SEWN PRODUCT ENGINEERING-1
PRELIMINARY VISION,
TO
GARMENT INSPECTION
BY
TALHA MALIK
&
NORAIZ NADEEM KHAN
LECTURER : Mr. BABAR RAMZAN
PREFACE
PROLOGUE
AQL
INSPECTION METHODS
GARMENT DEFECTS
AQL CHARTS
INSPECTION LEVELS
EXAMPLE
PROLOGUE
Today, most of the customer demand for high quality
products in low prices. So we should maintain the
quality from the beginning stage of the production
then only the final product with reach the consumer
with right quality and we can get the order
continuously from our customers. The garment
manufacturers inspect their products continuously by
designated responsible inspectors then only the right
quality product will reach the consumers.
AQL
AQL stands for Acceptable Quality level. The AQL
determines the maximum amount of admitted
defective units in a sample. AQL, for purposes of
sampling inspection, can be considered satisfactory as
a process average. The most commonly used AQL is a
major 2.5 minor 4.0.
This method constitutes taking random sample,
inspecting them and depending on the quality of the
sample inspected determining whether the entire lot is
acceptable or not.
INSPECTION METHODS
STAGES OF GARMENT INSPECTION
AQL RANDOM SAMPLING INSPECTION
INSPECTION SAMPLING PLAN
STAGES OF INSPECTION
Pre‐production Check
Final check on the raw material used, style, cut.
Initial Production Check
First batch of garments is inspected, make correction
before bulk production.
During Production Check
Final Random Inspection
Checking the total production quality by selecting the
samples from the order. AQL sampling inspection may
be applied.
AQL RANDOM SAMPLING
INSPECTION
The AQL inspection takes the samples from a goods, inspect
them and depends on the quality of samples inspected and
decide to accept or reject them.
The standard is based on Military Standard 105D (MIL‐STD‐
105D)
It provides with the sampling plans, the number of samples to
be inspected and the acceptable quality level (AQL)
AQL 1.5 is applied to very severe inspection on high‐class
expensive item.
AQL 2.5 is applied when textiles of normal/good quality are
involved.
INSPECTION SAMPLING PLAN
Single sampling plan - Normal inspection
Assurance as AQL 2.5% and a lot of 1,200 garments and
the sample size is 80 garments. If the number of
defective garments found are 5 the total lot is
"Acceptable" suppose if the garments found is 6, the
total lot is "Reject/Re-Check".
INSPECTION SAMPLING PLAN
Double Sampling Plan - Normal inspection
Assurance an AQL 4.0% and lot size is 1,200 garments
and the sample size is 80 garments. If the number of
defective garments found is 7, the total lot is
"Acceptable" suppose if the defective garments found
are 8, the total lot is "Reject/Re-check".
GARMENT DEFECTS
Once the samples are selected, each article is to be
individually inspected. Defects detected during an
inspection are buyer specific so therefore vary from
one buyer to another. Defects are classified within
the following categories:
Critical Defects
A serious defect that can cause harm or injury to the
user and/or result in a hazardous condition.
Major Defects
A defect that falls to meet the mandatory regulations
directly affecting the usability, salability, safety and
value of the merchandise or as specified by customer
are considered as major defects and are generally non
repairable for example fabric hole, shading among
panel, wrong measurement, foreign yarn, dye patches
etc. The measurement tolerate level may vary from
customer to customer.
Minor Defects
A defect that does not adversely affect the usability of
the product but does consists of a deviation from the
original sample, and may affect the sale of the product.
Some of these defects are due to workmanship and
some can be repairable but still can deteriorate the
serviceability of the merchandise for example stain,
skip stitch, wavy bottom hem etc.
AQL CHART
SAMPLE NUMBER 1.5 AQL 2.5 AQL 4.0 AQL 6.5 AQL
SIZE CODE OF
LETTER SAMPLES
A R A R A R A R
A 2 0 1
B 3 0 1
C 5 0 1
D 8 0 1 1 2
E 13 1 2 2 3
SAMPLE NUMBER 1.5 AQL 2.5 AQL 4.0 AQL 6.5 AQL
SIZE CODE OF
LETTER SAMPLES
A R A R A R A R
F 20 1 2 2 3 3 4
G 32 1 2 2 3 3 4 5 6
H 50 2 3 3 4 5 6 7 8
J 80 3 4 5 6 7 8 10 11
K 125 5 6 7 8 10 11 14 15
SAMPLE NUMBER 1.5 AQL 2.5 AQL 4.0 AQL 6.5 AQL
SIZE CODE OF
LETTER SAMPLES
A R A R A R A R
L 200 7 8 10 11 14 15 21 22
M 315 10 11 14 15 21 22
N 500 14 15 21 22
P 800 21 22
Q 1250
INSPECTION LEVELS
Special Inspection Levels General Inspection Levels
Lot or S-1 S-2 S-3 S-4 I II III
Batch size
2 to 8 A A A A A A B
9 to 15 A A A A A B C
16 to 25 A A B B B C D
26 to 50 A B B C C D E
51 to 90 B B C C C E F
91 to 150 B B C D D F G
151 to 280 B C D E E G H
Special Inspection Levels General Inspection Levels
Lot or Batch Size S-1 S-2 S-3 S-4 I II III
281 to 500 B C D E F H J
501 to 1,200 C C E F G J K
1,201 to 3,200 C D E G H K L
3,201 to 10,000 C D F G J L M
10,001 to 35,000 C D F H K M N
35,001 to 150,000 D E G J L N P
150,001 to D E G J M P Q
500,000
500,001 & over D E H K N Q R
EXAMPLE
If an order is 10,500 units. When using General
Inspection Level II, the factory learns from the
second chart that this quantity order equates to
"M". The factory then goes to the first chart and
sees that for "M" they should inspect 315
garments. If they want a 2.5 AQL they can have 14
defective units or less from the 315 that they
inspect. If they have 15 defective units or more
they are rejected. If they want a 4.0 AQL they can
have 21 defect units or less to pass and they have 22
defects they will be rejection.
REFERENCES
Textile school.
Fashion industry.
Ellis developments limited.
AVS Technical Research, Development & Training.
