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China Caps & Hats Factory - Wholesale Caps and Hats from Chinese Factory directly

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Quality Control


Our QC department is composed of 16 professional technicians and a big team of numerous inspectors. They test and inspect every production process. By using advanced testing equipment and strictly following inspection procedures and regulated quality standards, we make sure our final products meet our customers’ standards before delivery. With rich experiences of exporting to USA, Canada, Japan, Germany, UK etc. for years, we built up our own complete quality control system and clear understanding on quality requests from customers all over the world.


 

For Caps & Hats, we set up four steps of quality control:

We place great emphasis on refined workmanship, delivering superior quality fabrics and garment. Through training, supervision and management, we have implemented our quality philosophy from the conceptual design at our Design Workshop to production at our China's factory and to the final product delivery.


Quality Policy:

Base on Management – Continuously Running

Focus on Customer --- Keep improving

Quality Objective:

Our in-house QC personnel are well trained to perform stringent inspections on our fabrics and garment.

For garment inspection, we have adopted eight steps

Quality Assurance System. Modules include:

1.Piece goods inspection - 100%

2.Spreading inspection - in line random

3.Cut piece inspection - 100%

 


 

4.Sewing inspection - in line 100%

5.Trim & examine - 100%

6.Press fold inspection - 100%

7.Final audit on finishing & packing - 100%

8.Broken needle management system (metal detector) – 100%


 

We are committed quality requirements of the highest standard. We do not sacrifice on quality. We make sure quality is adhered to throughout our operation from sampling to final shipment. We take extra efforts in ensuring the suppliers comply with strict quality control. Quality Assurance is an inherent part of our services and we ensure that our customers do not face any problem at any stage.


 

Inspection Procedure:

1. Cutting

Defects to be seen

The cut bundles received from cutting department are inspected 100% for visual defects such as the following:

1. Knitting defects such as holes, barre, needle line, yarn shade variation, repeat difference etc.

2. Processing defects such as water marks component shading, compactor shoe marks, dead cotton slubs etc.

3. Mis-cuts, improper notching etc.

4. The front and back panel are matched as per the requirement of the buyer.

5. In case of design/repeats of parts same should match.

6. Sampling Quantity:

Visual Inspection 100%
Measurement Check 2 out of 10 pieces

In case of any variation in the above parameters, the complete bundle is returned to the cutting department for correction/replacement.

Acceptance Standard:

Bundle Size Defects allowed
Up to 5 Pieces 0
6 to 10 pieces 1
11 to 15 pieces 2
16 to 20 pieces 3
More than 20 pieces 4


 

Where it is possible to change the defective part by replacement, the quality inspector checks the exchanged part for shade variation, and measurement and ensure to put the same number that of the damaged part.


 

Reporting defects Rate:

Defects rate in cutting= The total defects found / No of bundle checked

Report generated of all procedures and archived

Cutting QA Report – Exhibit 3A

2. Sewing

Approved Sample

The QA follows the parameters stated below:

1. Fabric pattern, design, weight etc.

2. Stitch details

3. Placement accessories and trims

4. Folding and packing details


 

Potential Major faults


 

1. Any surface hole or weakening defects which could develop into a hole

2. Visible flaws

3. Shading within the garment

4. Dye spots, misprints

5. Cuts and tears

6. Non matching checks and stripes

7. Bowing of fabric, if it effects the appearance of the garment

8. Spots or stains

9. Deviation in measurement specs more than the given tolerance

10. Twisted or puckered seam

11. Broken stitches or open seam

12. Seams not bar tacked unless covered by another seam

13. Irregular or uneven top stitching and contrast stitching

14. Run-off in top stitching in visible areas.

15. Incorrect stitch counts

16. Incorrect seam allowance

17. Twisted hems and uneven hems

18. Missing bar tack

19. Uneven fronts, sleeves and other symmetric components

20. Poorly done and objectionable mending

21. Broken/skip stitch


 

Potential minor faults.


 

1. Removable stains

2. All other temporary defects other than listed above.


 

In-line quality audit

The quality inspector conducts in-line quality audit as per the steps mentioned below:


 

1. Pick up one bundle after any operation at random

2. Check the quality level of that particular operation

3. Repeat this procedure for minimum of 3 times of the same operation within a day


 

In case some type of rejection is encountered repeatedly, production is held temporarily until corrective action is ensured by line supervisor.


 

End of the line quality

Quality inspector station at the end of all sewing operation and check the following:


 

1. Stitch formation

2. Component shade variation

3. Sewing alterations and variations

4. Damaged parts

5. Size label jumping

6. Missed sewing operation

7. Broad measurement specification


 

Pilot run

Depending on the size of the order, pilot run is carried out. All the pieces are visually inspected and measurement for any quality defects. The sample sizes for pilots runs are as follows:


 

Order Quantity Pilot Strike Off
Up to 3000pcs 25pcs
3001 to 6000pcs 40pcs
6001 to 9000pcs 60pcs
9001 to 15000pcs 75pcs
Above 15,000pcs 100pcs

Any major deviation in measurement or style is incorporated in the pattern/sewing line before the bulk production start. Report generated and archived


 

1. Sewing in-line quality audit --4A

2. Pilot run quality audit ---4B

3. Embroidery

Approved Sample

5.1 The QA ensure quality through sample embroidery sew-out. Sample of a garment along with placement details is made before going in to mass production, parameters are strictly followed to ensure quality embroidery


 

Parameters


 

1. Right shade of threads

2. Positioning of the embroidery

3. Coverage, stitch density is as per the order

4. Embroidery alignment

5. Fraying of thread

6. Clarity in the design as per original

7. Right tension of the threads

8. Holes due to needle

9. Skip/missed threads

10. Shade variation within the box of thread


 

The pilot quantity of strike off:


 

Order Quantity Pilot Strike Off
Up to 2000pcs 15pcs
2001 to 5000pcs 25pcs
5001 to 8000pcs 35pcs
8001 to 15000pcs 50pcs
Above 15000pcs 60pcs

The pilot strike off panels/garments are 100% visually inspected and changes are incorporated in the bulk production.


 

Reports generated and archived

1. Embroidery pilot run quality audit report Exhibit ---5A

2. Daily embroidery quality report Exhibit –5B


 

4. Printing

Approved Sample

The QA ensures that an approved strike off of the print with the shade card giving the pantone references number. Is available with the Department. Sample of the garment along with the placement details must be available. Before starting bulk production, pilot strike off of using the actual garment /panel is taken and inspected for the following quality.

Parameters

1. Right shade of colors

2. Positioning of the print

3. Proper registration

4. Print alignment

5. Clarity in the design as per original

6. Properly cured surface

7. Stains

8. Skew ness of print


 

The pilot quantity of strike off

Order Quantity Pilot Strike Off
Up to 2000pcs 15pcs
2001 to 5000pcs 25pcs
5001 to 8000pcs 35pcs
8001 to 15000pcs 50pcs
Above 15000pcs 60pcs


 

The pilot strike off panels/garments are 100% visually inspected and changes are incorporated in the bulk production.


 

Reports generated and archived

1. Print pilot run quality audit report – Exhibit 6A

2. Daily print quality report Exhibit – 6B


 

5. Finishing and packaging

The purpose of pressing a knit/woven fabric product is to eliminate the wrinkle and yield original feeling. The following points are ensure by the QA inspector while ironing is in process:

1. Knit product must be iron finished at proper temp

2. The system press must have Teflon shoe and must be cleaned periodically

3. Areas such as collar, embroidery, printing, etc. should not be hard ironed.

4. No small wrinkles, defective luster and iron-pressed marks should be observed on the surface

5. The size of the iron finished product must conform to order specification

6. The garment must be allowed to be cooled for at least 1 hour before putting in poly bag.

7. The ironing table top cloth must have marking for horizontal and vertical markings matching the outline size of the garment.


 

Packing is an important aspect of a given garment. The following aspects are checked by the inspector:

1. The price ticket, hangtag, bar code stickers.

2. The right size of the poly bag should be used for the garment

3. After the garment is inserted in the poly bag, it should not be sloppy or too tight.

4. The ratio of pre-packs and qualities per carton must be checked randomly.

5. The garment through the poly bag must be visually symmetric

6. All carton markings must conform to the order requirement


 

Reports generated and archived

1. Ironing QA Report—Exhibit –7A


 

6. Final Audit

The purpose of the final, audit is to establish the quality level of the final pieces goods before it leaves the factory.


 

The QA manager has to conduct a final quality audit of the packed goods and this has to done at two stages:

1. Once 50% of the shipment is packed

2. Other when 100% of the shipment is packed


 

In case there is any quality problem at the above stages, the packed goods have to be screened for the specific quality aspects

Once corrected the above procedure has to be repeated again.

Reports generated and archived

Final quality audit report – Exhibit 8A

World Wide AQL Service

Table A: Sample Size



 

World Wide AQL Service

Table B: Single Sampling plans for normal inspection level II