Why the 4-point system?
The 4-point system is the global standard for grading fabric defects. Each defect is scored 1–4 points depending on its length and severity, and a roll is graded against a points-per-100-square-yards allowance.
- 3 inches or less — 1 point
- Over 3 up to 6 inches — 2 points
- Over 6 up to 9 inches — 3 points
- Over 9 inches — 4 points
What the inspection covers
- Shading — rolls are banded by dye lot; adjacent rolls must match within a grey-scale tolerance.
- Width and weight — measured against the agreed GSM and cuttable width.
- Defect mapping — slubs, holes, misweaves, dye streaks and edge defects recorded per position.
- Hand and smell — finishing residues or off-odours flagged before cutting.
Sampling: AQL in practice
For bulk orders use AQL sampling (e.g. AQL 2.5 for major defects). Inspect the required sample size per roll count, and reject the lot if the number of defective rolls exceeds the acceptance limit. Always agree the standard in writing before production.
A disciplined QC gate at the mill is cheaper than any claim — a single shaded roll found at your customer's site can cost ten times the inspection fee.
Inspection is not about finding faults — it is about keeping them from ever leaving the factory.
— QC Handbook, KCK.Fabric
Comments (3)
“Exactly the breakdown we needed before committing to a private-label run.”
“We switched to compressed models last season and warehouse cost dropped noticeably.”
“Quality held up well after unboxing. Foam recovery was faster than expected.”