AQL · 8D · Traceability · NOM-004-SCFI-2006
What we control before, during and after each production run. Written for quality teams and procurement, not for marketing: the inspection plan we agree with you, the statistical sampling applied on the line, the lot-level traceability we keep, and the non-conformance flow when something slips.
Before the first piece is cut, we share a quality plan specific to your order. The plan covers scope — runs, decoration techniques, materials and input suppliers — the acceptance criteria per product type, the agreed AQL level, the inspection lot size, when each inspection happens, the responsibility split between parties, and the criteria for release and rejection. For corporates already running under ISO 9001 or IATF 16949, we align the plan with their internal procedure.
The plan is signed by the workshop quality lead and the customer's named representative. Once signed, any change to the brief — decoration technique, material, input supplier — triggers a plan revision before production continues. The current plan version is filed under the internal production order and a copy goes to the customer on request.
We work with AQL 1.0, 1.5, 2.5 and 4.0 levels depending on the risk profile of the product. For t-shirts and polos on runs of more than five hundred pieces we use AQL 1.5 on critical defects and AQL 2.5 on major defects; for hard accessories and electrical items, AQL 1.0 on criticals. Sampling follows MIL-STD-105E / ISO 2859-1:1999 with normal or reduced inspection depending on supplier history. The sample is selected at random — not by operator convenience.
For every lot inspected we record the number of pieces reviewed, defects found, defect classification — critical, major or minor — and the decision: accept, reject or hold under retention. Rejected lots are physically segregated and the action plan is reopened. Re-inspection afterwards is done at a tighter AQL level — typically stepping up one notch — and is documented.
Every production order carries an internal lot number that follows the order through every stage — from raw material receipt, through cutting and sewing, screen-printing or embroidery, packaging, all the way to delivery. When a field claim comes in, we trace the affected lot back to the input supplier, the production date, the named operator who handled the marking, and the shipping document.
Traceability records are kept for at least three years for audit purposes. For clients in regulated sectors — medical devices, food, pharma — the retention extends to five years in line with sector practice. Traceability certificates are issued within forty-eight business hours of a formal request.
When a lot fails inspection, or when the customer reports a non-conformance, we open the 8D format. The 8D is the automotive industry's standard tool and we apply it for every customer regardless of sector: D1 team formation, D2 problem description, D3 immediate containment, D4 root cause, D5 corrective actions, D6 implementation, D7 recurrence prevention, D8 closure and team recognition.
Root cause is analysed through five whys, fault tree or fishbone as appropriate. Corrective actions are verified on the line before the 8D is formally closed. When a non-conformance lands on an already-shipped lot, we offer replacement, credit note or re-billing depending on the commercial agreement. The formal response to a non-conformance is five business days for containment and fifteen business days for 8D closure.
We catalogue defects in three levels. Critical: those that make the piece unusable for its purpose or that represent a safety risk — sharp edges on children's textile items, electrical components without insulation, runs or tears that compromise structure. Major: those that affect presentation or function without making it unusable — visible shade variation between pieces in the same lot, logo position outside the agreed range, seam misalignment greater than three millimetres. Minor: those that only affect finish — a loose fibre, a small die-cut mark, a screen-print halo outside the print area.
Acceptance criteria are agreed with the customer before production. When the customer submits physical samples or reference files with explicit tolerances, we align the inspection criteria against that reference. For customers that do not yet have defined criteria, we propose a conservative one based on sector practice.
On every run we verify that decoration matches the approved art — colour, position, size, technique — and that the textile composition matches what the label will declare. Colour verification happens under D65 normalised light in a viewing booth, comparing the produced piece against the approved standard within ΔE ≤ 2.5 tolerance. When the customer requires tighter tolerance — for example programmes where the colour is part of brand identity — we agree the specific tolerance before production.
Textile composition is verified against the supplier's documentation — composition certificate — and cross-checked against the label the garment will carry. The label must meet NOM-004-SCFI-2006 on textile labelling, with manufacturer info, country of origin, composition, care instructions and, when applicable, sizing per NOM-020-SCFI-1997.
AQL 1.5 on criticals and 2.5 on majors for typical apparel runs. We drop to 1.0 on criticals for electrical items. For small runs or pilot programmes we agree a different level based on risk.
Yes. For every run we deliver a quality certificate covering the lot size inspected, sample size, defects found per category and final decision. For programmes requiring extended traceability we additionally supply the textile supplier's composition certificate.
Immediate containment within five business days. Formal 8D closure, including root cause analysis and verification of the corrective action, is completed within fifteen business days. When the root cause requires supplier adjustments, closure can extend to thirty days.
Yes. We receive scheduled quality audits with at least five business days' notice. For customers with recurring audits, we set up an annual calendar and a checklist aligned with their criteria. Audit non-conformities are handled with the same 8D format.
If you are about to start a merch programme and want to lock down quality from the brief onwards, let's talk. We deliver a draft quality plan within five business days of the initial brief.
The AQL levels, response times and non-conformance handling described on this page are typical for corporate clients in Mexico. Specific conditions for each customer are confirmed in writing before the first order. Compliance with applicable regulation must be verified against current SAT and IMSS rules at the time of each operation. Corp-Merch.MX is a Mexican workshop for corporate merch; we operate independently.