Garment quality control and inspection in Bangladesh

Inspection is how a buyer who cannot stand on the factory floor learns whether bulk matches the approved sample. Garment quality control and inspection in Bangladesh happens at fixed points: fabric before cutting, inline during sewing, and a final random inspection once most of the order is packed. Each catches different faults. A problem found inline costs a day on the line; the same problem found at final can cost the ship date.

Garments Hub BD's own person carries out the inline inspection during sewing and the final random inspection at 80 percent packed, to AQL 2.5 unless you set another level. Every stage is photographed and the photographs belong to you. You may also book a third party inspector of your choice; where the two reports differ, theirs overrules ours.

Kinds of garment inspection

Fabric inspection

Rolls graded by the factory's fabric store before cutting, commonly on the four point system, for holes, slubs, shade bars and short width, so faults are not cut into every size. Ask on the quote form for the roll report, or book a third party inspector to cover it.

Pre production meeting

Before cutting, the factory walks through the approved PP sample, the comments and the trim card with the buyer's side, so open questions are settled on paper instead of on the line. Ask for one on the quote form so it is planned into the timetable.

Inline inspection

During sewing, once the line has steady output, on early pieces from each operation and size. Construction, measurement and workmanship faults are corrected while the line can still change.

Final random inspection

With at least 80 percent packed, cartons are drawn at random and pieces inspected to an AQL sample size. The lot passes or fails on the count of defects found.

Loading check

Cartons counted, their condition and marks checked, and the container sealed in view, confirming that what passed is what is loaded. A third party inspector of your choice can cover it.

What to agree before inspection starts

AQL and inspection level

AQL 2.5 for major and 4.0 for minor defects is a common setting; 1.5 is strict. State your choice on the quote form, or AQL 2.5 applies.

Defect list

What counts as critical, major and minor on this garment: a broken needle is critical, an open seam major, a loose thread end minor.

Measurement tolerances

A tolerance for every point of measure, usually plus or minus 1 cm on body points and less on neck and small points. Without tolerances, nothing can fail.

Approved references

The signed PP sample, approved lab dips, trim card and artwork the inspector compares against. Missing references are a frequent cause of disputes.

Function and on site checks

Zip runs, snap pull, a rub check on dark colours, carton drop, and needle detection for kidswear. List the ones that matter for your product.

Packing standard

Fold, polybag, size ratio per carton, carton marks and labels, so the packing check has something to measure against.

Standards behind garment quality control and inspection in Bangladesh

ISO 2859-1

The AQL sampling tables. They set how many pieces are drawn from a lot of a given size and how many defects pass or fail it.

General inspection level II

The usual ISO 2859-1 level for garments. Levels I and III draw fewer or more pieces from the same lot size.

AQL 2.5 major, 4.0 minor

A common apparel setting; 1.5 is strict and suits high value or sensitive orders. Critical defects are usually set at zero allowed.

ISO 105-X12

The lab method for rubbing fastness. An on site rub with white cloth only flags a risk; a dark shade that marks it should go to a lab before shipment.

What moves the cost of quality control

• Lot size and AQL level, which set the sample size and so the man days a third party inspector bills.
• Styles and colours in one lot, each needing its own count, measurements and photographs.
• Lab tests added to the inspection, charged by the lab per test and per colour.
• Re inspection after a failed lot, which a third party inspector charges again by the man day.
• A third party inspector of your choice, booked on top of the desk's own inspections and billed by that inspector.

Lead time for quality control and inspection

Inspection fits inside the production timetable rather than adding to it, if it is planned early. Inline checks begin once the line has steady output, usually in the first days of sewing. The final random inspection is held at 80 percent packed, a few days before the ship date. A failed final adds the days needed to sort and rework, plus a re inspection, so a date with no margin is a date at risk.

What we check in quality control and inspection

• Measurements against specPieces from each size are measured at every point of measure, and any reading outside tolerance is logged as a defect.
• Workmanship and appearanceSeams, stitching, prints, labels and shade are inspected piece by piece against the signed PP sample.
• FunctionZips, buttons, snaps and drawcords are worked and trims pulled on a set number of pieces per lot.
• Carton and packingCarton count, size ratio, marks, polybag warnings and barcodes are checked against the packing list.

Questions buyers ask about quality control and inspection