4 Point Fabric Inspection System and How Does It Really Work?
Many factories say they use the 4 Point Fabric Inspection System. Far fewer understand what it actually measures and more importantly, what it does not measure. So instead of repeating textbook fluff, let’s break it down clearly, challenge a few bad assumptions, and explain how to use it correctly in real garment production.
What Is the 4 Point Fabric Inspection System?
The 4 Point Fabric Inspection System is a visual method used to judge fabric quality before production starts. It turns fabric defects into numbers, making quality easier to compare and control. Instead of arguing whether fabric is “good or bad,” inspectors score what they can see. This system focuses only on appearance, not performance. That limitation matters more than most people admit.
In simple terms:
- Inspectors look for visible fabric defects
- Each defect is assigned 1 to 4 penalty points based on its size
- Points are totaled per 100 square yards
- The fabric either passes or fails based on an agreed limit
It is the most widely used fabric inspection system in apparel manufacturing because it is:
- Simple
- Fast
- Easy to train
- Easy to compare across suppliers
But here’s the first reality check It is a screening tool, not a quality guarantee.
Why the Industry Uses the 4 Point System?
The 4 Point System is popular because it is fast, simple, and easy to train. Factories can inspect large volumes of fabric without slowing production. Buyers and suppliers can speak the same quality “language” using numbers. It also helps stop bad fabric before cutting begins. However, popularity does not mean completeness.
The system works well because it:
- Converts subjective defects into numbers
- Creates a common language between mill, factory, and buyer
- Allows fast decisions on accept / reject / re-grade
- Helps prevent obvious disasters before cutting
Without a system like this, fabric inspection becomes: “Looks okay to me” which is how factories lose money.
What the 4 Point System Measures Well?
Let’s give it credit where it’s due. The system is effective at identifying visible fabric defects. It catches problems that affect garment appearance and cutting yield. Issues like holes, oil stains, and shade streaks are easy to detect. For visual quality control, it works as intended. Expecting it to do more is unrealistic.
The system is good at detecting:
- Weaving or knitting defects
- Dye streaks and shade bars
- Holes and tears
- Oil, dirt, or contamination
- Printing alignment issues
For visual appearance, it does its job. If your garment looks bad because of fabric defects, chances are the 4 Point System would have caught it if inspection was done properly.
The Big Limitation Most People Ignore
Now the uncomfortable truth. The 4 Point System does not test fabric performance. It cannot predict shrinkage, color fading, or fabric strength. A fabric can pass inspection and still fail after washing. This creates a false sense of security. Visual approval does not equal functional quality.
The 4 Point System does NOT measure:
- Colorfastness
- Shrinkage
- Fabric strength
- Pilling resistance
- Seam slippage
- Long-term durability
That means fabric can:
- Pass 4 Point inspection
- Look perfect on Day 1
- Fail after washing or wearing
So if you rely only on 4 Point inspection for critical styles, that’s not bad luck—that’s bad process.
How the 4 Point Fabric Inspection System Works (Step by Step)
Fabric is inspected visually as it runs over a machine under proper lighting. Inspectors look for visible defects like holes, stains, or weaving errors. Each defect is measured and assigned penalty points. All points are added and standardized per 100 square yards. The process sounds simple, but consistency is where most factories fail.
Step 1: Inspect the Fabric Visually
Fabric is run over an inspection machine under proper lighting.
Inspectors look for defects such as:
- Broken or missing yarns
- Holes
- Oil stains
- Color streaks
- Misweaves or needle lines
- Printing defects
Only visible defects are counted. Nothing else.
Step 2: Assign Defect Points (1–4 Points)
Defects are scored based on their length, not how serious they feel. Small defects receive fewer points, while larger ones receive more. The maximum score for a single defect is always four points. This rule keeps scoring consistent across inspectors. But it also means severe defects can be underweighted
| Defect Size | Points Given |
|---|---|
| Up to 3 inches | 1 point |
| 3–6 inches | 2 points |
| 6–9 inches | 3 points |
| Over 9 inches | 4 points |
Defects are scored by size, not by how “bad they feel.” => Important rule: No single defect can receive more than 4 points, no matter how ugly it is. That rule alone tells you something about the system’s limits.
Step 3: Calculate Total Points per 100 Square Yards
Raw defect points alone are meaningless without normalization. Fabric rolls vary in length, so scores must be calculated per 100 square yards. This allows fair comparison between rolls and suppliers. Without this step, inspection data becomes misleading. Many reports look precise but hide bad math.
All defect points are added up and then normalized to:
- Points per 100 square yards
This matters because:
- Fabric rolls are different lengths
- You need a fair comparison across rolls and suppliers
Step 4: Compare Against the Acceptance Limit
Most buyers use 40 points per 100 square yards as the acceptance limit. Fabric below this level usually passes inspection. Fabric above it may be rejected or downgraded. However, this number is not universal or automatic. Treating 40 points as a rule instead of a guideline is a common mistake.
The most common standard:
- 40 points per 100 square yards
If the fabric is:
- ≤ 40 points → usually acceptable
- > 40 points → usually rejected or downgraded
But here’s where people mess up: 40 points is NOT a law.
Buyers can (and often do) specify:
- 25 points
- 30 points
- Or special rules for critical zones
Always check the buyer’s manual.
Why the System Must Be Combined with Lab Testing
Visual inspection alone is not enough for modern apparel. Lab tests verify how fabric behaves over time and use. Colorfastness, shrinkage, and durability require controlled testing. The 4 Point System should filter obvious risks, not replace science. Skipping lab tests is a cost-saving illusion.
For responsible production, the 4 Point System should be paired with:
- Colorfastness testing
- Shrinkage testing
- Fabric weight and strength tests
- Performance tests based on end use
Think of it like this:
- 4 Point System = visual screening
- Lab testing = performance validation
Skipping either one is asking for trouble.
Common Mistakes Factories Make:
Let’s challenge a few lazy habits.
- “Fabric passed 4 Point, so it’s fine.” → Wrong. It only passed visual inspection.
- “40 points is always acceptable.” → Wrong. Buyer standards override everything.
- “Small defects don’t matter.” → Wrong. Small defects in critical garment zones can destroy yield.
- “Inspection after cutting is enough.” → Too late. Damage is already done.
The system works only if:
- Inspectors are trained
- Lighting and speed are controlled
- Results are actually reviewed and acted on
Otherwise, it’s just paperwork theater.
Conclusion (Final Takeaway)
The 4 Point Fabric Inspection System is not outdate, and it is not a guarantee of fabric quality. It is a control tool, designed to catch visible problems before production begins. When used correctly, it helps factories reduce risk, protect cutting yield, and create a shared standard with buyers. When used blindly, it creates false confidence and expensive surprises later.
It’s not perfect either. It is a tool, and like any tool:
- Used correctly → it saves money
- Used blindly → it creates false confidence
If you treat it as a gatekeeper, not a guarantee, it does its job.
Our Contact Information – MEKONG GARMENT FACTORY
- Vietnam Phone: +84 947 729 829
- WeChat: +84 947 729 829
- WhatsApp: +84 947 729 829
- Email: hanh@kimmy.vn
FAQs – 4 Point Fabric Inspection System
Inshort, What is the 4 Point Fabric Inspection System?
It’s a visual fabric inspection method that turns fabric defects into penalty points. Inspectors score each defect from 1 to 4 points based on size. Then they calculate total points per 100 square yards. The roll passes or fails based on a set limit.
Why is it called the “4 Point” system?
Because the maximum penalty for any single defect is 4 points. Even if a defect looks terrible, it still cannot exceed 4. This keeps scoring consistent but can also hide how severe some defects really are.
What kinds of defects does it check?
It checks visible defects, such as holes, stains, broken yarns, slubs, misweaves, needle lines, shade streaks, and print issues. If you can see it during inspection, it can be scored. If you cannot see it, the system will not catch it.
Does the 4 Point system check colorfastness or shrinkage?
No. This is one of the biggest misunderstandings. The 4 Point system is not a lab test and cannot predict wash results, fading, shrinkage, pilling, or strength.
How are defects scored (1 to 4 points)?
Defects are scored by length/size. Smaller defects get fewer points and larger defects get more. A common rule is: up to 3 inches = 1 point; 3–6 = 2; 6–9 = 3; over 9 = 4.
What does “points per 100 square yards” mean?
It means the defect score is standardized to a fixed fabric area. Rolls come in different lengths, so you convert the total points into a common unit. Without this, comparing rolls is unfair and misleading.
What is the common acceptance limit?
A very common limit is 40 points per 100 square yards. But don’t treat this like a law. Many buyers require stricter limits (like 25 or 30), or special rules for critical zones.
If fabric is under 40 points, is it always acceptable?
Not always. A roll can be under 40 points but still have defects in the worst places (like the center panel of a shirt). Placement matters. Also, buyers may have different limits or special rejection rules.
Can one large defect automatically reject a roll?
Sometimes yes—if the buyer’s rules say so. The basic 4 Point method limits defects to 4 points each, but buyers may add “automatic reject” rules for holes, continuous streaks, or repeat defects. Always follow the buyer manual.
