then we are used to adhere that.
▪ After completion of fabric spread, check splice laps to see that both plies extend past the marked
splice about ½ inch.
▪ Check for shading. Unless all parts are ply marked, it is essential to have a system to control
shading.
▪ At last the cutting marker is laid on the topmost layer to ensure cutting.
▪ Prepare report & keep record for future reference.
Lay Chart Check

▪ Fabric lay chart is maintained during fabric laying due to replace the same shade fabric against
reject part changes.
▪ Check the same roll, shade & dye lot is maintained.
▪ If found any mismatch, inform to the concern heads of production & Quality department.
▪ Prepare report and records for further reference.
Cutting Quality Check

▪ This process is to be checked during fabrics cutting.
▪ Randomly select some cut panel as size ratio & check few pcs from top, middle & bottom to ensure
measurement by comparing with hard pattern, shape, cut mark, over cutting, short cutting & other
quality issues.
▪ If found any defect, then separate the defect cut panels as defect category with proper
identification & information and take initiatives.
▪ Prepare report and keep record for future reference (also it’s called TMB report).
Numbering, Bundling and Cut Panel Inspection

▪ Cutting finished; after numbering & bundling, collect the cut panel bundles.
▪ All cut panels must be checked 100%.
- Check the continuation of numbering.
- Check bundle information like- buyer, style, color, shade, sizes and bundle no & quantity (here,
maximum allowed qty. per bundle 25pcs to 30pcs, but it can be changed as size).
- Check other quality parameters like- Cutting shape, fabrics fault, measurement etc.
identification & information and manage to replace by following lay chart report.
▪ Prepare report and keep record for future reference.
Embroidery Parts Check

▪ After receiving the cut panel from embroidery, all cut panels must be checked 100%.
- Check & confirm the panels are embroidered in approved factory.
- Check bundle information like- buyer, style, color, shade, sizes and bundle no & quantity to
ensure it is perfect or not.
- Check other quality parameters such as; styling, thread, thread color, shade, sizes, position,
thickness, shining mark and other quality issues.
identification & information and inform to concern heads of production & quality department.
Wash Test of Embroidery Parts

▪ Take embroidery completed 2 or 3pcs cut panel & wash as per buyer requirement.
▪ After completion of wash, check embroidery thread tension, color bleeding, shading, damage/hole
etc.
▪ Prepare a report and keep record for further action.
Embroidery Parts Check by Metal Detector M/C

▪ The cut panel from embroidery department should be checked by the metal/needle detector
machine to ensure no any metal contamination issue available or, in order to ensure product
safety.
▪ If found any affected pcs then control as per company metal contamination policy with proper
identification & store in a designated place.
▪ Prepare a report and keep record for further action.
Pocketing Inspection
▪ Check the pocketing fabric with approval swatch.
▪ Check the measurement as per buyer requirements.
▪ Check other quality issues like; cutting shape, fabric faults, shade, construction, composition etc.
Defective Parts Replacement Check

▪ Check that the cut panel is cut as follows as same dye lot, roll & shade.
▪ Check the replacement of defective parts as same procedure of ‘Cut Panel Inspection’.
Fusing Procedure & Bond Test

✓ Procedure
▪ QA team and Operator must instruct the specific area of fusing, temperature and pressure to be
set for fusing as per buyer requirements.
▪ Allot a specific time for cooling of the fused parts.
▪ Check fusing shrinkage and record incorporate with the patterns “as allowance for fusing”.
▪ Check shade variation of fusing parts. If shade variation is available then report to the Cutting
Manager/In Charge/Quality head and initiate corrective action.
▪ Inspect the fusing parts for defect like – block/line mark, peel off, bubbles, color or shade etc. and
Inform to the Cutting Manager/In Charge/Quality head for necessary corrective action.
▪ After completion of all tasks prepare a report and submitted to head of departments.
▪ Fusing machine calibration test must be carried out twice a day, once at the start of the machine
then in the afternoon.
Note: Also, any other requirement of buyer then we are used to adhere that.
✓ Bond Test
▪ Take fusing completed 3 or 5pcs parts from the beginning or 1st stage of the process.
▪ Test the stability of fusing parts. The testing procedure is as followed:
- Open thermo-fuse/interlining from one side then other side of shell fabric of parts.
- Put thermo-fuse/interlining frame into the jaws of the bond tester. Fuse frame should be
parallel.
- Hold the shell fabric with one hand and straight the bond tester with other hand.
- Make sure that don’t pull fast and observe the scale and read the bond strength in Newton or
KG (here, standard is 10-100 Newton, but buyer requirement will be highly appreciated).
▪ If found any defect, then inform to the Cutting Manager/In Charge/Quality head and initiate
remedial measures.
▪ Prepare a report and keep records for future reference.
Types of Cutting Defect

▪ Miss-cut, ▪ Oil stain,
▪ Ply not matching (asymmetrical parts), ▪ Fabric bias,
▪ Ragged cutting (uneven seam allowance), ▪ Improper marking,
▪ Spot, ▪ Number or Bundle no mistake.
3.4.2. Cut Panel Storage Procedure

▪ Inspection finished; before storing cut panel, the rack or bin and area must be cleaned.
▪ Keep the cut panel separately in rack as buyer, style & color with proper marking of tag.
▪ Maintain Bin card for identification easily.
▪ The Bin card is contented the following information- buyer’s name, Style, PO, Color and quantity.
▪ The rack distance from the wall should be ensured minimum 1’ (Feet).
▪ Confirm that the cut panel is not waiting more than 24-48hrs in delivering cutting to sewing area.
▪ Maintain a report for future references.
**********

3.5. Sewing Section

Sewing section plays a vital role in production process. The necessary activities should be done
properly to ensure quality in sewing section. Every person who involves with this operation must
follow some specific instructions/standard operating procedure & style as per buyer requirements
for on time shipment.
3.5.1. Quality Control Process & Procedure in Sewing

The following process must be considered in sewing section:
- Needle, Oil Leakage, SPI, Stitch Tension/Density, Pattern, Styling etc. Monitoring
- In-process Check (Front Part & Back Part, Inseam & Side Seam)
- 5/6/7/10pcs System Inspection (TLS)
- 1st output garments Styling & Measurement Check
- Inline Inspection (Process to Process)
- End Line/Final Output Check
- Daily Before & After Wash Measurement Check
- Lot Pass Audit
- Style/Po Wise 1st batch (60 pcs) After Wash Garments Review
Needle, Oil Leakage, SPI, Stitch Tension/Density & Styling Monitoring

▪ Check the needle size and its sharpness etc.
▪ Check the oil leakage on seam line & sewing parts.
▪ Check the SPI and stitch Tension/Density of seam line as per buyer requirements (the standard
SPI is 9-12 per inch).
▪ Check the others styling points such as; shape, stitch category/class etc.
▪ Prepare report and take sign from all related concern and records for further reference.
In-process Check (Front & Back Part and Inseam & Side Seam)
▪ Take the process completed bundle.
▪ Check the parts no. is same for one garment.
▪ Check stitch tension & SPI or density.
▪ Check other quality issues such as; skip, broken, puckering, uneven, drop stitch, irregular stitch,
run off stitch, gathering, needle mark, spot etc.
▪ Finally check the measurement of completed process randomly.
▪ Prepare report and take sign from all related concern and records for further reference.
5/6/7/10 pcs System Inspection (TLS)

▪ Auditor/Controller should check every process at least three times in a day. He / She should select
five/seven-piece samples randomly from a bundle and check every piece carefully.
▪ If he/she doesn’t find any defects, then he will check two times in a day and mark green card for
the M/C & Operators.
▪ If found defects in 1st time, then he will help to operator to understand the process clearly and
checks another three times continuously.
▪ If found defects during the 1st follow-up (2nd Times) then warn the operator and mark yellow
card for the M/C & Operator and inform to the supervisor & Line chief.
▪ During the 2nd follow-up (3rd Times) founds any defects then stop the machine and mark red
card also inform to the supervisor, Line Chief and PM for taking corrective measures. In this
process, he will maintain a record of time of closed machine.

▪ Supervisor, Line chief & Production Manager analyze the root cause of defects and solve the
problems; if found the problem of sewing machine then replace or repair the machine and if the
negligence is found of operator then trained the operator. Also, Supervisor, Line chief &
Production Manager will take responsible of the process.
▪ After solving the problem properly, operator will be permitted to run the machine again. And
change the card red to yellow/green (as per buyer instruction).
▪ Prepare a report; also find out the percentage of defects.
1st Output Garments Styling & Measurement Check

Take the 1st output garments and place it on the inspection table, comparing all the process &
styling with approved sample and measurement as per buyers provided spec sheet.
In-line Inspection (Process to Process)

▪ The process will be maintained by Line Quality Controller or GPQ to ensure the required quality of
garments.
▪ Collect garments as per lot size by following the AQL level – II for all buyers and AQL level – I for H
& M especially after the QC pass.
▪ Check all the process each & every pcs of collected garments at inside & outside and find out the
defects.
▪ If defects quantity within the acceptable range as per following the AQL level below, then lot will
be passed.
AQL level – II, 2.5 (Major) & 4.0 (Minor) for all buyers,
AQL level – II, 1.5 (Major) & 2.5 (Minor) for Just Group and
AQL level – I, 1.5 (Major) & 2.5 (Minor) for H & M
▪ If defects quantity exceeds the acceptable range, then lot will be treated as fail and by informing
all related concern the root cause analysis system will perform to find out the actual reason and
take corrective measures.
▪ Prepare report & records for further reference.
End-line/Final Output Check

▪ Check all the process each & every pcs of output garments at inside & outside and find out the
defects.
▪ Check the measurement also (if required).
▪ Prepare report in calculating DHU (Defect per Hundred Units) & Defective % and inform to all
related concern on hourly basis with acknowledgement. The formula is as follows:
No’s of Total Defects

DHU % = ---------------------------------------------------------- x 100 = Result
No’s of Total Inspected Garments
No’s of Total Defective Garments

Defective % = ---------------------------------------------------------- x 100 = Result
No’s of Total Inspected Garments
Daily Before & After wash Measurement Check

▪ The process maintains by Line Quality Controller to ensure the require measurement of garments.
▪ Collect few garments with cover all sizes.
▪ Check before wash measurement and send for wash.
▪ After receiving from wash, check after wash measurement and comparing both before & after
wash measurement make a report.
▪ If founds any difference, then by informing all related concern the root cause analysis system will
perform to find out the actual reason and take corrective measures.
▪ Records the report for further reference.
Lot Pass Audit

▪ Auditor will perform lot pass audit of output table QC passed garments by the following AQL level
below:
AQL level – II, 2.5 (Major) & 4.0 (Minor) for all buyers,
▪ If the lot is failed, then recheck the garments 100% and send for correcting the defects.
▪ Re-audit the garments lot and prepare report & records for further reference by informing all
related concern.
Style/PO Wise 1st Batch (60pcs) After Wash Garments Review

▪ The process maintains by Quality department to confirm the require quality of garments after
wash.
▪ Send the quantity to wash with maintaining any different identification symbol.
▪ After receiving from wash, the quality of garments will be checked by the quality department to
compare the wash standard with approved sample & swatch and the others required quality met
as per buyer reference.
▪ If OK, then go for the sewing & wash both bulk productions continue.
▪ If not OK, then find out actual reason by analyzing root cause and take corrective measures as per
individual affected area and inform to the related concern.
Types of Sewing Defect

▪ Broken stitch, ▪ Oil spot,
▪ Skip stitch, ▪ Dirty spot,
▪ Puckering stitch, ▪ Run off stitch,
▪ Gathering stitch, ▪ Missing back stitch,
▪ Twisting, ▪ In secured back stitch,
▪ High king ▪ In-correct SPI,
▪ Fabric looseness, ▪ Uneven bottom/side seam/In seam,
▪ Needle cut/mark, ▪ Irregular Stitch
▪ Miss-match stripe ▪ Poor neck shape,
▪ Open seam, ▪ Un-even stitch,
▪ Uncut thread, ▪ Point up-down,
▪ Misalign bottom, hem etc. ▪ Tension tight / loose,
▪ Needle hole, ▪ Raw edges,
▪ Missing bar tack, ▪ Zipper bowing
▪ Pleat, ▪ Fabric damage

3.5.2. Zero Defect Thread Control Procedure

It is the management authority to declare ‘0’ defect thread control procedure and ensure to
maintain by counseling the operator, asst. operator, supervisor, quality inspector, quality
controller, line chief, quality manager & production manager.
Sewing Section
▪ Auto trimming machines must be used for maximum process of the operation.
▪ Concern machine operator, line supervisor, line chief, line controller & line mechanic shall check
& ensure together the wiper of all auto trimming machine working properly and prepare report.
▪ APM/PM, Sr. PM, IE Manager, Quality Manager & Quality GM shall sign the report on daily basis
and update to CEO.
▪ If any operator uses manual machine then he/she must remove thread or by the helper and at
the same time of process checking, if found threads in any bundle during end line inspection then
all bundle will be return to the process operator without further checking.
▪ GPQ/RQS shall monitor continuously and do lot pass audit of every hour’s end line inspection pass
garments for uncut/loose thread and prepare report. Also, will sign in the washing register to
ensure.
▪ If any lot is failed at lot pass audit, all garments threads to be trimmed by two helpers before
sending to washing.
▪ As per daily quality & GPQ/RQS lot pass report, thread free process awareness raising training
must be conducted for all operators & helpers.
Finishing Section
▪ After receiving garments from washing, ensure every pc of garments thread cutting and thread
sucking machine is used.
▪ On completion of thread sucking, each garment must be ensured inside & outside checking by
nominated QI and prepare inspection report.
▪ Quality inspector/checker will not use any cutter and they will use sticker for defects and keep
the garments into the defect box.
▪ Quality Manager shall monitor continuously and perform lot pass audit of every hour’s end line
inspection pass garments for uncut/loose thread by quality controller/auditor and prepare report.
GPQ/RQS will verify the report and ensure for get-up, shade segregation & packing process.
▪ If any lot failed in lot pass audit then GPQ/RQS, Line In-charge, Line Quality Controller, Finishing
Manager & Quality Manager shall arrange meeting and find out the actual reason by “Root Cause
Analysis system” and take corrective actions so that it’s not repeated.
▪ Line In-charge, Line Quality Controller, Finishing Manager, Sr. PM, Quality Manager & Quality GM
shall sign the report on daily basis and update to CEO.
▪ Before poly of garments take dust and loose thread by gum tape.
3.5.3. Inspection Procedure for Wash Received Garments

▪ Check & confirm that garments are washed at nominated factory.
▪ Check the wash label & care label instruction to confirm the same wash procedure is followed as
per requirements.
▪ Collect the approved sample and check the color, shade, hand feel, dry/special finish etc. of
garments is same as approved sample.
▪ Check the bad smell of washing chemical in the garments.
▪ Check other washing defects such as; broken stitch, damage, uneven effect, hole, spot, crease
mark etc.

▪ If print/Embroidery is available, then check the color bleeding & other potential defects or the
print/embroidery points are OK as per approved sample.
▪ Prepare report as per findings and inform to In-charge/Manager/GM of production & Quality also
record the report for further reference.
3.5.4. Moisture Control Procedure for Washing

Garments drying
▪ Check the proper drying time is maintaining as per recipe.
▪ Follow-up the garments are not piling-up more than 2/4 hours after drying.
Garments Inspection
▪ Check the wetness of garments.
▪ Inspect the lot qty. of garment as per following the AQL level below:
AQL level – II 2.5 (Major) & 4.0 (Minor) for all buyers,
▪ Ensure the level of moisture in garments by using moisture meter after inspection. In this regard,
the acceptable level is minimum “18” and maximum “30” along with +/- 5%.
▪ If out of tolerance moisture level garments pieces are more than acceptable pcs of AQL then the
lot will be treated as fail and take the action immediately.
▪ Later, prepare report as per results in designated format and records.
Garments Delivery
▪ The moisture level of delivered garments is checked or not that must be mentioned in delivery
challan.
▪ Moisture checker name & sign must be clearly presented in delivery challan.
▪ The main copy of moisture check report must be included with delivery challan.
▪ The delivery challan of washed garments is not acceptable without moisture checker name & sign
and the main copy of moisture check report.
**********

3.6. Washing Section

Washing section; to fill trend demand it is the hottest process for any denim garments in the
fashion world. In this aspect, to ensure proper quality requirement every person who involves with
this process must follow specific instructions/standard operating procedure to meet buyer
requirements and timely shipment.
3.6.1. Quality Control Process & Procedure in Washing

- Pre-Development Process
- Development Process
- Risk Assessment Process
- Base Fabric and Wash Level Approval
- Shade Blanket Approval
- Bulk Fabric Approval
Pre-Development
Any samples to be tested prior to send to washing and check for any quality disclaimers. Records to
be kept and compared to factory initial sample.
Development
▪ Each Initial sample developed will be internally tested for dry and wet rub, prior to presentation
to the Buyer. Tested swatches will be attached to the initial sample.
▪ If test results are falling outside of requirements, then this is to be highlighted and options
discussed prior to order confirmation.
▪ A Fabric Pre-Production Assessment must be conducted prior to order confirmation. Fabric
performance must be discussed against customer standards and any issues highlighted.
Risk Assessment
At order confirmation, any style must be assessed for potential Fabric, Trim and Garment issues and
any additional testing requirements confirmed. Any concerns should be highlighted to the Buyer
and Garments Technical team and an action plan confirmed. Records to be kept for further
reference.
Base Fabric and Wash Level Approval

▪ A Base Hanger must be submitted to buyer for approval of fabric shade, wash effect and hand
feel. This should consist of an unwashed and washed fabric swatch and the washed fabric should
include a production seam.
▪ The weight of fabric must be checked, and the weight circles attached to the hanger for both
unwashed and washed fabrics.
▪ Test results showing expected results for colour fastness to dry and wet rubbing are to be
included along with the tested specimens. The results are to be no worse than agreed at
development.
▪ The wash recipe must be clearly stated on the hanger.
▪ If the results are not in line with those agreed at development stage, then further samples must
be submitted.
Shade Blanket Approval

Fabric Mill
▪ The fabric mill will produce a shade blanket before the fabric is delivered to the factory.
▪ The blanket consists of a square of fabric from each bulk roll.
▪ Each square is clearly labelled with the roll number/batch/Shade/Qty, so it can be traced back.
▪ The blanket will send to the garment factory for approval of shades.
Garment Supplier
Making Shade lots for Garments Production
▪ The squares are grouped into shade lots. Shade A may
consist of 10 rolls, B of 5 rolls and C of 5 rolls. There
should be no more than 5 shade bands.
▪ The fabric mill is advised of the rejected rolls which do not
fall within the approved shade bands. These rejected rolls
must not be accepted by the garment factory.
▪ Where possible any rejected shades which are too dark
should be separated and can be washed down using a different wash recipe to achieve the
required shade level.
▪ The fabric rolls are sorted into individual lots according to the approved shades and laid up and
then bundled accordingly for production of garments in the factory.
Making of shade bands for approval of wash shades by the Buyer

▪ After receipt of the approved fabric rolls in the factory warehouse and before washing of the bulk
garments, a shade blanket is produced. The blanket is then treated at the wash house in
production conditions to produce the shade which has been approved by the buyer. This will
show any shade variation between the rolls.
▪ A shade band hanger will be produced from the washed blanket and submitted for final approval.
3 copies must be submitted to ensure the Buyer, Factory and the wash house have a copy. The
shade bands submitted, should include a range of 3 to 5 shades which match to the approved
Base hanger.
▪ All wash recipes must be recorded for each shade and a record of the quantity in each lot.
Bulk Fabric Approval

Only when the shade band range from the shade hanger has been approved should the supplier
proceed to wash full production.
Wash House
▪ The approved base fabric hanger shade and approved
shade bands are sent to the wash house with their original
wash recipe which was filed by the garment factory. They
are also given a sample of the approved wash sample, leg
panel or initial sample.
▪ The garments factory will ensure to send bulk garments
define country/Delivery/PO/Shade/Size Ratio wise to the wash.
▪ The wash factory sorts the garments define country/Delivery/PO/Size Ratio wise into shade lots
according to the approved pre-washed shade bands.
▪ The separated garments are washed using the original wash recipe as a guide. Each lot will have a
different wash recipe which is adjusted to aim to achieve the approved shades, handle and
appearance.

▪ Garments which are found to be too dark can be re-processed to bring within the approved shade
and any which are too light must be removed.
Batch Testing
▪ Each wash load must be tested for color fastness to dry rub and wet rub. It is important to know
how many garments are in each wash load. The bigger the wash load the better the control and
less batch tests will be required.
▪ Tests can be conducted internally but must be produced using a reputable Crock meter and by a
trained operator.
▪ Otherwise, the swatches must be sent to an approved lab for testing.
Bulk Hanger and Test Reports

▪ A bulk hanger must be submitted from the finished garments to include a production seam. A
weight circle must be submitted and dry and wet rub test results. The bulk fabric should be
submitted from the middle shade to represent the original approved shade.
▪ The Garment Factory will 100% check the finished washed garments before buttoning or any
other finishing work against the approved shade band range. If any garments are found beyond
tolerance they will be separated and sent to buyer for approval.
Fabric Mill
▪ Clear records must be kept by the fabric mill of the dye recipes used for the approved shade
bands. These should be available to buyer & garments factory upon request.
▪ Yarns must be taken from production regularly to check continuity. The dyes should be checked
regularly during production.
▪ Each roll must be checked for weight, shrinkage and colour. Continuity cards must be produced to
record shade variation.
▪ Colour fastness to dry and wet rub must be checked on each roll.
▪ Continuity cards and batch test results must be clearly recorded and available to buyer &
garments Factory upon request.
**********

3.7. Finishing Section

In Finishing section, all produced garments become ready for shipment. Before final inspection it is
the responsibility of finishing section to make sure that expected quality has been ensured through
effective supervision, monitoring and control measures. They must ensure that all formalities have
been maintained to confirm shipment of final products as per target and required quality standard.
3.7.1. Quality Control Process & Procedure in Finishing

The following processes must be considered in Finishing:
- Shade Check
- Thread Cutting
- In-side, Top-side Inspection & Points Balancing Check
- Lot Pass Audit (After Thread Cut)
- Ironing
- Button & Rivet Attachment Check
- Pull Test
- Measurement Check
- In-side & Top-side Getup Check
- Final Getup Check
- Lot Pass Audit
- Size Ratio Wise Shade Segregation
- Size Ratio, Label, PO Check
- Finishing Accessories Attachment Check
- Metal Check by Metal Detection Machine
- Care Label & Hang Tag Check
- Poly & Folding
- Carton & Packing
- Day Packed Audit
Shade Check
▪ After receiving the garments in finishing section, the designated quality inspector will ensure to
check the required shade of garments as per reference of buyer.
▪ Collect the approved sample/shade and check the shade of garments are same as approved
sample.
▪ After completion of shade checking, shade wise garments shall be segregated separately.
▪ All matching shade garments shall be transferred to thread cutting area and non-matching
garments will be kept separately with bundling & proper identification also inform to In-
charge/Manager/GM of production & Quality.
▪ Prepare report & records for future reference.
Thread Cutting
Thread cutting is to ensure in removing the unwanted uncut thread from garments. The process is
done by the finishing helpers in process to process of each garments.
In-side & Top-side Inspection

▪ After completion of thread cutting, all garments shall be checked both in-side & out-side process
to ensure non-available loose/uncut thread.
▪ If found any uncut thread, then the garments shall be returned to the process for removing the
thread with marking sticker.
Lot Pass Audit (After Thread Cut)

▪ Auditor will perform lot pass audit from QC passed garments by the following AQL level below:
▪ Re-audit the garments lot and prepare report & records for further reference.
Ironing
▪ Only the lot passed audit passed garments from after thread cut will send for ironing.
▪ Before ironing must be collected the approval reference for iron with chop & sign and hang on
the iron table.
▪ Check the cleanliness of iron and iron table.
▪ Check the iron machine vacuum/air sucking system is working properly.
▪ Check the availability of steam and temperature by using thermal paper or temperature check
meter.
▪ After ‘on’ the iron machine, wait for minimum 5 mints to spill out the first drop of water from the
steam line.
▪ Iron the garments as per size & color. Light color garments must be ironed separately by using
iron shoe.
▪ After ironing all garments shall be checked to compare with the approved reference. If any poor
ironing issue, then return the garments for re-iron.
Button & Rivet Attachment Check

▪ After attaching button & rivet, the assigned quality inspector will collect the garments & check
the quality issue such as; using right button & rivet, placement of button & rivet, button & rivet
looseness, button & rivet damages, attached area damages, color scratch of button & rivet etc.
▪ If found any problem, then mark the garments with sticker & keep separate and inform to the
related concern to take corrective measures.
▪ Make report & records for further reference.
Pull Test
▪ After attaching button, rivet, drawstrings etc. in garments, randomly select 2/3 pcs covering per
color & size and perform test in every 2/3hrs later as per required of buyer by using pull test
machine.
▪ If anyone pulls out before the acceptance range 90n then inform to the related concern to take
the corrective measures with immediate effect.
▪ Prepare report & keep records for the future.
Measurement Check
▪ After finishing the button attachment, the measurement of each garment will be checked to
compare with the approved measurement sheet by the buyer.
▪ Only the key points of garments shall be checked.
▪ The measurement deviation garments shall be kept separately and inform to the related concern
to take necessary initiatives.
▪ Measurement report must be prepared and recorded for further reference.

In-side & Top-side Getup Check

▪ On completion of all above process in-side & top-side getup of every garments shall be checked
100%.
▪ The points of checking are ironing, stitching, trims attaching etc. If found any miserable condition
then keep the garments separate and send for correction.
▪ After correction, the garments must be re-checked and send for next process.
▪ Prepare report & records for reference later.
Final Getup Check

The passed garments from in-side & top-side getup check table will be re-checked for final getup to
ensure as same as the counter sample or all requirements are met as per buyer expectation.
Lot Pass Audit

▪ The designated auditor for getup will perform lot pass audit from QC passed garments by the
following AQL level below in every 1/2 hours.
▪ Re-audit the garments lot and prepare report & records for further reference.
Size Ratio Wise Shade Segregation

▪ The lot pass audit passed garments will be transferred to shade table for size ratio wise shade
segregation.
▪ Shade segregator must be expert on the shade segregation process.
▪ The shade segregation process will be performed as per size ratio and keep separate.
Size Ratio, Label, PO Check

▪ After completion the shade segregation part, the quantity of size ratio, label & PO will be checked
for each individual shade.
▪ The checker will keep a record to identify easily the size wise ratio quantity.
Finishing Accessories Attachment

▪ On completion of size wise ratio segregation, the garments shall be transferred to the accessories
attachment area.
▪ But in that case, ensure that the garments are delivered as per individual size ratio.
Garments Check by Metal Detection Machine (Metal Detection Procedure)

Basically, metal detection is done for ensuring the garments/products safety. On completion of
finishing all process it is performed. The process of metal check by Metal Detection Machine is as
follows:
▪ Metal detector Machine should be calibrated in every hour as followed by the buyer instruction &
report should be prepared.
▪ Only a single garment is allowed in a single time during garment passing by the metal detector
machine, in this reference multiple garments passing is strictly prohibited in a single time.
▪ If found any contamination issue, then the garment will be checked by hand detector machine to
identify the contaminated area.

▪ If the metal is founded and possible to remove, then send for removing separately and if not
founded and not possible to remove then the garment will be locked at designated red box with
maintaining proper report.
▪ In this reference, the contaminated garments will be stored in a designated red box & locked for
minimum 6 months.
▪ After every 6 months, Compliance Department will open the lock box along with factory RQS/GPQ
team and dispose all contaminated garments by burning in outside of factory premises.
▪ A disposal report must be prepared with Disposal Date, Buyer, Style, PO, Size, Color, Qty., Item,
Disposal method, Disposed by and pictorial evidence.
Care Label & Hang Tag Check

This process is done before poly & folding to ensure that no any mistake garments are going to
pack. The check procedure is as follows:
▪ Collect the buyer approval reference.
▪ Check the care label layout is correct and attached properly.
▪ Check other defects such as; composition, wash instruction, country, buyer information, size,
printing problem etc.
▪ Check the hang tag attachment position, stitching or tuck properly in right place.
▪ Ensure the hang tag information is matched as per buyer reference/instruction.
Folding & Poly

▪ Firstly, collect the poly & folding reference from the related concern.
▪ Make size wise hard pattern for folding to follow the measurement instruction as per buyer.
▪ Fold the garments by using the pattern then ensure for poly.
▪ Before poly must be cleaned the poly bag.
▪ Poly must be followed as per size ratio and size wise.
Carton & Packing

▪ Collect the carton & pack instruction from concern person.
▪ Check the carton quality, lettering & measurement as per buyer requirements.
▪ Put the garments into the carton as per given approval by the buyer.
▪ If Solid packs; put the garments into carton in maintaining same size, same color & same shade.
▪ If Assort packs; collect the approved assortment ratio from merchant/quality dept. and put the
garments into carton as per approved assortment ratio. The assortment methods are as follows:
- Solid Color Same Size
- Solid Color Assort Size
- Assort Color Assort Size
- Assort Color Same Size
▪ No damage carton is allowed for pack and over packed is not allowed for any carton.
▪ Ensure that gum tape quality and attachment of gum tape is properly done.
▪ Packed complete carton will be kept separately with identification marked.
▪ Daily Carton & packed report must be maintained.
Day Packed Audit

▪ The audit will be conducted by the nominated auditor as per total packed carton in a day.
▪ Carton will be selected to follow the formula square root (√) of total carton quantity and
garments will be selected randomly by the following AQL level below:

▪ After completion, the audit makes a report upon it, if fail then recheck the total day packed
quantity of carton & garments.
Types of Finishing Defect

▪ Accessories
- Damage accessories
- Malfunction of accessories
- Missing accessories
- Insecure accessories
- Bigger / smaller button hole
- Print peel off on accessories
- Sharpness of accessories
▪ Ironing
- Shinning mark
- Improper/poor ironing
- Pleated press/crease mark
▪ Packing
- Damage & Incorrect size of hangtag, hanger or poly bag
- Missing hangtag, hanger, size or price tag
- Illegible printing on hangtag / price tag / poly
- Mildew or Insect inside poly bag & carton
- Glue mark on poly
- Broken hanger or clip
- Wrong assortment
- Wrong shipping mark
- Carton broken or damage
- Illegible prints on carton or poly
- Wrong blister poly & carton sticker
- Carton bulky
- Sharp objects or Insects inside carton
- Wrong carton size/gross weight/condition (ply/staple)
**********

4. Product Integrity and Safety Procedure

4.1. Needle Control Procedure
This system relies on the fact that there must not be any needles, anywhere in the factory except
for those, which are attached to the machines for the purpose of sewing.
▪ There must be one person who is responsible for issuing new needles.
The new needles must be kept in a locked cupboard preferably away
from the sewing area.
▪ The person responsible must keep detailed records. The important
points to note are the entire broken needles, which are being replaced,
must be stuck to the page. If all the parts of the needle cannot be found
then the record must show what action was taken to ensure that the
broken parts had not contaminated any garments or cut pieces. When the new needle is issued
the person responsible must sign the record.
▪ Machinists must not have any extra needles (new or old) in his sewing area, He should not keep
spare needles in his drawer, stuck to the machine or under the sewing machine etc.
▪ When a needle needs replacing because it has broken, then all the parts must be found and
returned to the person who is responsible for issuing new needle can be issued.
▪ Needle control applies to the sample room and for any hand sewing needles, which may be used
for sewing special buttons etc.
▪ Needle control applies to the mechanic. If he requires needles while repairing a machine then this
must be recorded in the needle control records.
▪ A record of any metal contamination should also be kept. This should be similar to the needle
control records.
▪ All the children garments must be passed through the needle /metal detector before final
packing.
Broken Needle Control Procedure

▪ When a needle is broken during sewing, every effort has to be made to recover all fragments of
broken needle in the garments / machines, in the meantime machine remain stopped and have to
be informed to Line chief/Floor In-charge.
▪ The machines should be checked including such areas like machine throat plate, feed dog, oil
tank, hook set area and bobbin case.
▪ If all parts are not easily recovered, the use of magnet is recommended for location of the same.
▪ If all parts of the broken needle cannot be found, then the bundles of garments on the machine
have to be kept in a separate bin.
▪ The operator along with the Line chief will collect a request form from the needle issuer and will
take to the metal detector unit for location/removal of the same.
▪ Unauthorized persons should not be allowed to handle the bin where garments for
contamination check are stored.
▪ After location of the contamination, the garments should be re-passed through the metal
detector before certifying as acceptable.
▪ If fragmented parts not found finally then the operator & line chief fill the request form and the
QC supervisor & mechanic in charge will state that all parts not found they have followed all the
process.
▪ The request form will be submitted to the administration head with taking sign by RQS
Head/Quality Head/Factory Head.
▪ By the permission of above authorization new needle must be issued.

▪ At last the contaminated garments will be stored in a designated red box & locked for minimum 6
months and destroy as per buyer instruction by the permission of top management.
▪ If broken needle found, then it must be carried out by the transparent box.
▪ During replacement of broken needle, the machine number, operator name, designation, card
number, line number, section etc. must be listed in the designated format/register.
▪ All broken needles are stored in register till six months after the shipment of concern style and
will be disposed at off factory premises.
Used/Idle Needle Control Procedure

▪ All needles even when not broken must be checked regularly by the Line Chief / mechanic to
ensure that they are in good working condition. The following process is taken:
‐ To check machine needles every day.
‐ To take appropriate steps over the needle checking and replace the defective needle with
immediate effect.
‐ To ensure the M/C Needle check time every day morning and the lunch break.
‐ To maintain a needle check list job card for individual batch M/C’s included in it.
▪ No sewing operator should be in possession of any spare sewing needles, used/Idle or new other
than the needle installed in the machine.
▪ All replacement/spare/Idle sewing needles must be secured in a separate area, accessible only
the designated person.
▪ All new/spare/idle sewing needles must be replaced only by the mechanic / trained persons only
and directly handover to the needle man/supervisor.
▪ All Used/Idle needles must be taken for replacement only in a sealed magnet container and
recorded in the idle needle stock format/register. But the used/idle needle is not possible to re-
use then it will be recorded in the broken needle control format/register.
▪ The Quality GM /Factory Head/ RQS Head/ Factory product safety co-coordinator will check that
the needle control / replacement procedures are strictly enforced and also verify the stock of
needles on a regular basis.
4.2. Sharp Tools and Others Metal Control Procedure

Sharp Tools
Scissor, Cutter, Knife, and Blades can be used in every area of the factory from warehouses to
finishing.
▪ All new and used scissors, cutter, knife and blades must be stored under the Line
Chief/Supervisor.
▪ A register/format must be used for scissors, cutter, knife and blades.
▪ The issued scissors, cutter, knife and blades are to be numbered and stick the name and ID of the
user and keep records in designated format.
▪ Under no circumstance used scissors, cutter, knife and blades must not use in the production
area.
▪ Also issuing more than one sharp tools against one person is strictly prohibited.
▪ Old blades must be disposed of responsibly on a regular basis & keep records.
▪ All sharp tools such as scissors, cutter, knife and blades are surely attached to the work station &
machine.
▪ The sharp tools will be attached to maintain minimum distance 6” inch height from the floor.
▪ During lunch period and at end of each working day all scissors, cutter, knife and blades must
return to the Line Chief/Supervisors and he/she must check all have been returned and keep
record accordingly.
▪ If any sharp tool is lost, then search the whole area and may use the hand metal detector.
▪ If it is lost in packing area, then it is mandatory to open all packed carton and check to confirm.
Others Metal
▪ Loose snaps, rivets, zipper parts and other small components are stored in appropriate containers
and use with care in the production area.
▪ The control report will be maintained for stock and day & total issue quantity.
▪ All non-ferrous metal components stock on delivery is checked if they passed through a metal
detector.
▪ Spare parts and tools are stored away from the sewing floor in proper designated area.
▪ Ensure production areas are free of dangerous item like broken glass and splinters.
▪ Take extra care while use of jewelry by the operator in production area.
4.3. Disposal Procedure of Needle, Sharp Tools and Others Metal

▪ No any broken & used needle should be delivered to directly store. It must be hand over to
needle operator first.
▪ Needle operator will keep all broken & used needle to his/her account up to next Six months with
proper records.
▪ After Six months, needle operator will hand over all broken & used stock to the store with proper
records.
▪ Sharp tools & others rejected metal must be handed over to store during replacing on daily basis.
▪ All broken & used needle and sharp tools must be kept in a separate box & place with lock & key.
The box & place must be marked or highlighted with Red Color.
▪ Store will maintain a separate register/records with proper qty. and type of sharp tools.
▪ After every 6/12 months, store & compliance department will dispose all broken & used needle
and sharp tools in presence of Sharp Tools Committee.
▪ A disposal report must be prepared with Disposal Date, Disposal Item, Disposal method, Disposed
by and pictorial evidence.
4.4. Pest Control Procedure

▪ Check all products and equipment before operation & delivery.
▪ Stop operation & delivery that have signs of pest infestation.
▪ Keep closed all exterior openings tightly.
▪ Use electric insect control units to control insect.
▪ Use net and adhesive trap to control insect.
▪ Report any signs of pests to the concern authority.
▪ Report any openings, cracks, broken seals or other opportunities for pest infestation to the
concern authority.
▪ Review pest control procedure and keep records of control activities.
4.5. Mold Prevention Procedure

▪ Check & identify the affected area.
▪ Install humidity check meter at all individual section to check the humidity level.
▪ Check the moisture level of fabric at receiving time & during inspection.
▪ Must be ensured proper ventilation /air flow in pressing & finishing area.
▪ Use vacuum pressing table, so that steam cannot stay with garments.
▪ Maintain minimum 2/4 hours leisure time between pressings to packing.
▪ Keep packed carton on the palate with proper space from wall.
▪ Check moisture level during in-line & pre-final inspection.

▪ Check proper 7 points cargo checking system.

▪ Check moisture level in washing area and during washed garments received.
4.6. Rejected/Non-conforming Garments/Products Control Procedure

▪ Garments permanently rejected during an inspection must be kept separate with proper
identification and send to rejection room in day end.
▪ All label attached with rejected garments are carrying buyer information must be removed.
▪ The rejected garments must be permanently marked with a stamp as per buyer name such as
“Rejected for Buyer”.
▪ All rejected garments must be stored inside rejection room ensuring proper lock & Key with
proper information (Date, Buyer, Style, PO, Color, Size, Qty, Item etc.) in monthly basis.
▪ Prepared month wise summary report by extracting data from daily reports and the report must
be signed by authorized person and keep records.
▪ All report must be kept at the relevant master file and need to review by the top management
monthly basis.
▪ Rejected garments must be kept of minimum 6/12 months.
▪ Finally, the rejected garments will be disposed by management (CEO/Director/Chairman)
decision.
▪ A disposal report must be prepared with mentioned all information such as; Disposal Date, Buyer,
Style, PO, Color, Size, Qty, Item, Disposal method, Disposed by and pictorial evidence.
**********

5. Measuring Tools & Equipment Calibration Procedure

Some Special category of Machines needs calibration. Machines should be calibrated on regular
basis after specific interval. List of special machine & tools which need calibration is given below:
1. Needle Detector Machine
2. Fusing Machine
3. Pull Test Machine
4. Weighing Scale
5. Measurement tape
5.1. Needle Detector Machine Calibration Procedure

The following sections highlight the actual calibration process:
▪ The needle detector machine should be kept in an area free of
any metal.
▪ The same must be checked periodically using a 1 / 1.2 mm ferrous
ball test card supplied with the unit.
▪ The calibration must be done at all nine zones as specified in the
Fig: Needle Detector Machine
metal detector calibration log.
▪ The card should be mounted on top of a non-ferrous kit such that it passes through the center of
the aperture where the sensitivity is very less.
▪ The calibration should be done once every hour when the machine is running continuously and 3
times a day when not in use.
▪ The machine must be calibrated at the end of the working shift.
▪ Only product scanned between 2 certified calibrations should be taken up for packing. If any
calibration fails, then the entire product previous hour must be rechecked / re-passed through
the metal detector after rectification and re-calibration of the metal detector.
▪ Rejected product should be kept in a separate area with proper identification so that the same
does not get mixed with the product pending / passing metal detection.
▪ Place a calibration certificate on the machine and keep records.
5.2. Fusing Machine Calibration Procedure

▪ The proper system of fusing machine calibration is-
- Power switch
- Start switch
- Temperature 140 degrees
- Time / Running speed 10sec
- Pressure 1kg
▪ Check the input voltage 220V by Avometer. Fig: Fusing Machine
▪ Machine running speed should be checked by stop watch, if not correct, adjusted as per required.
▪ Machine temperature (127-1710C) should be checked by thermo paper or laser meter but not
acceptable if temperature more than 5%.
▪ Roller alignment should be checked by using 2” widths 3pcs fusing paper at left, middle and right
and tested the fusing strength by pull test machine.
▪ Check the automatic belt raping device.
▪ Check the Teflon coating and joint strength.
▪ Check the automatic stripe device.
▪ Check the timer switch is workable.
▪ Place a calibration sticker on the machine and keep records.

5.3. Pull Test Machine Calibration Procedure

▪ Check machine’s on/off switch and pressure indicator of force measuring
gage is workable.
▪ Check hook adjustment and accuracy with force measuring gage of machine.
▪ Weight indicator should be checked by hanging 15pounds weight with weight
force measuring gage of machine that it is indicating the measurement
accurately.
Fig: Button/Snap
▪ Place a calibration certificate on the machine and keep records.
Pull Test Machine
5.4. Weighing Scale Calibration Procedure

▪ Tare the scale so display reads all ‘0’s.
▪ On the calibration record document the requirement for a 1 gram scale.
▪ Place the 1 gram weight on Scale and record the scale's reading on the
calibration record next to the requirement.
▪ Repeat steps 1 gram through above as required weights.
▪ If any of the weight readings are out of the scale requirements, immediately Fig: Weighing Scale
take the calibration record to the Quality Manager/GM for their review. Quality Manager/GM
documents the review findings on the calibration record.
▪ Place a calibration certificate on the scale and keep records.
5.5. Measuring Tape Calibration Procedure

▪ Slide out one foot of the measuring tape.
▪ Inspect the body of the tape measuring area, the tape itself and the tabbed
metal clip on the start & end of the tape for damage, visibility of marks and
looseness.
▪ Should have smooth movement and its whole length & marking should be
Fig: Measuring Tape
clearly visible.
▪ Using measurement block; measure and record 5 different lengths but not acceptable more than
+/- 0.05” (1/16”) or 1mm.
▪ The measurements block must be calibrated by the authorized organization as well.
▪ Place a calibration sticker on the block and keep records.
**********

6. Inspection / Audit and Others Procedure

6.1. Pre-final/Final Inspection Procedure
Company is committed to ensure required quality of products. It gives instructions to the employee
ensure expected quality of every style/order. In order to ensure the required quality of finished
product company follow the Acceptable Quality Level (AQL) as described below:
* Generally, for maximum buyer -
Level of Inspection: II
AQL 2.5 (major)
AQL 4.0 (minor)
Critical defect – Zero (No critical defect is acceptable)
* And specially for -

Just Group -
Level of Inspection: II
AQL 1.5 (major)
AQL 2.5 (minor)
Critical defect – Zero (No critical defect is acceptable) and
H&M-
Level of Inspection: I
AQL 1.5 (major)
AQL 2.5 (minor)
Critical defect – Zero (No critical defect is acceptable)
Note: If there is any other requirement/specification of buyer then we are used to adhere that.
Required Documents
1. Master files with related PO sheet, spec sheet & in line inspection report.
2. Packing list.
3. GSM, Shrinkage, Washing and others test report.
Necessary Tools
1. Marker Pen
2. Measurement Tape
3. Highlight Pen
4. Trim Cutter
5. Approved Sample
6. Approved Shade band, Trim card & Swatch
7. AQL Table
Inspection Procedure (Pre-final/Final)

▪ For Pre-final/Final inspection number of carton is randomly selected by the formula of 2√ (total
number of carton).
▪ Carton shipping mark, dimension, net weight, gross weight & quality is verified as per
specification of PO sheet.
▪ Assortment checking must be done for the entire carton which is selected for inspection.
▪ Packing, packaging & accessories of the garments are checked based on the specification
mentioned in the PO sheet.
▪ Check all lab test reports are available for fabrics and accessories which is required as per buyer.
▪ Required quantity of sample is pulled from the selected carton as per ratio.
▪ Sample quantity of garments is checked & identified defects as per buyer required.
▪ To ensure the accuracy of measurement a required number of garments (3pcs/color/size) is
measured during inspection.
▪ Out of tolerance points is marked during the measurement.
▪ Sharp point, broken needle, country of origin mistake, composition mistake, Insects, button
broken, half stitch of button, any type components missing & carton damage/broken are treated
as critical defect.
▪ Pull test of button or rivet (2pcs/color/size) is conducted with the standard of 90 Newton.
▪ A required no. of garments (2pcs/color/size) is checked by Needle Detector machine during the
inspection.
▪ All necessary information as per findings during the inspection must be included.
▪ If the audit passes, then the garments can be ready for final inspection.
▪ If the audit doesn’t pass, then the heads of QA / Production Department must be notified to take
necessary actions.
▪ Follow up whether such garments were re-inspected.
▪ Maintain all report timely and keep as ready reference for the future.
Note: Pre-final inspection performs as per company policy and sometimes final inspection is
conducted based on customer’s demand by following the customer’s instructions.
6.2. Root Cause Analysis (RCA) Procedure

Root Cause Analysis (RCA) is a method that is used to address a problem or non-conformance, in
order to get the “root cause” of the problem. It is used to correct or eliminate the cause and
prevent the problem from recurring.
1.Problem
Identificatio
Procedure n
To analyze the root cause & prevent defects the procedure described 2.Understan
5.Monitor
below: the System
d & Define
the Problem
1. Problem Identification: Any problem or defect is detected

through effective inspection.
2. Understand and Define the Problem: Analyze and try to 4.Corrective
3.Analyse
the Root
understand and define the problem specifically. Action
Cause
3. Analyze the Root Cause: The root cause of the problems is

detected and analyze properly.
4. Corrective Action: To remove the cause of problems necessary action or corrective measures is
to take to remove and control the problems.
5. Monitor the System: Subsequently the result of corrective measures is to evaluate.
The concern quality persons will be responsible to ensure that the above mention activities have
been performed properly against each occurred problem individually.
Note: As a tool ‘5 why’ method may apply to find out the actual root cause of any specific problem.
The ‘5 why’ method works by making 5 questions using ‘why’ one after another against the fact and
the answer of pervious questions.
Mention that sometimes it may take more than 5 questions to reach the root as well.

6.3. Internal Quality Audit Procedure

An internal quality audit is to check, analyze & conforms the operational activities of quality control
based on the approved policy & procedure.
Pre-activities of Audit
▪ Prepare an audit plan.
▪ Prepare a checklist with require points for the area will be audited.
▪ Set expert persons and inform them in written to conduct the audit on due date. The auditing
date will be noticed to the auditors in advance of 3 days.
▪ Provide a notice to the concern head of audit area with concerning of the Top Management.
Responsibilities of Internal Auditor

The auditors are responsible for preparation of audit report after the completion of audit.
• The auditors shall collect the internal audit schedule and require checklist (if available) from
Management Representative (MR)
• The auditors shall notify department heads and senior staffs responsible for the area to be
audited in advance (at least 48 hrs.) before of the scheduled audit date.
• The audit will be full coverage of entire Quality Management System.
• Auditors shall not be audited their own area where they are working or responsible directly.
• The process to be audited shall be observed and the objective evidence shall be checked against
the process.
• Findings shall be categorized as under:
OK Where the findings are satisfactory
NC Where there is a failure to fulfill the requirements
OBS Where a weakness is found which if not addressed could lead to a future non-conformance.
• Non-conformity shall be recorded on the ‘description of non-conformity’ section in checklist with
the objective evidence and the attribution.
• The auditor shall sign under the description of the NC report.
• On completion of the audit, the auditors shall submit a completion report to the Audited
Department Heads/Senior Staffs and Management.
• The follow-up audit shall be arranged after completion of the implementation of the corrective &
preventive actions activity.
• The person performed the original audit shall perform follow-up audit after agreed period of
corrective & preventive actions and the follow-up audit must be conducted within 7 (seven) days
of agreed time for corrective & preventive actions.
• The follow-up audit shall verify the implementation and effectiveness of the corrective action
taken.
• If corrective & preventive actions taken is found satisfactory this shall be recorded in the original
audit report. The auditor shall forward the original audit report to the Management.
• If the corrective action taken is not satisfactory a new date shall be agreed by the audited
department & auditor and before that the audited department heads/ senior staffs must take
appropriate corrective & preventive actions.
• The auditors shall record the new date in the original audit report and in the copy retained by the
audited department heads/ senior staffs. The Auditors shall forward the same copy of original
report to the Management.

During Audit Procedure

An Internal Audit program is to be conducted in a systematic way. To conduct an Internal audit, the
key steps mentioned below need to be followed:
▪ Opening Meeting
▪ Factory Tour
▪ Workers Interview
▪ Factory Document review
▪ Internal discussion/Report writing
▪ Closing meeting & signing off the onsite report
▪ Opening Meeting
- Explain audit purpose, scope & procedure
- Confirm assistance & cooperation
- To exhibit transparency and share the challenges faced by the area
- Review process flow chart and layout of the area
▪ Area Tour/Visit
- Examine the machineries, work environment, require documents & activities etc.
- To ensure that there is no hazard for employee using machine in the work.
- To review the work environmental compliance implementations in the area.
- To choose samples for employee interview as working area.
▪ Workers Interview
- Ensure the sample covers the gender and the category of the area.
- Know the willingness of the worker for the interview.
- Select proper interview locations.
- Stress on the confidentiality statement.
- Make the workers comfortable.
- Hold combine (Group/Individual) interviews (If necessary).
- Use this interview as a tool to know what the gap is available in the area.
▪ Factory Document review

- All documents related to the work.
- All the documents reviewed have to be noted down, if required take the snap as well.
- The detail of each document has to be mentioned in the report. For e.g. Date of obtaining,
Validity period etc.
- If any documents are not available during the audit, mention the details.
▪ Internal discussion/Report writing

- Before conducting a closing meeting, internally discuss with the other auditors and prepare
the audit report.
- Check whether all the observations noted by the individual auditor are captured in the audit
report.
- Check all the observations are captured under right categories.
- Get to a common understanding (corrective actions & deadline) on all the observations by
sharing with concern head.
- If corrective measures taken on the day of audit, record the observations and corrective
measures taken.
- Mention with the details of the sampled workers, the place and the department in the audit
report if there are any non-conformities found.
▪ Closing meeting and signing off the onsite report

- Before signing off audit report, conduct the closing meeting to discuss the observations.
- Have the concerned staffs and the management representative of the factory for the closing
meeting.
- Copy the CAP report and provide to the concern department head for taken corrective
measures.
▪ Post-activities of Audit
- Follow-up the non-conformance area/points to confirm for correction within next 7 days.
- Update the CAP report based on follow-up result & review it in management review meeting.
6.4. Preparatory Works for External Quality Audit

As, an external quality audit is done by the external personnel so, there are some activities which is
considered for facing an external quality audit as preparation. The activities are as follows:
- Analyze the requirement standard of the proposed audit.
- Check the status through internal mock audit using the prescribe tools, formats, checklist etc.
- Identify the gap.
- Take initial corrective measures.
- Check further to know the progress.
- Make all concerned aware about the date & time of External quality audit
- Ensure all documents and records are available as ready reference for audit.
6.5. Customer Complaints Handling Procedure

A complaint is an expression of dissatisfaction made to an organization, related to its products, or
the complaints handling process itself, where a response or resolution is explicitly or implicitly
expected. In this subject, Shin Shin Group is committed to solve any complaints/claims from the
customer and the procedures are as follows:
- The complaints/claims from the customer will be discussed through merchandising department
with customer.
- Concern Merchandiser will communicate with factory concern to solve the customer
complaints/claim.
- Factory concern persons shall analyze the complaints/claim based on an appropriate complaint
category of Level-1, Level-2 and Level-3 to reflect customer’s seriousness and complexity and
assist the meaningful analysis of complaints data.
- The assessment level may be varied at any time by the person responsible for dealing with the
complaint based on further information received.
- Factory concern persons shall take initiative for corrective/preventive measures and time plan to:
- Remedy against the current complaints/claim.
- Avoid similar complaints/claim in the future.
- Monitor the taken measures.
- Communicate to the customer about the measures and success.
- All the records will be maintained by the RQS/GPQ department.

6.6. Product Recall Process & Procedure

In the present experience, the safety issues are arising in apparels industry with all products.
Everyone is giving priority to their physical health. In this sequence, company is committed to
protect public health by facilitating, identification and remove unsafe product from the start to
end-production.
Definition of Product Recall

Product recall is an act of getting returned any sales products that may cause danger to the
customer.
There are three types of product recall definition based on risk class:
a) Class I
b) Class II
c) Class III
Class I
Defects are potentially life threatening or cause a serious risk & long range effect to health or life.
Example: Chemical toxin, undeclared cautions, metal & other contamination etc.
Class II
Defects are potentially causes illness or hazard to health, but are not serious. Example: Twist-ties,
strings, pins etc.
Class III
Defects may not pose to health threat, but which may have wide-spreading for customer. Example:
pulling, sucking, unraveling etc.
Types of Product Recall

Product recall is two types:
a) External Recall
b) Internal Recall
External Recall
The defects product removes from the market in which distribution has been made beyond the
direct control of the buyer.
Internal Recall
The defects product removes from the production in which has been left the direct control of the
manufacturer.
Role & Responsibilities

The Recall Committee
The following persons should include in the recall committee:
- Head of Quality Department
- Head of Production
- Merchandising Manager
- Commercial Manager

The responsibilities of the committee would be:

- The head of merchandising will notify of product recall.
- Deciding the quickest and best overall procedure for handling the recall.
- Potential products recall and quickly report and investigate by a responsible decision maker who
has the authority to assign the recall classification to the situation.
- Quickly organize the hazard when Class I, II, or III situation exists.
- Receiving, communicating and approving all information.
- Maintaining all relevant records and samples.
- Communicating with the members of recall committee, customers & other related individuals in a
critical situation so that inaccurate information cannot accidentally replace facts.
- Reviewing the procedure. The recall procedures should be reviewed each year.
Note: A minor priority situation may handle at in-house level without a committee being organized.
Process & Procedure of Product Recall
1. Product Recall Flow Chart

Customer complaint Identification of a potential product
Internal Finding Any Non-compliance issue
Other Sources
Information to Quality Unit
Preliminary Recall
Assessment
Convene Recall Committee
1. Product Assessment
2. Technical Assessment
3. Documents for Recall
Recall Decision Implementation
2. Receive & Review Information/Complaints

After receiving complaints from the customer, the details information of product such as: product
code, style, description, order no, quantity, inspection or audit report, test report etc. should
review as per customer’s complaints to verify whether to recall the product or not.
3. Identification of Product
▪ The company will receive a complaint notice of a product and /or of a product recall by email,
fax or phone. It is the duty of the concern merchandiser who is so notified to pass on that
information at once to the top management of the company and the head of the QAD or
Inspection unit.
▪ Find out the suspected product’s identification codes and details of its manufacture.
▪ Detect where the entire product is located.

▪ Immediately notify the customer where the products are stored.
▪ Mandate a “stop sales.” If the product has been sold to consumers, contact the customers
and ask them to stop selling and withdraw all sold quantity with a list and return.
▪ Someone must be assigned to make and retain accurate records of what will be received and
regained. Also, a record of recall actions and their date & time should be needed for legal
protection.
4. Decision Making for Recall

The decision on whether to recall a product or not will be based on the identification of hazard that
makes a product unsafe. This should determine with careful and consider hazard. The recall
committee will conduct a risk assessment using the hazard class.
5. Notification to the Customer

If the decision is taken to initiate a withdrawal of a product, it must inform to top management first
then to customer and others who received the product within next 24 hrs.
6. Returning or Withdrawing the Product

In respect of notification to the customer, ask them to withdraw the product promptly and return.
All information should be done properly as much as possible based on the query.
7. Regaining control of the Affected Product

▪ If the affected product returns directly to us then the regained products should store in an
area that is separated from any other products.
▪ Accurate records must be kept of the amounts of the products regained and the products
code.
▪ If the regained products unfit for use, it must be destroyed under the supervision of the
company top management.
8. Monitoring, Testing & Auditing the Regained Product

▪ Progress of the regained product must be tested & audited so that its success can be
monitored. If it is decided that there is now little risk to the customer, the product recall may
be judged to have been a success.
▪ If there is few hazard and little response to a high-risk problem the product recall procedure
must be reassessed.
9. Report & Recording

▪ Report must be prepared mentioning with details point.
▪ The head of the Quality Assurance/ Inspection unit shall collect all written and printed matter
pertaining to the incident and ensure that it is properly recorded. Copies of all documents
shall be sent to the relevant Assessment unit for filing.
▪ The head of the Quality assurance/ Inspection unit shall ensure that the dates of all meetings
and the matters discussed are recorded, and these records shall be entered into the Recalls
file he is in charge of.
▪ The prepared report must be submitted to the customer within an agreed timeframe along
with a copy to the MR (Management Representative) also keep records for the further
reference.

10. Accompanying Documents and Recall Close out

Rectify the Recalled product according to decision recorded & take prompt initiative to resend
recalled product to the customer by conforming product accuracy.
Conclusion
The quality assurance manual is an authentic guideline for achieving expected quality standard of
the group. Concern all employee are expected to follow the instruction given in the manual as
practice standard of the company. This is a property of Shin Shin Group and should not be handed
over to external person without consent of appropriate authority from the ethical point of view.
Suggestion from any person to improve the manual will be appreciated.
**********


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Shin Shin Group

QUALITY ASSURANCE (QA) MANUAL

2. Product Development Process..……………………………………………………………………..... 7-11

3. Manufacturing Process…………………....……………………………………………………………... 12-44

4. Product Integrity and Safety……………….….………………………………………………………... 45-48

5. Measuring Tools & Equipment Calibration……………….…………………….……………….. 49-50

6. Inspection/Audit And Others Procedure………………………………………………………..… 51-59

**NB: This is a controlled document. Page: 2 of 59

1.1.2. Scope of Quality Management System (QMS)

1.1.3. Principles of Quality Management System (ISO-9001)

1.1.4. Main Components of Quality Management System (QMS)

1.1.5. What is Quality Assurance (QA)?

1.1.6. What is Quality Control (QC)?

1.2. Quality Policy

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**NB: This is a controlled document. Page: 4 of 59

**NB: This is a controlled document. Page: 5 of 59

Sr. Manager - Quality

Cutting Sewing GPQ Finishing

D/Asst. Manager- Asst. Manager- D/Asst. Manager-

**NB: This is a controlled document. Page: 6 of 59

2.1. Materials Requirement for Product Development

2.2. Responsibilities of Different Department in Product Development

Things to be considered to Product Development

**NB: This is a controlled document. Page: 7 of 59

Each of the stages is displayed in chart below:

Details Process of the above Activities

The following matters are discussed in Pre-sampling meeting:

✓ Photo Shoot Sample

**NB: This is a controlled document. Page: 9 of 59

✓ Size set Sample

The following steps are taken to make Size Set Samples:

✓ Gold seal/Production Sample

The below steps are followed to prepare Gold Seal/Production Sample:

**NB: This is a controlled document. Page: 10 of 59

**NB: This is a controlled document. Page: 11 of 59

3.1.1. Fabrics & Accessories Receiving Procedure

**NB: This is a controlled document. Page: 12 of 59

Fabric Inventory Procedure

Fabrics Roll Inventory

Accessories Inventory Procedure

Accessories & Trims Lot Inventory

**NB: This is a controlled document. Page: 13 of 59

3.1.3. Fabrics & Accessories Storing Procedure

3.1.4. Fabrics & Accessories Inspection Procedure

Four (4) Points System

Fabrics Qty. Inspection %

Tools for fabric inspection

**NB: This is a controlled document. Page: 14 of 59

Light sources Light types

The grading standard

Defect Length Points

**NB: This is a controlled document. Page: 15 of 59

Acceptance Point Range

Acceptance point Acceptance point

Defective Rolls Separation

**NB: This is a controlled document. Page: 16 of 59

3.1.4.2. Fabrics Accept & Reject Procedure

3.1.4.3. Shade band & Blanket Preparation

3.1.4.4. Shade band for approval of wash shades by the Buyer

3.1.4.5. Bulk Fabric Approval

3.1.4.6. Shade Segregation & Country/Delivery/PO wise Planning

3.1.4.7. Accessories Inspection Procedure

Accessories/Trims Card Verification Procedure