Pre-Production Quality Control System in Garments Industry

Pre-production quality assessment and control is the critical point for the garments industry. PP sample defines the correctness of measurement, shade, and construction of garments. Pre-Production Quality Control System in Garments Industry is set to check factory is able to produce full bulk orders without any issue. It is the preparation process of mass production.

Receiving Spec sheet, Materials, and QC File

Before starting pre-production sampling few important documents need to the quality department. Among them are spec sheets, PO sheets and QC files (trim cards) are the most urgent items. These documents help to know garments specification, size breakdown, measurements, and exact BOM sheet of an order.

Pre-production sampling –Size Set

Pre-production sampling (Size Set) aims to identify potential quality problems during bulk production as well as the availability of skill, machinery, work aids, and production capacity. The Pre-production quality control covers sampling activities done by production upon receipt of Approved Sealed Sample comments from the customer plus other necessities for production like actual fabrics, trims, and other order details. It is the responsibility of the Pre-production Control team to implement the procedure or system. It shall be composed of the following. The involved persons are Sample Room Head, Production Head, sewing in-charge, Technician, QA Manager, Cutting Room in-charge, Technical in-charge, IE, Planning & Finishing in-charge

Size set Sampling Procedure

1. The sample room must ensure that Pattern adjustments/Grading is made based on within 3 days upon receipt of the buyer’s final approval comments.
2. The planning department shall plan the schedule of the size set based on the master production Schedule.
3. The technical team shall make the size set in alignment with the sewing team where it is planned for bulk production. The use of possible work aids like sewing Folders needs to be tried during making a size set.
4. The Planning Department must ensure that the following information is available to the production line during the process of making the size set. Approved sample with complete specification sheet with Final approval comments. Actual fabric and trims should use in PP/ Size set sample
5. Respective line QA shall be tasked to make an initial evaluation using the Size Set Report
6. The Pre-production team shall evaluate the size set in terms of workmanship, and fit/presentation and formulate possible sets of solutions in accordance with the following agenda during the PP meeting.
7. Fabric Characteristics at cutting, Possible spreading and Cutting method, anticipated sewing difficulty, and methods, Potential quality problems in all aspects of production, Availability of work aids, machines, and skills, and Number of pieces to be made shall depend from customer to customer.

Initial/pilot production

The first trial lay of production considered the Initial/pilot lot. It is actually the first cutting load to the sewing line and the time to apply the anticipated method is foreseen during PPS/Size Set stage. To be able to apply Quality Standard for each and every sewing operation as well as work methods at the beginning of the process. To be able to identify potential problems not seen during the course of PPS. The production In-charges/APM/PM from Cutting to Finishing is responsible for ensuring that the PPS action plan is being applied during the pilot Production Run.

Initial/pilot batch production Procedure

Production in-charges & supervisors from Cutting to Finishing must see to it that SEAL samples and or PPS samples with respective comments, order details, and other relevant information are available in production in setting Standard Quality Reference for each and every operation. Based on the production schedule furnished by Planning Department, ensure that the following information is available to production in-charges before Pilot and bulk production starts.

• Approved Trim Card for Material information.
• Order Details
• Sealed Approved PPS sample
• Other relevant information is available.

Role of the Cutting department in pre-production

• The cutting Manager shall check style requirements based on the information on hand as follows:
  • Fabric information on Quality from Fabric Inspection
  • Shrinkage allowance details
  • Fabric Guidelines
  • Matching requirements if any
  • Consumption
• The cutting department is responsible to keep the Initial/First trial (Pilot) cutting panels ready two days prior to sewing Line loading.
• Consequently, check 100% of Pilot Cut panels on the following:
  • Cut pieces quality against the pattern
  • Fabric defects if any
• The cutting department can only precede cutting with subsequent markers of the same style on the following conditions.
  • If feedback on Cutting Quality is Good after Pilot Meeting Review.
• And 100% inspection proves no fabric defect on the Finished Garment.
• However, if quality rejections reach about 5% or more on fabric defects only, the cutting head shall notify the Merchandising department for immediate disposition.
• Based on the production schedule furnished by Planning Department, ensure that the following information is available to production managers/in-charges before Pilot and bulk production starts.
  • Approved Trim Card for Material information.
  • Order Details
  • Sealed Approved PPS sample
  • Other relevant information is available.

Role of Sewing department in pre-production

•  IE and Maintenance department ensure that the following are prepared prior to the Initial/pilot run
  • Operations break down and layout
  • Machines and folders requirements
  • Skill requirement
• Based on the Operations Breakdown/Layout, the operator and helpers shall be trained by the supervisor and Line in charge on the proper work methods in the attainment of Quality Standard.
•  Quality standards have been developed for each and every operation based on the Approved Seal samples and duly signed by the concerned Operator, Sewing line supervisor, Sewing in-charge, and Line QA & QA Supervisor. By doing so, all the operators are aware and agreed on the Quality Requirements of each operation and enabling them to achieve Right First Time Quality from each operation.
• Line QA inspector shall evaluate the pilot samples on the basis of workmanship, use of the right materials, and its specified position and measurement specs.

Role of Finishing Department in pre-production

• Finishing in-charges shall prepare the following immediately after receipt of advice from the Merchant department about Pilot Run.
• Packing Trim Card
• Packing Details of that particular style.
• Packing Methods
• The finishing Quality team shall set the quality standard for every single process in finishing with references to seal samples from customers.

Initial/Pilot/1^st output Review Meeting

It is called Pre-production(PP) meeting in the garments industry, chaired by Quality Manager and attended by Sample Room Head, Production Manager, sewing in-charge, Sewing Line Chief, QA In-Charge, Line QC/QA Auditor, Cutting Room in-charge, finishing in-charge to review Pilot samples and take necessary action to ensure that Right First Time Quality from Cutting to Finishing. Following parameter check in PP meeting:

• Accuracy of Production Patterns in achieving consistent specs.
• Before wash and after wash measurement.
• Fabric-related concern and necessary action
• Cutting concerns & necessary action plan
• Workmanship concern & action plan
• Achievement of Fitting as same as Sealed Approved sample.
• Shade and color evaluation report.

Hope this content gives us a clear idea of Pre-Production Quality Control systems in the Garments Industry, if you have any thoughts please share them in the comment box.