How to Inspect Garments?

Selim Reza

26 Mar, 2025

How to Inspect Garments?

"Garment Inspection: Ensuring Quality, One Stitch at a Time!"

Inspecting garments is a crucial process in quality control to ensure they meet the required standards before reaching customers. Here’s a step-by-step guide on how to inspect garments properly:

1. Preparation for Garment Inspection

Proper preparation before garment inspection ensures accuracy, efficiency, and reliability in quality control. Below are the key steps:

1. Pre-Inspection Setup

✅ Ensure a Clean and Well-Lit Environment
- Inspection area should be dust-free and well-illuminated.
- Use daylight or white fluorescent lighting to check colors and defects properly.
✅ Prepare Necessary Tools & Equipment
- Measurement tape – For checking garment dimensions.
- Inspection table & lamp – To examine defects clearly.
- Defect stickers – To mark defective areas.
- Fabric GSM cutter – For checking fabric weight.
- Needle detector – To ensure no metal pieces are in the garments.
- Barcode scanner – To verify labels and packaging.
- Tension tester – For checking seam strength.
✅ Review Garment Specifications
- Collect tech packs, measurement charts, and buyer requirements.
- Understand tolerance levels for measurements.
- Verify fabric, trims, and accessories against the standard.
2. Sample Selection

✅ Determine the Inspection Sample Size
- Use AQL (Acceptable Quality Level) chart to select sample quantity.
- Randomly pick samples from different cartons/lots.
- Ensure different sizes and colors are included.
✅ Check the Packing List
- Cross-check total order quantity with the packing slip.
- Confirm SKU codes, carton numbers, and labeling.
3. Communication & Documentation

✅ Coordinate with Quality Control Team
- Inform factory or supplier about inspection timing.
- Ensure all necessary documents are available.
✅ Prepare Inspection Checklist & Report Format
- Include sections for fabric defects, stitching quality, label checks, etc.
- List out acceptable and unacceptable defects based on buyer standards.
4. Pre-Inspection Checks

✅ Ensure Garments are Ready for Inspection
- Garments should be completely manufactured, ironed, and finished.
- No loose threads, unfinished trims, or incomplete labeling.
✅ Confirm Size Sets for Measurement Checking
- Select a sample set covering different sizes (S, M, L, XL, etc.).
- Ensure each size is available for measurement verification.
✅ Check Carton Packaging & Shipping Marks
- Verify that packaging matches buyer requirements.
- Check carton labels, polybag sizes, and folding method.
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2. Visual Inspection

Fabric Quality
- Check for any defects like stains, holes, wrinkles, color variation, and misprints.
- Verify fabric composition and feel (softness, stretch, texture).
Stitching and Seams
- Ensure all seams are correctly stitched (no loose threads, skipped stitches, puckering, or broken seams).
- Verify seam allowance and overlock finishing.
Labels and Tags
- Confirm the accuracy of size labels, care labels, brand tags, and price tags.
- Check for correct positioning and attachment.
Trims and Accessories
- Inspect zippers, buttons, snaps, and other fasteners for proper function and security.
- Ensure embellishments (prints, embroidery, beads) are securely attached.

3. Measurement Check

Compare garment dimensions with the measurement chart.
Measure key points such as chest, waist, hip, length, sleeve, and armhole.
Check for consistency in sizes within a batch.

4. Functional and Fit Inspection

Test buttonholes, zippers, and elastic for proper operation.
Verify stretch recovery in knitted garments.
Check overall fit against standard mannequins or live models if required.

5. Packing and Presentation

Ensure garments are folded properly according to packaging instructions.
Verify polybag quality, barcode stickers, and carton details.
Check for correct carton packing (size ratios, quantity per box).

6. AQL (Acceptable Quality Level) Inspection in Garments

AQL (Acceptable Quality Level) is a standard method used in garment quality control to determine the maximum number of defective units allowed in a sample batch before rejection. It ensures that garments meet buyer standards before shipment.

1. Why is AQL Important?

✅ Ensures consistent quality
✅ Helps in decision-making (Accept/Reject)
✅ Reduces returns and customer complaints
✅ Balances cost vs. quality by setting an acceptable defect level

2. AQL Standards and Levels

AQL levels vary based on buyer requirements and product sensitivity. Common AQL levels for garments include:

AQL Level	Industry Use	Defect Limit
1.0 – 1.5	High-end brands, premium quality garments	Strict (low defects allowed)
2.5	Standard apparel industry (casual wear, mid-range)	Moderate defect allowance
4.0	Low-cost garments, bulk production	More defects allowed

Most buyers accept AQL 2.5 for standard garments.

3. Defect Classification in AQL Inspection

Defects are categorized into three types:

Defect Type	Impact on Garment	Example
Critical Defects	Safety issues, regulatory non-compliance	Sharp objects in fabric, harmful chemicals
Major Defects	Affects functionality, durability, or appearance	Open seams, broken zippers
Minor Defects	Does not affect function but reduces overall quality	Loose threads, small stains

Critical defects = 0 tolerance (Immediate rejection).

4. AQL Sampling Plan (Single Sampling)

AQL follows ISO 2859-1 (formerly MIL-STD-105E) for sampling. Here’s a general guide:

Determine Lot Size (Total garments in the order).
Select Inspection Level (Level II is most common).
Find Sample Size from AQL Table (See example below).
Check Defect Limits (Accept/Reject based on the table).

AQL Sampling Table Example (AQL 2.5, Level II)

Lot Size	Sample Size	Acceptable Defects (Accept/Reject Criteria)
151 - 280	32 pcs	Accept: 2 / Reject: 3
281 - 500	50 pcs	Accept: 3 / Reject: 4
501 - 1200	80 pcs	Accept: 5 / Reject: 6

If defects exceed the limit, the batch is rejected.
If defects are within the limit, the batch is approved.

5. Steps in AQL Inspection

Randomly select samples as per the AQL chart.
Conduct physical & visual checks (fabric, stitching, labeling, trims, fit, etc.).
Count and categorize defects into Critical, Major, Minor.
Compare defects with AQL limit (Pass/Fail decision).
Prepare an inspection report with findings and corrective actions.

6. Action Based on AQL Inspection Results

✅ PASS: Order is approved for shipment.
❌ FAIL: Re-inspection is required after defect correction.

7. Reporting and Corrective Actions in Garment Inspection

After inspecting garments, it is essential to document findings and take corrective actions to maintain quality standards. Below is a structured approach:

1. Inspection Report Format

A standard garment inspection report includes:
✅ Inspection Date & Location
✅ Inspector’s Name & Department
✅ Order Details: Buyer, Style No., PO No., Order Quantity
✅ Inspection Level: AQL standard (e.g., 2.5, 4.0)
✅ Sample Size Inspected
✅ Defect Classification (Critical, Major, Minor)
✅ Defect Description & Photos
✅ Overall Inspection Result: Pass / Fail

2. Defect Classification & Reporting

Defects are categorized into three levels:

Defect Type	Description	Example
Critical Defects	Safety issues or defects making the garment unusable	Needle found, broken zipper
Major Defects	Defects that affect usability or appearance	Open seams, stitching errors
Minor Defects	Small issues that don’t affect function but reduce quality	Loose threads, minor stains

A Defect Summary table should be included, highlighting the number of defects found in each category.

3. Corrective Actions Based on Findings

Once defects are identified, appropriate actions must be taken:

A. Repairable Defects

Example: Loose threads, open seams, misaligned labels
Action: Send back to the sewing or finishing department for rework.

B. Rejection of Defective Pieces

Example: Severe color shading, major print defects
Action: Remove defective garments from the shipment or obtain buyer’s approval for discounts.

C. Production Process Improvements

Example: Frequent needle breaks, poor seam strength
Action: Review production techniques, train workers, and improve machine maintenance.

D. Material/Component Replacement

Example: Defective buttons, faulty zippers
Action: Replace faulty trims and accessories before shipment.

4. Preventive Measures for Future Orders

To avoid repeated quality issues:

Conduct root cause analysis of defects.
Implement quality control at each stage (fabric, cutting, sewing, finishing).
Provide worker training on stitching, handling, and finishing.
Improve supplier quality checks for fabric and trims.
Use inline and final inspections before shipment.

Final Thoughts

Regular garment inspection ensures high-quality standards, reduces returns, and improves customer satisfaction. Do you need a specific checklist format or an SOP for garment inspection?

How to Inspect Garments?