Fabric inspection is undoubtedly the most crucial and intricate part of the textile and apparel manufacturing process. This process becomes even more tiresome with the growing demands for huge amounts of high-quality apparel and garments. It’s because even today, the traditional methods of inspection are used in industries that are not just labor-intensive but also prone to human errors.
Well, imagine automating the entire fabric inspection process along with its grading. Wouldn’t it simplify the entire manufacturing process? Well, of course, it will. In this blog post, we’ll closely look into the fabric inspection process and how automation can be a game changer for the manufacturing industry.
What Is Fabric Inspection?
Fabric inspection refers to the systematic process of evaluating the quality of a fabric used for manufacturing. Also known as fabric checking, this is a crucial process wherein defects are identified.
It’s a pre-production inspection process used by fabric and garment manufacturers to ensure that the end textiles and apparel meet specific quality standards. After the inspection, the fabric is graded according to its quality.
The main objective behind fabric inspection is to ensure that the end products produced are of high quality, thus avoiding loss caused due to faulty garments.
Now, it might come to your mind that why is this process necessary? Instead of quality checking the fabric, we can even quality check the final product. Well, fabric is the most basic and costliest raw material used for manufacturing. Detecting the errors at the earliest stages can prevent waste of time, money, and effort.
Thus, fabric inspection is important for ensuring product quality, preventing production challenges, and delivering quality products.
Steps of Fabric Inspection
Fabric inspection is a crucial and comprehensive step of the entire manufacturing process. Here’s a step-by-step guide to the entire process being carried out in small steps.
- Before starting the inspection procedure, all the necessary equipment and tools are gathered. From the inspection checklist to measuring tape, all the essentials are collected.
- As the first step of inspection, the fabric undergoes visual inspection. Here, the most common and obviously visible defects, such as loose threads, stains, and holes, are detected.
- In the second step of the inspection, the dimensions of the fabric are measured according to the client’s specifications or industry standards.
- Then, the quality of the fabric is assessed with various parameters such as thread count, shrinkage, color fastness, etc.
- All the defects found are carefully noted down, along with their severity. Then, the fabric is graded using some standard fabric inspection methods.
Types of Fabric Inspection Grading Systems
Now, let’s explore some of the most common fabric inspection grading systems used in the textile and apparel industry. These grading systems are used to classify the fabric into first class or second class of fabric. Moreover, the entire fabric is not assessed. Instead, only 10% of the fabric roll is used for inspection.
1. Four-Point System
The four-point system is one of the most commonly used methods of fabric inspection. It’s also known as the American Apparel Manufacturers Association (AAMA) point grading system. It involves assessing the quality of fabric based on four main criteria: fabric defects, fabric quality, fabric construction, and fabric appearance.
In this method, each defect is graded or assigned with penalty points ranging from 1 to 4 based on its type and severity. In this process, only major errors are assessed. The defect present in the maximum part of the fabric earns 4 penalty points, and that in the minimum part of the fabric earns 1 penalty point.
The acceptance rate for a fabric in this system varies according to countries. However, the most common rate is 40 points per 100 yards.
2. 10-Point System
The 10-Point System of fabric inspection is pretty much similar to the four-point system. Developed in the 1950s, it was widely adopted by Textile Distributors and the National Federation of Textiles. The system assigns penalty points to fabric defects based on their severity, size, and location.
Each defect can receive a maximum of 10 penalty points in this system. The total penalty points for a roll should not exceed the length of the fabric in order for it to be considered “good.” If the penalty points exceed the length of the fabric, the roll is classified as “seconds” and may be rejected unless approved by the Fabric Quality Controller.
How Can Automation Help Improve Productivity in Fabric Inspection in Manufacturing?
We’ve discussed how fabrics are graded after inspection. Now, most industries use visual inspection techniques to identify defects and faults in the fabric. With the ever-rising demand for garments, industries constantly face the pressure of producing more in less time and with much more efficiency.
This is why the fabric inspection process needs to be more efficient and accurate. Automated inspection machines are the savior here. These inspection machines offer several benefits in the textile industry.
They provide accurate, quick, and consistent fabric inspection, reducing the need for manual labor. With features like auto-cut-pack and tensionless optimization, they optimize cutting and detect anomalies batch to batch. The anti-slip mechanism and edge guide ensures precise measurements, minimizing wastage.
Not just this, these machines offer both online and offline integration, enhancing inspection speed and maximizing output. Equipped with scanning heads and illumination systems, they enable fast and efficient defect detection. Overall, automated fabric inspection machines improve inspection processes, leading to increased production of high-quality fabrics while minimizing wastage.
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FAQ: Fabric Inspection
1. What is fabric inspection?
Fabric inspection refers to the systematic pre-production inspection process of evaluating the quality of a fabric used for manufacturing.
2. Why is fabric inspection important?
Fabric inspection ensures product quality, prevents production challenges, and delivers quality products.
3. What are the types of fabric inspection grading systems?
The two most common types of fabric inspection grading systems are: the four-point system and the ten-point system
4. What’s the four-point system of fabric inspection?
The four-point system is one of the most commonly used methods of fabric inspection. In this method, each defect is graded or assigned with penalty points ranging from 1 to 4 based on its type and severity.
5. How can automation help improve productivity in fabric inspection processes?
Automated fabric inspection machines improve inspection processes, leading to increased production of high-quality fabrics while minimizing wastage.
Wrapping up
Fabric inspection is a cumbersome and labor-intensive process. However, automating the process will enhance accuracy and productivity to unexpected levels. Automated machines can delicately scan, analyze, and flawlessly evaluate every inch of fabric efficiently and with more precision. So, are you ready to take your fabric inspection process to the next level with the power and magic of automation?
If yes, then we are here to help you in your industrial automation journey with our comprehensive solution, QodeNEXT. Get in touch with us now to help you make the best choice to manage your fleet and optimize your process!
