Our 7-Step QC Process: From Fabric Inspection to Final AQL Audit
The short answer
Our quality process has seven checkpoints: fabric inspection on arrival, pre-production sample approval, cutting inspection, in-line inspection during sewing, end-of-line 100% check, final random inspection at AQL 2.5 after packing, and carton verification before loading. Each checkpoint produces a record, and the order cannot move to the next stage until the previous one is signed off.
The purpose of seven steps rather than one is simple: defects get more expensive at every stage. A fabric fault costs a metre to fix; the same fault found in a finished carton costs a garment, a shipment and possibly an air-freight upgrade.
Last updated: September 2026.
Key takeaways
- Fabric is checked before cutting, using the 4-point system on a defined sample of rolls.
- In-line inspection is the highest-value checkpoint, because it catches systematic errors while the line can still be corrected.
- Final inspection happens after packing, not before, so the shipment is assessed as it will arrive.
- Every stage produces a written record with photos, quantities and the inspector's name.
- AQL 2.5 is the release standard, with zero tolerance on critical defects.
1. The seven checkpoints
| Step | Checkpoint | What is checked | Who signs | Record issued |
|---|---|---|---|---|
| 1 | Fabric inspection on arrival | Defects, shade, GSM, width, shrinkage data | Fabric QC | Fabric inspection sheet |
| 2 | Pre-production sample approval | Fit, measurements, branding, packing | QC and buyer | Approved sample card |
| 3 | Cutting inspection | Marker accuracy, panel count, shade matching | Cutting supervisor | Cutting record |
| 4 | In-line inspection during sewing | Stitch quality, measurement drift, component function | Line QC | In-line report and photos |
| 5 | End-of-line 100% check | Workmanship, thread trimming, labelling | Line QC | End-line tally |
| 6 | Final random inspection at AQL 2.5 | Full specification after packing | QC manager | Final inspection report |
| 7 | Carton and loading verification | Carton marks, assortment, count, weight | Warehouse and QC | Packing list verification |
2. Step 1: fabric inspection with the 4-point system
Fabric is graded on a defined sample of rolls using the 4-point system, where each defect is scored from 1 to 4 points depending on its length and severity.
| Defect size | Points |
|---|---|
| Up to 7.5 cm | 1 |
| 7.5 to 15 cm | 2 |
| 15 to 23 cm | 3 |
| Over 23 cm, or a hole | 4 |
A roll passes when the total score stays within the accepted threshold per 100 square yards. Rolls that fail are quarantined and returned to the mill, not cut into garments.
3. Step 4: why in-line inspection matters most
| Stage when a defect is found | Cost to correct |
|---|---|
| Fabric roll | A metre of fabric |
| Cut panels | The panel and the labour |
| In-line, during sewing | A few minutes of operator time |
| End of line | A garment, or a repair operation |
| After packing | Unpacking, repair, repacking |
| At the customer's warehouse | Return, replacement, freight and reputation |
The in-line visit is also where measurement drift is caught: if the first 50 pieces are correct and the next 200 are 1.5 cm short, the specification sheet will not tell you, but an in-line measurement check will.
4. Step 6: the final AQL audit
| Element | Our standard |
|---|---|
| Timing | After 100% packing, before loading |
| Sampling | ISO 2859-1, general inspection level II |
| Accept level | AQL 2.5 major, 4.0 minor |
| Critical defects | Zero tolerance |
| Measurement | Key points measured against the approved sample |
| Records | Report, defect photos, carton list |
| Outcome | Pass, rework and re-inspect, or fail |
For certified protective garments we add a functional check on the compliance features: tape reflectivity, tape position, closure function and label accuracy.
5. What the buyer receives
- Fabric inspection summary and any roll rejections
- Approved pre-production sample reference photos
- In-line inspection report with defect categories
- Final inspection report with AQL result and photographs
- Packing list verification and carton count
- Test reports and, for PPE, the declaration of conformity
These records are what allow a buyer to audit the process months later without visiting the factory.
6. Frequently asked questions
What is the 4-point fabric inspection system?
It is a standard method where defects are scored from 1 to 4 points based on size and severity, and a roll passes if its total score stays within the accepted threshold per 100 square yards. It gives fabric quality a number instead of an opinion.
When is the final inspection carried out?
After 100% of the order is packed, so the inspection assesses the shipment in the form it will arrive. Inspecting before packing misses carton, assortment and labelling errors.
What AQL level do you work to?
AQL 2.5 for major defects and 4.0 for minor defects, with zero tolerance for critical defects such as needle fragments, missing compliance markings or uncertified tape.
Do you allow third-party inspection?
Yes. Independent inspection is welcome at any stage, and we will provide the carton list, packing plan and access to the production floor. Inspection access is written into our quotations.
What happens if the final inspection fails?
The order is held, the defects are categorised, and rework or replacement is agreed with the buyer before any re-inspection. Nothing ships on a failed inspection.
How long does the QC process add to production?
Almost nothing, because the checkpoints run alongside production. The only scheduled addition is the final inspection, typically one to two days depending on quantity.
Can we see the QC records for our order?
Yes. Every checkpoint produces a record, and buyers receive the in-line and final inspection reports with photographs as part of the shipment documents.
How do you handle a systematic defect found in-line?
Production stops, the cause is identified (pattern, machine setting, operator or fabric), the affected pieces are segregated, and the process is corrected and re-checked before the line restarts.
See the process on a live call
Ask us to walk you through the seven checkpoints on a live video call, and we will show you the records, the inspection area and the current production. If you prefer independent verification, we will arrange third-party inspection access.
