SOP Final Inspection Certification Program Training Manual (English)

S.O.P FINAL AUDIT FLOWCHECK GARMENT FOLDING METHOD CHECK THE APPROVED SHADE BANDS CHECK TICKETS & TAG CHECK P.P.. CHECK UNDER“MACBETH” LIGHT BOX COLOR CONTINUITY ON WHOLE SAMPLE LOT SAME

S.O.P Final Inspection Certification

Program (Training Manual)

Prepared By: Technical Service Team

Leo ChanRavi HurPaulStephen ZhouPrashant Pattam

5/30/2010 2

• Revision History

3/20/2007 PAGE 5,16,62

S.S.C REVISED

5/30/2010 Page 6, add “critical areas” for 2 points

S.S.C Revised

Date Summary Of Changes

Author Issue

PART (1) CLASS TRAINING

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1 The Flow of

“S.O.P Final Audit”

S.O.P FINAL AUDIT FLOW

CHECK GARMENT FOLDING METHOD

CHECK THE APPROVED SHADE BANDS

CHECK TICKETS

&

TAG

CHECK P.P & TOP SAMPLE CONSTRUCTION IN/OUT SIDE

CHECK P.P SAMPLE

& TOP SAMPLE COMMENTS

LAB TEST REPORT

1 Please clarify with Mast office related Person/department if any information is Not clear, no approval signature,

or does not make sense.

2 Ask your supervisor if the information appears confusing Do not assume.

CHECK

IN LINE REPORT

CHECK UNDER

“MACBETH”

LIGHT BOX

COLOR CONTINUITY

ON WHOLE SAMPLE LOT

SAME FABRIC DIRECTION

1 LABEL THE OFF SHADE SAMPLE FOR END RESULT COUNT.

2 CARRY ON THE FOLLOWING PROCESS

TAKE MEASUREMENT

ACROSS COLOR/SIZE

1 LABEL THE “O.O.T.” SAMPLE(S) FOR REVIEW AND FOR END RESULT COUNT.

2 THE SHIPMENT SHOULD BE REJECTED IF “O.O.T”

6% ON KEY POINT.

3 CARRY ON THE PROCESS.

SAMPLE PLAN FOR MEASUREMENT FOLLOW THE S.O.P.

MANUAL REQUIREMENT

FOLLOW THE RIGHT WAY OF MEASURING.

CRITICAL AREAS

- LEARN THE MEASURING METHOD BY MEASURING

THE PP SAMPLE FIRST

-Measure In-line sample & keep record.

BOTTOMS: TWISTING (LEG) HIKING (SEAMS,FRONT/BACK), HIPS LARGER OR SMALLER THAN

STANDARD

TOPS: UNBALANCE, OVER EASING,OVER STRETCHING, SLEEVES,NECKLINES,SHOULDERS, BODICE.

1 LABEL THE DEFFECTIVE SAMPLE(S) AND LOCATION FOR END RESULT.

2 CARRY ON THE PROCESS.

END RESULT

NO MATTER THE RESULT “ACCEPT” OR “REJECTED”,MAST QA SHOULD TAKE THE FOLLOW

ACTION:

1 REVIEW ALL DEFECTIVE SAMPLES WITH FACTORY RESPRESENTATIVE

2 MAST Q.A AND FACTORY RESPRESENTATIVE HAVE TO SIGN THE REPORT, TO

ACKNOWLEDGE THE END RESULT.

3 IF THE FACTORY RESPRESENTATIVE DISAGREES WITH THE END RESULT IS “REJECT”, THE

DISAGREEMENT HANDLING BY MAST Q.A SHALL BE:

A TAKE PHOTOS OF THE DEFECTIVE SAMPLES.

B SEND THE REPRESENTATIVE DEFECTIVE SAMPLES TO MAST OFFICE./Q.A.MANAGER AND

AWAIT FOR THE FINAL DECESION.

4 BASED ON THE DECESION ENTER THE FINAL END RESULT INTO THE T.S WEB.

CHECK ALL SEAMS

POCKET BAG IN//OUTSIDE

LINING TURN INSIDE OUT

CHECK ACCESSORIES

BAD SMELL

HAND FEEL

1 LABEL ALL THE DEFECTIVE SAMPLE FOR FINAL REVIEW.

2 IDENTIFY “MIN” & “MAJ” FOR END RESULT COUNT.

3 CARRY ON THE FOLLOWING PROCESSING.

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2 Audit Preparation

• Must be a proper audit work room with minimum size of 30 square meters, not a

conference room nor inside of the office.

• All walls covered by white board.

• Floor color must be painted “dark grey” or “black” not light color.

• Well lighted, without window (not being affected by outside daylight or other light

sources).

• ‘MACBETH’ light box should be set in small room (or separate compartment) of the audit area, closed with wooden door (or black opaque curtain) to keep away all light sources.

• Air-conditioned.

the inspection room view (1) the inspection room view (2)

2.1 Audit work area standard.

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2.2 Standard of audit room facilities

PC (Mast standard),

Printer, FAX

Lighting and Temperature Condition

.Range 110-120 candle light

.C.W.F light tubes placement should be under ceiling and 12” away from the edge of

inspection table

C.W.F light tubes model

Brand: PHILIPS Model # TLD 36W/33

.Temperature: Around 18 C – 24 C

.Humidity: Around 40 – 70%

.With A/C and IDD plug for internet connection Or I.Pass Mast specification

The light tubes

2.2 Standard of audit room facilities

Inspection Table and QC Chair

.Table color in mid-grey with dull surface

.Table size: H34 1-/2” x W48” x L96” x T1-1/2”, with edge surrounded by solid wood and

smooth surface

.4-tables component preferred - big enough to lay bulk samples for testing

.High stand and high back QC chair, removable and adjustable

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2.3 Audit Tool

• 2.3.1 Ball pen.

• 2.3.2 Soft measuring tape

for woven, cut & sew

(ensure the sticker does

not leave any mark on the

garment)

• 2.3.6 Inspection report for

Final Audit.

3 S.O.P Audit Procedures

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3.1 Selection of samples and cartons (at least8%)

a/ The sample cartons for audit should be randomly selected from different

location & pallet from the storage areas.

b/ The garment samples for audit should be randomly selected from the

different layers of carton.

c/ MAST q.c should escort the selected cartons and samples to the

designated audit area/room.

d/ If the packing list is temporary or not available, the auditor must select carton available randomly and should not just take cartons which are conveniently accessible.

e/ Carton number shall be called out randomly across sizes & colors according

to factory temporary packing list.

f/ Upon the completion of 95% of the goods packed into carton , the order can

be taken for final inspection.

3.2 Q.C inspection file check.

3.2.1 VPO

order to know the type

of defects that were

found

3.2.3 Accessory Card

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3.2.4.Approved Shade Band

3.2.5 Lab Test

Folding Instructions

Measurement

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3.2.6(c) Tech Pack- PANTS

Style DiagramConstructionConstruction detail

Trim & Color

Labeling PositionLabeling Requirement

Measurement

Folding Instructions

3.2.6(d) Tech Pack-PANTY

Style Diagram

Construction Details

Folding Instructions

Measurement

Measurement Grading

3.3 Review the approved P.P sample

(comments, fitting and construction).

3.4.2 Check shipping mark.

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3.4.3 packing method & units in carton.

3.5 Check garment presentation ( packed & unpacked).

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3.6 Check color shade.

3.6.1 Color continuity (garment to garment).

3.6.2 Color shading (within a garment).

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3.7 Check garment measurement and record exactly what you have observed.

Follow the measurement sampling chart.

If over 6% of garments where the key

point(s) are out of tolerance of the total

sample measured, the audit is failed (for

example, 3 pieces out of 50 pieces, result

is “pass”, 4 pieces or more, result is “fail”.

3.8 Check the fit and balance of garment.

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Fitting-Unbalance

Fitting-Over stretching

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Fitting-Twisting

Fitting-Hiking at Back

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Fitting-Armhole Bulky

Fitting-Wide Neckline

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Fitting-Bodice Edge Curling

Fitting-Hem Rise and High Low Vent

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Fitting-Off Shape at Placket

Fitting-Low Hip Big Ear (front view)

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Fitting-Low Hip Big Ear (side view)

3.9 Check workmanship and visual

defects.

(i) For sampling, please follow the brands’ requirement

(ii) For AQL standardized, refer to standardized S.O.P manual (iii) Visual audit definition Which means visible to the eyes.

Examples of defective garments (iiii) For audit regulation, please follow standardized S.O.P

manual.

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3.10 Marking defects properly for.

(i) Color shade garment(s) off standard.

(ii) O.O.T (out of tolerance/measurement) (iii) Visual defects (workmanship /

construction / accessories etc.)

Marking Defects

In case you are advised to take digital photo

or send defective garment to your supervisor

or merchandiser for further review during final/in line inspection, the defective sample should be marked properly per following instructions

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Ensure sticker/label size is big enough to write down

Remark: Finally, do not forget to put your signature and

inspection date on sticker/label

Example of marking color shade Defect

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II Mark Measurement Defect

Ensure sticker/label size is big enough to write

down information below :

• Description of Measurement Defect

Remark: Finally, do not forget to put your signature and

inspection date on sticker/label

Example of marking measurement Defect

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III Mark Visual Defect

• Use arrow sticker to mark defect

• Mark arrow to the direction of defect

• Avoid arrow sticker covering the defect

Proper distance should be maintained

between sticker and defect

Workmanship(1) - Mis-matched

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Workmanship(2) – Sewing Defect

Construction

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Fabric Defect

Accessories

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3.11 Issue Audit Report.

(a) Clear & clean.

(b) Visualable & recognized.

3.12 Disagreement Handling.

In case of disagreement raised during final inspection, please keep calm

and do not get excited and be influenced by factory personnel You should look for help from your direct supervisor/manager if you are unsure Please followed the instructions below when dealing with this type of situation

1 Report to your supervisor/manager the inspection results with

• The order details

• Which color has problem

• What is the defect

• The rejection details

2 Take the digital photo and send to your supervisor/manager if looking

for help The photo must be clear and visible on the defect.

5/30/2010 Attached 1:The pattern 60

3 The information must be one pattern (see attached 1)

4 Do not hesitate to consult your supervisor/manager if in doubt.

5 Marginal Shipment - if final inspection failed due to a minor flaw, you should refer the (ship no ship) decision to the technical manager And all conversation / discussion / decision with merchandising

department or technical manager should be recorded on report.

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3.13 Final Inspection Result

Data Input

3.13.1 The Website

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3.13.2 enter the “Username” & “Password”

3.13.3 the Main Window

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(1).Click the “Final Inspection” ,Select the “Final Inspection New”.

3.13.4 Final Inspection