A final inspection, often called a pre-shipment inspection, is carried out on finished and packed goods before they leave the factory. It is usually done by the buyer's quality team or a third-party inspection company, using an AQL sampling plan. The goal is to confirm that the lot meets the buyer's requirements.
When it happens#
Most buyers require that the lot is 100% produced and at least 80% packed before final inspection starts. Check the buyer's manual: some require 100% packed. Inspecting before the lot is ready usually leads to a failed or cancelled inspection.
What is checked#
| Area | Typical checks |
|---|---|
| Quantity | Produced and packed quantity by style, color and size against the order |
| Packing | Carton marks, dimensions and weight, assortment, polybags, folding, hangtags, barcodes |
| Workmanship | Visual defects on the sampled garments, classified critical, major and minor |
| Measurements | Key points of measure on a sample per size, against the spec and tolerance |
| Style and color | Style details, color and shade against the approved sample |
| Labels and trims | Care labels, size labels, country of origin, trims, accessories |
| On-site tests | Examples: carton drop, seam slippage pull test, barcode scan, color fastness to rubbing, needle detection (as the buyer specifies) |
The order of work#
- Readiness check: confirm quantities, packing progress, documents and approved samples.
- Carton selection: the inspector selects cartons at random from across the lot. The number of cartons is often the square root of the total, rounded up, but follow the buyer's method.
- Packing and assortment check on the opened cartons.
- Sample draw: garments are taken from the selected cartons across sizes and colors to the AQL sample size.
- Workmanship inspection: each sampled garment is checked in a set order, inside and out.
- Measurements on the required number of pieces per size.
- On-site tests as specified.
- Result: defect counts compared with the accept and reject numbers. See AQL.
- Report signed by the inspector and factory representative.
Preparing to pass#
- Do your own final audit first, using the same AQL plan and defect definitions.
- Keep an approved sample, trim card and measurement spec at the inspection area.
- Provide a good inspection table: clean, well lit, with a measuring tape and a light box or daylight lamp where needed.
- Have packing lists ready, with carton numbers.
- Separate the lot from other orders so cartons are easy to reach.
- Fix known problems before offering the lot; do not hope the sample misses them.
When a lot fails#
A failed lot is usually sorted (100% inspection of the affected defect type), repaired or replaced, and offered for re-inspection. Record the cause and fix the process. Repeated failures point to problems that inline controls should have caught. See inline inspection and root cause analysis.
Common reasons for failure#
- Measurement out of tolerance on one or more sizes. See measurement variation.
- Shade variation between garments in a carton. See shade variation.
- Stains, loose threads and untrimmed ends.
- Wrong or missing labels, hangtags or barcodes.
- Wrong assortment or carton marks.
Record results with the AQL inspection sheet.
Related guides#
- Right first time: first-pass quality on the line.
- Sewing defects: the workmanship defects inspectors look for.
- Process flow chart and layout of garments finishing: preparing packed goods for inspection.