By Your Brand Team October 10, 2024
Shipping defective products is the fastest way to destroy your brand’s reputation. Use this 12-point checklist to catch defects before they reach your customers.
Pre-Production Checks
1. Fabric Quality
- Check dye lot consistency across all rolls
- Test for colorfastness (rub test and wash test)
- Verify GSM matches the tech pack (±5% tolerance)
- Inspect for weaving defects: holes, slubs, missing threads
2. Sample Approval
- Never approve a sample without washing it 3 times
- Measure all size specs after wash (not before)
- Compare stitching density against your spec (stitches per inch)
In-Line Production Checks
3. Cutting Accuracy
- Measure 5 random pieces from each size
- Check pattern alignment on stripes/prints
- Verify collar, cuff, and body pieces match
4. Stitching Quality
- No skipped stitches (run hand along all seams)
- No broken needles left in garment (use a needle detector)
- Seam allowance consistent (typically 1cm)
- No raw edges showing on flat-felled seams
5. Measurement
- Chest, length, sleeve, shoulder, hem — all within ±1cm tolerance
- Check at least 3 pieces per size, per color
6. Color Matching
- Compare to approved lab dip under D65 light box
- No color variation between panels of the same garment
- Panelling: sleeve body color must match body fabric
Finishing Checks
7. Labels and Tags
- Care label: correct wash instructions, fiber content, country of origin
- Brand label: correct logo, sewn straight, no fraying
- Size label: matches the actual measurement (not just the label)
8. Pressing and Finishing
- No shine marks from iron (especially on polyester)
- Collars and cuffs properly shaped
- No wrinkles in packaging
9. Packaging
- Poly bag thickness ≥ 0.04mm (to prevent tearing)
- Desiccant included for ocean freight
- Carton quantity matches PO exactly
- Carton weight under 15kg (for safe manual handling)
Final Random Inspection (FRI)
10. AQL Sampling
Use ISO 2859-1 (AQL 2.5 for major defects, 4.0 for minor):
| Lot Size | Sample Size |
|---|---|
| 500-1,200 | 80 |
| 1,201-3,200 | 125 |
| 3,201-10,000 | 200 |
11. Defect Classification
- Critical: Safety issue (sharp needle, choking hazard) → reject entire lot
- Major: Visible defect affecting sale (hole, stain, wrong size) → count toward AQL
- Minor: Cosmetic issue (loose thread, slight shade) → count toward AQL
12. Shipping Documentation
- Commercial invoice matches PO
- Packing list accurate (sizes, colors, quantities)
- Certificate of origin if required for customs
Need Professional QC?
Our QC team conducts inspections at every stage — fabric, in-line, and final. We provide detailed photo reports within 24 hours. Contact us to schedule an inspection.