| Material Selection | Selection of polyester, nylon, cotton, elastane, modal, or blended fabrics according to moisture management, stretch, softness, and durability requirements. | Fabric specification review, supplier documentation, laboratory swatches, and fiber-content verification. | Fiber composition, fabric weight, color consistency, hand feel, stretch recovery, and absence of visible defects. | Fabric weight is normally verified against the approved specification; fiber content should match the declared composition within applicable legal tolerances. | ISO 1833 for quantitative chemical fiber analysis; applicable textile labeling regulations; approved buyer specification. |
| Incoming Fabric Inspection | Inspection of fabric rolls before cutting to identify holes, stains, shade variation, slubs, broken yarns, and knitting defects. | Fabric inspection machine, light table, four-point defect grading system, roll measurement, and shade-band review. | Defect classification, usable width, roll length, color lot consistency, and fabric relaxation condition. | Defect limits and tolerance points are defined by the purchase specification; shade lots are separated to reduce panel-to-panel variation. | Four-point fabric inspection practice; ASTM D5430; internal approved sample and inspection specification. |
| Fabric Testing | Laboratory testing before bulk cutting to confirm performance for sports T-shirts and innerwear. | GSM cutter, tensile and bursting-strength tester, stretch-recovery tester, colorfastness equipment, and moisture-management testing equipment. | Weight, dimensional stability, pilling, colorfastness, bursting or tensile strength, wicking, drying, and elastane recovery. | Acceptance values depend on the product specification; wash shrinkage and colorfastness limits are agreed before production. | ISO 6330 for domestic washing procedures; ISO 5077 for dimensional change; ISO 12945 for pilling; ISO 105 series for colorfastness; AATCC test methods where specified. |
| Pattern Development | Creation and grading of patterns for different sizes, body shapes, seam positions, necklines, armholes, waistbands, and support zones. | CAD pattern system, digital grading, 3D fitting review, and physical prototype sampling. | Measurement accuracy, balance, ease, seam allowance, stretch direction, print placement, and compatibility with the selected fabric. | Finished measurements are checked against the approved size chart; tolerances are typically specified separately for each measurement point. | Approved size specification, measurement method, tolerance chart, and product technical package. |
| Sample Making and Fit Approval | Development of first samples, revised samples, pre-production samples, and size-set samples before bulk production. | Sample sewing line, mannequin or live fitting, 3D simulation, wash trial, and technical review. | Fit, comfort, range of motion, seam placement, hem balance, waistband pressure, transparency, and appearance after washing. | Bulk production starts only after written approval of the final sample, construction details, measurements, color, and labeling. | Approved reference sample, technical pack, size chart, bill of materials, and signed pre-production approval. |
| Fabric Spreading | Layering fabric in preparation for cutting while controlling tension, grain direction, face direction, and shade grouping. | Manual or automatic spreading machine, relaxation racks, ply alignment tools, and shade-lot control. | Fabric tension, edge alignment, usable width, nap direction, stripe matching, and prevention of distortion. | Relaxation time and lay height depend on fabric structure; stretch fabrics require controlled tension to prevent dimensional errors. | Approved cutting procedure, fabric supplier instructions, and product-specific work instructions. |
| Cutting | Cutting of body panels, sleeves, collars, gussets, binding, waistbands, and other components according to graded markers. | CAD marker making, straight-knife cutter, automatic cutter, laser cutter, or die cutting for selected small components. | Panel accuracy, notches, drill marks, grain direction, quantity reconciliation, and correct size or color identification. | Cut panels must remain within the approved pattern and measurement tolerances; mismatched shades and incorrect sizes are segregated. | Approved marker, cutting-room inspection checklist, and traceability records. |
| Printing, Heat Transfer, or Embroidery | Application of functional graphics, care marks, reflective elements, labels, or decorative details when required. | Screen printing, digital transfer, sublimation, heat press, embroidery machine, or silicone application. | Position, color, adhesion, coverage, cracking, edge definition, and resistance to laundering or rubbing. | Artwork position and dimensions follow the approved placement sheet; durability is verified by wash, rubbing, and visual inspection. | ISO 105-X12 for colorfastness to rubbing; ISO 6330 or specified laundering method; approved artwork and placement guide. |
| Sewing and Assembly | Joining panels, attaching sleeves, setting collars, closing side seams, inserting gussets, and assembling innerwear components. | Overlock, flatlock, coverstitch, lockstitch, bartack, elastic attaching, and computer-controlled sewing machines. | Seam strength, stitch density, skipped stitches, puckering, raw-edge control, thread tension, and panel alignment. | Stitch type, seam allowance, stitch density, and seam tolerance are controlled according to the approved construction specification. | ISO 4915 stitch types; ISO 4916 seam types; ASTM D1683 or specified seam-strength method; approved construction sheet. |
| Elastic and Support Component Control | Attachment of waistbands, leg elastics, shoulder straps, support panels, cups, binding, and other stretch components. | Elastic-feeding machines, tension-controlled sewing, bartacking, bonding, and manual comfort inspection. | Elastic recovery, attachment security, pressure distribution, symmetry, exposed-edge comfort, and absence of sharp or irritating components. | Elastic extension and recovery are tested against the product specification; components must not twist, roll, or detach during normal use. | Component specification, stretch and recovery test method, approved fit sample, and applicable apparel safety requirements. |
| Inline Inspection | Inspection during sewing to identify defects before products move to finishing and packing. | Operator self-checks, line quality checkpoints, measurement audits, defect tickets, and statistical sampling. | Construction accuracy, measurement points, seam appearance, shade consistency, label placement, and workmanship. | Defects are classified as critical, major, or minor according to the quality plan; corrective action is required for repeated defects. | AQL-based inspection plans; ISO 2859-1 sampling principles; factory quality-control procedure. |
| Washing and Finishing | Relaxation, softening, moisture conditioning, steaming, thread trimming, pressing, folding, and final appearance preparation. | Industrial washing machine, tumble dryer, steam iron, vacuum table, thread-trimming station, and folding equipment. | Appearance, hand feel, shrinkage, shade change, odor, pilling, seam distortion, and surface cleanliness. | Washing conditions follow the care label or agreed test method; dimensional change and appearance must remain within approved limits. | ISO 6330; ISO 5077; ISO 3759 for preparation and measurement of dimensional change; approved care-label instructions. |
| Final Inspection | Comprehensive inspection of finished garments before packing and shipment. | Measurement table, inspection lighting, garment appearance review, metal detection where required, and AQL sampling. | Size measurements, workmanship, fabric defects, stains, holes, color, labeling, packaging, and product count. | AQL level and sample size are agreed in the purchase order; no critical safety defects are accepted. | ISO 2859-1 sampling principles; buyer inspection protocol; approved golden sample and measurement chart. |
| Chemical and Restricted-Substance Testing | Verification that dyes, finishes, prints, elastics, and accessories meet applicable chemical and safety requirements. | Qualified third-party laboratory testing, supplier declarations, material traceability, and risk-based testing plans. | Restricted substances, colorants, formaldehyde where applicable, heavy metals, pH, odor, and chemical residue. | Limits depend on the destination market and product category; testing is performed against the applicable legal or customer standard. | OEKO-TEX Standard 100 where specified; GB 18401 for applicable textile products in China; REACH requirements for the European market; CPSIA requirements for applicable U.S. products. |
| Traceability and Documentation | Recording material lots, production batches, inspection results, rework, packing quantities, and shipment information. | Batch cards, barcode systems, enterprise resource planning records, inspection reports, and corrective-action reports. | Linkage between raw materials, cutting bundles, sewing lines, finished goods, and shipment cartons. | Records should be complete, legible, retrievable, and retained for the period required by the quality agreement or applicable regulation. | ISO 9001 quality-management principles; documented production procedures; customer-specific traceability requirements. |
| Packing and Shipment Release | Folding, insertion into polybags or recyclable packaging, carton packing, carton marking, and shipment authorization. | Folding boards, automatic bagging or labeling equipment, carton scales, barcode scanners, and final carton audit. | Correct size and color assortment, barcode accuracy, carton quantity, packaging integrity, moisture protection, and shipping marks. | Carton dimensions, gross weight, assortment, and labeling must match the approved packing list and shipping instructions. | Approved packing specification, carton drop or compression requirements where applicable, and shipment release checklist. |
