PHASE 1: PRE-INSPECTION PREPARATION

(Before the inspector arrives at factory)

Step 1: Document Review & Planning

1. Gather Specification Documents:
   • Approved lab dip/swatch cards
   • Approved strike-off/print strike-off
   • Approved trim cards (zippers, buttons, threads)
   • Tech pack with detailed measurements (POM sheet)
   • Approved fabric quality standard
   • Packaging specifications (polybags, hangers, cartons)
   • Purchase Order with quantity breakdown
2. Define AQL (Acceptable Quality Level):
   • Select appropriate AQL for defects:
     • Critical Defects: AQL 0.0 (e.g., safety issues, branding errors)
     • Major Defects: AQL 2.5 (e.g., holes, stains, wrong color)
     • Minor Defects: AQL 4.0 (e.g., loose threads, minor stitching issues)
   • Determine sample size based on MIL-STD-105E/ANSI Z1.4 tables
3. Schedule Inspection:
   • Ensure 80-100% of order is completed and packed
   • Arrange proper lighting and workspace at factory
   • Confirm factory representative will be available

PHASE 2: ON-SITE INSPECTION PROCESS

Step 2: Initial Verification

1. Quantity Verification:
   • Count total cartons/pieces
   • Verify packing list matches PO quantities
   • Check packing ratio (units per inner/outer carton)
2. Carton & Packaging Check:
   • Inspect carton quality (strength, water resistance)
   • Verify shipping marks: Style #, PO #, Color, Size, QTY, Destination
   • Check barcode labels accuracy
   • Inspect inner packaging (polybags, tissue, hangers)

Step 3: Random Sampling

1. Select Sample Pieces:
   • Use random sampling method across colors, sizes, and cartons
   • Select sample size according to AQL table
   • Ensure samples represent entire production run

Step 4: Visual & Dimensional Inspection

1. Visual Inspection – General:
   • Check overall appearance and presentation
   • Verify against approved sample/prototype
   • Look for obvious defects from 3 feet/1 meter distance
2. Fabric Quality Check:
   • Color: Check against approved lab dips under proper lighting (D65)
   • Shading: Compare color consistency within garment and across panels
   • Fabric Defects: Identify holes, stains, slubs, yarn variations, knitting defects
   • Hand Feel: Verify fabric weight, texture, and drape match standard
3. Measurement Verification (POM Check):
   • Measure 3 pieces per size against tech pack tolerances:
     • Key measurements: Chest/Bust, Waist, Hip, Length, Sleeve
     • Use calibrated measuring tape on flat surface
   • Check symmetry (sleeve lengths, shoulder seams, side seams)

Step 5: Construction & Workmanship

1. Stitching Quality:
   • Check stitch density (SPI – stitches per inch)
   • Verify thread color matches specification
   • Inspect seam neatness and consistency
   • Check for skipped stitches, loose threads, broken stitches
2. Seams & Finishing:
   • Inspect seam allowances (宽度)
   • Check seam strength (pull test on sample seams)
   • Verify seam type matches spec (flat-felled, overlock, French)
   • Examine edge finishing (serging, binding, hemming)
3. Trims & Embellishments:
   • Verify all trims match approved samples:
     • Zippers (brand, color, functionality)
     • Buttons/Snaps (size, color, placement)
     • Labels (care, size, brand – content accuracy)
     • Elastics (width, recovery, placement)
   • Check embroidery/print quality:
     • Registration and placement
     • Color matching
     • Stitch density for embroidery

Step 6: Functionality & Safety

1. Garment Function Tests:
   • Try on sample garments (or use form) for fit
   • Test all closures: zippers, buttons, snaps, hooks
   • Check pocket placement and functionality
   • Verify ease of movement
2. Safety Compliance:
   • Check for exposed sharp objects (pins, needles)
   • Verify choking hazard compliance for childrenswear
   • Inspect flammability compliance labels (if required)
   • Check drawstring safety for children’s hoodies

Step 7: Labeling & Packaging

1. Label Verification:
   • Care Labels: Content accuracy (symbols/wording), permanence
   • Size Labels: Correct placement, size grading accuracy
   • Brand Labels: Correct logos, placement, stitching
   • Country of Origin: Correct as per trade regulations
   • Fiber Content: Accuracy as per test reports
2. Final Packaging:
   • Check folding/presentation
   • Verify polybag thickness and warning stickers
   • Inspect hanger quality (if applicable)
   • Verify assortment by size/color in master cartons

PHASE 3: TESTING & VERIFICATION

Step 8: On-Site Testing

1. Perform Quick Tests:
   • Colorfastness Rub Test: Dry and wet crocking test
   • Zipper Test: 50 open-close cycles minimum
   • Button/Snap Pull Test: Verify security
   • Stretch/Recovery Test for knits
2. Fabric Verification:
   • Verify fabric composition by burn test (if trained)
   • Check fabric weight (GSM) against specification
   • Inspect knitting/weaving consistency

PHASE 4: DOCUMENTATION & REPORTING

Step 9: Defect Recording & Classification

1. Document All Defects:
   • Record each defect with clear description
   • Take photographic evidence (with measurement scale if needed)
   • Classify each defect: Critical/Major/Minor
   • Tally defects against AQL limits
2. Prepare Inspection Report:
   • Summary page with Pass/Fail recommendation
   • Detailed defect breakdown with photos
   • Measurement chart with variances noted
   • Quantity verification summary
   • Packaging and labeling assessment

Step 10: Final Verification & Communication

1. Hold Exit Meeting with Factory:
   • Present preliminary findings
   • Show defect samples
   • Discuss any immediate corrective actions
2. Issue Final Report:
   • Send comprehensive report within 24 hours
   • Include clear recommendation:
     • PASS: Ship as is
     • PASS WITH CONDITIONS: Minor issues noted but within AQL
     • FAIL – HOLD FOR SORTING: Requires 100% sorting
     • FAIL – HOLD FOR REPAIR: Specific repairs needed
     • FAIL – REJECT: Critical issues, do not ship

PHASE 5: POST-INSPECTION FOLLOW-UP

Step 11: Corrective Action Monitoring

1. If Failed:
   • Request Corrective Action Plan from factory
   • Schedule re-inspection if required
   • Verify repairs/sorting before shipping approval
2. Final Shipping Authorization:
   • Provide written release for shipment
   • Verify final packing list against inspection findings
   • Retain inspection report for quality records

---

CRITICAL CHECKPOINTS FOR SPECIFIC TEXTILE CATEGORIES:

For Woven Garments:

• Seam puckering prevention
• Pattern matching at seams
• Bias grain alignment
• Interlining attachment quality

For Knitted Garments:

• GSM verification
• Shrinkage control
• Recovery/stretch consistency
• Laddering prevention

For Technical/Performance Wear:

• Waterproof seam taping
• Bonded seam integrity
• Specialty fabric performance verification
• Reflective element placement

For Home Textiles:

• Four-way pattern matching
• Hemming consistency
• Fabric bow and skew measurement
• Drape quality assessment

---

TOOLS REQUIRED FOR TEXTILE PSI:

1. AQL sampling cards
2. Digital camera with macro capability
3. Measuring tape (metric/imperial)
4. Color matching light box (D65)
5. GSM cutter and scale
6. Magnifying glass/loupe
7. Seam ripper (for construction analysis)
8. Zipper gauge/button gauge
9. Crockmeter for rub tests
10. Fabric shrinkage ruler
11. Label verifier/measuring gauge