Key Responsibilities
Pattern Development, Fit & Measurement:
- Draft, test, and grade block and style patterns from tech packs, measurements, and reference samples.
- Maintain master blocks, grading rules, and pattern libraries.
- Evaluate fabric behaviour and adjust darts, seams, ease, balance, and silhouette for accurate fit.
- Implement fit corrections based on customer feedback; ensure all patterns are production-ready and optimised for manufacturing.
- Measure garments using approved Points of Measure (POMs); verify all measurements against specifications and tolerances.
- Establish and maintain measurement tolerance standards; ensure size consistency across all graded sizes.
Sample Management & Approval:
- Direct and coordinate the production unit in the development of proto, fit, salesman, size-set, pre-production, and client submission samples.
- Evaluate and approve samples against approved specifications for measurements, workmanship, construction, and appearance.
- Manage the full sample lifecycle: review, correct, approve, document, and archive reference samples.
- Participate in style risk assessments prior to production; ensure no bulk production commences without an approved sample.
Quality Control & Production Inspection:
- Supervise quality control activities from raw material receipt through final inspection.
- Define and enforce quality specifications for cutting, sewing, finishing, pressing, and packing.
- Apply AQL 2.5/4.0 standards for inline and final bulk inspection.
- Inspect first-off production pieces before line release; conduct inline and final inspections covering stitch quality, seam appearance, trims, labels, pressing, packaging, and wash performance.
- Approve or reject production lots; investigate and resolve customer complaints; maintain defect logs and trend analysis reports.
Training, Problem-Solving & Continuous Improvement:
- Train sewing operators on construction methods, stitch types, seam allowances, and quality checkpoints; develop operator skills matrices and grading systems.
- Conduct regular refresher coaching and reinforce operator self-inspection practices.
- Investigate recurring fit, measurement, construction, and sewing defects through root-cause analysis; implement corrective and preventive actions.
- Develop SOPs, quality procedures, sample boards, and defect guides; conduct process audits to drive continuous improvement.
Team Leadership, Documentation & Reporting:
- Lead, supervise, and develop QA inspectors; ensure consistent application of inspection standards, defect classifications, and client requirements.
- Maintain pattern libraries, grading rules, approved samples, and QC records.
- Submit weekly quality reports covering sample approvals, production risks, and quality trends.
- Keep accurate records for repeat orders and style revisions.
