A fabric fault found in the store costs a phone call to the supplier. The same fault found after cutting costs fabric, labour and often the delivery date. Receiving inspection is the cheapest quality check in the factory.
Receiving - before inspection
- Match delivery to the PO and packing list: order, colour, quantity, roll numbers.
- Check roll labels (length, width, weight, lot/shade) and packing damage.
- Enter a GRN and keep rolls in the inspection area - not in the issue racks yet.
Fabric inspection - the 4-point system
Inspect at least 10% of rolls (buyer standards vary; some require more), choosing rolls from every lot/colour.
| Defect size (length) | Points |
|---|---|
| Up to 3 inches | 1 |
| Over 3 up to 6 inches | 2 |
| Over 6 up to 9 inches | 3 |
| Over 9 inches | 4 |
| Holes / openings up to 1 inch | 2 |
| Holes / openings over 1 inch | 4 |
No more than 4 points per linear yard, however many defects it has.
Formula: Points / 100 sq yd = total points × 3600 ÷ (yards inspected × cuttable width in inches)
Example: a roll of 100 yards, 60" width, 38 points → 38 × 3600 ÷ (100 × 60) = 22.8 points → pass if the limit is 40.
Also check: width (at several places), GSM, shade against the approved swatch and between rolls (make a shade band), skew/bow, hand feel, and a shrinkage test before cutting.
Trims inspection
Check every trim against the approved trim card:
- Quantity per PO and per BOM (plus allowance).
- Colour, size, print, artwork, language, barcode data.
- Function: zippers run smoothly, snaps close and hold, buttons have no cracks.
- Labels: fibre content, care symbols and country of origin correct.
- Metal trims: needle-detector safe if the buyer requires.
Handling results
| Result | Action |
|---|---|
| Pass | Move to storage, update bin card |
| Minor issues | Accept with deviation approved by merchandiser/buyer |
| Fail | HOLD area with red tag, inform supplier and merchandiser same day, replacement or claim |
Tip: Keep an inspection report per roll. When a cutting or sewing defect appears later, you can trace it back to the roll and supplier.
Key points
- Receive against PO, inspect before storage.
- 4-point system: points per 100 sq yd decides pass/fail.
- Rejects go to HOLD - never mixed with good stock.
