Garment Quality Control Checklist — What to Check Before Accepting Bulk Production

Pre-Production Inspection

Pre-production inspection happens before bulk production begins. Check the sample against your approved design. Verify fabric quality, color accuracy, and construction details.

Check fabric GSM matches specifications. Verify color matches your approved swatch. Test fabric for shrinkage, color fastness, and pilling. Check that all trims and accessories match requirements.

Measure the sample against your size chart. Check all critical measurements. Verify seam allowances match specifications. Check that labels and tags are positioned correctly.

Approve the sample in writing. Do not start bulk production until you approve the pre-production sample. This is your quality baseline.

In-Line Inspection

In-line inspection happens during production. Check garments at 20-30% completion. This catches problems early before they affect the entire batch.

Check sewing quality. Look for skipped stitches, loose threads, and uneven seams. Verify stitch length matches specifications. Check that seams are straight and consistent.

Check fabric handling. Look for fabric distortion, puckering, or stretching. Verify that pattern pieces match correctly. Check that prints align at seams.

Check trims and accessories. Verify zippers work smoothly. Check buttons are secure. Verify that labels are attached correctly. Check that embroidery or printing matches approved design.

If problems are found, stop production. Discuss issues with the manufacturer. Agree on corrective action before continuing.

Final Inspection

Final inspection happens after production is complete. Check a sample of finished garments using AQL standards. This is your last chance to reject defective goods.

Check measurements against size chart. Measure a sample from each size. Verify that measurements fall within tolerance. Check that sizing is consistent across the batch.

Check color consistency. Verify that all garments match approved color. Check for color variation within the batch. Verify that dye lots are consistent.

Check construction quality. Look for loose threads, skipped stitches, and poor finishing. Check that hems are even. Verify that closures work properly.

Check packaging. Verify that garments are folded correctly. Check that polybags are sealed properly. Verify that shipping labels are accurate.

AQL Standards Explained

AQL stands for Acceptable Quality Level. It is a statistical sampling method used in quality control. AQL defines how many defects are acceptable in a batch.

Common AQL standards for garments are AQL 2.5 for major defects and AQL 4.0 for minor defects. Major defects make the garment unusable. Minor defects do not affect function but affect appearance.

For a batch of 500 pieces, AQL 2.5 means inspecting 50 pieces. If more than 3 major defects are found, reject the batch. If more than 7 minor defects are found, reject the batch.

For a batch of 1,000 pieces, AQL 2.5 means inspecting 80 pieces. If more than 5 major defects are found, reject the batch. If more than 10 minor defects are found, reject the batch.

Defect Categories

Major defects include holes, stains, incorrect color, wrong size, broken zippers, missing buttons, and poor construction that affects function. These defects make the garment unsellable.

Minor defects include loose threads, slightly uneven seams, minor color variation, and cosmetic issues. These defects do not affect function but affect appearance.

Critical defects include safety issues, hazardous materials, and legal non-compliance. These defects are never acceptable. Any critical defect means automatic rejection.

Document all defects. Take photos. Keep records. This helps if disputes arise with the manufacturer.

What to Reject

Reject garments that do not match approved samples. If the fabric, color, or construction differs from your approved sample, reject the batch.

Reject garments with sizing errors. If measurements fall outside tolerance, reject the affected sizes. Sizing errors cause customer returns.

Reject garments with construction defects. If seams are weak, stitching is poor, or finishing is sloppy, reject the batch. These defects affect durability.

Reject garments with missing or incorrect branding. If labels, tags, or packaging are wrong, reject the batch. Branding errors affect your brand identity.

Third-Party Inspection

Consider hiring a third-party inspection company. They provide unbiased quality assessment. This is especially useful for new buyers unfamiliar with local factories.

Third-party inspectors follow international standards. They provide detailed inspection reports. Their reports include photos and measurements.

Cost for third-party inspection ranges from $200 to $500 per inspection. This is a small cost compared to the cost of accepting defective goods.

SDF Clothing welcomes third-party inspection. We provide access to our factory for inspection. We work with your chosen inspector to ensure transparency.

Measurement Tolerance

Measurement tolerance is the acceptable variation from specified measurements. Standard tolerance is plus or minus 1 centimeter for body measurements. For critical measurements like neck or sleeve, tolerance is plus or minus 0.5 centimeters.

Establish tolerance in your tech pack. Specify acceptable variation for each measurement. This provides clear criteria for inspection.

Measurements outside tolerance are defects. Reject garments that exceed tolerance. Consistent sizing is essential for customer satisfaction.

Color Fastness Testing

Color fastness testing checks if color transfers during washing or rubbing. Poor color fastness causes color bleeding and fading.

Test color fastness to washing. Wash a sample garment according to care instructions. Check if color bleeds or fades.

Test color fastness to rubbing. Rub a white cloth against the fabric. Check if color transfers to the cloth.

Test color fastness to light. Expose fabric to light for a period. Check if color fades. This is especially important for garments displayed in stores.

Shrinkage Testing

Shrinkage testing checks if garments shrink after washing. Excessive shrinkage changes fit and sizing.

Measure garments before washing. Wash according to care instructions. Measure again after washing and drying. Calculate shrinkage percentage.

Acceptable shrinkage is typically 2-3% for cotton, 1-2% for synthetic fabrics. Shrinkage above 5% is unacceptable.

SDF Clothing pre-shrinks fabric before production. We test shrinkage and ensure garments meet shrinkage standards before shipment.

Documentation Review

Review all documentation before accepting shipment. Check packing lists, commercial invoices, and certificates of origin.

Verify that quantities match your order. Check that sizes and colors match your specifications. Verify that packaging meets your requirements.

Check that certificates are valid and current. This includes GOTS, OEKO-TEX, and other relevant certifications.

For a complete overview of clothing manufacturers in Bangladesh — including quality control, inspection, and standards — read our complete clothing manufacturers guide.