Quality Assurance & QC Standards
We operate an independent quality assurance system that monitors production from raw yarn delivery to final carton sealing. Discover our inspection gates and AQL standards.
1. Independent Quality Assurance Structure
Our QA teams do not report to production line leads; they report directly to the operations director. This separation guarantees that quality is never compromised for speed:
- Inline Inspectors: Positioned within sewing lines to audit parts assembly and prevent defect runs.
- Endline Inspectors: Evaluate 100% of finished sewing output under specialized D65 visual hoods for shading, measurements, and seam cleanliness.
- Final Auditor Team: Executes random pre-shipment inspections on sealed export boxes.
2. AQL Sourcing Inspection Standards
Our audits are conducted according to internationally recognized **Acceptable Quality Limits (AQL)**:
- Standard B2B Orders: Inspected using **AQL 2.5** for major defects (e.g. holes, skipped stitches, sizing errors) and **AQL 4.0** for minor defects (e.g. loose threads, slight ironing variances).
- Premium & Japanese Accounts: Audited under a strict **AQL 1.5** limit to meet the precise standards of high-end brands.
3. Rolled Fabric: 4-Point Inspection System
We employ the **ASTM D5430 standard (4-Point System)** to check fabric quality prior to cutting:
- Defect Penalty Scale: Faults are penalized from 1 to 4 points based on length. Any fabric roll exceeding 40 penalty points per 100 square yards is rejected.
- GSM & Width Checks: Roll width and weight stability are tested across three separate points (start, middle, and end of the roll) to verify uniform thickness.
4. Pre-Shipment Audits (FRI)
Before container stuffing, we execute a **Final Random Inspection (FRI)** based on ANSI/ASQ Z1.4 sampling plans:
- Carton Count & Weights: Verification of correct carton count, barcode tags, sealing tape, and gross box weights.
- Measurement Tolerance Checks: Audits checking finished chest, sleeve, waist, and length measurements to ensure they fall within the +/- 1cm design tolerance.
- Inspection Reports: All inspection logs, photographic proof, and AQL sheets are compiled and shared with the buyer for port booking authorization.