For quality management we follow the following process:
For quality management we follow the following process:
Fabric Quality Check
Fabric is checked 100% for various defects like:
- Weaving defects
- Holes
- Printing / dyeing defects
- Water / crease marks
- Width wise segregation
- Skew / torque
- Colour variation
All the fabrics are checked for:
- Count / construction
- Shrinkage
- Tear strength
- Crocking (dry / wet)
- Appearance after wash (Garment 45 min. Cycle machine wash)
- Tensile strength
- CF to washing
- CF to light
- Seam slippage
Trims
- All trims are checked for durability and performance and are ensure for compliance with care instructions.
- All trims are attached correctly using proper attachment methods.
- Trim materials are checked to perform consistently with the base fabric performance with no differential shrinkage.
- Join seams are kept neat and raw edges are removed.
- Lace panels are paired / matched.
- Pre-shrunk elastic is always used for respective styles.
Cutting (Physical)
- Layering is done on the basis of fabric weight / GSM and size / ratio.
- Dye lot numbers are given on each layer cut, to keep track of lots cut at the packing stage, if needed.
- Each dyelot is to be cut in ratio to maintain color consistency, when the goods finally reach the rack.
- Each layer cut, is checked for cutting consistency and records are maintained.
Cutting (Technical)
- All component parts of the garment are laid parallel to the warp (length) of fabric unless style warrants others positioning of parts.
- All component parts of a garment are laid in one general area and are shade controlled.
- Each layer edge is checked for unacceptable skew / torque.
- All plaids, horizontal stripes and vertical stripes are matched as per the requirement of Buyer.
- Lightweight fabrics or off grain fabric use to relax & make it tension free to prevent problems in stitching.
- Any block or placement print is cut individually to ensure correct print appearance on the garment.
Stitching
- Time and motion study is done before any style commencement.
- R&D department does product engineering to increase productivity using folders & attachment also do all necessary requirement to maintain quality standard.
- In-line quality check are maintained at each level and the same are followed religiously with regard to core aspects of stitching:
- Needles
- Threads
- Seams
Needle Checking
- We follow the broken needle policy with utmost importance in zero tolerance zone. All records are maintained for the same.
- Needles are checked and replaced regularly in order to avoid needle damage and over heating.
- Needles are compatible with the fabric and thread to avoid seam quality problems.
- We ensure that compatible constructed fabrics are made with corresponding ball point/sharp point needles.
Washing & Finishing
- All the garments are given sufficient time to relax and dry thoroughly prior to packing.
- Thread cutting, ironing, spotting and other finishing processes are done under strict quality control measures.
- Each finishing process is done under the supervision of a senior Q.A. and all the garments go through 100% quality check.
- All the garments are passed through a metal detecting machine.
- 100% garments are checked for:
- Correct labeling, hangtag positioning and carton marking.
- Off specs garments are corrected or removed.
- Correct ratio packing.
- Same dyelots within carton.
- Quantity check in each carton as per the packing instruction.
Final Quality Inspection
- All the packed garments are inspected 2.5AQL quality audit before forwarding goods to the buyer's Q.A. team.
- Records are maintained for all these internal inspections.
Children Safety
- Small parts/choking hazards: For children age 3 and under, anything which can pass through a choke tube is strictly avoided.
- Garments with small parts embellishments as sequins, beads etc. are labeled with "WARNING...CHOKING HAZARD".
- Accessory items with sharp points and edges are not used on children garments.
- Garments are ensured to be free from all residual skin irritants using a pH controlled soap wash.
- Lead and formaldehyde contents are regularly checked through nominated labs.
- Contentious checking of Button pulling strength, sequence as per the buyer's requirement.