Our coding system can track down every single apparel to the level of every individual stitcher and the Checking Supervisor even long after we have made the garment. Lower percentage of defects in our garments compared to international standards and lower incidents of complaints reinforces our faith in our systems. A well-defined system of accountability has helped us to achieve levels of precision and quality acceptable to even high-end international customers.

 

Product Manual

The step-by-step procedure for controlling the quality of garments begins with the Product Manual. When a counter sample is developed for a client, a detailed product manual is prepared. Amongst other things it includes the detailed description of the garment measurements of various sizes, list of accessories, packing details, a sketch of garment with special emphasis on the critical & complicated parts, label designs, prints/embroidery design if any etc.

 

Patterns - Gerber Auto-Cad System

Patterns for all sizes are drawn in the Gerber Auto Cad System, if the same has not been supplied by our clients. We have 3 sets of Gerber Auto-Cad System & most of our clients send to us the patterns by e-mail as they themselves are manufacturing these garments in Europe.

 

The Patterns in Gerber Auto Cad ensures accuracy in measurement and shape.

 

Fabric Testing

Stringent Fabric Testing for various parameters such as shrinkage, color fastness, color matching according to the customer's requirements for each lot of fabric received is carefully conducted. In case the deviation is more than the tolerance, a prior approval is sought from client.

 

Accessories QC

For each of the accessories, we have defined our own quality parameters in detail. The accessories are checked on these parameters before they are accepted in the warehouse.

 

Pre-Production Sample

The Pre-Production Sample is made in various sizes to identify problems in fittings and measurements and these are sent to clients for their approval.

 

This is very-very important & helpful for us as it reduces the scope of misunderstanding between our clients & us regarding any issue related to style, measurements packing etc. The production of garments of a new style is not started before getting the approval from our clients. The suggestion & improvements if any, received from our client are incorporated in the product manual before the production is started.

 

Checking the fabric cut-pieces

After the fabric is cut with the help of Gerber Auto Cad markers, the fabric cut pieces are distributed to various units for production alongwith accessories, packing material, a copy of the product manual & a pre-production sample. The unit supervisor checks the cut pieces with the product manual to ensure that the fabric has been cut properly. He can issue the cut pieces for production, only if the cut pieces are to his satisfaction.

 

 

Production Sample

To ensure that the unit supervisor has understood the product manual completely & there is no confusion in style, measurement etc, he makes a sample from the fabric cut pieces & accessories received, compares it with pre-production sample received & sends it to the technical department for approval. The fabric cut pieces are issued to production only after this production sample is approved by the technical department.

 

 

Line Checking

Each line supervisor has a set of workers under him who are doing operations such as single needle, feed-o-arm and 5 thread sewing. The supervisor checks 10% of garments made by each of these workers for identifying problems due to difference in measurement & style.

 

Finishing Checking

This is the checking, which is done for 100% of the garments. Here the finishing checkers check each garment for defects relating to buttons stitching, button holing, bar-trucking etc to ensure that each & every garment have gone through these operations, so that these are not missing from even a single garment.

 

The finishing supervisor checks 10% of garments checked by each checker. This ensures that there is no negligence by the checkers. This checking is done before the garments are sent for ironing.

 

QC by Unit Supervisor (PF-1)

After the garments are packed, before dispatching them to central warehouse, the unit supervisor checks 5% of the garments.

 

QC by Central QC Supervisor (PF-2)

Once the garments are ready for dispatch to the central warehouse, the appointed QC supervisor from the central QC department visits the unit & checks about 10% of each item. The approval for dispatch to the central warehouse is given only if the quality is as per the product manual and as per the required standard.

 

QC at the Central Warehouse (PF-3)

After the garments reach the central warehouse, the central QC department checks 5% of the garments & the garments are accepted at the warehouse only if they are of acceptable standard.

 

QC for the full Consignment (PS-1)

Once all the garments of any particular consignment are received at the central warehouse, the boxes are numbered and Invoice & Pcking list is prepared. At this stage head of the central QC department checks 5% of the garments.

 

Pre-Shipment QC (PS-2)

Before loading the goods in container the most experienced QC person does sample checking of all the items and the consignment leaves our premises only after the quality is approved by him.

 

Weighment before loading

Before the boxes are loaded in a container, each box is weighed & the weight of different boxes relating to the same size of each item are compared to ensure that the number of garments packed in each box is correct.

 

 

The sampling at the each stage is done in very scientific way so that each item is checked in each size & colour. Manual for sampling procedure forms the basis for all QC supervisors to follow. This avoids subjectivity. This Quality Control System ensures that the garments despatched by us are as per the quality specifications of our customers.