The Garment Buyer’s Complete Guide to Pre-Shipment Inspection: AQL, Defect Classification, and How to Stop Defective Shipments
Everything garment buyers need to know about pre-shipment inspection: AQL sampling explained, defect classification (Critical/Major/Minor), what inspectors check, common failures, and how to read your report.
Understanding the 4 Point Fabric Inspection System
Quality Control Understanding the 4 Point Fabric Inspection System Fabric issues that are missed early often become expensive problems later. A fabric inspection is a practical quality control step that helps catch defects before cutting and sewing begin, when changes are harder and more costly. For best visibility, inspections are typically completed on a fabric inspection machine before the fabric is spread or moved into production, so only approved rolls enter the garment line. What the 4 Point System Is & How the 4 Point System Scores Defects In the garment industry, waiting until a dress is finished to find a fabric hole is a costly mistake. Fabric inspection is a critical preventative measure. We highly recommend using specialized inspection machinery to review rolls before they ever reach the cutting table. This ensures that only high grade materials enter your production line, saving you from “dead stock” and wasted labor. The 4 Point System is one of the most widely used methods for grading fabric through visual inspection. It is commonly referenced in the textile and garment industry and is aligned with ASTM D5430. Instead of labeling fabric as good or bad, the system assigns demerit points to defects. The total points help buyers and suppliers decide whether a roll meets their agreed acceptance criteria. This approach can be used on different fabric types and stages, including greige fabric and finished fabric. Under the 4 Point System, each defect is given a penalty score based on size and severity. Points are assigned on a scale from 1 to 4, with 4 points as the maximum for any single defect. Defects can be measured in either direction, length or width, depending on how they appear on the roll. In most setups, only major defects are counted toward the score, while minor issues may be recorded but not penalized, depending on the inspection agreement. How Fabric Rolls Are Graded After inspecting a roll, the inspector totals the defect points and converts them to a standard rate based on 100 square yards of fabric. This creates a consistent way to compare rolls of different widths and lengths. Once the points per 100 square yards are calculated, the roll is evaluated against the acceptance limit defined by the buyer or brand. Acceptance limits can vary by product type, fabric type, and customer standard. 4 Point System Calculation Example & What Is an Acceptable Score To calculate points per 100 square yards: Total points per 100 square yards =(Total defect points in the roll x 36 x 100) / (Fabric width in inches x Fabric length in yards) Example:Roll length: 120 yardsRoll width: 45 inchesTotal defect points: 22 (22 x 36 x 100) / (45 x 120) = 14.66 points per 100 square yards There is no single universal pass level. Some factories use internal limits such as 40 points per 100 square yards, but many buyers set their own thresholds based on brand standards, fabric type, end use, and risk tolerance. The most important point is that acceptance criteria should be agreed before production and applied consistently across shipments. How the Penalty Logic Works Defects are assigned points ranging from 1 to 4 based on their size and impact on the final garment. A single flaw can never exceed 4 points. 1 Point: Small defects (up to 3 inches).2 Points: Medium defects (3 to 6 inches).3 Points: Large defects (6 to 9 inches).4 Points: Major defects (over 9 inches) or holes. By focusing only on major defects, the system ignores minor inconsistencies that do not affect the final product, allowing for a fair evaluation of the factory’s output. How Global QC Gate Supports Fabric Inspections Global QC Gate provides independent fabric inspections for textiles and garment production, including inspections using the 4 Point System when required by buyer standards. Our inspections help confirm fabric quality before production begins, reduce the risk of defects reaching finished goods, and support consistent decision making across suppliers. If you would like a sample fabric inspection report or support setting acceptance criteria for your sourcing program, contact Global QC Gate today. Order Inspection
Fabric Defects In Knitting
Textiles and Apparel Fabric Defects in Knitting & How to Prevent Them Fabric defects in knitting are a common challenge in garment production and often remain hidden until cutting or sewing begins. When defects are discovered too late, brands face delays, increased costs, and rejected shipments. Early inspection and quality control are essential to prevent defective knitted fabrics from entering production. Common Fabric Defects in Knitting Some of the most frequently identified fabric defects in knitting include: Dropped stitches that create holes or weak areas Needle lines caused by damaged or misaligned needles Uneven stitch density leading to inconsistent fabric appearance Oil stains from poorly maintained machines Barré effects resulting in visible stripes or shading These defects can affect fabric strength, appearance, and overall garment quality. Why Fabric Defects Occur During Knitting Fabric defects in knitting usually occur due to: Poor machine maintenance Low quality yarn or inconsistent yarn tension Untrained operators Lack of in process quality checks Without proper inspection, these issues often go unnoticed until final production stages. The Importance of Fabric Inspection for Knitted Fabrics Fabric inspections help identify defects before fabrics are approved for cutting and sewing. Inspections are typically conducted using fabric inspection machines under controlled lighting to ensure clear visibility of defects. Early detection allows manufacturers to: Reject defective fabric rolls Reduce production waste Maintain consistent quality standards How Global QC Gate Helps Prevent Fabric Defects Global QC Gate provides independent fabric inspections and during production checks to help brands control quality at every stage. Our inspectors verify fabric quality, identify defects, and ensure only approved materials enter production lines. Protect your production from costly fabric defects. Contact Global QC Gate to schedule a fabric inspection. Order Inspection