Issued by: Guangdong China Inspection and Testing Co., Ltd |
Defect Levels
1. Critical Defect (Zero Tolerance,AQL=0): Sharp foreign object, broken needle, heavy mildew, harmful odor; small-part choking hazard for children hats. Even one defective unit → full-batch rejection, shipment prohibited.
2. Major Defect (AQL=2.5): Severe cap-shape distortion, dimension out-of-spec, large-area embroidery / print defect, insufficient accessory pull-off strength, fabric hole. Reject batch if over-limit, re-inspection required after rework.
3. Minor Defect (AQL=4.0): Few loose threads, tiny stain with no impact on appearance. Acceptable within allowed quantity, process improvement required.
Sampling Rules
Follow GB/T2828.1-2012 (equivalent to ANSI/ASQ Z1.4), General Inspection Level-II, random sampling. Destructive pull-force test sampled as required. If calculated sample size exceeds total lot quantity, perform 100% inspection.
1 Inspection Items & Acceptance Criteria
1.1 Cap Shape & Appearance
- Cap shape shall match approved sample. Left-right height symmetrical; brim centered with correct curvature.
- Bottom edge smooth; no bubbling, delamination or wrinkle on bonded interlining.
- Front panel full without concave waist. Crown point converges neatly for 6-panel / octagonal caps, no sharp corner or chrysanthemum-shape defect.
- Seams between crown and wall natural, no sharp edge (except special styles). Double-stitch seams no wrinkle for bucket / military hats.
- Embroidery & print: pattern, color and position comply with sample. No broken stitch or exposed base fabric; thread ends trimmed clean. Print no color-transfer or cracking (except special crack-effect craft).
- Fabric material, color and combination match sample. No batch color difference, fabric defect or stain.
- Binding tape, sweatband, crown button, main label and care label conform to approved sample.
1.2 Sewing & Craft Requirement
- Stitch density: 10-12 stitches per 3 cm.
- Sweat-band inner non-woven paper: 70 g / 85 g, white color without yellowing.
- Binding tape seal finished on outer edge.
- Sweat-band sewing flat without cracking; stitch density at brim shall not be too large.
- Crown button mostly 3-point fastened, minimum pull-off resistance: 15 lbs.
- Eyelets fully punched, color matches main fabric.
- Embroidery / PVC badge position: 2-2.5 cm from bottom edge, centered left-right. PVC badge no curling or chipping.
- Iron-press condition: temperature 105-110 ℃, pressing time 7-8 seconds.
- Head-circumference dimension meets specification. Brim assembled without offset.
- Hook-and-loop tape corners trimmed into round shape.
1.3 Packaging & Iron-press Inspection
- Final iron-pressed shape matches sample. Lining & binding tape no wrinkle. Hard interlining fully iron-opened. No twisted bottom edge.
- For straw shaped-hats: pressing force moderate, shall not crush cap body.
- No gloss mark or press-burn after iron-press, especially for 100% polyester fabric. Main label & care label flat, no scorch.
- Qualification tag & price hang-tag position comply with order requirement. Carton quantity and color ratio consistent with packing list.
2 Inspection Workflow
1. Determine sample quantity per GB/T2828.1-2012; destructive pull-force test sampled as required.
2. Inspect cap shape, fabric, embroidery, labels.
3. Check sewing craft, stitch density, accessory pull-force, hook-and-loop tape.
4. Evaluate iron-press & shaping quality.
5. Verify hang-tags, qualification tags, carton packing ratio.
6. Count critical / major / minor defects, judge accept / reject against AQL table.
7. Generate inspection report. Qualified lots for warehousing & shipment; non-conforming lots segregated for full rework and re-inspection.
3 Defect Classification
- Critical Defect: Broken-needle / sharp foreign object inside cap, heavy mildew, pungent harmful odor, choking risk of small accessories for children hats. One found → full-batch rejection.
- Major Defect: Severe shape distortion, head-circumference out-of-spec, defective embroidery / print, insufficient crown-button pull-strength, fabric hole, chipped / curled PVC badge. Reject batch if over-limit, full rework required.
- Minor Defect: Few loose threads, tiny stain, minor cosmetic blemishes. Allowed for release within AQL limit, continuous process improvement required.
4 Conclusion
Caps involve multi-dimension risks of fabric, sewing, accessory and heat-setting craft. Guangdong China Inspection and Testing Co., Ltd delivers comprehensive Inspection Service, covering Product Inspection Service, Pre-production inspection, Container Loading Supervision, Pre-Shipment Inspection in China and general China quality inspection. This standard can be referenced by local and overseas Inspection Company, Quality Inspection Company for bulk-shipment quality risk mitigation.
