1. A three-tier QC system
- Incoming fabric and trim inspection: fabric is scored with the 4-point system — if the points per 100 yards exceed the threshold, the whole batch is rejected; trims are batch-sampled for measurements and colour variation;
- Inline QC: semi-finished pieces are spot-checked mid-line, and a systemic problem stops the line immediately for correction — ten times cheaper than waiting to rework finished goods;
- Final inspection: after pressing, sampling to AQL or full inspection — the last gate that decides whether the order can ship.
2. AQL 2.5: the numbers every buyer needs to know
AQL (Acceptable Quality Limit) is the limit of acceptable quality. Womenswear bulk runs commonly use AQL 2.5 (major defects) / 4.0 (minor defects). The logic, by example: on a 1,000-piece order, sample 80 pieces at AQL 2.5 — find up to 5 pieces with major defects and the whole batch passes; from 6 pieces it fails, and the factory must 100% inspect and rework, then re-sample. Defect classes:
- Critical defects: broken-needle residue, safety hazards — zero tolerance: the batch is frozen the moment one appears;
- Major defects: affect wear or appearance (obvious colour variation, holes, out-of-tolerance measurements);
- Minor defects: small flaws that don't affect use (light thread ends, tiny white marks).
3. Wash testing: the step most often cut — and the one you can least afford to cut
Shrinkage, colourfastness and fibre content must be tested at the PP-sample stage, not after bulk — because the results in turn shape the pattern (the shrinkage allowance) and the process (print and rhinestone parameters). The standard tests:
- Shrinkage: wash three times to standard and measure — cotton typically shrinks 2%–5%; the pattern is cut with the measured allowance added;
- Colourfastness: washing ≥ grade 3, rubbing ≥ grade 3, and light depending on the market's requirements;
- Content verification: the fabric test report must match the label's fibre content (mandatory for export to the EU and the US).
The essence of QC is trading luck for data. Sampling pass rates, test reports, rework records — these numbers are the real “insurance policy” on bulk quality.