What is the Responsibility of Quality Department in Garment Industry?

The Garments Quality Team plays a critical role in ensuring that the products manufactured meet the required standards of quality before they are delivered to customers. Their responsibilities encompass various stages of the production process, from raw material inspection to the final product evaluation.  The Quality Department in the garment industry ensures that every stage of production meets the required standards, reducing defects and maintaining customer satisfaction. This department is responsible for raw material inspection, in-process quality control, and final product inspection to ensure compliance with buyer specifications.

Here’s a detailed breakdown of their duties and responsibilities:

1. Raw Material Inspection

Raw material inspection is a crucial step in garment manufacturing to ensure fabric, trims, and accessories meet quality standards before production begins. This process helps prevent defects, reduce wastage, and maintain consistency in the final product.

• Fabric Inspection: Checking the fabric for defects such as color variations, holes, tears, stains, or incorrect measurements. 4-Point System: A widely used method for grading fabric defects. Older method, mainly for woven fabrics. Ensuring fabric rolls have uniform color. Verifying width and weight per square meter.
• Trims and Accessories Inspection: Ensuring that buttons, zippers, threads, and other accessories meet the required quality standards. Checking durability and color matching. Ensuring correct branding and placement. Testing bonding strength and shrinkage.
• Measurement Verification: Confirming that the raw materials adhere to the specified measurements and tolerances.

Inspection Methods

• Visual Inspection: Detecting surface defects like stains, holes, and color variations.
• Physical & Mechanical Tests: Tensile strength, shrinkage, and stretchability tests.
• Chemical Testing: Verifying compliance with safety standards like azo-free dyes.

2. In-Process Quality Control (IPQC)

In-Process Quality Control (IPQC) is a crucial step in garment production that ensures defects are identified and corrected at various stages of manufacturing, reducing rework and rejection rates. This helps maintain consistency, improve efficiency, and meet buyer requirements.

• Inline Inspection: Conducting quality checks at different stages of production to identify and correct defects early. Conducted at different sewing operations to detect stitching defects. Ensuring correct stitch density for durability. Preventing seam slippage and puckering. Ensuring each piece follows size specifications.
• Process Monitoring: Ensuring that sewing, cutting, stitching, and other processes are carried out according to standard operating procedures (SOPs).
• Workmanship Evaluation: Checking the workmanship of the garments, including seams, hems, and finishing.

Inspection Methods Used in IPQC

• 100% Inline Inspection: Every piece is checked at different stages.
• Random Sampling (AQL Method): Acceptable Quality Level (AQL) is used for sampling inspections.
• Traffic Light System: A visual quality control method that highlights defect trends.

Benefits of IPQC

✔ Reduces defect rates and rework costs.
✔ Ensures smooth workflow and timely delivery.
✔ Improves customer satisfaction with consistent quality.

3. Finished Product Inspection

Finished Product Inspection is the final quality check before garments are packed and shipped to ensure they meet buyer specifications and industry standards. This process helps prevent defective products from reaching customers and ensures brand reputation and customer satisfaction.

Inspection Methods

• AQL Sampling Method (Common AQL levels: 2.5 for major defects, 4.0 for minor defects).
• 100% Inspection for High-Value Orders.
• Random Sampling by Third-Party Auditors.

Types of Finished Product Inspection

1. Final Random Inspection (FRI): Conducted after the full production is completed and packed. Based on Acceptable Quality Level (AQL) standards. Inspecting finished garments to ensure they meet the company’s quality standards, including checking for defects like loose threads, uneven seams, or incorrect sizing.
2. 100% Final Inspection: Every garment is checked before shipment. Used for high-end or luxury brands.
3. Pre-Shipment Inspection (PSI): Conducted by buyers or third-party agencies before shipping. Ensures compliance with buyer requirements.
4. Packaging Inspection: Ensuring that the garments are correctly folded, tagged, labeled, and packed according to customer specifications.
5. Size and Fit Verification: Confirming that the garments match the approved samples in terms of size, fit, and design.

Common Defects Found in Finished Products

🔴 Major Defects (cause rejection):

• Wrong size or incorrect measurement.
• Torn fabric, visible holes, or broken seams.
• Incorrect print or logo placement.

🟡 Minor Defects (can be repaired):

• Loose threads or minor stitching errors.
• Slight color variation or minor dirt marks.
• Incorrect folding or packing issues.

4. Quality Reporting and Documentation

Quality reporting and documentation play a crucial role in maintaining transparency, tracking defects, and ensuring compliance with buyer requirements. Proper documentation helps improve product consistency, analyze defect trends, and enhance overall quality management.

• Quality Reports: Preparing detailed reports on the quality of raw materials, in-process goods, and finished products.
• Non-Conformance Reporting: Documenting and reporting any deviations from quality standards and initiating corrective actions.
• Trend Analysis: Analyzing quality data to identify trends and areas for improvement.

Types of Quality Reports in the Garment Industry

1. Raw Material Inspection Report: Details defects found in fabric, trims, and accessories. Includes fabric width, GSM, color variations, and shrinkage test results.
2. Inline Inspection Report (IPQC Report): Captures defects identified during the production process. Includes stitch quality, seam strength, measurement accuracy, and defect rates.
3. Final Inspection Report (Finished Goods Report): Summarizes findings from pre-shipment quality control checks. Includes AQL sampling results, defect classification, and corrective actions.
4. Defect Analysis & Corrective Action Report: Highlights recurring quality issues and their root causes. Suggests preventive measures and corrective actions for improvement.
5. Audit & Compliance Report: Includes factory compliance with ISO, WRAP, or buyer standards. Ensures ethical sourcing, environmental safety, and worker welfare compliance.

Essential Quality Control Documentation

📌 Inspection Checklists – Used at different stages (fabric, cutting, sewing, finishing).
📌 Quality Standards Manual – Defines the required quality benchmarks for production.
📌 Defect Classification Chart – Lists major and minor defects for easy identification.
📌 Testing Reports – Includes results from fabric strength, shrinkage, colorfastness tests.
📌 Buyer Specification Sheets – Contains garment measurements, fabric details, and trim instructions.

Key Metrics in Quality Reporting

✔ Defect Rate (%) = (Number of defective garments / Total inspected garments) × 100
✔ First Pass Yield (FPY) – Percentage of garments passing inspection without rework.
✔ Rejection Rate – Percentage of garments rejected due to major defects.
✔ Rework Percentage – Number of garments requiring repair before approval.

Benefits of Quality Reporting and Documentation

✅ Ensures consistency in product quality.
✅ Helps identify recurring defects and prevent them in future production.
✅ Supports continuous improvement and efficiency.
✅ Strengthens buyer confidence and reduces order rejections.

5. Supplier Quality Management

Supplier Quality Management (SQM) ensures that raw materials, trims, and finished goods from suppliers meet the required quality standards. Effective SQM minimizes defects, reduces production delays, and maintains consistency across orders.

• Supplier Audits: Conducting audits of suppliers to ensure they meet the required quality standards.
• Incoming Material Approval: Approving or rejecting raw materials and components based on quality assessments.
• Supplier Feedback: Providing feedback to suppliers on quality issues and working with them to improve quality.

Key Aspects of Supplier Quality Management

1. Supplier Selection & Evaluation

✔ Quality Certifications – ISO 9001, OEKO-TEX, GOTS (for organic textiles), etc.
✔ Manufacturing Capability – Production capacity, technology, and workforce efficiency.
✔ Compliance & Sustainability – Ethical sourcing, environmental impact, and labor policies.
✔ Past Performance & Reputation – Feedback from previous buyers and industry reputation.

2. Supplier Quality Agreement (SQA)

📌 Defines quality expectations, including fabric GSM, color consistency, stitching standards, and defect tolerance levels.
📌 Specifies testing requirements – Shrinkage, colorfastness, tensile strength, etc.
📌 Outlines inspection processes – AQL (Acceptable Quality Level) for fabric and trims.
📌 Includes corrective action policies – Supplier responsibility for defective materials.

3. Raw Material Inspection & Approval

✔ Pre-Production Sample Approval (PPS) – Ensuring fabric, trims, and accessories match specifications.
✔ Fabric Inspection (4-Point System) – Checking for weaving defects, stains, and shade variations.
✔ Trim & Accessory Testing – Strength of zippers, buttons, interlining adhesion, etc.

4. In-Process Quality Monitoring

✔ Supplier In-House Quality Control (QC) – Ensuring in-line inspections before shipment.
✔ Factory Visit & Audits – Periodic checks to verify compliance with agreed standards.
✔ Process Control Implementation – Monitoring defect rates and providing supplier feedback.

5. Supplier Performance Evaluation

🔹 Defect Rate (%) = (Defective units / Total inspected units) × 100
🔹 On-Time Delivery Rate – Percentage of shipments delivered as per schedule.
🔹 Corrective Action Effectiveness – Supplier’s response to quality issues.
🔹 Cost of Poor Quality (COPQ) – Losses due to defects, rework, and delays.

6. Corrective & Preventive Actions (CAPA)

✔ Root Cause Analysis (RCA) – Identifying why defects occur and taking preventive measures.
✔ Supplier Training Programs – Educating suppliers on quality control improvements.
✔ Penalty & Incentive Programs – Rewarding quality consistency and penalizing repeated issues.

Benefits of Effective Supplier Quality Management

✅ Reduces defects and rework costs.
✅ Ensures consistent product quality.
✅ Improves supply chain efficiency.
✅ Strengthens supplier relationships.
✅ Enhances brand reputation and customer satisfaction.

6. Customer Quality Assurance

Customer Quality Assurance (CQA) ensures that garments meet customer expectations and buyer specifications before shipment. It involves proactive quality control measures, compliance with standards, and continuous improvement to enhance customer satisfaction.

• Customer Specification Compliance: Ensuring that all products meet the customer’s quality requirements and specifications.
• Complaint Handling: Addressing and resolving customer complaints related to quality issues.
• Sample Approval: Coordinating with customers for the approval of pre-production samples to ensure alignment with their expectations.

Key Responsibilities of Customer Quality Assurance (CQA)

1. Understanding Customer Requirements

✔ Review buyer’s technical specifications, measurement charts, and quality standards.
✔ Ensure compliance with brand guidelines, packaging, and labeling instructions.
✔ Conduct risk assessments to identify potential quality concerns before production.

2. Pre-Production Quality Planning

✔ Approve pre-production samples (PPS) and fabric swatches before bulk cutting.
✔ Conduct pilot runs to detect potential production issues.
✔ Ensure trims, accessories, and embellishments meet customer standards.

3. In-Process Quality Monitoring

✔ Implement Inline Quality Control (IPQC) to identify defects early.
✔ Monitor stitching, fabric shade consistency, and finishing accuracy.
✔ Ensure adherence to buyer’s Acceptable Quality Level (AQL).

4. Final Inspection & Pre-Shipment Audit

✔ Conduct Final Random Inspection (FRI) before shipping garments.
✔ Verify packaging, labeling, barcodes, and tags meet customer specifications.
✔ Work with third-party auditors (SGS, Intertek, Bureau Veritas) for independent inspections.

5. Customer Complaint Handling & Corrective Actions

✔ Analyze customer feedback, complaints, and returns.
✔ Conduct Root Cause Analysis (RCA) for quality failures.
✔ Implement Corrective and Preventive Actions (CAPA) to avoid repeated defects.

6. Compliance & Ethical Standards

✔ Ensure garments meet global compliance standards (ISO, OEKO-TEX, GOTS).
✔ Monitor factory conditions to maintain ethical manufacturing practices.
✔ Address sustainability concerns (eco-friendly materials, reduced waste).

Benefits of Customer Quality Assurance

✅ Reduces product returns and rework costs.
✅ Enhances customer satisfaction and brand reputation.
✅ Ensures compliance with international quality standards.
✅ Improves production efficiency by reducing defects.

7. Continuous Improvement

Continuous Improvement (CI) in the garment industry focuses on enhancing quality, efficiency, and reducing defects through systematic methods like Lean, Six Sigma, and Kaizen. It helps manufacturers stay competitive, reduce waste, and improve customer satisfaction.

• Quality Improvement Initiatives: Leading and participating in initiatives aimed at improving product quality and reducing defects.
• Training and Development: Training production staff on quality standards, techniques, and best practices.
• Implementation of Quality Tools: Utilizing quality management tools like Six Sigma, 5S, or Lean Manufacturing to enhance the production process.

Key Continuous Improvement Strategies

1. Kaizen (Continuous Incremental Improvement)

✔ Encourages small, daily improvements at all production levels.
✔ Involves employees in problem-solving and process enhancement.
✔ Uses tools like Kaizen events to address specific production issues.

2. Plan-Do-Check-Act (PDCA) Cycle

🔹 Plan – Identify quality problems and set improvement goals.
🔹 Do – Implement corrective actions in small-scale trials.
🔹 Check – Analyze results and measure effectiveness.
🔹 Act – Standardize successful improvements across production.

3. Lean Manufacturing

✔ Eliminates waste in production (defects, overproduction, waiting time).
✔ Implements 5S system (Sort, Set in order, Shine, Standardize, Sustain) for workplace organization.
✔ Uses Just-in-Time (JIT) production to reduce excess inventory and lead times.

4. Six Sigma (Defect Reduction & Process Control)

✔ Uses DMAIC (Define, Measure, Analyze, Improve, Control) methodology to reduce defects.
✔ Ensures process consistency and reduces variation in garment production.
✔ Measures defect rates using statistical tools to drive improvements.

5. Root Cause Analysis (RCA) & Corrective Actions

✔ Uses Fishbone Diagram (Ishikawa) and 5 Whys Analysis to identify defect causes.
✔ Implements Corrective & Preventive Actions (CAPA) to avoid repeated issues.
✔ Ensures defects are not only fixed but prevented in future production.

6. Employee Training & Skill Development

✔ Conducts Quality Awareness Programs for operators and QC teams.
✔ Implements multi-skill training to enhance workforce flexibility.
✔ Encourages operator feedback for process improvement.

Benefits of Continuous Improvement in Garment Manufacturing

✅ Reduces defects, rework, and production delays.
✅ Enhances efficiency and minimizes material waste.
✅ Improves overall product quality and customer satisfaction.
✅ Boosts factory compliance with international quality standards.
✅ Strengthens a culture of innovation and teamwork.

8. Compliance and Standards

Compliance and standards in the garment industry ensure that factories meet legal, ethical, and quality requirements set by buyers, governments, and international organizations. Adhering to these regulations helps maintain product safety, fair labor practices, and environmental sustainability.

• Regulatory Compliance: Ensuring that all products comply with relevant regulations and standards, such as ISO, ASTM, or customer-specific requirements.
• Environmental and Safety Standards: Ensuring that the production process adheres to environmental and safety standards, reducing waste and promoting sustainability.

Compliance and Standards in the Garment Industry

Compliance and standards in the garment industry ensure that factories meet legal, ethical, and quality requirements set by buyers, governments, and international organizations. Adhering to these regulations helps maintain product safety, fair labor practices, and environmental sustainability.

1. Types of Compliance in the Garment Industry

A. Social Compliance (Worker Rights & Ethical Standards)

✔ Ensures fair wages, working hours, and safe working conditions.
✔ Prohibits child labor, forced labor, and discrimination.
✔ Follows labor laws such as ILO (International Labour Organization) standards.

🔹 Key Certifications & Audits:

• SA8000 (Social Accountability Standard)
• BSCI (Business Social Compliance Initiative)
• WRAP (Worldwide Responsible Accredited Production)
• SEDEX (Supplier Ethical Data Exchange)

B. Environmental Compliance (Sustainability & Eco-Friendly Practices)

✔ Reduces water and energy consumption in textile processing.
✔ Minimizes chemical use, hazardous waste, and carbon emissions.
✔ Promotes sustainable sourcing of materials (organic cotton, recycled polyester).

🔹 Key Certifications & Standards:

• OEKO-TEX Standard 100 (Chemical-free textiles)
• GOTS (Global Organic Textile Standard)
• ZDHC (Zero Discharge of Hazardous Chemicals)
• Higg Index (Environmental & Social Impact Assessment)

C. Quality & Safety Compliance (Product Standards)

✔ Ensures garments are free from harmful chemicals and defects.
✔ Meets customer requirements for fabric quality, stitching, and durability.
✔ Follows product safety regulations for exports.

🔹 Key Certifications & Standards:

• ISO 9001 (Quality Management System)
• AQL (Acceptable Quality Level) for inspections
• REACH (EU chemical safety regulation)
• CPSIA (Consumer Product Safety for the USA)

2. Factory Compliance Audits & Certifications

✔ Buyer Compliance Audits – Brands like H&M, Zara, and Nike conduct audits before approving suppliers.
✔ Government & Third-Party Audits – Local labor laws and agencies (SGS, Intertek, Bureau Veritas) verify compliance.
✔ Corrective Action Plan (CAP) – Factories must correct non-compliance issues to maintain approval.

3. Benefits of Compliance & Standards

✅ Ensures ethical and safe working conditions.
✅ Reduces production risks and legal penalties.
✅ Improves brand reputation and buyer trust.
✅ Enhances product quality and customer satisfaction.
✅ Opens doors to international markets (EU, USA, Canada).

9. Coordination and Communication

Effective coordination and communication are essential in the garment industry to ensure smooth production, maintain quality, and meet customer deadlines. Strong internal and external communication helps prevent errors, reduces delays, and enhances overall efficiency.

• Cross-Departmental Coordination: Working closely with other departments, such as production, design, and procurement, to ensure quality is maintained throughout the supply chain.
• Customer Communication: Communicating with customers regarding quality issues, specifications, and improvements.

Coordination and Communication in the Garment Industry

Effective coordination and communication are essential in the garment industry to ensure smooth production, maintain quality, and meet customer deadlines. Strong internal and external communication helps prevent errors, reduces delays, and enhances overall efficiency.

1. Internal Coordination & Communication (Within the Factory)

A. Between Departments

✔ Merchandising ↔ Production → Ensure correct fabric, trims, and order details.
✔ Production ↔ Quality Control (QC) → Report defects and take corrective actions.
✔ Production ↔ Supply Chain → Ensure timely material availability.
✔ HR ↔ Compliance → Maintain ethical standards and worker safety.

B. Tools & Methods for Internal Communication

✔ Daily production meetings – Address issues in cutting, sewing, finishing.
✔ Standard Operating Procedures (SOPs) – Ensure clarity in quality standards.
✔ Digital tools (ERP, PLM systems) – Track orders, defects, and workflow.
✔ Visual management (Kanban, 5S) – Improve efficiency on the factory floor.

2. External Coordination & Communication (With Buyers & Suppliers)

A. Communication with Buyers

✔ Share pre-production samples (PPS) for approval.
✔ Provide real-time production updates (order status, delivery schedules).
✔ Handle quality concerns & corrective actions to maintain customer trust.

B. Communication with Suppliers

✔ Ensure timely material sourcing (fabrics, trims, packaging).
✔ Address issues like delayed shipments, material defects, and replacements.
✔ Maintain strong relationships with reliable suppliers to avoid disruptions.

3. Importance of Effective Coordination & Communication

✅ Reduces production errors and defects.
✅ Ensures timely order completion and shipment.
✅ Improves quality control and minimizes rework.
✅ Enhances customer satisfaction and buyer confidence.
✅ Strengthens teamwork and problem-solving efficiency.

The Garments Quality Team plays a pivotal role in maintaining the reputation of a garments factory by ensuring that every piece produced meets the highest standards of quality. Their work is integral to minimizing defects, reducing waste, and ensuring customer satisfaction.