What “Quality Control” Means Here
QC is not a final glance before shipping. It is built into three gates — incoming fabric, in-process stitching, and final inspection — so problems are caught early, not after the whole order is packed.
Three Inspection Gates
| Gate | When | What we check |
|---|---|---|
| Incoming fabric | Before cutting | Weight (GSM), color, defects, shrinkage |
| In-process | During sewing | Stitch density, seams, trims attachment |
| Final | Packed | Measurement, appearance, function, packaging |
Common Defects, Simply
- Skew / off-grain panels — fabric not aligned before cutting.
- Uneven print or misaligned embroidery.
- Broken stitches, raw or unfinished edges.
- Color deviation vs the approved swatch.
How We Hold 99%+
- Fabric is inspected on arrival, before a single panel is cut.
- Inline checks at every operator hand-off, not just at the end.
- Final audit measured against your approved sample, not a generic house standard.
- Photo proof sent before bulk ships, so you see it before it leaves.
Acceptance Sampling, Plainly
We do not inspect every piece by hand — that is slow and still misses patterns. Instead we use acceptance sampling (AQL): a statistically set number of units is checked, and the whole lot passes only if defects stay under the limit. For apparel, AQL 2.5 is the common general-inspection level.
| AQL level | Meaning | Use |
|---|---|---|
| 1.0 (tight) | Fewest allowed defects | High-value or strict brand |
| 2.5 (general) | Standard apparel level | Most orders |
| 4.0 (relaxed) | More tolerance | Promotional / low-risk |
What You Can Specify
- Measurement tolerance — e.g. ±1 cm on length.
- Colour standard — Pantone or your sealed swatch as the yardstick.
- Packaging — flat pack, folded with tissue, or hung on hangers.
- On-care labels — language and content per your market.
Defect Class A / B / C
| Class | Example | Action |
|---|---|---|
| A (Critical) | Broken seam, missing print | Reject unit, fix lot |
| B (Major) | Off colour, misaligned logo | Re-work or discount |
| C (Minor) | Loose thread, tiny mark | Accept within AQL |
Photo Proof & Reports
Before bulk leaves, we send you a photo set: a top, a detail of the decoration, a measurement check and the packaging. You sign off, then it ships. This is your last checkpoint, not ours.
- Top shot — overall look and colour.
- Close-up — print / embroidery density and alignment.
- Measurements — key points against your spec.
- Pack shot — how the carton arrives.
How to Read an Inspection Report
An inspection report is not a pass-or-fail verdict — it is evidence. Two buyers reading the same report can reach different decisions, and the one who understands the structure usually makes the better call. Here is what each section is actually telling you.
| Report section | What it tells you | How to use it |
|---|---|---|
| Lot size and sample size | How much was inspected relative to the batch | A small sample against a large lot means less certainty — read the rest accordingly |
| AQL level applied | The acceptance threshold used | Confirm it matches what you specified in the order, not the factory's default |
| Defect log with counts | Exactly what was found, classed by severity | Look at the pattern, not the total. One recurring defect matters more than three isolated ones |
| Photo evidence | The defects as they actually appear | Ask for photos of the defects specifically, not generic product shots |
| Measurements against spec | Whether the garment matches the size chart | Check the extremes of the size run, which is where drift appears first |
| Result and next step | Whether the lot passed, failed, or passed with concession | A concession pass is a decision, not an approval — you still have to accept it |
The one habit that most improves report reading: compare this report against the previous one on the same style. A single report describes a moment; two reports describe a trend, and trends are what tell you whether a supplier is improving or slipping.
What to Do When Bulk Fails Inspection
A failed inspection feels like a crisis, but it is usually a negotiation with four possible outcomes. Knowing the options in advance is what keeps a failed inspection from becoming a lost order.
- Rework and re-inspect — the factory corrects the specific defects and the lot is inspected again. Appropriate when the defect is localised and correctable, such as a labelling error or a loose seam.
- Sort and ship — the defective pieces are removed and only the conforming ones ship. Appropriate when the defect affects a minority of pieces and you can accept a smaller delivery.
- Concession with price adjustment — you accept the lot at a reduced price. Appropriate when the defect is cosmetic and your customer base will tolerate it, and when rework would delay a launch beyond the selling window.
- Reject and remake — the lot is remade. Appropriate when the defect is structural, unsafe, or affects the product's core promise. It is the most expensive outcome and the one the inspection exists to prevent.
- Whatever is agreed, get it in writing before goods move. Verbal rework agreements are the single most common source of a later dispute.
- Adjust the next order's specification. If the same defect appears twice, the cause is usually in the brief or the reference sample, not the operator.
- Review the payment position. Do not release the balance before the rework is verified — this is the main practical leverage you hold at this point.
FAQ
What if bulk differs from the sample?
That is exactly what final audit prevents. Bulk is measured against your approved sample, not a house average. If something drifts, we flag it in the photo proof before shipping.
Can I ask for 100% inspection?
Yes, for high-value or strict orders we can run full inspection at added cost. Tell us the risk level and we will quote it.
Who pays if defects are found?
If a defect is our making and beyond AQL, we re-work or replace at our cost. Clear acceptance criteria are agreed in the tech pack so there is no argument later.