Quality template

Inline Quality Inspection Sheet

A roving inline inspection record: pieces checked and defects found per operator and round, with DHU and a green, yellow or red result based on limits your quality manager sets.

What this template does#

This sheet records roving inline inspection. For every check, the inspector enters the operator, operation, pieces checked, defects found and the main defect type. The sheet calculates DHU and shows a green, yellow or red result from the limits set in the header. The action column makes sure every yellow and red result gets a response.

The method is described in inline inspection.

When to use it#

  • Throughout the day on every sewing line with roving inspectors.
  • For first piece checks after a style, machine or operator change.
  • As the source for inline DHU by operation in daily quality meetings.

How to complete it#

  1. Set the limits for green and red in the header. These are factory decisions based on operation risk; the example values are only a starting point.
  2. For each round, check the agreed number of pieces from each operator.
  3. Record defects and the main defect type.
  4. Act on yellow and red results: show the operator, check the machine, find the cause, and record the action.
  5. Summarise daily: operators and operations with repeated red results need root cause work.

Common mistakes#

  • Checking different numbers of pieces each round without noting it.
  • Leaving the action column empty after red results.
  • Inspectors repairing garments instead of showing the operator.

Download formats#

The Excel workbook contains the DHU and traffic light formulas. The CSV contains headings and an example row only.

Field guide

FieldWhat to enter
Line and traffic light limitsGreen if DHU at or below the first limit; red if above the second. Set these with your quality manager.
Round, operator and operationOne row per check.
Pieces checked and defects foundCount of pieces sampled from the operator's recent work, and defects found in them.
Main defect typeThe most frequent or most serious defect in the check.
DHU and resultCalculated DHU for the check and its traffic light color.
Action takenWhat was done about a yellow or red result.

Related guides

Quality & DefectsHow-to3 min read

Inline Inspection in Sewing Lines: Catch Defects at the Source

Inline inspection checks work at or near each operation while the line is running. How the traffic light system works, how to choose operations to check, sample sizes and frequency, and how to act on the results.

Quality & DefectsGuide3 min read

DHU (Defects per Hundred Units): Formula and How to Use It

DHU counts defects per hundred garments checked. The formula, how it differs from defective percentage, a worked example from end-of-line checking, and how to turn DHU data into action on the line.

Quality & DefectsGuide3 min read

Right First Time (RFT) in Garment Production

Right first time measures the share of garments that pass inspection without any repair. How to calculate RFT, how it relates to DHU and defective percentage, and how it is also used for lab dips, samples and shipments.

Quality & DefectsHow-to3 min read

Root Cause Analysis for Garment Defects: A Practical Method

Repairing defects fixes garments; root cause analysis fixes the process. A step-by-step method for garment factories using defect data, the 5M categories, fishbone diagrams and 5 Why, with a worked example on open seams.

Was this useful?