Quality Control · Cap Encyclopedia
Cap QC Checklist
Pre-shipment inspection separates a return-rate under 1% from a full recall. Here's the checklist an AQL 2.5 inspector uses on the factory floor — the same one your third-party QC should be running.
AQL standard
2.5
Major defects
Stitch density
10–12 SPI
Crown seams
Symmetry tol.
±1.5 mm
Panel-to-panel
Colour tol.
ΔE ≤ 1.5
Pantone match
Panel symmetry & construction
- Front-panel seam alignment: left and right panels within ±1.5 mm of centre.
- Crown circumference: within ±3 mm of the size spec.
- Panel embroidery / logo centred within ±1 mm of the front-panel seam.
- Sweatband seam: cleanly folded, no exposed raw edge.
- Top button (squatchee) covered evenly, matching the crown fabric.
Stitch density & seam integrity
- Crown seams: 10–12 SPI (stitches per inch). Below 10 = weak seam.
- Visor top-stitch: 8 or 12 rows per the tech pack, evenly spaced.
- Sweatband tack: reinforced bar-tack at seam junctions.
- Thread tension: no loops, no puckering, no skipped stitches.
- Embroidery back: clean bobbin, no bird's nest, backing trimmed.
Visor / brim inspection
- Curvature: pre-curved brim matches sample curve within a small tolerance (checked against a template).
- Insert: HDPE insert fully seated, no wrinkles in the visor sandwich.
- Undervisor colour: matches tech pack (grey / green / black are common).
- Edge binding: bias-tape wrapped cleanly, no gaping at the tip.
- Flat-brim programmes: brim held flat under 24 hr press-check.
Closure function
- Snapback: all 7 (or 9) snaps engage cleanly; no missing tooth on female snap.
- Buckle: metal buckle slides freely, tri-glide holds tension.
- Hook-and-loop: full contact area, no fraying at the edge.
- Elastic: uniform stretch, no twisted band inside the sweatband channel.
- Fitted: interior taping smooth, no exposed edges.
Colour matching
- Fabric-to-Pantone: ΔE ≤ 1.5 in D65 daylight; a slight reddish or greenish cast will show at retail.
- Embroidery thread to Pantone: matched under the same light.
- Undervisor and sweatband: no colour bleed after wet rub test.
- Fastness: 4+ on the grey scale after 20 rubs (cotton twill baseline).
Labels, trims & packaging
- Main label centred and sewn straight on the front sweatband.
- Size label matches carton content — the most common mislabel.
- Care and origin label present and legible.
- Hangtag attached; barcode scans cleanly.
- Polybag suffocation warning printed, moisture pack included in humid seasons.
- Master carton labelled with brand SKU, size mix, quantity and destination.
Sampling plan (AQL 2.5)
| Lot size | Sample size | Major accept / reject |
|---|---|---|
| 501–1,200 | 80 | 5 / 6 |
| 1,201–3,200 | 125 | 7 / 8 |
| 3,201–10,000 | 200 | 10 / 11 |
| 10,001–35,000 | 315 | 14 / 15 |
Want our full QC checklist as a PDF?
Send a request — we'll share the AQL 2.5 checklist we run on every pre-shipment inspection.