Acceptable Quality Level [AQL Chart] In The Garments Industry 2022


A.Q.L means Acceptable Quality Level (AQL). Some of them use A.Q.L meaning Acceptable Quality Limit. There are many types of A.Q.L systems followed in the apparel garments industry.

A sampling of quality audit or inspection system, use for quality audit or inspection process in Garments industry. AQL sampling information shows in an AQL chart, QC used for Quality Audit when 100% quality inspection is not possible. AQL inspection used in Fabric inspection or Fabrics roll sampling, trims inspection, cutting panel inspection, Sewing, Finishing, and Final Inspection.

Though there is 100% inspection also available in sewing and finishing AQL audit is done for checking the quality control process. There is various type of AQL sampling plan in the world, I have given the most commonly used 3 types of AQL chart.

Uses of Acceptable Quality Level or A.Q.L. Chart

  • In-house or incoming fabrics roll sampling for inspection.
  • In-house or incoming trims and accessories inspection.
  • After fabric Cutting cut panel inspection time.
  • Sewing section end table Quality inspection time.
  • Sewing section quality auditor sampling inspection time.
  • GPQ sewing inline sampling inspection time.
  • Finishing Quality section packing inspection time.
  • Finishing quality inline inspection time.
  • GPQ Pre-final Inspection time.
  • Final inspection time.

How many types of A.Q.L systems are followed in the apparel garments industry?

There are a total number of six types of AQL systems followed in the apparel garment industry. Note below for a better understanding

  • AQL-1.0%,
  • AQL-1.5%,
  • AQL-2.5%,
  • AQL-4.0%,
  • AQL-6.5%,
  • AQL-10%.

Acceptable Quality Level or A.Q.L chart for quality inspection

AQL chart for quality inspection followed in the apparel garments industry in every section. Buyers submit huge order quantity orders in the garments apparel industry. Large order quantity not possible pcs to pcs inspection. So every apparel garment industry follows the A.Q.L system. AQL (Acceptable Quality Level) chart needs in the Garments industry to do the quality inspection, lot by lot AQL Audit or inspection. AQL chart systems are like 1.0, 1.5, 2.5, and 4.0.

Noted below A.Q.L (Acceptable Quality Level) chart…

A.Q.L (Acceptable Quality Level) flow chart
LOT SIZE SAMPLE SAMPLE A.Q.L
  SIZE CODE SIZE 1.0 1.5 2.5 4.0
             
2-8 A 2 0 0 0 0
9-15 B 3 0 0 0 0
16-25 C 5 0 0 0 0
26-50 D 8 0 0 0 0
51-90 E 13 0 0 0 0
91-150 F 20 0 1 1 2
151-280 G 32 1 1 2 3
281-500 H 50 1 2 3 5
501-1200 J 80 2 3 5 7
1201-3200 K 125 3 5 7 10
3201-10000 L 200 5 7 10 14
10001-35000 M 315 7 10 14 21
35001-150000 N 500 10 14 21 21
150001-500000 P 800 14 21 21 21
500000 OVER Q 1250 21 21 21 21
* If 1.5 Major then 2.5 consider to Minor
* If 2.5 Major then 4.00 consider to Minor
 
Acceptable Quality Level
Acceptable Quality Level or A.Q.L Chart

How can I understand the Acceptable Quality Level or A.Q.L chart

Related Posts:

  1. Trims and Accessories learn inspection procedure 
  2. What is GPQ? GPQ means in the garments sector

AQL-1.5

Above the AQL chart, for example, if the lot size is 50000 then the inspection sample quantity will be 500 pcs. If inspection time finds any major defects quantity among inspection quantity 14 or less than 14 will be passed or more than 14 defects will be failed or rejected in the inspection.

If inspection time finds any minor defects quantity among inspection quantity 21 or less than 21 will be passed or more than 21 defects will be failed or rejected in the inspection. If inspection time finds major or minor both defects accept quantity will be passed if will be failed to accept defect quantity above. If Inspection time finds any critical defect inspection result will be failed.

AQL- 2.5

  • 1. Suppose we follow AQL 2.5.  As per the above AQL chart, if the lot size is 4000 then the audit quantity will be 80 pcs major defects quantity among audit quantity 10 pcs or less than 10 pcs will be passed or more than 5 defects will be failed or rejected in Audit.
  • 2. Suppose we follow AQL 2.5.  As per the above AQL chart, if the lot size is 4000 then the audit quantity will be 80 pcs major defects quantity among audit quantity 10 pcs or less than 10 pcs will be passed or more than 5 defects will be failed or rejected in Audit.

AQL-4.0

As per the above AQL chart, if the lot size is 4000 then the audit quantity will be 80 pcs. Major defects quantity among audit quantity 5 or less than 5 will be passed or more than 5 defects will be failed or rejected in Audit.

Why do we need AQL Audit?

When you want to check quality inspected goods or you do not have time to check 100% of goods you can do an AQL audit. The final inspection is done in AQL Audit; factories have an internal AQL audit system. To check suppliers’ fabrics and trim quality, you need an AQL audit of suppliers’ Raw materials. Sewing end line and operator bundle wise AQL audit also done in the apparel industry.

What is AQL in the Garments Industry?

The term AQL stands for acceptable quality level or acceptance quality level. It is one of the most used terms in the readymade garments industry when it comes to considering the quality. It should be noted here that, most of the acceptance decisions of garment export order shipments are made based on AQL-based sampling plans. To ensure the right quality products, an AQL chart has to follow during an inspection of apparel which varies from product to product, process to process, and even buyer to buyer. Acceptable Quality Level (AQL) has great importance in the ready-made apparel business.

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Flow Chart Manufacturing Process In The Garments Industry 2021


Flow chart of the garments manufacturing process: Read this article fully cover for you

Flow Chart of Garments Manufacturing Process / Technology:

A basic garment manufacturing flow chart is presented below:

  • Buyer/ Customer
  • Marketing and Merchandising
  • Design
  • Pattern Making
  • Development sample making
  • Fit Sample Making
  • Fabric trims, and accessories in-house
  • Trims card Approval
  • Fabric test report before cutting
  • Trims test report before sewing
  • Fabric inspection
  • Trims and Accessories inspection
  • Pre-production sample making or P.P. sample making
  • Top sample making
  • Production Pattern Making
  • Size set making
  • Pre-production meeting or P.P. meeting
  • Grading
  • Marker Making
  • Fabric Spreading
  • Fabric Cutting
  • Cutting Parts Sorting or Bundling
  • Sewing
  • Garments Inspection in the sewing line
  • Garments Ironing and Finishing
  • Garments packing approval from BUYER/ Customer
  • Garments Packing
  • Make packing list
  • Garments Cartooning
  • Pre-Final Inspection
  • Final Inspection
  • Shipment
Flow chart
Flow chart of garments manufacturing process

Buyer/ Customer: First of all buyers submit orders to the garments factory through a factory merchandiser.

Marketing and Merchandising: Merchandiser always works under the factory. They receive orders from buyers or customers. Also, the merchandiser works on marketing of garments factories.

Design: After order quantity submits buyer in the factory. The buyer makes design a garment and sends this design-related factory merchandiser. The merchandiser follows this design for Pattern Making.

Pattern Making: Merchandiser forward design sheet in a related Pattern Maker or Master. Pattern Master makes the Pattern follows the design sheet.

Development sample making: After making to complete pattern then go to make the development sample for the buyer’s approval.

Fit Sample Making: After development sample approval from buyer then make fit sample and its approve from buyer merchandiser go to bulk fabric trims and accessories color-wise and style-wise in-house in the factory.

Fabric trims, and accessories in-house: After fabric trims and accessories color wise approval from buyer merchandiser in-house all trims which need style wise.

Trims card Approval: Make the trims card and send to buyer for approval in the bulk production.

Fabric test report before cutting: Merchandiser test all bulk fabric and make report and send to buyer for approval.

Trims test report before sewing: Merchandiser test all bulk Trims and make the report and send to buyer for approval.

Fabric inspection: Factory quality team all in-house bulk fabric minimum 10% inspection and make report. If fabric inspection pass inform to related merchandiser and if fabric inspection is fail must be inform to merchandiser and supplier for solution.

Trims and Accessories Inspection: Factory quality team all in-house bulk trims and accessories minimum 10% inspection and make the report. If trims and accessories inspection pass inform to related merchandiser and if trims and accessories inspection is failed must be informed to merchandiser and supplier for solution

Pre-production sample making or P.P. sample making: After bulk, all fabric, trims, and accessories approved by the buyer then proceeds of pre-production sample making or pp sample making for approval.

Top sample making: After the p.p sample is approved by the buyer then proceed with Top sample making for approval.

Production Pattern Making: After going to bulk production before making production pattern.

Size set making:

  • Pre-production meeting or P.P. meeting
  • Grading
  • Marker Making
  • Fabric Spreading

Fabric Spreading| Objects of Spreading:

Fabric spreading is one of the most important processes in the readymade garments sector, by which fabric plies are spread to get the required length and width as per marker dimension. If fabric spreading is perfect then fabric wastage will be decreased, which ultimately helps to achieve higher profit from a garment export order. As its importance in the garments manufacturing sector, today I will present here some key purposes or objects of fabric spreading.

Definition of Fabrics Spreading:

Fabric spreading means the smooth laying out of the fabric in superimposed layers of definite length. It is a preparatory operation for cutting and consists of fabric lying. Marker paper is laid on top of the fabric layers. It should be noted here that, during spreading, the number of the plies should be not more than three hundred, where the number of layers depends on the height of the fabrics and thickness of the fabrics.

Purpose of Fabric Spreading:

  1. It helps to place the number of plies of fabric to the length of the marker.
  2. It helps to cut the fabrics in bulk quantity at the same time.
  3. It helps in saving fabric cutting time for bulk garments production.
  4. During cutting the fabric, it helps to use multi clothing markers at the same time.
  5. It helps in cutting many fabric plies at the same time.
  6. It helps to make every fabric ply plain and flat.

Speech from the writer:
If you read this article with full concentration then you can answer the below questions in the interview:

  1. What do you mean by fabrics spreading in the clothing industry?
  2. Point out various purposes of fabrics spreading in the garment manufacturing sector.
  3. Mention the significance of fabrics spreading in the apparel manufacturing sector.

Fabric Cutting: After all p

  • Cutting Parts Sorting or Bundling
  • Sewing
  • Garments Inspection in the sewing line
  • Garments Ironing and Finishing
  • Garments packing approval from BUYER/ Customer
  • Garments Packing
  • Make packing list
  • Garments Cartooning
  • Pre-Final Inspection
  • Final Inspection
  • Shipment



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What Is GPQ? GPQ Meaning Learn In Garments Sector Update [2021]


What is GPQ? job description in the garments sector: GPQ meaning or stand for “Guideline for Production and Quality”. Every garment industry or apparel textile industry follows their nominated GPQ for quality production.

This article discusses the garments industry GPQ meaning, GPQ abbreviation, the full meaning of GPQ in garments, GPQ job description, GPQ responsibility, and GPQ procedure in the apparel garments industry or textile industry. In this article, we also share about the quality of the garments full meaning for learning garments related people find this on easily.

Garments quality full meaning

Garments quality full Stand for Quest Unity Active Leadership Intelligent truthful and Youthful. That’s the means below.

  • G= Quest
  • U= Unity
  • A= Active
  • L= Leadership
  • I= Intelligent
  • T= Truthful
  • Y= Youthful

GPQ Meaning GPQ Job Description and responsibilities

What is GPQ in the garment industry?

Every buyer their first requirement or want to a good quality product from in the apparel industry or apparel garment industry. Evey apparel garments industry buyer quality requirement follow up and implement which are followed up by GPQ. Usually, GPQ is the helping hand of the buyer-nominated QC. GPQ ensures the best quality product or goods which is a buyer requirement.

gpq meaning
GPQ meaning – gpq job description and responsibilities

GPQ meaning – GPQ job description in the garments sector

Every buyer explained their quality manual as a part of the GPQ in the apparel textile industry or garments sectors. Many garments people use as GPQ meaning for Garment Process Quality. GPQ is the most essential part of the apparel textile or apparel garments industry.

GPQ meaning and job description in the garments sector

If you are an employee in the garments sector as a GPQ. You must know GPQ meaning, job description, duties, and responsibilities as a GPQ job in the apparel textile industry or apparel garments sector.

If you are want to job in the apparel garment sector or the apparel textile industry as a GPQ. In this article, I hope very helpful post for you. GPQ Job Duties and Responsibilities Arranging a meeting with the buyer QC and giving the necessary tasks for the PP meeting.

  • Follow up quality requirements in Cutting, Sewing, and finishing in the factory.
  • To follow up as per buyer’s quality sample. To ensure sample quality and timely delivery to the buyer.
  • Check all the quality points especially in Garments Sewing to Finish.
  • To ensure Section Wise Quality Inspection.
  • The last message of the buyer regarding quality control is reported in the related section.
  • To ensure product quality before final inspection.
  • Arrange & approved the file before the inspection.
  • Ensure everything is in the QC file.
  • Ensure Sample Approval from Buying House.
  • Communicate Buyer QC with quality issues.
  • Implement to buyer quality control manual in the garment factory (all Sections).
  • Work as a representative of Buyer QC in a Garment Factory.

 

GPQ Job Role in Garments Industry

  1. Conduct in-line inspection and assist the buyer representative in the Final inspection in the Factory.
  2. Handle and execute all PP Meeting and Pilot Run meeting
  3. Implement and follow up customer requirement in every section
  4. In-line inspection of every lot of sewing and finishing section.
  5. Check and ensure pattern size and confirm it for the bulk production according to buyer instruction.
  6. Communicate with the fabric department regarding the fabric quality and assist the fabric QA to ensure online quality control of the fabric.   
  7. Approve the fabric and all accessories for the final bulk production.
  8. Rectify the sewing defect and ensure the accurate shape and design of the product as per the client’s requirement.
  9. Checking out all the accessories in-house for bulk production.
  10. Check the fitting of the garment as per the buyer measurement chart.
  11. Checking and matching the accessories such as sewing threads, buttons, care labels, size labels, main labels, photo board polybags, etc. comparing with a trim card as per customer requirements.
  12. Maintain all work and report of buying house QC, work on behalf of buying house QC.
  13. Arrange PP meeting before bulk production running, pilot run meeting, sewing inline, finishing inline, final inspection as substitute or assistance of buyer QC.
  14. GPQ check garments product using all quality criteria, fill up all QC inspection checklist.
  15. GPQ bears special authority about any quality issue by buyer QC, in absence of buyer QC. So a GPQ is a good decision-maker in any quality parameters of the garments industry.

The works list that GPQ do directly in their daily routine maintain

  1. PP meeting
  2. Pilot Run Meeting
  3. Measurement check of PP and Pilot run, involve in the pattern correction process.
  4. Sewing Inline Inspection
  5. Finishing Inline Inspection
  6. Pre-final Inspection
  7. Final Inspection
  8. Sample inspection
  9. IQC section followup
  10. Cutting secction follow up

GPQ job in Garments industry

Fresh resume/ CV not accepting in GPQ job, must be experienced in the quality control field, experience in sewing quality control is preferable but finishing QC also can join in GPQ team. In the Bangladesh garments sector, from GPQ auditor to GPQ manager job designation is available for work. A career as GPQ personnel is not bad for any who is involved with the garments QC team.

What does GPQ have full mean?

GPQ stands for “Guideline for Production and Quality” as explained in all buyer Quality Manual. But this term is also commonly known as Garment Process Quality.



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4 Point System Knit Fabric Inspection Formula In Garments Industry


4 point system knit fabric inspection formula is a standard method that is widely used in the Textile and Apparel Industries, and the garments industry.

Standard Operating Procedure

Title:  SOP for Fabric Inspection Procedure

Reference: QA-FIP-0

Custodian: Technical Corn • fiancé I Total Pa • e # 02

Effective Date: 02-01-2018 I

Revision: 02 Reviewed on 16-01-2021

Next revision Date: When Applicable

SOP for Fabric Inspection Procedure

Related Posts:

  1. Trims and Accessories inspection procedure For Garments Industry
  2. Flow chart manufacturing process in the garments industry 2021
  3. Acceptable Quality Level use in the apparel garments industry 2021

Purpose:

The main purpose of this inspection is to assure the quality of the received fabric and lace before sending it to the cutting section.

Scope:

  • Collect packing list from the warehouse, and approved swatch from Merchandising department.
  • Randomly select fabric rolls to order, article and color-wise, and lot/ batch-wise.
  • Conduct fabric inspection with a 4 point system.
  • Conduct inspection initial 10%. If fail we conduct another 20%, if another failure we conduct 100%. QC Manager and Merchandiser will make a decision. Fabric sample and inspection report to be sent with supplier for evidence.

4 Point System Penalty Points

4 Point System                              Penalty Points
Length of Defect
0 to 3″                                                        1
3.1″ to 6″                                                   2
6.1″ to 9″                                              3
9.1 ” to above                                           4
4 Point System
4 Point System Penalty Point

4 point system knit fabric inspection formula

Total penalty points X 100 X 36 Square Formula.   = Result (For Fabric Square Yards) Fabric Length (Inspected) X Fabric Width (Inch)

Total penalty points X 100

Linear Formula: ————————————— = Result (For Lace Linear Yards)

Inspected Length

Defect Classification

  • Fabric shading – Side to side & Side to the center of fabric will be checked for shading. During the fabric inspection, any shading is noticeable, the fabric will be checking every 3 yards. If fabric shading found continuously, this will be informed to QC Manager and account merchandiser for decision.
  • Fabric with contamination like dye spots, foreign yarn, dirty marks, etc. will be categorized depends on defect length.
  • Holes are categorized for 4 points.
  • All fabrics and lace must be inspected on the face side for defects.
  • Selvage holes on both sides for more than 1/2″ will be considered as reject.



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Trims And Accessories Inspection Procedure For Garments Industry


Trims and Accessories Inspection Procedure should be done properly in the garment industry to achieve the required quality products. If you are an employee in the apparel industry or garments sector, must be knowledge remain of trims and accessories that use in the garments industry. Hope this article fully covers and grows my knowledge of in garments section Trims and Accessories inspection procedure.

Trims and Accessories Inspection Procedure in the garment industry

Objective:- To establish a strong and smooth flow process for Trims and Accessories inspection to ensure Buyer/Customer Quality standards are met.

Scope:- This policy is applicable to all persons in charge responsible to implement the procedure in the workstation in any readymade garment industry or apparel sector.

SOP for Trims and Accessories (Lace) inspection procedures

Lace Inspection:-

The main purpose of this inspection is to assure the quality of the received Lace before Supplying it to the cutting or sewing section. To do the inspection we select 10% quantity out of order total qty. randomly, if 10% inspection is failed we go to 20% inspection and if 20% is failing, we communicate with our concern Merchandiser as well as Supplier. Based on Merchandiser confirmation, we release the lace & go for 100% panel inspection. Or we go for 20% and 100% lace inspection if necessary. But for the Acceptable level for Lace, we are following FOUR POINT SYSTEM.

4 Point System:

Length of Defect Penalty Point
Less than 3″ 1
Over 3″ but less than 6″ 2
Over 6″ but less than 9″ 3
Over 9″ 4
Linear Formula
Linear Formula

                                           Total Penalty Point × 100     

Linear Formula:-          ————————————-      =     Result

                                           Lace Length (Inspected)

Acceptance Level is

  • Only Major defects are considered. Such as Hole, Yarn Contamination.
  • Dye/Coating Spot, Stain/ Dirty Spot, Shading, Crease, Streak, Stop Mark, Shade Bar, etc.
  • Holes all wage 4 points.
  • All lace is to be inspected on the face side for defects.
  • The defect must be measured lengthwise.
  • Maximum penalty points per linear yard are 4.
  • Acceptance level up to 40-points per 100 linear yards.
  • Above 40 points per 100 linear yards, the lot will be rejected.
  • Length shortage 0.50% is exceeded then the length will fail.
  • The defect must be marked by an arrow sticker.
  • Lace length, Width, roll no. defect & other information must be recorded properly.
  • The passed roll is marked by a green tag.
  • The reject roll is marked by a red tag.

SOP for trims and accessories (elastic, wire casing & ribbon)

Elastic, Wire casing, Ribbon, Etc. Inspection: The main purpose of this inspection is to assure the quality of received materials before supplying them in the sewing section. To do the inspection we select 10% ctn. randomly if 10% is failing, we go to 20%, and if 20% is failing then we communicate with our concerned Merchandiser as well as Supplier. Based on Merchandiser confirmation, we release the materials & go for 100% inspection. Or we go for 20% and 100% materials inspection if necessary. But, 15t inspection (10%) materials rejection below 1.5% we pass the lot.

Elastic Inspection:

Collect approved swatch & match against received Elastic. Check Width, running shade, Spot, curve, Elasticity, Construction fault, Picot reveres, etc.

Wire casing Inspection:

Collect approved swatch & match against received Wire casing. Check Width, running shade, Spot, Construction fault, etc.

Ribbon Inspection:

Collect approved swatch & match against the received ribbon. Check Width, running shade, Spot, Construction fault, etc. Standard Operating Procedure:

  • We check 10% quantity if fail, we go to 20% and if 20% is failing then go to 100% inspection.
  • Make defect swatch.
  • Make Quality Report.
  • Make Quantity Report (if necessary).
  • Defect Swatch Signature with Quality Officer and Quality Manager then send to Merchandiser. Merchandisers arrange to Replenish if need.
  • One joint allows within 50 meters.
  • One defect count 0.25 meters for elastic/ribbon/wire casing.

SOP For Accessories/Trims Inspection: Countable

The main purpose of this inspection is to assure the quality of received materials before supplying them to Sewing. To do the inspection we follow AQL- 1.5(Level-11) of our received goods. We are checking the below materials:

  • Label
  • Bow
  • Ring & Slider
  • Hook & Eye
  • Stone
  • Logo
  • Cup wire
  • All packing trims

Trims and Accessories Checkpoint:

Check all materials against approval trims card and follow below check point:

Related Posts:

  1. Acceptable Quality Level use in the apparel garments industry 2021
  2. Flow chart manufacturing process in the garments industry 2021
  3. 4 point system knit fabric inspection in garments industry
  4. What is GPQ? GPQ meaning in garments sector now update 2021

Label:

Collect label layout or CMS sheet to match the Size, Composition, Care instruction, country of origin, Color, Check Letter problem, Barcode number, UPC number, Stroke number, Department number, Series number, Supplier code number, Date code number, etc.

  • Bow: Check construction, Width, spot, shade, Open, etc.
  • Ring & slider: Check width, spot, shade, etc.
  • Hook & Eye: Check measurement, color, Hook to Eyeshade, Spot, Open, etc.
  • Stone: Check Broken, Placement problem, shading, etc.
  • Logo: Check buyer name, style order, color, measurement, Broken, spot, missing, shading, etc.
  • Cup wire: Collect a size-wise wire chart then match the received cup wire. Should be following reference number or article number (if necessary)
  • Foam Cup: Collect a size-wise Foam cup chart then match the received foam cup. Check measurement, color, pair to pair shade, Spot, broken, etc. Should be following reference number or article number (if necessary)
  • All packing trims: Packing trims are check as per approval standards.

Procedure:

  • We check AQL- 1.5(Level-11) system-wise. If pass we make the pass report, if fail we go to check 100%.
  • Make defect swatch.
  • Make Quality Report.
  • Make Quantity Report if necessary.
  • Defect Swatch Signature with Quality Officer and Quality Manager & send to concerned Merchandiser. Merchandisers will arrange the Replenishment.



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