The Four-Point System: Practical Fabric Inspection in the Mill
The four-point system converts defects into a comparable score, giving buyers and mills a shared language for fabric quality.
Below is a working summary of the key decisions, the values worth writing down and the tests that confirm performance.
Point allocation
Defects are scored one to four points according to length or size, with holes always scored four points.
Experience shows that small specification decisions here have an outsized effect on the customer experience.
Inspection method
Fabric is inspected across the full width at a defined viewing distance with controlled lighting.
Add the value to the pre-production sample approval sheet so it is checked before bulk rather than after shipment.
- Agree tolerances in writing before the first sample is made
- Define the measurement condition and the direction measured
- Review the limit each season against real performance data
Conversion to a score
Total points are converted to points per 100 square yards to make rolls of different sizes comparable.
Record the machine settings for each approved lot, so a repeat order can be reproduced rather than re-invented.
Acceptance levels
Twenty points per 100 square yards is a common target, with individual roll limits around twenty points.
Where results are borderline, decide in advance whether to accept, re-test or negotiate, rather than arguing later.
- Record settings and raw material lots for every approved production run
- Check in-process rather than relying on final inspection
- Escalate deviations the same day they appear
Follow-up actions
Photographs, roll numbers and corrective action requests turn inspection into improvement rather than argument.
Expect the cost and lead time implications to appear in sampling and capacity booking rather than in the yarn price alone.
Summary
Buyers who verify rather than assume obtain better fabric at the same price, and fewer surprises after the goods arrive.
