Quality Control and Industrial Practice
What the exam tests
This domain tests inspection, defect classification, quality systems and corrective action in garment production. Expect numerical questions on the 4-point fabric inspection system and questions on AQL, calibration and root-cause analysis.
Core rules and concepts
- Quality assurance covers the system that prevents defects; quality control covers inspection and testing. Both are needed.
- The 4-point system assigns 1 point for a defect up to 3 inches, 2 points for over 3 to 6 inches, 3 points for over 6 to 9 inches and 4 points for over 9 inches. Holes and cuts are penalised by size.
- Score per 100 square yards = total points × 100 ÷ fabric area in square yards. Buyer limits vary, so state the limit used.
- Classify defects as critical, major or minor. Use root-cause analysis and corrective action, not repeated inspection alone.
- Calibrate measuring tools and machines; control needles and metal contamination; record inspection results.
Worked example
A roll is 150 yards long and 60 inches wide. Area = 150 × 60 ÷ 36 = 250 square yards. Inspection records 40 points. Score per 100 square yards = 40 × 100 ÷ 250 = 16 points. If the buyer limit is 20 points per 100 square yards, the roll passes on this measure. The reasoning is that points alone are meaningless without fabric area; the score normalises defects to a standard area.
Traps that cost marks
Treating AQL as zero defects, inspecting only final garments, mixing critical and minor defects, and failing to calibrate tools are common errors.