How do you ensure quality control?

Part of Hula Global’s Private Label Program is Quality Control. When brands engage in x10 scaling production, from 10,000 to 20,000 pieces per style or full container shipments, consistency, reliability, and predictability become non-negotiables.

To achieve assurance that all garments produced are in line with the agreement, Hula Global engages in rationalized measures of Quality Protocols that are inline with the applicable AQL 2.5 standard. Quality control is executed at each of the stages of the production cycle: inline, pre-final, and final.

Quality Control is based, first and foremost, on AQL 2.5. AQL is an internationally accepted sampling standard that is applied to all areas of production for the purpose of defining the number of defective items within a production batch.

AQL 2.5 control tolerates very few, diplomatically and strictly limited, minor, major, and critical defects. Because of this, it is critical to understand that bulk production and AQL prioritize safety and performance over all control measures. To comply with global standards, enterprise brands and retailers must use AQL 2.5.

With quality assurance, it is essential to understand that the process takes place long before mass production starts. Quality assurance begins at pre-production. The final approved sample, known as the “golden sample,” becomes the target to operationalize.

This means the sample becomes the quality control standard for dimensions, details on how to stitch, tactile feel of fabrics, trims, labels, where labels are to be located, the positional placement of labels, and finishing standards. After quality control ratios succeed, production "golden samples" are sent to our factories to replicate exactly what the sample indicates.

The first production quality control check is known as inline inspection. Inspectors conduct inline inspections as production workers are performing the final stitching of the garment. Instead of waiting until the end of the production cycle, the inline quality control inspectors are able to find and fix issues.

Inspectors check the accuracy of the stitching, the strength of seams, consistency of the measurements, the quality of the fabric, the php of different fabric colors, and the attachment of trims.

If inspection criteria are not met, inspectors take immediate corrective action. Inspectors drastically mitigate the presence of defects and eliminate costly value re-engineering.

Inline inspections are critical for large private label orders, given that large quantities of repetitive mistakes are much harder to address than singular small mistakes. This helps improve production efficiency and keeps order promises.

Next up are pre-finals inspections that take place when about 70-80% of production is finished. At this point, inspectors determine if the production is meeting the quality and approved production standards on the balance of semi-finished and finished items. Inspections include dimensional checks, assessment of the quality of fabric, accuracy of labels, and packaging.

Pre-final inspections minimize the risk of mass rejection after orders are completed. To identify the potential pre-or post-finished orders, and if no revisions are made, mass rejections are to be expected.

The final and most thorough checkpoint is the final inspection, which takes place once the entire order is finished and packed (or at least ready for packing). This inspection is usually carried out using AQL sampling standards, whereby a statistically calculated number of cartons or pieces are randomly selected for inspection.

The inspectors examine workmanship, size, labeling, packaging, and overall appearance.

Flaws are classified into three types: minor, major, and critical. Critical flaws, such as safety issues or major construction errors, are not acceptable. Major flaws, such as size or stitching errors, are strictly controlled within AQL standards.

Minor flaws, such as minor cosmetic blemishes, are acceptable only within the acceptable limit set by AQL 2.5 standards.

In addition to garment construction, quality control also extends to packaging standards. Carton labeling, barcode location, size sticker location, and folding are checked to ensure that the packaging is acceptable for retailer or distribution center requirements.

Misleading packaging can result in customs hold or retail rejection, and therefore, these aspects are strictly checked.

Fabric testing can also be carried out as per brand needs. This may include shrinkage testing, colorfastness testing, GSM checking, and wash resistance testing. For eco-friendly fabrics, the certification papers can also be checked for authenticity.

The quality control system implemented by Hula Global is more about prevention than inspection. The factories are also briefed extensively before the start of production, technical documents are explained clearly, and the tolerance levels of measurements are also noted in advance.

Another good thing about this system is that it is transparent. The inspection results are also recorded and communicated to the clients as needed, giving them a clear insight into the production process.

More importantly, quality control is also incorporated into the timelines and not just an afterthought. Every stage of inspection is also incorporated into the production timeline so that there are no unexpected delays in maintaining quality.

In conclusion, Hula Global’s quality control is guaranteed by following the AQL 2.5 standards and multi-level inspections that include inline, pre-final, and final checks.

By incorporating early detection, systematic sampling, and documentation, the Private Label Program provides large-scale production with consistency, compliance, and reliability, assuring enterprise brands that their products conform to global retail standards.

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