Quality control ensures that every seam, stitch, and fit meets a clothing brand’s required standards. 

With over 15+ years of experience in the fashion industry, I’ve witnessed firsthand how closely tied quality control is to my work as a fashion designer, and I’ve seen some horror stories.

A good friend of mine skipped QC during the pre-production phase because it was her second round of production with the same factory. She neglected to get a PP (pre-production) sample, and the fit came out all wrong. She lost a ton of money and had to offload hundreds of garments to TJ Maxx, an off-brand retailer.

Another friend of mine didn’t have proper QC during the post-production phase, and all her garments were delivered in trash bags. Yes, literal trash bags.

That’s what happens when you don’t implement proper quality control for your clothing brand!So, in this article, I’ll walk you through the quality control process in garment manufacturing step-by-step. Because whether you’re an in-house designer, freelance fashion designer, or starting your own brand, you need to understand and implement various QC checks to ensure designs are made right!

What is Quality Control in Garment Manufacturing?

Quality control in garment manufacturing is all about ensuring that the clothes meet the company’s standards. It involves checking everything from fabric and stitching to size and color – ensuring the garments are good enough to sell. 

This process includes inspecting materials, looking for fabric defects, ensuring production methods are up to par, and reviewing the garments to address any inconsistencies from the desired specs. 

At its worst, botched production, product returns, and recalls due to quality control failure are not only a big expense to fashion brands but also impact the brand’s name negatively.

Importance of Good Quality Control in Garment Manufacturing

Having solid QC practices gives you peace of mind and a good reputation for your clothing brand. 

• Customer Satisfaction: Consistent quality leads to satisfied customers who are more likely to return and recommend your brand to others. 
• Strong Brand Reputation: Reliable quality control enhances a brand’s reputation for producing high quality garments and keeps customers coming back.
• Minimized Defects and Returns: Tight quality control means fewer defects slipping through, saving you returns (and a lot of headaches). 
• Time and Money: Catching problems early prevents wasted materials and costly rework.
• Streamlined Processes: Keeping an eye on quality helps identify areas for improvement, making your operations smoother and more productive.

Types of Quality Control Methods

There are a couple of ways to implement quality control during garment manufacturing. These can be sorted into the different stages of production – in pre-production, while in production, and upon finishing production (post-prod). 

Each phase of quality control inspection has a different goal, so, having these checkpoints throughout the entirety of the garment manufacturing process ensures potential issues are taken care of early, avoiding further complications down the line.

Pre-production Quality Control

This phase ensures that all necessary quality requirements are met before actual production begins. It involves inspecting fabrics, reviewing patterns and samples, and conducting tests on materials to ensure they are suitable for manufacturing.

For example, the inspectors examine fabric rolls for any defects, such as holes or distortions, that could affect the quality of the garments. Identifying these issues early helps prevent production delays and ensures that garments are made with high-quality materials.

Types of Pre-production Quality Control Methods include:

• Material Inspection: Thoroughly examining fabric, trims, and components before production to identify any defects or discrepancies.
• Fabric Shrinkage and Color Fastness Tests: Fabric quality control tests like these anticipate potential issues like shrinkage, bleeding, fading, and other fabric defects.
• Sample Testing: Creating and inspecting prototype garments to confirm the pattern and materials match the intended design. (This is where my friend messed up by skipping sampling and had her entire bulk production ruined.)

In-line Quality Control

In-line Quality Control takes place during the manufacturing process itself. For example, in-line quality control can be done during fabric cutting, sewing and assembly, finishing, and so on. This method ensures that potential defects are identified and fixed in real time, minimizing the likelihood of large-scale quality issues during the next phase.

Types of In-line Quality Control Methods include:

• Random Inspections: Periodic checks during production to ensure random samples meet quality standards. 
• Dimensional Checks: Verifying garment measurements and dimensions to ensure they follow the specifications in your tech pack. 
• Stitching Inspection: Monitoring the sewing process to catch any stitching defects or irregularities.

Post Production Quality Inspection

Post Production Quality Inspection is the final step of quality checking before garments are packaged for delivery. This phase involves a comprehensive inspection to verify that the finished products meet the desired quality standards and get the green light for distribution.

Inspectors make sure everything from labeling to packaging requirements meets an acceptable quality level. (QC at this level would have caught the issue of my friend’s garments being delivered in trash bags.)

Types of Post Production Quality Control Methods include:

• Final Random Inspection: Selecting random samples from production batches for additional quality checks.
• Functionality Testing: Ensuring that zippers, buttons, and other features work as intended. 
• Appearance Assessment: Evaluating overall appearance, including color, print alignment, and overall aesthetics.

Who Should be in Charge of Quality Control Inspections?

In manufacturing facilities, quality control managers or supervisors oversee QC procedures.

However, many fashion brands, especially larger ones, opt to employ their own quality control inspectors or hire third-party inspectors to ensure unbiased evaluation of their garments.

The Manufacturer’s QC Team 

Manufacturers have their own team of quality inspectors in their factories. They can be tasked to check every step of the production process – from fabric spreading, garment assembly, up until final inspection. 

While it’s highly convenient to have QC inspectors from the manufacturer, a lot of fashion brands worry about bias and inconsistencies when it comes to using the factory’s own inspectors.

Here are the pros and cons of working with the manufacturer’s own QC team:

Pros:

• Familiarity with Production Processes: The manufacturer is intimately familiar with their own production processes, which can facilitate efficient quality control inspections.
• Immediate Access: Inspections can be conducted on-site as garments are being produced, allowing for timely identification and resolution of quality issues.
• Cost-Effective: In-house QC may be cheaper than outsourcing to third-party inspectors, especially for smaller brands with limited budgets.

Cons:

• Potential Bias: There may be a conflict of interest if the manufacturer is responsible for both production and quality control, potentially leading to biased inspection results.
• Limited Expertise: Manufacturer staff may lack specialized training or expertise in quality control, leading to oversight of critical quality issues.

True Story: I once evaluated a poorly fitting garment with “perfect” dimensions as per the manufacturer’s measurements. My instinct prompted me to cross-check these measurements, and to my surprise, they were waaay off tolerance. I’m not saying all manufacturers are like this, but it’s really important to be proactive when it comes to quality checking.

Third Party Quality Inspectors

Bringing in outside inspectors can give a fair, unbiased look at garment quality. While it is possible to hire individuals or teams and train them up to do quality control inspection, there are also existing organizations that offer these services and have trained inspectors.

Here are the pros and cons of working with third party quality inspectors:

Pros:

• Objectivity: Third-party inspectors offer an unbiased evaluation of product quality, as they are not directly affiliated both with the manufacturer and fashion brand.
• Specialized Training: Third-party inspectors often have specialized training and experience in quality control, ensuring thorough and accurate inspections.
• Accountability: Contracting third-party inspectors holds them accountable for the quality of their inspections.

Cons:

• Cost: Hiring third-party inspectors can be expensive, especially for frequent or extensive inspections.
• Coordination Challenges: Coordinating inspections with third-party providers may introduce logistical complexities and potential delays in the production process.

In-House Quality Inspectors

Larger brands may employ in-house inspectors who oversee the entire manufacturing process right from selecting raw materials to approving the finished products when they get to the warehouse.

Here are the pros and cons of employing in-house quality inspectors:

Pros:

• Direct Oversight: Having an internal team dedicated to quality control allows for direct oversight and management of inspection processes.
• Tailored Inspections: An in-house team can customize inspection protocols to align with the brand’s specific quality standards and requirements.
• Continuous Improvement: Internal QC teams can provide ongoing feedback and implement process improvements to enhance product quality over time.

Cons:

• Resource Intensive: Establishing and maintaining an in-house QC team requires significant resources, including staffing and training.
• Expertise Acquisition: Building an effective QC team may require recruiting individuals with specialized expertise in quality control, which can be challenging and time-consuming.

Pro Tip: Big fashion brands may deploy not only one but two or all of the quality control methods mentioned above. Deciding which one to use for your fashion brand ultimately depends on your own circumstances including your fashion brand’s size, budget, and priorities.

Best Practices for Quality Control in Garment Manufacturing

Here are some more tips to keep your quality control processes in check.

• Establish clear quality standards: Establish detailed quality standards for your garments, materials, and processes. This is where your standard documents in the apparel industry like your How to Measure Guide, tolerances, and other QC related regulations come into play.
• Provide comprehensive training: Train your staff, including quality control inspectors and production workers on quality standards, defect identification, and best practices to maintain consistency.
• Collaborate with suppliers: Do not underestimate the power of working closely with your manufacturers and suppliers. Have open communication between quality control teams and production staff to address issues promptly. Collaborate with suppliers to address any recurring quality issues and work together to implement effective solutions. 
• Document processes and findings: Make sure to maintain clear records of quality control processes, inspections, and identified defects. This documentation will help in tracking trends and making informed decisions down the line.
• Continuous improvement: Regularly review quality control processes to identify areas you can improve. Encourage feedback from production teams to implement refinements.

While QC can add time and cost to the development and manufacturing process, it will actually save you from bigger and more expensive mistakes in the long run. Build a quality control process into your workflow before you learn firsthand what can go wrong if you don’t!