Key takeaways
- Inspect against an approved sample and written specification, not memory.
- Separate critical, major and minor defects before inspection begins.
- AQL is a sampling decision tool; it is not permission to ship known defects.
- Do not release goods until corrective action and reinspection rules are clear.
Three layers of control
Quality control should happen at material receipt, during production and before shipment. A final-only approach discovers systematic problems after every unit is already affected.
| Control point | What to check | Decision |
|---|---|---|
| Incoming materials | Colour lot, width, weight, defects, shrinkage, trims, labels | Accept, segregate or replace before cutting |
| Inline / mid-production | First finished units, measurements, construction, workmanship | Correct the process before the defect spreads |
| Pre-shipment | Quantity, random sample, measurements, appearance, function, packaging | Release, rework and reinspect, or reject |
Build the inspection specification
The inspector needs the approved sample, measurement chart with tolerances, bill of materials, workmanship standard, colour references, label and packaging artwork, order quantity and size breakdown.
Define defect classes in advance. A sharp object, missing safety component or legally incorrect label can be critical. A broken seam, wrong measurement or visible shade difference is usually major. A small removable thread may be minor. Classification depends on product and sales market.
- Confirm sample selection method and lot definition.
- List functional tests: zips, snaps, drawcords, adhesion, sole flex or water resistance as relevant.
- Define measurement points and whether tolerances are one-sided or two-sided.
- Photograph recurring defects with a scale.
- Reconcile packed quantity against purchase order.
How AQL should be used
ISO 2859-1:2026 defines acceptance sampling schemes indexed by AQL for lot-by-lot inspection. In apparel, teams often start discussion around AQL 2.5 for major and 4.0 for minor defects, but the agreed plan must reflect product risk, customer and contract.
The sample size and accept/reject number depend on lot size, inspection level and chosen AQL. Do not turn “AQL 2.5” into a flat claim that 2.5% defects are acceptable. It is a statistical sampling parameter, not a promised defect rate.
Measurement and workmanship checks
- Measure on the agreed surface and garment condition.
- Check several sizes, not only the base size.
- Compare shade within one garment and across the packed lot.
- Inspect seam type, stitch density, puckering, skipped stitches and reinforcement.
- Test closures, buttons, snaps, drawcords and attached trims.
- Verify fibre composition, care, country-of-origin and size labels for the destination market.
- Check folding, protective material, barcode, assortment and carton marks.
Release, rework or reject
A failed inspection needs a written corrective-action plan: defect population, sorting method, repair standard, responsible party, completion date and reinspection.
Do not accept a promise to repair without verifying the repaired lot. If a defect is systematic, increase the inspection scope; a small random sample cannot prove a process correction by itself.