IN-PROCESS INSPECTION - Textile Document

IN-PROCESS INSPECTION The purpose of an In-Process inspection is to check the following: raw materials, marker layout, spreading, cutting, sewing, wet processing, screen printing, pressing and other embellishments. Sampling plan should not be used at this stage since a lot size is a bundle. For woven and knit production, the first In-Process inspection begins when knitting/weaving commences. While inspecting semi-finished goods and batches during work-in-process, QA must keep records on defects found for discussion and communication with the manufacturer/GIS production representatives. The number of defects found during a cutting, measurement or visual inspection should be noted on the various In- Process reports. It is not the purpose of the In-Process inspection to try and measure percent defective, but to identify potential problems that arise during these operations. These In-Process reports will be the basis for data collection and evaluation and to help drive improvements in the operations. IN-PROCESS INSPECTION FORMS At the relevant In-Process Inspection stages, QA will use the following forms: • In-Process Inspection Report (Appendix I, form # 4) • In-Process Audit Worksheet (Appendix I, form #5 & 6) • In-Process Graphics Worksheet (optional ~ not included) Please note these forms must be used as is during the In-Process Inspection. If there are questions or change requests regarding the forms, contact the GIS QA lead or Corporate QA in San Francisco. CUTTING INSPECTION PROCEDURES The following are QA procedures when performing an In-Process cutting inspection: • Verify and record fabric test reports. • After cutting, perform visual and measurement (i.e. top to bottom ply, hard pattern to cut pieces) inspection of cut parts using the In-Process Inspection Report (use the Fabric/Cutting Checklist and defective portion) (Appendix I, form #4). • Discuss the problems found and recommend solutions to factory management. • If the factory can not correct the problem, the production representative should be contacted for corrective action. • If questions regarding specifications, fabric/material standards, color, etc. arise, the production representative should be contacted for corrective action. TRIM & SE WING INSPECTION PROCEDURES The following are QA procedures when performing an In-Process inspection: • All fabrics, components, trims, and labels should be checked against production approved standards, and must reflect correct country of origin and fibers and component contents. • Review and record all required Gap, Inc. fabrics, components, and product test reports. • Verify needle control and safety procedures are being followed. • Check to make sure that all components, trims, and labels are available to meet production schedules. • Perform random checks in sewing lines and finishing. • Verify factory is inspecting at least six pieces of each operator’s semi-finished goods to check for workmanship defects ~ Record finding on the appropriate In-process Inspection report. • Check hand and color against approved standards ~ If standards are not available, send the production representative examples of fabric colors and range of shades. SHIPMENT AUDITS The purpose of a shipment audit is to determine the quality of the products by its visual appearance, measurement to specifications and packing execution. The shipment audit must be performed before the finished product is shipped. This is done in order to minimize the risk of shipping defective product to Gap Inc. distribution centers, stores or other designated locations. AUDIT METHODS Two audit methods as listed below can be used in relation to the timing of the audit. Non-destructive Audit is preferred as it is considered the proactive approach. Non-destructive Audit A non-destructive audit is usually performed for measurements, visuals, and packaging before the garments are boxed. Packing audits must be performed during the boxing/packing process to verify labels, assortments, and counts. Destructive Audit This type of audit covers measurement, visual and packaging audits and is performed during packing process when garments are boxed for shipping. S H I P ME NT I N S P ECT I ON F ORMS At the relevant shipment inspection stage QA will use the following forms: • Visual Inspection Worksheet (Appendix I, form #7) • Finished Garment Measurement Sheet (Appendix I, form #9) • Box Audit (Appendix I, form #10) Please note, these forms must be used as is during the Shipment Inspection. If there are questions or change requests regarding the forms, contact the GIS QA lead or Corporate QA in San Francisco. Acceptable Quality Level is the maximum percent defective that, for the purpose of sampling inspection, is considered satisfactory as a manufacturing process average. The table on the following page shows the AQL for each brand. Gap Inc. requires that vendors must meet or exceed these standards on every purchase order shipped to Gap Inc. AQL STANDARDS Table 1: AQL Standards for Gap, Old Navy, Athleta & Outlet brands ANSI/ASQC Zi.4 1993 Single Sampling Plan, Level I Gap Body Gap Adult & Kids Baby Gap Old Navy Athleta BRFS Gap Outlet Hardlines all Brands Critical Defects 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 Major Visual Defects 2.5 2.5 2.5 4.0 2.5 2.5 4.0 2.5 Minor Visual Defects 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 Measuremen t Audit* 2.5 (A) 4.0 (B) 4.0 4.0 6.5 4.0 6.5 6.5 6.5 OCR/Ticket Audit 0.25 major 0.25 major 0.25 major 0.25 major 0.25 major 0.25 major 0.25 major 0.25 major * = Defect is a Defect. *(A) = Gap Body departments 165,167 & 168. *(B) = Gap Body (excluding departments 165,167 & 168). Table 2: AQL Standards for Banana Republic ANSI/ASQC Zi.4 1993 Single Sampling Plan, Level I = BR & BR UK ANSI/ASQC Zi.4 1993 Single Sampling Plan, Level II = BR Japan & BR Monogram BR & BR UK BR Japan & BR Monogram Critical Defects 0.1 0.1 Major Visual Defects 2.5 2.5* Minor Visual Defects 2.5 0 Measurement Audit* 2.5 Wovens & Denim** 4.0 Knits & Sweaters 2.5 Wovens (a) & Denim(a)** 4.0 Knits & Sweaters OCR/Ticket Audit 0.25 major 0.1 major * = Defect is a defect. * = Starting Spring 2010. (a) = Except for Measurement which remains at level I sampling plan. Note: The use of an AQL does not imply that the vendor has the right to supply any defective product to Gap Inc. Therefore, Gap Inc.’s expectation is that the vendor will incorporate adequate controls in the manufacturing process and quality inspections at appropriate stages to deliver a defect free shipment. CRITICAL DEFECT S A Critical Defect is defined as anything that can potentially pose a hazard or cause an injury or be considered harmful to the product user. A Critical Defect can be, but is not limited to, sharp points and edges, broken needles, loose components or other foreign items which are potentially harmful and/or may pose a hazard. Improper or inaccurate country of origin or fiber, component content markings and Consumer Product Safety Commission (CPSC) “snug fitting sleepwear” measurements that are greater than tolerance are also considered Critical Defects. (For details on design restrictions for snug fitting children’s sleepwear please refer to Section III on Flammability outlined in the Softlines Manual at: http://gapsource.gap.com/manuals/productguidelines/sl/flammability.pdf ). Visual Critical Defects To find Critical Defects pertaining to product safety, component content markings and country of origin, the method used is visual inspection. Measurement Critical Defects To find Critical Defects pertaining to “snug fitting sleepwear”, the method used is the measurement audit. The AQL for appraising Critical Defects is 0.1 If a critical defect is found either during visual inspection or during measurement of snug fitting sleepwear audit, the audit automatically fails and requires the entire lot to be inspected. All critical measurements must be removed before the lot can be submitted for a second audit. Procedure for Measurement Audit of “Snug Fitting Sleepwear” • Determine if the product is “snug fitting sleepwear" by looking at the sketch on the front page of the spec (GSS). It will state if it is a "snug fitting sleepwear" style subject to CPSC regulations. On the measurement page of the Karat GSS governed by CPSC regulations will be in CAPITAL LETTERS. On the measurement page of the PLM GSS governed by CPSC the initials “CPSC” will be at the beginning of each point of measure description. • Use the standard measurement sampling plan as stated in the measurement audit procedures section of this manual. (Refer to the Measurement Audit Sampling Plan: Page 18). • Any CPSC regulated measurement - those in CAPITAL LETTERS or with the CPSC at the beginning of the description - that is greater than tolerance on the plus (+) side will be considered a critical measurement defect. • Any CPSC regulated measurement - those in CAPITAL LETTERS or with the CPSC at the beginning of the description - that is greater than tolerance on the minus (-) side will be considered a measurement defect. • The AQL for appraising Critical Measurement Defects is 0.1 and shipping decision should be made only when the audit is in compliance. MAJOR AND MINOR VISUAL DEFECT S Visual defect is defined as a product flaw that prevents the product from realizing its full market value. There can be several reasons for visual defects and can be attributed to fabric defects, defective trims or components, poor workmanship, construction defects, poor housekeeping, poor handling, transportation damage, etc. The visual defects are classified as Major or Minor based on the location on the garment. Visual Audit Methods There are two methods for auditing visual defects. The vendor should contact the GIS quality manager to get the recommendation on what method to be used. Option 1: Non-Destructive Visual Audit (audit performed before garments boxed). Option 2: Visual Auditing begins after boxing/packing process has started. Visual Audit Forms and Reference Sheets At relevant stages of the Visual Audit, use the following forms: • Shipment Inspection Report (Appendix I, form #8). • Visual Inspection Worksheet (to be used for non-destructive audits that occur over an extended period of time) (Appendix I, form #7). Please note these forms and sheets must be used as is during the Visual Audit. At relevant stages of the Visual Audit, reference the Classification of Visual Defects Sheets (Appendix II). VISUAL AUDIT SAMPLING PLANS Table 3: Visual Audit Sampling Plan for BabyGap, GapKids, Gap Adult, Gap Body, Banana Republic, Banana Republic UK, Old Navy, Athleta, BRFS, & Gap Outlet ANSI/ASQC Z1.4 1993 Single Sampling Plan Level (I) Shipment Size Lot Garment Vi suals Ticket Check (OCR) Sample Size Critical AQL 0.1 Pass/Fail AQL 2.5 Pass/Fail AQL 4.0 Pass/Fail AQL 0.25 Pass/Fail 0-500 20 0/1 1/2 2/3 0/1 501-1,200 32 0/1 2/3 3/4 0/1 1,201-3,200 50 0/1 3/4 5/6 0/1 3,201-10,000 80 0/1 5/6 7/8 0/1 10,001-35,000 125 0/1 7/8 10/11 1/2 35,001- UP 200 0/1 10/11 14/15 1/2 Table 4: Visual Audit Sampling Plan for Banana Republic Japan & Banana Republic Monogram ANSI/ASQC Z1.4 1993 Single Sampling Plan Level (II) Shipment Size Lot Garment Visuals Ticket Check (OCR) Sample Size Critical AQL 0.1 Pass/Fail AQL 2.5* Pass/Fail AQL 0.1 Pass/Fail 1-25 5 0/1 0/1 0/1 26-50 8 0/1 0/1 0/1 51-90 13 0/1 1/2 0/1 91-150 20 0/1 1/2 0/1 151-280 32 0/1 2/3 0/1 281-500 50 0/1 3/4 0/1 501-1,200 80 0/1 5/6 0/1 1,201-3,200 125 0/1 7/8 0/1 3,201-10,000 200 0/1 10/11 0/1 * = Defect is a defect. VISUAL AUDIT PROC EDURE FOR NON-DESTRUCTIVE This type of audit may take place over an extended period of time i.e. more than one day. When the non-destructive visual audit is performed over more than one day, the results are recorded on the Visual Inspection Worksheet This worksheet must be reviewed and signed by factory management. The information on this worksheet must be transferred and attached to the Shipment Inspection Report (Appendix I, form #8). If any defects are found during this visual audit, a Gap Inc. representative will ensure that corrective action is taken to address the defects. Sample Size for Auditing Sample size that is to be used for auditing will depend on the size of the lot and sampling plan used. The lot size is the total number of units in a given shipment. Samples are to be taken randomly and must include all sizes and colors. Therefore in such cases samples should be drawn based on the ratio of each size and color to the total units in that shipment. When multiple Purchase Orders are ready for shipment, they can be combined and the audit performed on a sample taken from this combination. However, if the audit fails all Purchase Orders will fail and if it passes all Purchase Orders will pass. Major Defects During this audit any defects as described below will be counted as major: • Incorrect size strip (31x31 strip on a 34x31 pair of pants). • Incorrect flasher. • Incorrect logo label (wrong size). • Incorrect non-OCR (BARCODED) price ticket (These items must correspond to the Bill of Materials (BOM) as to item number and size). • More than one major defect per product should only be counted as one major defect. • Above items are coordinated by size and style. Minor Defects If consistent minor defects are seen that affect the overall appearance of the product, the shipment audit fails. This failure must be brought to the attention of the production representative. However, there is no need to notify production representative when the minor defects are within acceptable range. Labeling Incorrect country of origin and/or incorrect fiber content label on any portion of the shipment will result in failure of the shipment. For details on country of origin information please refer to Softlines Manual Section I: http://gapsource.gap.com/manuals/productguidelines /s l/label%20guidelines .pdf Shade Variation If shade variations occur within a shipment, the production representative must be notified and samples should be sent for approval. The vendor should also re-inspect 100% and sort units by shade band. The results of shade variation observed during re-inspection must be reported to the production representative for a decision. If the production representative requests that the shades be separated then all cartons should be checked and accordingly segregated for different shades. OCR Audit Any trim that contains OCR (BARCODE) information must be audited during the visual auditing process. This will be a separate audit and results must be posted to the Shipment Inspection Report (Appendix I, form #8). When an incorrect OCR trim/label/ticket is detected, the facility must perform an additional audit of OCR trims to determine the severity of the problem as well as the correction. MEASURING THE WEIGHT OF SWEATERS Gap, Old Navy and Athleta Sweaters: Three pieces of the median size (the average of the smallest to the largest in the range) are weighed. The results are added together, and then divided by three (3). This will determine the average weight per sweater. Banana Republic Sweaters: Sweaters of every size in a program must be weighed individually and calculated for average weight based on the required size ratio in a placement memorandum according to the below listed procedures: • Assuming that the required size ratio is 1:2:2:1 (XS/S/M/L). • Randomly select four sweaters of every size; weigh them individually and record the results for the interim audit report. • Calculate the average weight of each sweater size by adding the four (4) readings together and dividing by four (4). • Based on the size ratio 1:2:2:1, the average overall weight of a sweater is calculated in the following manner: (avg. wt. of sizes “xs” x size ratio 1) + (avg. wt. of size “s” x size ratio 2) + (avg. wt. of size “m” x size ratio 2) + (avg. wt. of size “l” x ratio 1) /six (6) = overall weight of sweater. Visual Audit Acceptance Criteria • If the number of visual defects is equal to or less than the number allowed per the sampling plan, the audit passes. The defective products found are to be sent back for repair or seconds. • If the number of visual defects is more than the number allowed, the audit fails. The production representative is to be notified to determine the disposition of the shipment. The vendor has the option to perform 100% inspection to get an assessment of percentage that is defective. • If the audit fails, record in the comment column as to when the re-audit will take place. When the re-audit is done use the same procedures as new audit, including packing. • Pass or fail status of Visual Audit is determined based on the sample plan and the corresponding AQL Standards for each Brand as listed in Tables 1, 2, 3 & 4. MEASUREMENT AUDIT PROCEDURE Measurement Defects While performing a shipment audit, all measurements that are out of tolerance are considered “Measurement Defects.” Procedure for Measurement Audit: Measurements should be taken on products after wash, after press and sometimes before packing. Measurement audits must be done using a metal or fiberglass tape measure. Vinyl and plastic tape measures are prohibited. • Fiber glass tape measures should be calibrated using a Metal ruler. • Vendors in-house QA supervisor must calibrate the QA /DA fiberglass tape measures monthly. • All calibrations should be recorded and dated for reference as requested by Gap Inc QA. Only critical measurement points highlighted on the specification sheet (PLM specification sheets utilize QC “yes” boxes to denote the criticals) are taken at the time of the shipment audit. A product with more than one measurement defect is counted as one defect only. • Select samples at random. • Measure products at critical measurement points which are noted with a QC “yes” on the PLM specification sheet. • Record all measurements taken on the Finished Garment Measurement Sheet (Appendix I, form #9). • Highlight all measurement defects but make sure that a product with more than one measurement defect is counted as one defect only. Determining the Acceptance of a Measurement Audit Acceptance is based on the AQL (See AQL Standards Tables #1 - 4) pass/fail levels for Measurement defects. Accept • An audit is considered acceptable when total numbers of measurement defects is less than or equal to the number of defects allowed (see guideline and calculations below). Fail • An audit is considered failed when total numbers of measurement defects exceed the number of defects allowed (see guideline and calculations below). Exceptions The above criteria does not apply to the children’s “snug fitting sleepwear” program as it is governed by the CPSC Children’s Snug Fitting Sleepwear Regulations. MEASUREMENT AUDIT SAMPL ING PLAN S Table 5: Sampling Plan for Measurement and Pass/Fail Chart – Single Color ANSI/ASQC S1.4 1993 Single Sampling Plan Level (1) Lot Size by Color Sample Size AQL 2.5 Pass/Fail AQL 4.0 Pass/Fail AQL 6.5 Pass/Fail Five (5) sizes or less 20 1/2 2/3 3/4 More than five (5) sizes 32 2/3 3/4 5/6 Table 6: Sampling Plan for Measurement & Pass/Fail Chart– Multiple Colors ANSI/ASQC Z1.4 1993 Single Sampling Plan Level (1) Lot Size by Color Sample Size AQL 2.5 Pass/Fail AQL 4.0 Pass/Fail AQL 6.5 Pass/Fail 1 Color 20 1/2 2/3 3/4 2 Colors 32 2/3 3/4 5/6 3 Colors 50 3/4 5/6 7/8 4 Colors 80 5/6 7/8 10/11 5 Colors 80 5/6 7/8 10/11 More than (5) Colors 125 7/8 10/11 14/15 Vendor Managed Inventory (VMI) Audit Procedures Gap QA will check the pre production sample, take part in pre production meetings and will conduct random shipment audits at the vendor site. Select regions have empowered Gap Designated Auditors (DA) to release the goods for shipment if no quality issues are found. Any audit (measurement, visual, OCR, packing) that fails is repaired/reprocessed and re-audited before shipment. If the DA fails an audit they will contact Gap QA for disposition. If the audit passes the DA audit, the PO will ship. There are safeguards in place around this process, and Gap will de-certify a DA if they find issues. ALL AUDITS MUST PASS CURRENT MEASUREMENT, VISUAL, OCR, AND PACKING STANDARDS AS PER OUR ESTABLISHED SAMPLING TABLES BEFORE SHIPPING TO GAP INC. DISTRIBUTION CENTERS (DCS). Production Lot and DPO Audits FOR VMI STYLES, MEASUREMENT, VISUAL, AND OCR AUDITS ARE PERFORMED ON PRODUCTION LOTS VERSUS DPO’S BECAUSE THE UNITS ARE READY EARLIER THAN THE ACTUAL SHIP DATES. IF THERE IS TO BE ANY REWORK OR REPROCESSING THIS ALLOWS THE VENDOR THE TIME NEEDED TO MAKE THE APPROPRIATE CORRECTIONS PREVENTING DELAY OF SHIPMENTS. PRODUCTION LOTS ARE DEFINED AS UNITS THAT ARE READY TO BE PACKED WITH APPROPRIATE SIZE AND QUANTITY BREAKDOWNS. PACKING AUDITS ARE PERFORMED AT THE DPO LEVEL VERIFYING COUNTS, LABELING, AND ASSORTMENT ACCURACY. PACK AUDIT REQUIREMENTS The vendor is required to perform the packing audit to determine packing accuracy compliance. The shipment is to be checked for assortment accuracy, counts verification, and labeling accuracy. This is the final audit before goods are shipped. There are two types of packing audits, one done by the vendor entitled Factory Audit (“FA”) and the other done by Gap Inc. QA entitled Acceptance Audit (“AA”) to assess the packing accuracy. It is necessary to use “FA” and “AA” terms to differentiate similar terms used in the Distribution Centers. The “AA” is the responsibility of the facility/vendor and as per Gap Inc.’s Policy this audit is mandatory. Gap Inc. QA or those designated by Gap Inc. to perform shipment audits will be responsible for a full “AA” of the vendor. Pack Audit Defects include the following • Incorrect quantity. • Carton labeling errors. • Incorrect Pre-Pack. o Assortments. o Amounts. o Pre-Pack Stickers. • Carton not as specified (size and construction). • Crushed or damaged cartons. • Use of wire or metal strapping to strap cartons. Pack Audit Procedure • When performing the pack audit, the vendor must place “FA” on each box audited. This “FA” must be placed in a one inch by one inch space (1x1) at the top right hand corner of the box information label (the label containing Purchase Order, style, quantity, etc.). This “FA” must not be covered with tape or other labels because it will be used as a guide by Gap Inc. field personnel and Gap Inc. distribution centers to verify audits and assess these cartons. • Upon failure of an assessment, the auditor will continue the random sampling, using the Factory Pack Audit Sample Plan (see Table 14). If the Factory Pack Audit fails, the factory must then take appropriate action to correct the problems found. Discuss the results with factory representatives. Receive and record the factory action plan to correct the issues found in the audit. A re-audit will then be performed (not assessment) to verify the packing errors were corrected. A re-audit will be performed and recorded on a separate Shipment Inspection Report (Appendix I, form #8). This re-audit must be attached to the original report. • Upon completion of this assessment and/or audit, complete the appropriate section in the Shipment Inspection Report (Appendix I, form #8). Record the results of the “PA” and the results of the “FA”. • If problems found create shipping delays, notify the merchandiser/production representative for corrective action. Table 7: AQL and Sampling Plan for Pack Audit for Factory/Vendor: ANSI/ASQC Z1.4 1993 Single Sampling Plan Level II - 0.65 AQL Factory Pack Audit Sample Plan - AQL 0.65 # of cartons Sample Size Pass Fail 5-15 3 0 1 16-50 8 0 1 51-150 20 0 1 151-500 50 1 2 501-1,200 80 1 2 1,200- UP 125 2 3 F U LL CA RT ON PA CK P R OGRA MS Each vendor who participates in Gap, Inc.’s full carton pack program should establish a packing audit system. Prototype Pack For each Full Carton Purchase Order, the vendor is required to have in their packing department a prototype packed carton for training. This prototype is to be approved by Gap QA. Sample Size The Vendor should determine what quantity of cartons can be packed, and held, before closing the cartons. This carton quantity becomes the population from which the sample is drawn. The way a sampling plan works is the larger the population the smaller the sample size is as a percent of the population. To optimize the inspection time, the maximum quantity of cartons packed and labeled but not closed is desired. Once that number is determined, the vendor should choose the sampling size from the pack audit’s sampling plan (0.65 AQL). F U LL CA RT ON PA CK A U DI T PR OC E D U RE S The factory is responsible for the full carton pack audit. The following are procedures for performing a full carton pack audit: • It is important for the vendor to keep the population size at a level that takes into consideration the staging area available as well as the factory’s accuracy history. If an audit does not take place until the population is large, a great deal of extra handling will take place if it fails. We recommend that in the beginning, a vendor that is new to full carton pre-packs choose a small population to audit until history can be developed and expertise learned. • A same criterion for major packing errors is to be used as a normal shipment audit; use the same criterion as listed under Pack Audits (FA and AA procedures). • Gap Inc. will perform an assessment after the audit is completed by the factory/vendor. • Should vendors allow improperly packaged merchandise to ship, it will be the responsibility of the vendor to pay for any special handling required later in order to correct those errors at Gap Inc.’s distribution centers. SECONDS AND OVERRUNS Vendors must be reminded that all seconds or overruns sold to anyone other than Gap Inc. must have all Gap Inc. logos, labels, or other identification removed in accordance to the guidelines outlined in the Vendor Handbook. After all are removed, then an audit must be scheduled with Gap QA to verify that the removal has been executed correctly. COMMUNICATION AND RECORDS The vendor is responsible to communicate all failed shipment audits to merchandising and/or production representative immediately for resolution. The vendor will keep all records of the audit for review by QA or any other person designated by Gap Inc. It is mandatory for the vendor to maintain audit records for a period of 2 years and safety related records such as “children’s snug fitting sleepwear” audits; snap and button attachment audits etc. for a period of 7 years. While Gap QA must maintain a close communication with vendor’s in-house QA team, it is important to ensure that the factory manager/production manager/line supervisor are also informed of quality and production issues to enable timely action to address the issues. In regards to product safety issues, Gap QA must maintain a high level of vigilance, and in addition to informing the merchant, these issues must be highlighted to the QA manager/spoke office manager and GIS product safety team copied on issues. The communication process to GIS product safety team is crucial when it involves out of tolerance measurements for “children’s snug fitting sleepwear”, insecure snaps and buttons or uneven foundation issues. These issues could have legal implications if not resolved . AQL 0.1 Pass/Fail AQL 2.5* Pass/Fail AQL 0.1 Pass/Fail 1-2 5 5 0/1 0/1 0/1 2 6-5 0 8 0/1 0/1 0/1 5 1-9 0 13 0/1 1/2 0/1 9 1-1 50 20 0/1 1/2 0/1 15 1-2 80 32 0/1 2/3 0/1 28 1-5 00 50 0/1 3/4 0/1 50 1-1 ,200 80 0/1 5/6 0/1 1,20 1-3 ,200 125 0/1 7/8 0/1 3,20 1-1 0,000. These In-Process reports will be the basis for data collection and evaluation and to help drive improvements in the operations. IN-PROCESS INSPECTION FORMS At the relevant In-Process Inspection. Plan Level II - 0.65 AQL Factory Pack Audit Sample Plan - AQL 0.65 # of cartons Sample Size Pass Fail 5-1 5 3 0 1 1 6-5 0 8 0 1 5 1-1 50 20 0 1 15 1-5 00 50 1 2 50 1-1 ,200 80 1 2 1,20 0- UP 125 2 3 F