Garment Quality Control System: AQL, Inline, and Final Inspection
Ninghow is a clothing manufacturer focused on stable bulk quality. This QC guide explains the system we use—AQL, inline checks, and final inspection—to keep bulk consistent and reduce returns.
What Is a Garment Quality Control System?
A garment QC system is a set of checks that happen at the right time, not just at the end.
A complete system usually has three layers:
- Inline QC (during production)
- Final Inspection (when goods are finished and packed)
- AQL Sampling Rules (how many pieces to check and what counts as a pass)
When brands rely only on a final check, problems are found too late. By then, the factory has already made most of the order.
Why Apparel Quality Problems Happen (Even With “Good” Factories)
Most defects come from a few common causes:
- Specs are unclear (no clear tolerances, weak tech pack)
- Fabric changes (shrinkage, color shade, different batches)
- Workmanship varies (different operators, rushing, weak training)
- No process checkpoints (issues repeat until the end)
- No proof or reporting (brands can’t see what is happening)
The 3-Part QC System That Protects Your Brand
Part 1: Inline QC (During Production)
Inline QC means checking quality while garments are being made—before the order is finished.
Why inline QC matters
- Finds defects early (cheaper to fix)
- Stops repeat issues (same defect across hundreds of pieces)
- Protects your delivery time (less rework at the end)
Best moments for inline QC
- After cutting (panel accuracy, shade grouping)
- After first sewing lines (seam quality, stitch density, key measurements)
- After decoration (print/embroidery placement, durability checks)
- Before packing (labeling, trims, overall workmanship)
What inline QC should check
- Stitching and seam strength on stress areas
- Clean finish (no loose threads, no holes, no stains)
- Measurement points that matter most (chest, body length, sleeve length)
- Decoration quality (cracking, peeling, puckering, misalignment)
- Fabric issues (shade difference, shrink risk, defects)
Simple rule: Inline QC is not one check. It is checkpoints.
Part 2: Final Inspection (Finished Goods + Packing)
Final inspection happens when production is completed and the goods are ready for shipment.
What final inspection should confirm
- Correct size distribution (size ratio is accurate)
- Measurements are within tolerance
- No major defects (holes, open seams, broken stitching)
- Printing/embroidery matches the approved sample
- Labels and hangtags are correct
- Packaging is correct (polybag, barcode, carton marks)
- Carton count and packing list match the order
Final inspection is essential—but it should be your last filter, not your only protection.
Part 3: AQL Inspection (The Sampling Standard)
AQL means Acceptance Quality Limit. In simple terms, it’s a rule for:
- How many pieces are checked from a batch
- How many defects are allowed before the batch fails
AQL does not mean “perfect.” It means “controlled risk.”
Why brands use AQL
- It creates a clear pass/fail standard
- It reduces arguments between brand and factory
- It sets the same expectations for every order
AQL categories (simple)
- Critical defects: unsafe or not allowed (example: sharp needle, serious labeling safety issue)
- Major defects: customers reject the product (example: open seam, wrong size, big stain)
- Minor defects: small issues many customers may accept (example: small loose thread)
Your brand should define what counts as critical, major, and minor for each product type.
How to Set QC Standards That Actually Work
A good QC system needs clear standards. Without them, inspection becomes opinion.
1, Create a “Golden Sample” standard
Before bulk production, confirm:
- Fabric and color standard (shade)
- Key measurements + tolerances
- Stitching and construction details
- Decoration placement and size
- Labeling and packaging
This approved sample becomes the “golden sample” for production.
2,Use measurement tolerances
Tolerances reduce returns because size control becomes clear.
Example approach:
- Set key measurement points (not 30 points)
- Define tolerance ranges for each point
- Require measurement checks during inline QC and final inspection
3, Lock decoration rules
Common decoration failures:
- Print cracks after wash
- Embroidery puckering
- Wrong placement on different sizes
- Color mismatch
Make sure decoration rules are written and checked.
The Most Common Garment Defects to Watch
Here are defects brands should track across polos, T-shirts, hoodies, and shorts:
Construction defects
- Open seams, skipped stitches, uneven topstitch
- Twisted side seams, wrong seam allowance
- Weak stress areas (pocket corners, placket, zipper ends)
Measurement defects
- Chest and body length out of tolerance
- Sleeve length mismatch
- Waist/hip errors in shorts
Fabric defects
- Shade differences within one order
- Excess shrinkage after wash
- Pilling or rough handfeel different from sample
Decoration defects
- Misaligned logo
- Print peeling/cracking
- Embroidery thread breaks or messy backing
Packing defects
- Wrong labels or hangtags
- Wrong size ratio in cartons
- Missing polybag or incorrect barcode
A Simple QC Workflow Brands Can Ask For
If you want quality you can trust, ask your factory to follow a workflow like this:
Pre-production meeting
(confirm specs, tolerances, golden sample)
Inline QC checkpoints
(cutting → sewing → decoration → pre-pack)
Final inspection
(finished goods + packing)
AQL report
(with defect photos and clear results)
Corrective action
(what was fixed, how it won’t repeat)
If the factory cannot show proof or reports, quality becomes guesswork.
How QC Connects to Cost, Lead Time, and Returns
If you want quality you can trust, ask your factory to follow a workflow like this:
A strong QC system can:
- Reduce rework and scrap
- Lower return rates
- Protect delivery dates
- Improve repeat orders
It also makes pricing clearer. When quality standards are defined, the factory knows exactly what to build.
Why Brands Choose Ninghow for Stable Quality
If you want quality you can trust, ask your factory to follow a workflow like this:
For mature brands, the goal is simple: bulk quality should match approved samples.
Ninghow supports this with:
- Clear QC checkpoints during production
- Measurement tolerance control
- Sample-to-bulk consistency rules
- Packing accuracy checks
- Simple reporting that buyers can understand
If you are unhappy with your current supplier’s QC transparency, a controlled trial order is a safe start.
Want Bulk Quality That Matches the Approved Sample?
Ninghow is an apparel manufacturer with inline QC checkpoints and AQL-based final inspection. If your returns are rising or quality varies order to order, we’ll show you a QC plan you can verify.
Actions:
- Request a QC Checkpoint Plan (inline + final, buyer-friendly)
- Get a Sample Defect Report Template (what you should receive)
- Run a QC-Focused Trial Order (pass/fail rules agreed before bulk)
