Product inspection in Pakistan should focus on the actual product, production stage and buyer specifications. For textiles and apparel, the main checks usually include fabric, shade, measurements, stitching, construction, trims, labels and packing. For sports goods, leather products, footwear, kitchenware and other general goods, the focus shifts to materials, dimensions, assembly, function, workmanship and packaging. UTS supports Initial Production Inspection (IPI), During Production Inspection (DPI) and Final Random Inspection (FRI) in Pakistan according to the order stage and client requirements.
Pakistan's textile and apparel sector accounts for around 56% of the country's total exports, and textile and apparel exports increased by 7.4% in FY2024-25 compared with the previous financial year.[1] This makes textile, apparel and home-textile inspection especially relevant for buyers sourcing from Pakistan.
Pakistan Product Focus
Pakistan's export mix shows why a country inspection plan should not use one generic checklist. Pakistan Bureau of Statistics reported the following major textile exports for July 2025.[2]
| Product Group | July 2025 Export Value | Main Inspection Focus |
|---|---|---|
| Knitwear | PKR 145,799 million | Fabric, GSM where specified, shade, measurements, stitching, printing, labels |
| Readymade garments | PKR 113,683 million | Measurements, workmanship, construction, trims, size assortment, packing |
| Bedwear | PKR 84,180 million | Fabric, dimensions, shade, seams, set contents, labels, retail packing |
| Cotton cloth | PKR 40,281 million | Width, fabric weight where required, shade, surface defects, printing |
| Towels | PKR 26,666 million | Dimensions, weight or GSM where specified, pile appearance, hemming, embroidery |
Pakistan also has export manufacturing in sports goods, leather products, gloves, footwear, kitchenware, knives and cutlery. TDAP identifies Sialkot as an important manufacturing center for these products.[3]
The country tells the buyer which product groups are common. The purchase order and approved specification still decide what UTS checks.
Inspection Timing
| Inspection | Production Stage | Main Checks | Useful For |
|---|---|---|---|
| Initial Production Inspection (IPI) | Usually about 5%–10% produced | Materials, components, early finished units, specifications | New suppliers, new products, complex specifications |
| During Production Inspection (DPI) | Usually about 30%–50% produced | Production status, workmanship, dimensions, function, repeated defects | Large orders, long production runs, high-value orders, many SKUs |
| Final Random Inspection (FRI) | 100% produced and at least 80% packed | Quantity, AQL sampling, workmanship, function, dimensions, labels, packing | Final shipment review |
FRI is the most common option for normal shipment control. For a first order, a new product or a product with many material and construction details, earlier inspection can catch problems before the full batch is finished.
For example, a wrong fabric used at 5% production may still be corrected without reworking the whole order. The same error found after 100% production can affect every finished unit. DPI is useful where the buyer wants to check whether the same defect is appearing repeatedly while production is still running.
Textile Inspection
Textile inspection should use the buyer's approved material specification, color reference, size information and packing requirements. A fabric should not be accepted only because it looks or feels similar to the approved sample.
| Check | What to Verify |
|---|---|
| Fabric type | Matches the approved specification or sample |
| Fabric weight | GSM or other stated weight requirement where included in the scope |
| Width | Actual width against the buyer's stated requirement |
| Shade | Consistency between panels, pieces, lots or packed sets |
| Surface | Holes, stains, contamination, yarn defects and visible fabric faults |
| Printing | Artwork, position, alignment, missing areas and visible print defects |
| Finish | Visible coating, surface or finishing condition where applicable |
If the buyer specifies fabric weight, the actual reading should be compared with the stated requirement and tolerance. UTS should not create an acceptable tolerance when the buyer has not provided one.
Exact fiber composition, restricted substances, some color-fastness properties and other chemical or performance requirements cannot always be confirmed through normal visual inspection. These points may require laboratory testing under a defined method.
Shade Check
Shade problems can appear between fabric lots, different garment panels or different items packed as one set.
Where an approved color reference is available, our team may compare:
- front and back panels;
- sleeves and the garment body;
- collars, cuffs and main fabric;
- rib fabric and body fabric;
- different pieces in a retail set;
- samples taken from different cartons;
- different production lots where available.
Two parts can both be described as "navy" and still show an obvious difference when placed together. The report should record where the difference appears rather than simply stating "color problem."
Measurements
Garment dimensions should be checked against the buyer's size chart. Both the measurement point and the tolerance should be clear before inspection.
| Product | Common Measurement Points |
|---|---|
| T-shirt | Chest, body length, shoulder, sleeve length |
| Shirt | Chest, shoulder, sleeve, collar, body length |
| Jacket | Chest, shoulder, sleeve, body length, hem |
| Trousers | Waist, hip, rise, inseam, outseam, leg opening |
| Shorts | Waist, hip, rise, inseam |
| Dress | Bust, waist, hip, total length |
Example: if the approved chest width is 52 cm ±1 cm, a result of 52.5 cm is within the stated tolerance. A result of 54 cm is outside it.
The report should record the actual value. Writing only "measurement failed" does not tell the buyer whether the difference is 1 mm or 20 mm.
The measuring method also needs to match the buyer's instructions. Chest width, sleeve length or rise can produce different numbers when the measuring points are not defined clearly.
Apparel Workmanship
For garments, workmanship checks should separate sewing defects from construction errors.
| Area | Typical Findings |
|---|---|
| Stitching | Open seams, skipped stitches, broken stitches, uneven stitching, puckering |
| Seams | Twisted seams, poor edge finishing, damaged fabric around seams |
| Construction | Wrong seam type, wrong panel arrangement, incorrect reinforcement |
| Pockets | Wrong size, position or construction |
| Collars and cuffs | Incorrect shape, construction or visible asymmetry |
| Zippers and fasteners | Wrong type, wrong position, jamming or poor fixing |
A loose thread and an open crotch seam should not be treated the same way. The first may be a small cosmetic finding. The second can affect normal use and durability.
The final defect classification should follow the buyer's agreed defect list and product requirements.
Decoration and Trims
Printed and embroidered products need checks against the approved artwork.
For printing, the inspection may cover:
- correct design;
- print size;
- position and orientation;
- color;
- missing areas;
- blurred or uneven edges;
- visible cracking or peeling;
- pattern alignment where required.
For embroidery, useful checks include size, position, thread color, missing stitches, loose threads, distorted artwork and damage around the embroidered area.
Trims may include zippers, buttons, snaps, hooks, buckles, drawcords, elastic, hook-and-loop fasteners, patches and badges. The inspection should check both the correct specification and normal operation. A zipper can be the correct color and model but still jam during use.
Home Textiles
Bedwear and towels are large Pakistan export categories, so they should not be treated as ordinary garments.
| Product | Useful Checks |
|---|---|
| Bed sheets | Finished dimensions, fabric appearance, shade, seams, hems, printing, labels |
| Duvet covers | Dimensions, closure, seams, button or zipper function, print position |
| Pillowcases | Size, matching shade, stitching, quantity per set |
| Bed sets | Correct pieces, sizes, colors, folding, labels and retail packing |
| Towels | Dimensions, weight or GSM where specified, pile condition, loops, hemming, embroidery |
Set completeness is particularly important. A retail pack may look correct from outside but contain the wrong pillowcase quantity, wrong size or mismatched shade.
For towels, pulled loops, damaged pile, poor hemming and shade differences should be recorded where found. If the buyer specifies unit weight or GSM, measured results should be compared with the approved tolerance.
General Goods
Sports goods, leather products, gloves, footwear and kitchenware need product-specific checks rather than a textile checklist.[3]
| Product Group | Main Checks |
|---|---|
| Sports goods | Materials, dimensions, weight where specified, construction, stitching or bonding, artwork, accessories, function |
| Leather goods | Surface condition, color matching, dimensions, stitching, lining, zippers, buckles, logo, packing |
| Gloves | Pair matching, size, stitching, shape, material appearance, closures, labels |
| Footwear | Size, left/right matching, symmetry, upper workmanship, sole bonding, glue marks, accessories, packing |
| Kitchenware | Material against specification, dimensions, finish, dents, scratches, burrs, handles, assembly, packaging |
For these products, our team may compare the production goods with the purchase order, technical drawing, approved sample and other buyer documents.
Useful checks can include:
- model and product configuration;
- material identification that can reasonably be checked on site;
- color and surface finish;
- length, width, height, diameter or thickness;
- product weight where specified;
- assembly and component fit;
- fasteners and accessories;
- opening, closing, locking, folding or other normal functions;
- scratches, dents, cracks, deformation, burrs and glue marks;
- retail and export packing.
A useful measurement record should show the requirement and the actual result. For example:
Required width: 150 ±2 mm / Actual width: 154.6 mm / Outside stated tolerance
This gives the buyer more information than writing only "dimension problem."
Quantity and SKU Checks
A total quantity check is not enough for an order containing several sizes, colors or models.
Our team may compare:
- total finished quantity;
- packed quantity;
- carton quantity;
- units per carton;
- SKU quantity;
- size breakdown;
- color breakdown;
- model breakdown.
Example:
| Size | PO Quantity | Packed Quantity | Difference |
|---|---|---|---|
| S | 1,000 | 900 | -100 |
| M | 2,000 | 2,100 | +100 |
| L | 1,500 | 1,500 | 0 |
The total is still 4,500 pieces, but the assortment is wrong.
Three checks should therefore be kept separate:
- Quantity: Is the required number of units available?
- SKU: Are the correct sizes, colors and models available?
- Label: Does the carton or retail pack correctly identify what is inside?
A carton can contain 20 correct Size M garments while the outer label says Size L. The unit quantity is correct, but the packing information is not.
AQL Sampling
FRI normally uses random sampling rather than checking every finished unit. The sample size is determined from the lot size and selected inspection level, not from a simple fixed percentage.
ISO 2859-1:2026 defines AQL-indexed acceptance sampling schemes for lot-by-lot inspection by attributes.[4] ANSI/ASQ Z1.4 also provides attribute-sampling plans with normal, tightened and reduced inspection arrangements.[5]
The normal process is:
- confirm the lot size;
- select the agreed inspection level;
- find the sample-size code letter;
- find the required sample size;
- apply the selected AQL column;
- compare the counted nonconformities with the Ac and Re numbers.
Using the UTS sampling table as an example:
| Item | Value |
|---|---|
| Lot size | 4,000 units |
| Inspection level | General Inspection Level II |
| Code letter | L |
| Sample size | 200 units |
| Example AQL | 2.5 |
| Acceptance number | Ac 10 |
| Rejection number | Re 11 |
This does not mean that AQL 2.5 allows 2.5% of the whole shipment to be defective. It also does not mean that every type of defect shares one allowance of 10.
The selected defect class, AQL value and sampling table need to be read together.
AQL decides how the sampled lot is assessed. It does not decide whether a product specification is correct. The approved specification decides whether a measurement, color, function or construction is acceptable.
Buyers who need to review the sampling table itself can also use the UTS ANSI Sampling Tables reference.
Defect Classes
Critical, major and minor classifications should reflect the actual effect of the problem and the buyer's approved criteria.
| Finding | Typical Review Logic |
|---|---|
| Open main seam on a garment | May be Major because normal use or durability can be affected |
| Small loose thread | May be Minor if the product remains usable and appearance impact is small |
| Footwear sole separation | May be Major because product use is affected |
| Large visible scratch | May be Major when it affects the saleable appearance of the product |
| Accessible sharp condition that can cause injury | May require Critical classification depending on the product and approved criteria |
AQL should not replace product judgment. A small cosmetic mark and a safety-related finding do not carry the same risk simply because both count as one observed defect.
Packaging and Labels
Packaging checks should cover both the product pack and the export carton.
| Area | Checks |
|---|---|
| Retail pack | Correct product, SKU, size, color, accessories, manuals, inserts and packing method |
| Retail label | Product name, model, size, color and other approved information |
| Garment labels | Main label, size label, care label, composition label and hangtag where required |
| Carton | Condition, dimensions where specified, units per carton, sealing and packing arrangement |
| Carton marks | PO, SKU, model, quantity and other required shipping information |
Information should match across the product and its packaging. A Size M garment should not have a Size M sewn label, Size L hangtag and Size L carton identification.
Cartons should also be checked for visible crushing, tearing, damaged corners, poor sealing or wet areas. Moisture-related findings should describe the actual condition seen during inspection. We do not apply a universal moisture or humidity percentage unless a buyer specification or agreed test method provides one.
A carton drop test may be included when it is suitable for the product and part of the agreed inspection scope. The test method and acceptance criteria should be confirmed before inspection.
Barcodes
Barcode and QR-code checks should stay simple and practical:
- Is the print clear and complete?
- Can the code be scanned?
- Does the scanned information match the approved barcode, SKU or label data?
When barcode or QR-code verification is included in the inspection scope, 100% of the checked samples must scan successfully.
An unreadable code, a code that returns the wrong information or a code that does not match the approved product data should be recorded. The affected codes should be corrected and rechecked according to client requirements.
A 97%, 98% or 99% scan rate should not be written as an acceptable standard.
Routine UTS inspection does not need barcode grades or scoring when the required check is print condition, scan success and data matching.
Factory Evaluation
Product inspection checks a specific production order. A factory evaluation checks a different set of questions before supplier approval or a larger order.
Depending on the agreed scope, our team may review:
- supplier and site information;
- declared factory location;
- visible production areas;
- visible equipment and active production;
- warehouse conditions;
- available operating evidence;
- areas or information that could not be checked.
The report records what was observed and what could not be confirmed. It does not certify the supplier, guarantee future production quality or replace order-specific product inspection.
For a new development sample, a separate Sample Evaluation can be used before mass production to compare the sample with the buyer's drawings, specifications and approved requirements.
Inspection Limits
On-site product inspection can provide useful evidence for:
- quantity;
- appearance;
- workmanship;
- dimensions;
- assembly;
- basic function;
- labels;
- barcodes;
- retail packing;
- cartons;
- agreed on-site tests.
It cannot automatically confirm every technical or regulatory property.
Depending on the product, laboratory testing may still be required for items such as:
- exact fiber composition;
- restricted chemical substances;
- some color-fastness properties;
- regulated electrical safety performance;
- specific material-performance claims;
- other requirements that need a defined laboratory method.
UTS does not treat a visual inspection as proof of a property that cannot be verified on site. Inspection findings, supplier documents and laboratory results should be used for the questions they are designed to answer.
Inspection Report
The report should show enough evidence for the buyer to understand the sampled order without relying on a short PASS or FAIL statement.
Useful report information includes:
- PO and inspected quantity;
- production and packing status;
- sample size and sampling basis;
- critical, major and minor defect counts;
- clear defect photos;
- actual measurement results;
- function-test results;
- label and barcode findings;
- packing and carton findings.
The buyer should also look at defect patterns.
Five unrelated small cosmetic findings are different from five garments showing the same open seam in the same location. The second result may point to a repeated production problem.
The same applies to measurements. One out-of-tolerance result and the same deviation across several sizes or cartons do not show the same level of risk.
After inspection, our team provides the report for client review. Shipment release remains the buyer's decision.
Failed Inspection
When FRI finds problems, the next step should match the type and spread of the defect.
| Finding | Possible Corrective Action |
|---|---|
| Workmanship defects | Sort, repair or replace affected goods |
| Wrong labels | Relabel affected products and recheck |
| Unreadable barcodes | Correct printing and recheck scanning |
| Wrong carton marks | Correct carton identification before shipment |
| Missing accessories | Complete the packs and verify the corrected quantity |
| Repeated dimensional or functional defect | Review the affected scope and consider reinspection after correction |
A few photos of corrected products do not always show whether the same problem has been fixed across the full affected quantity. If the original inspection found the same problem repeatedly, another inspection may provide stronger evidence.
The UTS guide on reviewing a failed inspection report also explains how buyers can separate defect evidence, corrective action and recheck decisions.
Buyer Documents
Clear documents make the inspection more objective.
| Document | What It Is Used For |
|---|---|
| Purchase order | Quantity, model, SKU and order information |
| Product specification | Materials, construction, dimensions, functions and required features |
| Approved sample | Appearance and construction reference where available |
| Size chart | Garment measurement points |
| Tolerance table | Allowed measurement deviation |
| Approved artwork | Printing, logos, packaging and labels |
| Packing specification | Retail packing and carton requirements |
| Packing list | SKU, size, color and carton assortment |
| Barcode data | Comparison with the actual scanned result |
| Defect criteria | Critical, major and minor classification |
| Test instructions | Required on-site function or performance checks |
"Blue" is weaker inspection information than an approved color reference. "Correct size" is weaker than a size chart showing measurement points and tolerances. "Standard packing" is weaker than a packing specification showing quantity per pack, accessories, labels and carton arrangement.
Our office team reviews the available order documents and inspection requirements before arranging the inspection. If an important requirement is missing or unclear, it should be clarified before the inspection rather than replaced with an assumed tolerance.
Finally
For Product Inspection in Pakistan, the main control points should follow the product and production stage. Textiles and apparel account for around 56% of Pakistan's exports, so fabric, shade, dimensions, workmanship, trims, labels and packing deserve close attention. IPI is usually arranged around 5%–10% production, DPI around 30%–50%, and FRI when production is 100% complete and at least 80% packed. In the UTS AQL example, a 4,000-unit lot at General Level II requires a 200-unit sample. When barcode verification is included, checked codes must achieve 100% scan success. Buyers should use the final report to review defect counts, repeated problems, measurements, SKU accuracy and packing before deciding whether the shipment is ready.
