Definition of a quality inspector:
A Quality Inspector is a person who checks the quality of products in raw-material form or final form or in any phase of processing, such as cutting, sewing, finishing, packing, and prior to shipment. An inspector generally checks whether the manufactured product conforms to quality specifications given by the buyer.
Buyers provide quality specifications in the form of order sheets/worksheets, special, instructions, drawings and approved samples, acceptable quality level (AQL), etc.
The warehouse inspector checks whether materials received in the warehouse conform to those in the packing list & material bill in terms of color, size, type, brand, quality, quantity, etc.
Any mismatch should be immediately reported to higher management for onward transmission to supplier & buyer so that urgent corrective actions may be taken. There are two types of inspectors for the warehouse: Fabric inspectors & the other one for inspection of trims, accessories & other incoming goods.
Job description of fabric inspector:
* He inspects 10% of color-wise rolls & records the result
* If there is any discrepancy in quality, 100% of the rolls are inspected
* He inspects the rolls to identify general defects & shading if any
* For general defects he will use the 4-point system to penalize defects and will accept if penalty points are below 40 or otherwise specified by the buyer.
* For shading problems, he will inspect the rolls rigorously, and separate them shade-wise.
* If a spectrophotometer is available, he will inspect the rolls with it.
* He will number each roll with a 3-digit code.
* He will document the result of the inspection and send them to the appropriate authority for onward submission to the supplier & buyer.
Job description of trim & accessory inspector:
* He conducts inspection of the trims for quality & quality
* He conducts 10% inspection of the goods. In case of discrepancy, he will conduct a 100% inspection
* He will document the result of the inspection and send them to the appropriate authority for onward submission to the supplier & buyer
Cutting section inspector:
Cutting room inspectors inspect a number of issues like pattern, marker, spreading, cutting, numbering, lot binding, etc.
Job description of pattern & marker inspectors:
* He ensures that the pattern and its grading are OK
* That the marker is OK and within specified consumption
* He documents his inspection report.
Job description of inspector for spreading, cutting, numbering, lot binding:
* Checks whether fabric lay is correct;
* Checks whether fabric lay height is correct;
* Whether cutting is conducted correctly;
* Checks whether size & color-wise bundling is done correctly;
* Checks whether there is any defect in fabric, lining & interlining, etc.
Job description of line inspector:
* He ensures that all inputs are covered so that they do not stain
* He detects defects at needlepoint and at a very preliminary stage;
* Checks if there are defects due to fault in machine, needle, thread or feed mechanism, etc;
* Checks if the right color & types of thread, button, zipper, lining, shell, label, logo, etc have been used;
* Checks if buyer’s instructions are followed;
* Ensures that machines, tables, operators’ hands, floor are clean & free of dust & dirt, etc.
* He checks all processes in a production line on a random basis;
* He marks defects on a specially designed chart (Traffic light chart)
* He identifies the highest 3 defects in the line
* He identifies defect level, defect rate, etc.
Job description of table inspector:
* He conducts 100% inspection of all goods on an inspection table;
* He checks the garment zone-wise
* Checks all types of defects and rejects defective garments;
* Checks if there is any oil or, stain mark, needle mark, point up-down, etc.
* Compares buyer’s specifications with actual garment quality;
* Check size specs rigorously;
* Checks if the right color & type of thread, button, zipper, lining, shell, label, etc have been properly attached;
* Takes special care about major defects and defects in the most critical areas.
* He carefully inspects issues about which there is a special instruction for the buyer.
* He passes goods, which conform to the buyer’s specification
* He segregates rejects and transfers them to the separate baskets as-signed for each type
* He ensures that repaired & washed garments come to him separately for re-inspection
* He ensures that there are a few categories of the separate baskets-one group for incoming sewn goods, one group for rejects, one group for washable garments, one group for repairable garments & one group for passed goods. These baskets should be easily identifiable.
Job description of lot pass inspector:
Lot pass is an SQC technique used on goods that underwent table inspection. This is a reinforced inspection to ensure quality.
* He takes a lot of goods passed by table inspectors and counts the number of goods in the lot;
* He draws samples from the lot using a normal/tight sampling plan and an AQL of preferably 1.5%.
* He inspects the garments of the sample size;
* If the number of rejects exceeds the Acceptable level of the sampling Plan, the lot to the table inspectors for re-inspection otherwise accept it.
Job description of finishing inspector:
* He controls the heat of the iron so that goods are not damaged by overheating;
* He ensures that goods are folded as per standard practice or as per instruction of the buyer;
* Ensures cleanliness of finishing tables;
* Checks for defects & rejects;
* Takes special care about oil marks, stain marks,s, etc.
* He checks if puckering develops after washing or ironing of garments.
* Inspects goods before poly packing.
* Ensures buyer specified assortment;
* Ensures that finished & packed garment matches approved finished garment
* Ensures quality of packaging, side marks of cartons, etc.
Job description of final inspector:
The final inspector generally conducts a pre-shipment inspection, which is often called a final inspection.
* Ensures that the whole consignment (lot) is stacked in one place;
* Ensures that samples are drawn from the lot on a random basis;
* He inspects each sample and records the outcome;
* He counts the number of rejects out of the sample size;
* He compares it with that allowed as per the inspection sampling plan
* If a number of rejects exceed the allowable limit given in the Inspection Sampling Plan, he rejects the lot, otherwise accepts it.
* Checks whether assortment matches buyer specified assortment;
* He checks if poly bags, cartons, inners, etc are of specified quality;
* He checks shipping marks & side marks, gross and net weight, etc.
* He checks if the destination is correctly given.