A quality inspection report does two jobs: it tells the workshop clearly what needs fixing, and it shows the buyer which inspection the goods have passed. A note like "the thighs are a bit tight" does neither. A good report states, with photos, in which order, in which size and in how many pieces a defect was found, and what will be done about it.
When are inspections carried out?
A single final inspection is often too late: by the time a defect is found, the whole lot has been sewn. Garment manufacturing commonly uses three inspection points:
| Inspection | When? | Purpose |
|---|---|---|
| First piece inspection | When the first pieces of bulk production come off the line | Catch measurement and sewing defects before they spread through the run |
| Inline inspection | About halfway through production | See whether a defect keeps recurring |
| Final inspection | When the goods are being pressed and packed, before shipment | Decide whether the lot is accepted |
The buyer's own inspector or an independent inspection company usually carries out the final inspection. If the manufacturer carries out the first two inspections itself, the risk of the lot being rejected at final inspection drops significantly.
How many pieces are inspected? (AQL)
At final inspection, not every piece in the lot is checked; a sample is drawn according to lot size. In apparel, the most common method is AQL (acceptable quality limit) sampling, based on the ISO 2859-1 (ANSI/ASQ Z1.4) tables. Most buyers ask for AQL 2.5 for major defects and AQL 4.0 for minor defects; no critical defects are allowed.
Some examples at general inspection level II:
| Lot size | Sample | Major (AQL 2.5) accept / reject | Minor (AQL 4.0) accept / reject |
|---|---|---|---|
| 281–500 pcs | 50 pcs | 3 / 4 | 5 / 6 |
| 501–1,200 pcs | 80 pcs | 5 / 6 | 7 / 8 |
| 1,201–3,200 pcs | 125 pcs | 7 / 8 | 10 / 11 |
How to read it: from a lot of 800 pieces, 80 pieces are drawn. If there are 5 or fewer major defects, the lot is accepted; if there are 6 or more, it is rejected. If your buyer's inspection instructions call for different levels, use their table; the values above are only an example of common practice.
Defect classes: critical, major, minor
- Critical: a defect that could harm the user or cause a legal problem. Example: a broken needle fragment, a small part on childrenswear that could come off, a wrong care label.
- Major: a defect that stops the product being sold or used. Example: a measurement out of tolerance, an open seam, a visible stain, the wrong colour.
- Minor: a defect that is noticeable but does not make the product unsaleable. Example: an untrimmed thread end, a slightly uneven seam.
Agree the classification with the workshop in advance. "Is this defect major or minor?" should not be debated on inspection day.
What should the report contain?
| Section | Example |
|---|---|
| Order details | LN-324 · Linden · Chino · 903-1 Brown · 500 pcs |
| Inspection type and date | Inline inspection · 28/09/2026 · Inspected by: Nurten Koç |
| Workshop | Delta Tekstil |
| Sample | 50 pcs (with size breakdown) |
| Findings | Major: thigh measurement −1 cm, sizes 98–108, 7 pcs · Minor: thread ends, 4 pcs |
| Measurement chart | Measured value, tolerance and difference for each size |
| Decision and action | Affected sizes to be corrected at pressing; re-inspection on 30/09/2026 |
Write measurements together with the tolerance. "Waist 82" on its own says nothing; "waist 82, expected 84 ± 1, difference −2" does.
How to take the photos
- Two photos per defect: one of the whole garment (so it is clear where the defect is) and one close-up.
- For a measurement defect, get the tape measure in the frame, with the figure legible.
- Shoot in daylight or under white light; colour differences don't show under yellow light.
- Don't downsize the photo. The buyer or the workshop will want to zoom in on the detail.
- Keep the photo with the report; a photo left in a phone's gallery can't be found two weeks later.
What happens after the report?
A report should not be closed without an action and a date. Record the quantity to be corrected, who will correct it and the re-inspection date. The result of the re-inspection is added under the same order too, so when the customer asks "what was found and what was done?", the answer is in one place. If the same defect keeps recurring at the same workshop, that also feeds into the decision on which workshop gets the next order.
The quality report lives inside the order. Photos are stored at original quality; every finding is logged with who and when. 15 days free.
See garment production tracking