The AQL (Acceptable Quality Level) system is commonly used for textile garments inspection during the manufacturing process to ensure that they meet predefined quality standards. Here’s how the AQL system is applied to inspect textile garments:
Establish Quality Standards:
Define clear and specific quality standards for the textile garments. These standards typically include criteria related to fabric quality, stitching, color, size, labeling, and any other relevant attributes.
Determine the AQL Level:
Choose an AQL level based on the criticality of the product, customer requirements, and industry standards. The AQL level defines the maximum acceptable defect rate in the inspected batch.
Sampling Plan Selection:
Select an appropriate sampling plan based on the AQL level and the size of the production lot. The sampling plan specifies the sample size (the number of garments to be inspected) and the acceptance criteria (the maximum allowable defects) based on statistical calculations.
Random Sampling:
Randomly select garments from the production lot for inspection. This randomization ensures that the sample is representative of the entire batch.
Inspection and Evaluation:
Inspect each garment in the sample according to the predefined quality standards. Inspectors may check for defects such as stitching irregularities, fabric flaws, color discrepancies, size variations, label accuracy, and other relevant attributes.
Defect Classification:
Classify defects into different categories based on their severity. The system typically categorizes defects as critical, major, or minor. The classification depends on the impact of the defect on the garment’s quality and functionality.
Counting Defects:
Count the number of defects in the sample and record the results. Compare the total defect count to the acceptance criteria specified in the sampling plan.
Statistical Analysis:
Perform statistical analysis to determine whether the batch of garments meets the acceptable quality level. This analysis considers factors such as the number of defects found in the sample, the sample size, and the acceptable defect level defined by the AQL.
Decision Making:
Based on the statistical analysis, make a decision about whether to accept or reject the entire production lot. Reject the lot if the number of defects in the sample exceeds the allowable limit specified by the AQL.
Reporting:
Document the inspection results, including the number and types of defects found, and generate a detailed inspection report. You may share this report with the manufacturer and the client.
Corrective Actions:
Reject the batch or identify critical defects, and you may need to take corrective actions. These actions may include rework, repair, or further inspection to ensure that the garments meet the required quality standards.
Continuous Monitoring:
Implement ongoing quality control measures to monitor the quality of garments throughout the production process. This helps identify and address quality issues in real-time. The AQL system provides a systematic and statistically based approach to quality control in textile garment manufacturing. It helps ensure that the produced garments meet the desired quality standards while allowing for a practical and efficient inspection process, especially in the context of large production lots.
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