8 Dimensions of Quality (Car)
Performance:Essentialfunction. Mileage, handling, brakes. Durability:
Longevity. Break needs to be changed after 5000 km.
Reliability: Performance over time. MTTF(Mean time to failure). Breakdown.
Features: Extra-functionality. GPS, Music, Camera.
Serviceability: Time, accessibility, quality of repair.
Aesthetics: Color, outlook.
Conformance: Standard, Customization, As per requirement. Blue seat leather.
Perceived Quality: Brand, reputation, experience, word of mouth. Toyota.
8 Dimensions Of Quality (Polo Shirt)
Performance: Comfort,
Durability: Longevity
Reliability: Color Fastness
Features: Stein proof fresh
Serviceability: 50 Time Wash (Lands end)
Aesthetics: Hand fill, Appearance
Conformance: Customized Print
Perceived Quality: Recommendation
Garment Quality Control Process - YouTube
One visible major defect can
Buyer expectations & brand risk trigger shipment hold, re-
inspection or chargeback
Rework, repairs, extra
Cost impact (COPQ) inspection, air freight, claims
Why
Quality Speed impact
Defects consume capacity;
rework queues delay shipment
Matters? Compliance & traceability
Labeling, fiber content, safety,
restricted substances
documentation
Higher Right-First-Time
Competitive advantage improves OTIF and repeat
orders
Cost of Quality: the Iceberg Idea
Visible costs (often tracked)
• Rework labor
• Repairs
• Extra inspection
• Scrap
Quality cost categories
• Prevention: training, SOP, maintenance, supplier
control
Hidden costs (usually bigger) • Appraisal: inspection, tests, audits
• Line stoppage & low productivity • Internal failure: rework, scrap
• Late shipment penalties • External failure: returns, claims, reputation damage
• Claims / chargebacks
• Loss of future orders
• Management time
What is “Quality”? (Customer vs Manufacturer)
Manufacturer view
• Customer view • Conformance to tech pack/spec
• • Fit & comfort • Stable process with low variation
• • Appearance & hand-feel • Repeatability across lines/suppliers
• • Color consistency (shade) • Evidence-based decisions (data + reports)
• • Durability (seam strength, pilling)
• On-time shipment with minimal rework
• • Safety & labeling
• • Value for money
QC vs QA vs TQM
Inline/endline/final inspection, measurement checks, testing
QC (Detect)
Output focused
SOPs, training, audits, calibration, process controls
QA (Prevent)
Process focused
TQM (Culture Leadership commitment + continuous improvement + supplier partnership
+ system) Organization/value-chain focused
Where QC Happens: apparel process map
Fabric: 4-point
Inline: first-off Final: AQL
Shade
Patrol checks Pass/Fail
band/GSM
Fabric
Fabric Sewing Sewing Final
Inspectio Cutting Finishing Packing Shipment
Receiving (Inline) (Endline) AQL
n
Insert photo here
Insert photo: fabric inspection /
sewing line / final inspection
Fabric Related
• holes, slubs, shade variation, GSM variation
Common Cutting Related
Apparel • wrong panel, ply slippage, notch mismatch
Sewing Related
Defects • open seam, skip stitch, puckering, wrong SPI, broken stitch
(Bangladesh Finishing Related
• stain, poor pressing, wrong trim/label
Examples) Packing Related
• wrong barcode, wrong size sticker, missing polybag, carton
marking error
Defect vs Defective (Avoid Confusion)
Defective item = a unit that
Defect = a nonconformity (e.g.,
fails acceptance criteria (may
open seam, oil stain, shade
contain one critical or multiple
difference).
major/minor defects).
Classification
Measurement failures can be
(Critical/Major/Minor)
“major” even when garment
depends on buyer spec and
looks OK.
risk.
Activity: Classify Defects
In pairs: classify each as Critical / Major / Minor and justify.
• Missing size label
• 2 cm measurement out of tolerance
• One loose thread inside hem
• Needle hole on front panel
• Barcode does not scan
Short video: Garment Quality Control
Process
▶ Garment Quality Control Process (YouTube)
Garment Quality Control Process (YouTube)
While watching, note:
• Where are inspection points?
• What checklists/tools are used?
• How are defects recorded?
What is TQM? • EXTERNAL CUSTOMERS
• INTERNAL CUSTOMERS
• SUPPLIER MANAGEMENT
CUSTOMER
▪Total Quality Management is an ORIENTATION
organization or value chain wise
management system for assuring
quality, continuous improvement TQM
and overall productivity
management.
CONTINUOUS
IMPROVEMENT
•PROBLEM SOLVING
APPROACH
• TRAINING AND EDUCATION
Total Quality Management (TQM) - YouTube • PROCESS MANAGEMENT
In a Nutshell
Identification &
Correction
Prevention Identification &
Correction
QC
Organization wide quality
QA
management
TQM/QMS
TQM “House” (apparel factory)
Continuous improvement (PDCA/Kaizen) +
fact-based decisions
Outcomes
• Higher RFT
Customer Process People Supplier
• Lower COPQ
Focus Mgmt Involvement Partnership
• Better OTIF
• Fewer claims
• Buyer trust
Foundation: SOP + training + 5S + preventive maintenance
PDCA example: reduce open seam defects
Mini-project steps
• Pareto shows open seam top defect; target -50% in 2 weeks
• Fix machine tension + seam guide; retrain operators
• Daily DHU and rework minutes; verify by size/operation
• Standardize setting; update SOP; share across lines
Check Do
Act Plan
7 Basic QC Tools (with Apparel Use-cases)
Check sheet Endline defect tally by type/operation
Pareto chart Prioritize defects causing most rework
Fishbone diagram Root causes of shade variation / measurement failure
Histogram Distribution of chest width vs tolerance
Control chart Trend of DHU or seam strength over time
Scatter plot Defects vs machine age / operator experience
Flowchart Map rework loops and inspection flow
Pareto Example: Focus Improvement where it Matters
Illustrative data: Typically, a few defect types drive most rework. Use Pareto weekly in sewing.
Fishbone (Ishikawa) example: “shade
variation in garments”
Material: Machine:
Different dye lots Method: Lighting differences
Fabric stored mixed No bundling control Pressing temp variation
No shade band Mixed panels in cutting
No shade segregation
Effect: Shade variation
Measurement:
Man: No spectro data Environment:
Inspector inconsistency No Delta E limit Warehouse humidity
Operator mixing bundles Sun exposure
Short video (3 mins): Total Quality
Management (TQM)
▶ TQM overview (YouTube)
TQM overview (YouTube)
While watching, note:
• What does “everyone owns quality” look like?
• Which pillar is hardest in RMG?
• Which metrics would you track weekly?
Decide accept/reject a lot by inspecting a
sample (instead of 100%).
Acceptance
sampling Commonly used in final inspection of finished
(AQL) — why goods in export RMG.
& when Sampling plan is agreed in advance (buyer
standard / ANSI/ASQ Z1.4 concept).
Sampling reduces inspection cost but does not
improve quality by itself—use data for CAPA.
AQL terms you must get right
Lot A defined batch: usually one PO + style + color + (sometimes) size range
Sample size How many units to inspect from the lot
Defect vs A unit may have multiple defects; defective is the unit failing criteria
defective
Ac/Re numbers Acceptance and rejection numbers for each defect class
Inspection level Determines sample size given lot size
Defect classes used in AQL (apparel)
Defect type Typical rule Example
Critical 0 allowed (reject if found) Needle/metal piece, wrong safety label, sharp object
Major Affects function/appearance/measurement Open seam, wrong measurement, wrong label
Minor Small deviation, not affecting usability Small loose thread, slight inside skip stitch
Common buyer AQL example: Critical 0.0 | Major 2.5 | Minor 4.0 — Always follow buyer manual.
Inspection levels General levels
(how sample I (relaxed), II (normal—most common), III (tight)
size is chosen)
Special levels
S1–S4 (smaller sample sizes; often for
packaging/barcode checks)
Lot size + level → code letter → sample
size → Ac/Re numbers
AQL workflow (simple)
Choose plan Random Compare
Inspect Count
Lot ready (Level + carton with Decision
sample defects
AQL) selection Ac/Re
Hands-on example: 8,000 pcs lot
(illustrative numbers)
• Scenario: 8,000 pcs polo shirts (1 PO, 1 color). Inspection level II.
AQL: Major 2.5, Minor 4.0, Critical 0.
• Typical plan example: code letter “L” → sample size 200 pcs.
• Example Ac/Re for 200 pcs (illustrative): Major Ac 10/Re 11; Minor
Ac 14/Re 15; Critical Ac 0/Re 1.
• If 9 major + 12 minor + 0 critical → PASS; If 11 major → FAIL.
Technique video (3 mins): Clock-wise
garment inspection (Polo shirt)
▶ Clock-wise inspection method (YouTube)
Clock-wise inspection method (YouTube)
While watching, note:
• What is the standard path?
• How does it reduce missed defects?
• How would you train new inspectors?
PGD-GB | IBA, University of Dhaka | Apparel QC (Bangladesh)
Common AQL mistakes (and how to avoid
them)
Treating AQL as Inconsistent
Non-random sampling
“allowed defect %” classification between
(only top cartons). Use
(wrong). AQL is a inspectors. Use defect
carton list + random
sampling-plan handbook + calibration
selection.
parameter. sessions.
Mixing lots (different
Passing without CAPA.
PO/colors) in one
Use defect data to
inspection. Inspect lot-
remove root causes.
by-lot.
Inspection report: purpose
Formal record: what was Evidence for
inspected, how sampled, acceptance/rejection:
what was found, and the reduces disputes with
decision. buyer/3rd-party.
Supports traceability
Input for CAPA and
(who/when/where/which
continuous improvement.
lot/carton/size).
Types of Quality Control
➢Full Inspection: Raw Material, Sample production, generally all
products.
➢Sample Inspection
➢Acceptance Sampling: Acceptable Quality Level. Finished Product. Against Target
➢Statistical Quality Control: Finished product, each stage end control through
control chart.
➢Statistical Process Control: End to End process control through control chart.
➢Process Capability Study: Against target
Acceptance Sampling
▪ Is a type of selected inspection.
▪ Done on products.
▪ Generally, inspection criteria is set by customer (B2B) or industry/internal standard
(B2C).
▪ Acceptance sampling guideline and plan are set beforehand.
▪ Instead of doing full inspection, an inspection of sample products are done.
▪ In RMG, AQL (Acceptable Quality Level) is applied in most cases.
Acceptable Quality Level In RMG
▪Maximum number of defective items that could be considered acceptable during the
random sampling of and inspection.
▪ It is expressed in a percentage (%) ratio number of average defective items and
number of total inspected items
AQL: Basic Concepts
▪ Defects: A mistake in a particular product.
▪ Defective: Mistake in a product that make the products rejected by the customer.
▪ Generally, defects can be of four categories.
Defect Type AQL Remarks
Critical 0 (Zero or no defect) Any defect makes the product Defective and rejected
Major 2.5%
Minor 4.0%
Slight 6.5%
A Sample List of Critical
Defectsiu
How to Clock Wise Inspection (Polo-Shirt) - YouTube
AQL Basic Concepts
❑ Six types of AQL
❑AQL-1.0%,
❑AQL-1.5%,
❑AQL-2.5%,
❑AQL-4.0%,
❑AQL-6.5%,
❑AQL-10%.
ANY FAILUREIN AQL TESTLEADSTO FULLINSPECTION!!!
Inspection Levels
❑ General Inspection Level: Higher sample size. Main product.
❑ I: Relaxed
❑ II: Normal: Most used one.
❑ III: Strict
❑Special Inspection Level: Lower sample size. Generally related to packing and barcode
scanning.
❑ S1 to S4 with S4 having more samples.
AQL Sample Code
Inspection report essentials (must-have
fields)
• Header/traceability
– Buyer, factory, style, PO, color, size range, lot size, date/time, inspector,
location
• Sampling plan
– AQL, inspection level, sample size, carton selection method
• Checks performed
– Workmanship, appearance, measurements, labeling, packing, accessories
• Findings & evidence
– Defect list + counts + classification + photos + measurement table
• Decision
– PASS/FAIL + Ac/Re numbers + remarks
• CAPA link
– Root cause, corrective & preventive action, owner, due date, verification
Measurements: reporting tolerances
clearly
POM Spec Tol Measured Result
Chest (1" below armhole) 54.0 cm ±1.0 55.2 OK
Body length HPS 72.0 cm ±1.0 73.5 Fail
Sleeve length 24.0 cm ±0.7 24.2 OK
Neck width 17.0 cm ±0.5 16.2 Fail
Tip: Always define the POM method (how measured), tool used, and number of garments measured.
Inspection report No clear lot definition (PO/color/size) → report
not traceable
pitfalls (what
makes buyers Missing sampling plan or sample size → decision
reject reports) cannot be audited
Photos without scale/annotation → weak
evidence
Defect descriptions vague (“bad stitching”) →
not actionable
No CAPA owner and due date → issues repeat
No linkage to carton/size → containment fails
From report to improvement: CAPA workflow
Issue found Contain Root cause Corrective Preventive
(NCR) segregate 5-Why action standardize
Example (open seam)
• Root cause: tension variation + worn needle + seam guide not followed
• Corrective: standard tension range; replace needle; retrain; rework affected cartons
• Preventive: hourly patrol checklist + PM schedule + visual guide at machine
• Verify: defect rate tracked 7 days and held below target
Workshop (15–20 mins): build a mini
inspection report
• Form groups (4–5). Choose product: Polo/T-shirt/Jeans.
• Assume: lot size 5,000 pcs; AQL Major 2.5, Minor 4.0, Critical 0;
Level II.
• Draft 1-page report: header + sampling + top 5 defects + decision +
CAPA.
• Present in 2 minutes: Pass/Fail + why + next actions.
Quick quiz (5 questions)
• 1) Give one example each of QC, QA, and TQM in a garment factory.
• 2) Why must AQL sampling be random?
• 3) If you find 1 critical defect in sample, what is typical decision?
• 4) Name two “must-have” items in the report header.
• 5) Corrective vs preventive action—explain with an example.
QC detects; QA prevents; TQM builds culture and
system for continuous improvement.
Place controls early (fabric/cutting) to avoid
downstream rework.
AQL is a decision tool; it requires randomness +
Key takeaways consistent classification + clear evidence.
Inspection reports must be auditable: traceability +
sampling + evidence + clear result.
Use inspection data to drive CAPA and stabilize
processes—not just to “pass”.
