Quality Processes

 

Quality Assurance System

Quality assurance has derived certain working system in factory which is stated as below:

 

Quality Assurance

A planned and systematic pattern of all actions necessary to provide adequate confidence that the product optimally fulfils customers' expectations i.e. is problem-free and well able to perform the task it was designed for.

     
     


 

Fabric Quality System

We follow 4.0 point system for fabric inspection. Simultaneously we also go rigorous 100% fabric checking for all kind of fabrics.

Inspections are done to identify following flaws
  • Knitting/Weaving defects
  • Printing/dyeing defects
  • Needle Run/Dye Streaks
  • Skewing/Bowing
  • Holes/Needle Chew
  • Color Variation/Center Selvage

Various other defects are also detailed in report. All fabric lots are inspected & Color continuity card is prepared for every lot.

All our fabric has to go through the tests listed below in our in-house laboratory
  • Shrinkages
  • Fabric Weight
  • Color Fastness
  • Crocking (Dry/Wet)
  • Dimensional stability.
  • Torque
  • Ph Test.

 

     
   

Trims

We at Sabs do 100% inspection of trim before issuing it to production. All trims such as labels, Twill tape, Ribbons, Laces, Patches, Buttons undergoes lab testing. Twill tapes, Woven trims & Elastic are all pre shrunk.

     
 

Cutting

Cutting is the heart of garment industry. We follow defined procedure in cutting from fabric issue to cutting storage. Our aim is to have class of cutting & with minimal defect, by following all said norms & agreed quality standards at each individual process. We have dedicated Cutting QA, who assures cutting quality at each & every process. QA monitors following guide lines for each process to ensure correct cutting. Fabric is relaxed prior to cutting

  • Cad markers are checked for ratio & grain direction.
  • Hard Patterns are checked for grading and specs.
  • Layering & spreading is monitored to avoid stretched or relaxed lay.
  • Every lot is separated by inserting fabric strip & every roll is separated by reversing last lay of the roll.
  • Every individual component is numbered to ensure no mixing up of sizes or shades is being done.
  • Plaids, stripes are matched as per the requirement of buyer.
  • All small components are cut on band knife machines to ensure proper shapes are maintained.
  • Every bundle has barcode so that it can be tracked.
     
 

 

 

Sewing

Sewing is the multiple operation based process, here the different components are assembled to form complete product. The main objective of sewing is to give scrupulous look to the garment. Every individual style undergoes through R & D, to ensure correct attachments & folders are provided to achieve best productivity with desired quality standards. R & D makes time study of each & every style & based on time study assembly line plan is made. Each line is monitored by roving quality checker, who supports the line with technical assistance. Every single operation is monitored by roving checker & report is generated for the same. All end line checkers do a 100% check of garments and prepare it’s report. All roving and end line checkers are monitored by sewing QA supervisor.

     
   

Needle Policy

We have strong needle policy to control broken needle fragments. Needles are only issued to operator who returns all broken parts. If any part is missing than he has to get the semi stitched garment to get checked with hand metal detector for missing needle fragment. Needles are replaced on regular basis to avoid needle holes. Needle logs are maintained.

     
   

Finishing Section

Objective of finishing is to give aesthetic look to the garments, hence finishing is called the brain of garment industry. Finishing is the most momentous division where in the raw products move rapidly from various stages to redefine it. Each & every stage in finishing has its role to play in to give the product its desired look. Presentation of the finished products itself tell about the product quality. To ensure garments are defect free, 100% garments are checked by passing through initial checking & final checking.

Garments are checked for
  • Oil Stains / Stains.
  • Sewing defects such as open seam or skip/jump stitch.
  • Button/Button Hole placement.
  • Pressing & balancing
  • 100% spec evaluation.
  • Main label, Care label, Embroidery, Print, Hangtag & Price tickets.
  • Packing is done as lot wise.

 

     
 

Washing:

Many buyers request for garment wash programs. So garments are sent for washing.

  • Washing recipes are set prior to washing.
  • Based on washing recipes 10 garments are washed to ensure desired hand feel is achieved.
  • Bulk lot is then taken for washing once hand feel is approved.
     
 

Quality Inspections

Final Inspections are conducted at AQL1.5 & AQL2.5 based on buyer’s requirement. Besides final inspection every shipment undergoes Inline & Midline inspection to ensure product is maintained right from initial stage. We aim at First Time Right & hence continuous monitoring is done at end product.

Packing audit is conducted for every shipment to ensure garments are packed as per the buyer’s ratio. We have our internal Packing AQL which fulfills the requirement of international standards. Records are maintained for all internal inspections which are carried at every stage.