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SOP Quality Control Process For Fabric Suppliers: Purpose

The SOP defines the quality control process for fabric suppliers to ensure consistent inspection across locations. It requires suppliers to inspect 100% of fabric before shipment and segregate rolls that do not meet requirements. The inspection process involves checking fabric rolls for defects at an inspection table under regulated lighting and conditions using a 4-point scoring system. Rolls exceeding 10% defects over the allowance will cause the entire shipment to be rejected. Local labs also test fabric properties like count, density, width, and strength on the first bulk yardages.

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599 views

SOP Quality Control Process For Fabric Suppliers: Purpose

The SOP defines the quality control process for fabric suppliers to ensure consistent inspection across locations. It requires suppliers to inspect 100% of fabric before shipment and segregate rolls that do not meet requirements. The inspection process involves checking fabric rolls for defects at an inspection table under regulated lighting and conditions using a 4-point scoring system. Rolls exceeding 10% defects over the allowance will cause the entire shipment to be rejected. Local labs also test fabric properties like count, density, width, and strength on the first bulk yardages.

Uploaded by

sahil
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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SOP Quality Control process for fabric

suppliers
This SOP defines clear roles, responsibilities
and activities within the organization to
Purpose manage the quality control and inspection
process for woven fabric. The intention of this
SOP is to ensure a consistent fabric inspection
process across all locations and suppliers.

The SOP is applicable for all fabrics undertaken


within VIP sourcing
Scope
Procedure
The fabric supplier must carry out a full inspection of 100% of the to be shipped fabric to ensure that it complies with
the VIP requirements.
Only those rolls that meet the VIP requirement can be shipped as first quality.
All rolls that do not meet the inspection criteria must be classed as second or third choice and segregated from the
shipment.
The following process describes the procedure followed by either VIP fabric inspectors or agents carrying out an
inspection on behalf of the fabric mill as required by VIP and is therefore also a guide for fabric mills to follow when
doing their own 100% inspection.
Sampling approach for VIP inspection
Fabric lot size in Meters/Yardage Quantity to be inspected
0 to 500 - Full quantity (100%)
501 to 1000 - 50% of the lot
1001 to 2500 - 20% of the lot
Above 2500 - Square root of total yardage of the lot x 8
Inspection process & conditions
Inspection Table - Illumination on fabric surface. Over 1000 watts.
Light Source - Artificial Day Light - D 65
Inclination of inspection 45-70 Degrees. (Normally inspected at 45 Degrees)
Fabric width if width is under 50 inches - Inspected by one inspector and if over 50 inches
inspected by 2 inspectors.
Light source must be directly above the inspection surface
Speed - This cannot be specified. Inspector should be able to cover the total surface of the
inspection table : (in the normal conditions it should be less than 20 yards per min)
Inspection procedure
At the beginning of each roll a 6” full width cutting (head end) should be taken as a color reference and also
to check for side to center and side to side shading. The head-end should be marked with fabric style number,
color, actual length and inspector’s code.
Measure useable width edge to edge of fabric at the start, middle and end of the roll.
Check the recorded length on piece ticket against actual length of roll for variance.
During inspection, fabric is checked for defects which are rated using the 4 point system as follows :
 Defects up to 3” in length : 1 Point
 Defects up to 6” in length : 2 Points
 Defects up to 9” in length : 3 Points
 Defects over 9” in length : 4 Points

The entire shipment will be rejected if 10% of the inspected rolls have faults/points in excess of the
acceptable allowance.
The entire shipment will be accepted if the total number of failed rolls is less than 10% of the total inspected.
However the mill must remove all rolls with a point value in excess of the individual roll allowance.
Local Testing of First of Bulk Yardages
Keqiao Local Lab testing
1. Yarn Count
2. Fabric Density
3. Gsm and Width
4. Tear & Tensile
5. Seam Strength
Roll Heads
Cut 15 cms full width fabric strip from the beginning and the end of
the inspected roll

Use “Checked” stamp approved by VIP Quality controller at the end


and the beginning of the roll after inspection of a particular roll

Collect roll heads for lot wise color segregations


Labdips: Purpose
From the buyer’s perspective
The lab dip should be developed to make sure their design will be made matching with their required colors. The
designer needs to see the appearance of the color and shade before going for actual garment production. If the
designer likes the shade, lap dip is approved. Normally, the supplier arranges the lab dip for the buyers. During lab
dip submission, a couple of shade options are sent to the buyer for approval. So that the buyer can see the right
color (best color) in the fabric substrate and choose the one that's closest to your color standard. When the buyer
gets the correct lap dip (matching fabric color shade), they approve the fabric and ask for sample development
with the original fabric and original fabric shade. There will be always a chance of slight variation of shades in bulk
fabric compared to the color standard or the approved fabric lab dip swatch. In such a case, suppliers need to take
approval on all shades whether those shades can be used for making garments.

From fabric supplier’s or fabric dyeing plant's perspective


Though they are skilled in producing any color or shade, they need to show that they dye the fabric in the desired
shade. During the lab dip process, dyeing plants develop the dyeing recipe for the desired shades on the specific
fabric. There are different types of dyes used for different fabrics and different shade development. In this stage,
the fabric dyeing unit knows which dyeing will be used for the bulk production. If they can develop it in their lab
(sample fabric), they can ensure their customer (garment manufacturers) that in bulk fabric dyeing they can
develop the same shade. Lab dip approval is a standard process in apparel sourcing.
Lab Dips: SOP
Use Actual base (Pre-treated) fabric only

Submit 3 options for approval

Submit finished look fabric for quality approval along with lab
dips for color approval

Standard Lead time for Lab dips is 3-4 days


Flow Chart of Dyeing Lab/Lab Dip Development
Receiving standard swatch from the buyer
↓
Determination of the sample’s possible to color combination with the help of Spectrophotometer or manually
↓
Dispersion by autodoser
↓
Trial dyeing of the first recipe
↓
Unload
↓
Normal wash
↓
Hot wash with detergent
↓
Oven drying
↓
Ironing
↓
Shade matching in a lightbox ( If Ok then send to buyer for approval)
↓
Finishing
↓
Hydro
↓
Drying
↓
Compare with a standard swatch
↓
If ok
↓
Send for buyer’s approval
↓
Bulk production by considering the buyer’s approved sample as standard
Concept of ‘Bulk to Lab’ dyeing

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