Last Updated on June 30, 2026
Introduction
A strong fabric inspection SOP helps a factory catch defects before cutting, reduce rework, and keep quality consistent across lots. It also gives QC teams a clear method for sampling, checking width and shade, recording defects, and separating non-conforming rolls. In this guide, you will learn the practical steps used in everyday fabric inspection, along with the records and controls that support better results.
Fabric Receiving and Sampling Plan
After getting fabric receiving status from the material department, QC people will make a plan for sampling inspection and confirm the lot number, roll count, color, and fabric type before opening the rolls.
Inspection Method
ANSI/ASQ Z1.4, the current civilian replacement for MIL-STD-105D according to ASQ, General inspection level II, AQL 2.5 (If there is no buyer’s other specification). AQL is the lot acceptance plan, while the 4 point system is the fabric defect scoring method, so they should be tracked separately in the SOP. Follow 4 point system; they conduct 60% inspection of a specific consignment. If 60% fail then need to inspect 100%, and the lot should be kept on hold until reinspection is closed. In this case of 100% inspection, QC personnel may claim to supplier through sales division for 100% inspection charge by a particular format i.e. called claim sheet.
Pass Point
Generally Garments Manufacturers standard 40 points per 100 square yards, according to ASTM D5430/D5430M fabric inspection practice.
4 Point System
Attached with details. Each defect is scored by its length, and the total demerit score is used to decide pass or fail.
Inspection Tools and Ticket Verification
Measuring tape, scissors, defect sticker or chalk, fabric defect display board, reference sample & blank inspection form worksheet/BOM sheet. Use the worksheet to record the exact defect position, roll number, and shade observation for later traceability.
Check ticket information, item number & Lot No. and match them with the packing list before inspection starts.
Log Book and Red Tag Control
QC should maintain a Log book to see receiving situation and inspection situation at a glance & also maintain a Red Tag Logbook. A separate hold, reject, and reinspection record helps prevent mixed inventory.
Width Inspection
Penalty 4 points to each linear yard of fabric where the cut-able width is less than the minimum specification and inspector will measure 4-5 yards continuously at the Beginning,
Middle and End of roll and record in inspection report. Initial disposition should be taken as a base on a penalty point. If the width issue repeats in the same lot, keep the full lot under review before cutting release.
Lab Test Follow-up
Material department will send fabric for lab test as soon as receive fabric, and QC will follow up it’s done or not. As per fabric criteria and care label instructions Lab’s personnel are responsible for doing the necessary test as per buyer guideline. Bulk cutting should wait until the required test report is approved.
Color Control and Shade Assessment
Color Control: Validated and updated 1st consignment sample by Decathlon are available in inspection machine. Initial disposition should be taken on the basis of color comparison. Always compare against the approved master sample under standard light and on the correct face side.
Color Shading Check: Inspector will check Side- Center- Side & Side to Side shading check randomly after completion of the report; it will be dispatched to concerned section and keep a master copy of record. Shade variation should also be checked roll to roll, especially for dyed and printed fabrics.
Non-Conformity Materials
Material department has to keep designated place as red tag and yellow tag. To use red tag fabric, it must be approved along with sufficient documents from Buyer/supplier or factory management approval. Yellow tag can be used after discussion with the supplier by short replacement. Keep approved fabric physically separated from red-tag and yellow-tag stock until the final disposition is closed.
Final Summary Report
After visual inspection have to make a summary report for giving to all concerned department and keep one master copy for record. Include roll number, total points, defect type, width result, shade status, and final disposition in the summary report.
Good fabric inspection depends on consistent sampling, clear defect recording, and fast communication with material and production teams. If the issue is traced early, you save cutting loss, rework, and supplier disputes.
Conclusion
A well-followed fabric inspection SOP makes quality control more reliable, improves communication between departments, and helps prevent costly production mistakes. When inspection is done with the right method, clear records, and quick action on defects, the factory can protect both efficiency and final garment quality.
Frequently Asked Questions (FAQs)
Q1. What is the 4 point system in fabric inspection?
Ans: The 4 point system assigns 1, 2, 3, or 4 points based on defect length. In most mills, fabric passes if the total score stays within the buyer or factory limit, commonly 40 points per 100 square yards.
Q2. What does AQL 2.5 mean in fabric inspection?
Ans: AQL 2.5 means the sample plan accepts a lot if the defect count stays within the allowed limit at the chosen sample size. It is an acceptance sampling rule, not the same as a fabric demerit score.
Q3. Is MIL-STD-105D still used for fabric inspection?
Ans: MIL-STD-105D is obsolete. Most factories now use ANSI/ASQ Z1.4 or ISO 2859-1 for acceptance sampling.
Q4. How much fabric should be inspected from each roll?
Ans: The sample size depends on the buyer specification, roll length, and risk level. A common practice is to inspect the beginning, middle, and end of the roll, then increase to 100% if the defect rate is too high.
Q5. How do you check shade variation in fabric?
Ans: Check side to center to side and side to side under standard light with the approved master sample. Record the shade issue by roll number so cutting and bundling can separate the affected fabric.
