Our 5-Step Quality Control Process (AQL 2.5 Standard).
Mar 06, 2026
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Understanding the AQL 2.5 Standard
AQL stands for Acceptable Quality Limit. It defines the maximum number of defective units allowed in a shipment batch.
Most global apparel retailers use:
AQL 2.5 for major defects
AQL 4.0 for minor defects
Major defects affect functionality or brand reputation.
Examples include:
Broken seams
Incorrect size measurement
Dye bleeding
Fabric holes
Missing labels
Minor defects affect appearance but not function.
Examples include:
Loose threads
Slight shade variation
Small printing imperfections
Inspection follows ISO sampling tables based on order quantity.
Example:
| Order Quantity | Sample Size |
|
Reject (Major) |
| 1,200 pcs | 80 pcs | 5 | 6 |
| 3,200 pcs | 125 pcs | 7 | 8 |
| 10,000 pcs | 200 pcs | 10 | 11 |
If defects exceed the reject number, the shipment fails inspection and must be reworked.
The Reely Apparel 5-Step Quality Control System
Our quality control process follows five stages.
1.Incoming Material Inspection
2.Pre-Production Sample Approval
3.Pre-Production Meeting
4.Inline Production Inspection
5.Final Random Inspection
Each stage prevents different categories of defects.
Step 1: Incoming Material Inspection
Quality begins before cutting starts.
Fabric, trims, elastics, and packaging materials are inspected upon arrival.
Fabric Inspection Standards
Each fabric roll is checked for:
GSM accuracy
Color consistency (Pantone tolerance)
Fabric defects (holes, oil stains, knitting errors)
Fabric width consistency
Dye uniformity
Shrinkage rate
Color Fastness
For swimwear fabrics, we test:
Chlorine resistance
UV resistance
Stretch recovery
Elastane durability
Fabric inspection uses the 4-point system.
Rolls exceeding the defect threshold are rejected or downgraded.
Shrinkage & Wash Testing
Fabric samples undergo washing and drying tests to verify:
Shrinkage rate ≤ 3%
Color Fastness grade ≥ 4
Shape stability after wash
This prevents size inconsistency during bulk production.
Step 2: Pre-Production Sample (PPS)
Once fabric is approved, the Pre-Production Sample (PPS) is developed.
This sample represents the exact construction used in bulk manufacturing.
PPS verifies:
·Pattern grading accuracy
·Stitch type selection
·Label placement
·Elastic tension
·Fabric behavior after sewing
Measurements must match the Tech Pack tolerance.
Example tolerance:
·Bust: ±1 cm
·Waist: ±1 cm
·Hip: ±1.5 cm
·Strap length: ±0.5 cm
The PPS is reviewed internally and then sent to the buyer for approval.
No bulk cutting begins before PPS confirmation.
This step protects buyers from costly specification errors.
Step 2: Pre-Production Sample (PPS)
Once fabric is approved, the Pre-Production Sample (PPS) is developed.
This sample represents the exact construction used in bulk manufacturing.
PPS verifies:
·Pattern grading accuracy
·Stitch type selection
·Label placement
·Elastic tension
·Fabric behavior after sewing
Measurements must match the Tech Pack tolerance.
Example tolerance:
·Bust: ±1 cm
·Waist: ±1 cm
·Hip: ±1.5 cm
·Strap length: ±0.5 cm
The PPS is reviewed internally and then sent to the buyer for approval.
No bulk cutting begins before PPS confirmation.
This step protects buyers from costly specification errors.
Step 3: Pre-Production Meeting (PP Meeting)
Once the PPS is approved, a pre-production meeting is conducted.
Participants include:
·Production manager
·Pattern technician
·Sewing line supervisor
·Quality control team
The team reviews:
·Tech Pack details
·Sewing construction
·Fabric handling instructions
·Label requirements
·Packaging specifications
·Measurement tolerances
·Defect risk areas
Common risk points in swimwear include:
·Elastic tension control
·Bar tack reinforcement
·Seam stretching resistance
·Flatlock seam alignment
The meeting ensures the sewing team understands the exact production standards before starting bulk manufacturing.
Step 4: Inline Production Inspection
Inline inspection occurs during bulk sewing.
Inspectors monitor the production line to detect defects early.
Typical checkpoints:
·Stitch density consistency
·Seam alignment
·Thread tension
·Elastic insertion accuracy
·Print alignment
·Logo placement
For stretch fabrics used in yoga wear or swimwear, we test seam durability under stretch conditions.
If defects appear repeatedly, production stops and the line supervisor corrects the issue.
Inline inspection prevents defect multiplication across hundreds of garments.
Step 5: Final Random Inspection (FRI)
When production reaches 100% completion, a final inspection is conducted.
Inspection follows the AQL 2.5 sampling standard.
Garments are randomly selected from packed cartons.
Inspectors check:
Visual Quality
Fabric damage
Oil stains
Color variation
Loose threads
Measurement Verification
Key dimensions are measured against the Tech Pack.
Tolerance must fall within approved limits.
Functional Testing
Seam strength
Elastic stretch recovery
Label durability
Packaging accuracy
Packaging Inspection
Cartons are inspected for:
Correct quantity
Barcode accuracy
Polybag thickness
Hangtag attachment
Only shipments that pass AQL inspection are approved for export.
Fabric Performance Comparison
Fabric selection also affects quality performance.
| Metric |
|
Recycled Nylon Fabric |
| Typical GSM |
|
200–230 GSM |
| Cost Index | Medium | Medium–High |
| Durability | High | High |
| Color Fastness | Grade 4–5 | Grade 4 |
| Shrinkage Rate | ≤3% |
|
| MOQ | Moderate |
|
Both fabrics can meet swimwear standards when properly tested during incoming inspection.
Why Multi-Stage QC Protects Buyers
Factories that rely only on final inspection carry significant risk.
If defects appear late:
Rework delays shipment
Labor cost increases
Air freight may be required to meet deadlines
A structured QC system solves these issues.
Early inspection ensures:
Stable fabric quality
Consistent sizing
Reduced defect rate
On-time delivery
For brand owners, this protects margin and brand reputation.
Work With a Manufacturer That Controls Quality
When evaluating an OEM partner, ask direct questions:
Do they inspect fabric before cutting?
Do they approve a PPS before bulk production?
Do they run inline inspections during sewing?
Do they follow AQL 2.5 sampling for shipment?
Factories that cannot answer clearly usually rely on reactive quality control.
At Reely Apparel, quality control is built into the production workflow.