Gap Inc. Quality Assurance Manual

Gap Inc Quality Assurance Manual December 2009 (A Supplement to the Vendor Handbook) Table of Contents Page # I Introduction, Scope and Contacts Introduction ………………………………………………………………………………………… Purpose……………………………………………………………………………………………… Policy on Quality …………………………………………………………………………………… Scope ……………………………………………………………………………………………… Contacts …………………………………………………………………………………………… 4 4 II Requirements for Pre-Production and Pilot Run Pre-Production Requirements …………………………………………………………………… Purpose of Pre-Production Meetings …………………………………………………………… Preparing for Pre-Production Meetings ………………………………………………………… Meeting Participants ……………………………………………………………………………… Meeting Materials …………………………………………………………………………….…… Meeting Timing …………………………………………………………………………………… Purpose of the Pilot Run ………………………………………………………………………… Pilot Cutting ………………………………………………………………………………………… Wet Processing ………………………………………………………………………………….… 6 6 7 7 III Bulk Production Requirements In-Process Inspection …………………………………………………………………………… 10 Purpose …………………………………………………………………………….……………… 10 In-Process Inspection Forms …………………………………………………………………… 10 Cutting Inspection Procedures …………………………………………………………………… 10 Trim & Sewing Inspection Procedures …………………………………………………………… 10 Shipment Audits …………………………….……………………………………………………… 11 Audit Methods ……………………………………………………………………………………… 11 Shipment Inspection Forms ………………………………………………………………………… 11 Acceptable Quality Level (AQL) ………………………………………………………………… 11 AQL Standards …………………………………………………………………………………… 12 Critical Defects …………………………………………………………………………………… 13 Major and Minor Visual Defects ………………………………………………………………… 14 Visual Audit Sampling Plans ……………………………………………………………………… 14 Visual Audit Procedure for Non-Destructive …………………………………………………… 15 Measurement Audit Procedures ………………………………………………… ……………… 17 Measurement Audit Sampling Plans ………………………………………………………… 18 Vendor Managed Inventory (VMI) Audit Procedures …………………………………………… 18 Pack Audit Requirements ………………………………………………………………………… 18 Full Carton Pack Programs ………………………………………………………………………… 19 Full Carton Pack Audit Procedures ……………………………………………………………… 20 Seconds and Overruns …………………………………………………………………………… 20 Communication and Records ……………………………………………………………………… 20 IV Safety Procedures Safety Procedures ………………………… …………………………………………………… 21 V Needle and Sharp Metal Objects Policy ………………………………………………………………………………………………… Back Charge Policy ……………………………………………………………………………… Needle Control ……………………………………………………………………………………… Needle Detection …………………………………………………………………………………… Other Metal and Sharp Object Contamination …………………………………………………… Verification of Factory’s Needle Control Procedures …………………………………………… Logs …………………………………………………………………………………………………… 22 22 22 25 26 26 28 I Introduction, Scope & Contacts Introduction This Quality Assurance Manual for Vendors is developed by Gap Inc as a supplement to the Vendor Handbook and outlines the quality expectations of all apparel products The requirements have been carefully established considering ongoing business conditions and Gap Inc.’s constant desire to excel in the quality of the product they design and develop Gap Inc.’s Quality Assurance program is not intended to replace the vendor’s own quality control program as Gap Inc expects its vendors and suppliers to develop a positive culture of quality to enable them to deliver products that comply with all Gap Inc.’s requirements This culture must begin with vendor management’s commitment to develop a quality organization and to embrace a proactive approach to drive continuous improvement in product quality Gap Inc expects vendors to particularly focus on following areas: • Allocating appropriate resources to ensure quality systems are working and effective • Encouraging active participation of all workers in improvement efforts • Ensuring that manufacturing processes are stable, capable, and under control at all times and are producing defect free products • Ensuring that adequate in-process inspections and testing are in place to monitor quality • Documenting systems, processes, procedures, etc to maintain effective operations • Creating open, honest and timely communication with Gap Inc.’s sourcing offices Purpose The purpose of the Quality Assurance Manual is to communicate product quality requirements to vendors, suppliers and agents as it outlines the policies, procedures and quality expectations Vendors, suppliers and agents that business with Gap Inc must be familiar with the contents of this manual and the Appendix worksheets and forms Certain Chapters are written to outline procedures for Gap Inc’s internal QA teams However, the vendor may use it to train their QA teams or use it in any manner to supplement their QA processes Policy on Quality Gap Inc.’s policies on quality of apparel products are developed by defining various measures and by setting standards that vendors are required to meet or exceed when shipping every purchase order to Gap Inc Scope This manual deals with quality requirements of apparel products only This manual is also a useful resource for Gap Inc.’s internal Quality Assurance, Production and Merchandising teams This manual is the property of Gap Inc While in your company’s possession, the Manual is to be maintained in strict confidence and must not be divulged to anyone other than those who need to know its contents for the purpose of your dealings with Gap Inc or its vendors The Manual shall be returned to Gap Inc immediately upon termination of your dealings with Gap Inc or its vendors, or upon Gap Inc.’s request Contacts For any questions or clarification on this Manual please contact your regional QA leads at the GIS office listed below or Corporate QA at following address: Gap Inc Corporate Quality Assurance Folsom, 6th Floor San Francisco, California 94105 USA Email: Corporate Quality Assurance GIS Offices GIS Americas 5200 Blue Lagoon Drive, Suite 300 Miami, Florida 33126 USA Tel: 305-476-7500 Fax: 305-476-7545 GIS Hong Kong 20-22/F, BEA Tower, Millennium City 5, 418 Kwun Tong Road, Kwun Tong Kowloon, Hong Kong Tel: 852.2.730.9883 Fax: 852.2.736.8903 GIS India B-1/I-2, Mohan Co-operative Industrial Estate, Mathura Road, New Delhi, India Tel: 91.11.418.22222 Fax: 91.11.628.0978 GIS Korea 36-37, Itaewon-Dong, Seoul, Korea Tel: 822-6733-6000 Fax: 822-6733-6088 GIS Mediterranean Suzer Plaza Askerocagi Caddesi No:15, Kat: 17 Sisli, 34367 Istanbul, Turkiye Tel: 90-212-282-0420 Fax: 90-212-282-0417 II Requirements for Pre-Production and Pilot Runs Pre-Production Requirements This section has been written as a guideline for Gap Inc.’s QA personnel but the vendor can apply and adopt it to train their internal QA staff as well In-depth preparation is a critical step to ensure success of any manufacturing program Gathering timely and accurate information of styles and production details from the Merchandising is a critical preparation step Purpose of Pre-Production Meetings The purpose of the pre-production meeting is to ensure that all teams that are involved get an opportunity to go over the details and are able to develop plans to deliver product that complies with all the requirements The intent of preparation is to facilitate early detection of potential quality issues and help develop action plans to prevent it in bulk production Pre-production requirements are outlined below Preparing for Pre-Production Meeting Pre-production Samples: In preparation for a pre-production meeting, once a final Garment Size Specifications sheet (GSS) with size set comments is available, a factory must prepare either a jump size set or a full size set of pre-production samples, incorporating all the fit comments, for evaluation during the pre-production meeting QA will evaluate the samples on: • Measurement • Construction • Sewing method • Trims/accessory placement • Potential safety issues • Aesthetics This step is expected to help speed up the production process as potential production issues are likely to surface during such runs and can be addressed before the start of bulk production This can be a critical step for large programs Order Placement Information: QA should get a Confirmed Placement Summary (CPS) from the merchandising department that provides visibility to styles being placed with each vendor and its facilities QA must therefore work with merchandising and the factory to obtain production information such as production planning, raw materials and accessories status, etc This will help the QA to plan meetings and/or visits to support pre-production activities Meeting Participants The pre-production meeting must involve all parties responsible for the quality of the production The following personnel are recommended to be in a pre-production meeting QA should make an effort to schedule and coordinate the meeting to time it with facility’s production planning or other such key meetings From the Factory • Factory manager/Production manager • Production floor supervisor/s (cutting/sewing/finishing/packing) • Gap certified QA • Merchandiser From Gap Inc • QA/Garment technician/appropriate QA handling the program • Merchandiser • Product safety specialist (for kids/baby program) if based at source It is recommended that either the spoke merchant or the hub merchant get involved in pre-production meetings as well Involve the product safety specialist in these meetings as necessary if there are special safety issues that need clarification Meeting Materials The pre-production meeting may be conducted with samples and key relevant production information as listed below • Garment Size Specifications with size set comments • Purchasing Order • Trims card (the factory can prepare this in advance) • Dye lots (as made available by the mill) • Pre-production garment samples • Sample with final size set comments sent by merchants • Product Safety Line review comments or equivalent (for kids/baby programs) Special comments & specific quality issues must be recorded on a Pre-production Sample Evaluation Checklist (Appendix I, form #2) to ensure proper follow up action by the factory, in-house QA, and the line supervisor For baby/kids garment production, QA must review any product safety recommendations contained in the line review report so that they are correctly implemented in production Meeting Timing The most appropriate time to hold a pre-production meeting is before the cutting operation As previously stated the intent of pre-production meeting is to consolidate all information and to ensure that all parties have the same details and understanding of the program If possible the evaluation of pre-production samples should also be done prior to the meeting Purpose of the Pilot Run The main objective of a pilot run is to review and anticipate potential production issues that may arise during various operations such as cutting, sewing, finishing, pressing and also to review any issues related to production measurements, product safety and overall quality For programs that require special wet processing treatments, the pilot run samples may be kept aside for wash pilot at a later date when the wash standard is approved The factory should start a pilot run soon after the pre-production meeting Pilot Cutting Cutting is the first process prior to the commencement of a pilot run QA should review the following points at the pilot cutting stage with the factory personnel and/or in-house QA: • Proper shrinkage has been built into the paper patterns • GSS used is “Final” and critical fit comments are interpreted onto the paper pattern • Fabric testing has been done & meets the basic testing standard • Dye lot or shades have been sorted and grouped; out of tolerance (i.e off shade) rolls removed & put aside for a later discussion with the fabric mill • Face and back of fabric has been clearly defined and identified This is critical for certain fabrics where the back may be used as the face e.g sheeting, poplin or satin fabrics Factory should proceed with the cutting operation only when above details are verified and confirmed, The details should be reported on an Shipment Inspection Report (Appendix I, form #8), using the Fabric/Cutting Checklist and defect portion If questions arise concerning specifications, fabric or material standards, color or shade, QA must contact the merchandising representative for clarification It is a good practice to verify with merchandising representative if there are discrepancies between their own information and those of the factories before proceeding with bulk production Pilot Run Set up The pilot run should be set up to simulate a small production run comprising of the entire size range or having at least a jump size range in three possible color ranges The minimum recommended units are 200 Depending on the availability of colors, the vendor may be required to more than one pilot run QA must check that all components, trims, accessories and labels are available to meet the production schedule If certain components or trims are not available a pilot run may be done using prototype or available trims and components In such cases QA will ensure that a proper audit is later performed to verify that the correct trims and components are used in bulk production Evaluating Pilot Run As pilot runs are mini production runs, they are audited according to Gap Inc.’s visual and measurement audit standards for shipment These standards may vary according to the brand, and are located within the QA Manual However, the sample size to be audited should not exceed 50 pieces The audit results should provide the quality level so that the vendor can address any noncompliance issues in bulk production Pilot runs are evaluated in following areas: • Hand feel and color against approved standards If standards are not available examples of fabric colors and range of shades should be forwarded to the merchandiser or production representative for their records • Placement and size of pattern pieces against specification sheet • Seam construction, thread color and size against specification sheet • Check that all small parts for baby’s and kids’ wear are securely attached and are meeting product safety regulations • Attachment quality of buttons, rivets and grommets on adult garments • Garment measurements against specification sheet QA must inform merchandising of any quality issues that cannot be corrected and are beyond control of the vendor (e.g excessive fabric defects making cutting difficult) Merchandising will work with SF GP to set an acceptable tolerance for such PO’s Wet Processing Setting Shade Band Standards and Tolerance In case of programs that go through wet processing and special washes, it is the responsibility of the vendor to sort fabrics into appropriate shade groups and dye lots, prepare a shade blanket, sew together shade lots from the fabric inventory assigned for use, and wash those blankets to match the approved standards In doing so it is assumed that the vendor will remove any out of tolerance fabric rolls and only use those that match the finish and the wash standard In case of woven fabrics it is recommended to sew 12 leg panels using three depths of colors so as to assess overall aesthetics, high-low effect, and abrasion Pockets and other embellishments should also be sewn on the leg panel to assess for abrasion Wash Pilot Once the shade band tolerance is set and the aesthetics approved, QA follows up with the factory on performing a wash pilot so that final bulk production tolerance can be confirmed Garments from pilot run or from bulk production may be used in a wash pilot, depending on timing of final wash approval Evaluating a Wash Pilot A wash pilot is performed on the first 500 garments of a bulk production run or as early as possible when a wash standard has been approved and set The wash pilot must include appropriate light, medium and dark shades or dye lots to enable proper assessment of bulk production A representative sample size of 50 pieces of garments are inspected according to a statistical sampling plan and evaluated for the following criteria: • Shade tolerances are within approved shade bands or dye lots Check this by: Stacking up the different shades and reviewing them against approved shade bands Vendor can rework as necessary to match the standard Shades that are out of tolerance must be sorted and communicated to merchant for further decision • QA may reject small quantities of production with shade bands outside of standard tolerance if it does not impact size ratio • • • • High-lows and abrasive effects are in the correct position & not over abraded: Hold a garment up when checking for high low and abrasive effect and numbers of nicks against approved standards • Key areas of garments to check are the edges along waistbands, bottom hem, outseam and inseams, pocket edge and belt loops • • Sandblasting, permanganate, localized bleaching, whisker-finish: Hang a garment up when checking for correct positioning and size of an appropriate finish This helps to give a more accurate assessment of the required three- dimensional look In most cases, for localized effects, they should be gradually faded out at the edge for a natural look • • • QA can always seek technical assistance of a hub wet processing specialist to address and resolve wet processing problems at the pilot stage Once the wash standard is set, in-house QA should follow up on the process by monitoring routine bulk production to ensure shade continuity and matching to approved standard III Bulk Production Requirements 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 InProcess 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 & Sewing 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 10 Needle Detection Gap Inc requires that all factories producing baby, kids, intimate apparel (any age) and Banana Republic Japan products utilize a needle detector prior to packing The needle detector is an extra safeguard to prevent against whole or broken needles in the product to be shipped; however, the use of the needle detectors must not replace due diligence in following the Needle Control Procedures • Intimate apparel includes underwear/shirts, camis, robes, sleepwear, and swimwear Note: bras and swimwear constructed like bras (underwire, hook & eye, etc.) are excluded at this stage due to the high number of stainless steel trims that will cause false alarm on needle detection • The number of needle detectors must meet the peak production capacity of the facility • Needle detectors must be tunnel type with conveyer system able to detect ferrous metal and with sensitivity less than 1.2mm sphere Some of the approved brands of needle detectors are: ƒ Cintex ƒ Hashima ƒ Dae Kwang (Besta) ƒ Lock ƒ Nissin (Mother’s Eye) ƒ Safeline ƒ YDS ƒ Sanko (Nikka Densok) For contact information and further details on approved models, vendors should contact their GIS Hub office • • • • • The needle detector must be kept in a permanent location according to supplier’s instructions with a clear area around sufficient to avoid electrical interference ƒ A stabilizer/regulator is to be installed to minimize false alarms caused by power fluctuations, according to the supplier recommendations ƒ If relocated it must be re-calibrated by the equipment supplier ƒ The detector must be serviced according to the supplier’s maintenance requirements Records must be kept of these services and any supplier recalibration; the Gap Inc QA or product safety officer will check these during safety audits All personnel involved in operating and supervising the needle detector must be trained by the supplier to understand the system, the operating procedures and how to make minor adjustments A calibration/sensitivity check must be carried out at least at the beginning, middle and end of a working shift, using the 1.2 mm diameter test card supplied with the unit ƒ This calibration must be recorded in the Needle Detector Calibration Log ƒ If the machine fails during a calibration check, it must be stopped immediately and recalibrated by a trained operator; all products that were passed through after the previous calibration must be re-checked ƒ Once a detector has failed a calibration test it must not be used until corrected, access to a back up detection unit is therefore highly recommended A log is to be maintained at the PO level, for each style passed through the detector The log must be signed by the packing supervisor A copy is to be available for the Gap Inc QA at final audit to verify that all garments have passed through needle detection Procedures must be in place to ensure that garments, including repaired and re-inspected garments, not go to packing without passing through detection and the following best practices can assist in this: ƒ Garments awaiting detection and those that have passed should be clearly separated and identified ƒ Locating the detector in the finishing area such that the only access to the packing section is via the needle detector 25 • • When the alarm sounds the garment must be put to one side in a clearly marked area, and a designated person must check the garment for contamination ƒ Use of a hand held detector is recommended ƒ If no contamination is found, the garment must be passed through the detector again and if clear it may be returned to the production area/passed to packing ƒ If the alarm sounds on the second pass, the garment must again be searched for the contamination and if the problem cannot be identified, the garment should be destroyed and management informed ƒ If contamination is found, once it has been removed, the garment must pass through detection again before being returned to production/passed to packing, this is to verify that is there is more than one piece of contamination it is found Any contamination found must be logged in the Metal Contamination Log (located at end of chapter) and must include corrective action taken to prevent a reoccurrence Other Metal and Sharp Object Contamination In addition to broken needles, the following are other potential sharp object contamination Factories should take all possible measures to ensure that these not enter Gap Inc product • • • • • • • • • Straight Pins Scissors/Clippers Razor Blades / Utility Knives Bundling Wire Staples Metal paper clips Mechanic tools like screw drivers, hammer and etc Broken glass Prong snaps and rivets Thus the following procedures are required: • No pins, wires, staples or metal clips may be used in any manufacturing process, including bundling, tacking, securing components, or packaging of any product Also none of these items can be used in the sample room nor should pins be used for notice boards in sewing room • If metal components must be used in specific garment manufacturing process, such as check fabric laying, the factory must maintain a record to control the use • Scissors and clippers must be secured to the workstation to prevent them from being accidentally packed with the garments When they cannot be secured, an issue log should be maintained • The production area must be kept free of such dangerous items as broken glass, splinters, etc This is particularly important, as these items will not be picked up in needle detection Verification of Factory’s Needle Control Procedures This is a clearly defined method to verify that factories are following needle control procedures All Gap Inc QA representatives who conduct in-factory audits on Gap Inc.’s behalf such as sourcing channels/agents/QA staff and product safety staff are responsible for this task The inspection steps outlined in these procedures will allow you to quickly determine if factories are correctly following our needle control procedures: • On a regular basis you should walk through the production lines to verify needle control procedures, completing the Product Safety Standard Checklist • Ask a few operators, at random, to explain what they if a needle breaks If they are not following the correct procedure, discuss your findings with the factory manager 26 • • • Search the floor for used or broken needle parts; pick up and save any you find to discuss with factory management Check around a few operators’ machines for spare or broken needles Lift the machine head to see if used or broken needles are present in the oil pan Collect and save needles to discuss with factory management Check the Broken Needle Log for accuracy Sign and date the log if it is in order Make sure all broken parts have been found and are taped to the log for each entry If only part of the broken needle is attached to Log, further investigation is required Logs As described above, various logs are required to track the enforcement of the above procedures Examples of these logs are included here If need be, additional columns and information can be added to the forms for documenting information; however existing columns/formatting cannot be removed from the logs page# Needle Inventory Log ………………………………………………………………………………… 28 Needle Inventory Log ~ Sample ……………………………………………………… …………… 29 Used Needle Disposal Log …………………………………………………………………………… 30 Used Needle Disposal Log ~ Sample …………………………………………… ………………… 31 Broken Needle Control Log …………………………………………………………………………… 32 Broken Needle Control Log ~ Sample ……………………………………………………………… 33 Metal Detection Log …………………………………………………………………………………… 34 Metal Detection Log ~ Sample ………………………………………………………………………… 35 Needle Detector Calibration Log ……………………………………………………………………… 36 Needle Detector Calibration Log ~ Sample ………………………………………………………… 37 27 Needle Inventory Log Type of Needle : Date Sewing Line : Receiving Time Qty Accumulated Qty Exchange Qty Balanc Counter Check Broken Used e Qty Time Name / Needle Needle Signatur e Remarks 28 Needle Inventory Log Type of Needle : Date Sewing Line : Receiving Time Qty 7/12/2004 9am 50 7/13/2004 7/14/2004 10am 50 7/15/2004 7/16/2004 9am 50 Accumulate d Qty 50 Exchange Qty Balanc Counter Check Broken Used e Qty Time Name / Needle Needle Signatur e 10 12 28 6pm Lim 28 10 12 6.15pm Lim 62 14 12 36 6.15pm Lim 36 13 14 6pm Lim 59 12 10 37 6pm Lim Remarks 29 30 31 32 33 34 35 Needle Detector Calibration Log Factory Name: Needle Detector Brand: Country: Model #: Remarks: The Needle Detector Operator must verify the calibration and accuracy times per day, at the beginning, middle and end of a working period by using the 1.2mm sphere ferrous checks cards to check machine sensitivity CROSS SECTION OF NEEDLE DETECTOR TUNNEL TOP A7 A8 A9 CENTRE A4 A5 A6 BOTTOM A1 A2 A3 Switch on the machine and adjust sensitivity level to less than 1.2mm sphere Place the 1.2mm sphere ferrous check card onto the conveyor belt at position A1, let the test card passes through the search head The needle detector should be activated (alarm should sound) Repeat the procedure 2-3 by placing the 1.2 mm sphere ferrous card on the conveyor belt at position A2 & A3 The needle detector should be activated (alarm should sound) Test A1, A2 & A3 with 1.2mm ferrous check card only No garment or paper is allowed during testing Repeat the procedure 2-3 by placing the 1.2 mm sphere ferrous check card on the top of a non-detectable block (plastic or other inert material), and placing this stand onto the conveyor belt at position A4, A5, A6, A7, A8 & A9 Record all the results Date Tim e Buye r A A A POSITION A A A A A A Operator’s Signature FQA / PSS Date Signature 36 “Y” = the needle detector activated (alarm sounded) when 1.2mm ferrous check card pass through the search head “N” = the needle detector did not react (no alarm) when 1.2mm ferrous check card pass through the search head 37 Needle Detector Calibration Log Kim Koon Factory Name: Country: Singapore Needle Detector Brand: Cintex Model #: Needlesearch FM Remarks: Needle detector must verify the calibration and accuracy times per day, at the beginning, middle and end of a working period by using the 1.2mm sphere ferrous checks cards to check machine sensitivity CROSS SECTION OF NEEDLE DETECTOR TUNNEL TOP A7 A8 A9 CENTRE A4 A5 A6 BOTTOM A1 A2 A3 Switch on the machine and adjust sensitivity level to less than 1.2mm sphere Place the 1.2mm sphere ferrous check card onto the conveyor belt at position A1, let the test card passes through the search head The needle detector should be activated (alarm should sound) Repeat the procedure 2-3 by placing the 1.2 mm sphere ferrous card on the conveyor belt at position A2 & A3 The needle detector should be activated (alarm should sound) Test A1, A2 & A3 with 1.2mm ferrous check card only No garment or paper is allowed during testing Repeat the procedure 2-3 by placing the 1.2 mm sphere ferrous check card on the top of a nondetectable block (plastic or other inert material), and placing this stand onto the conveyor belt at position A4, A5, A6, A7, A8 & A9 Record all the results Gap A Y A Y A Y POSITION A A A Y Y Y A Y A Y A Y Gap Y Y Y Y Y Y Y Y Y Ah Lian Gap Y Y Y Y Y Y Y Y Y Ah Lian Gap Y Y Y Y Y Y Y Y Y Ah Lian Gap Y Y Y Y Y Y Y Y Y Ah Lian Date Time Buyer Mar “ 8.30 am 12.30 pm 5.30p m 8.30 am 12.30 “ Mar “ Operator’s Signature Ah Lian FQA / PSS Date Signature Mar Mar Mar Mar Jen Jen Jen Jen Jen 40 “ Mar “ “ 4Ma r “ “ pm 5.30p m 8.30 am 12.30 pm 5.30p m 8.30 am 12.30 pm 5.30p m Gap Y Y Y Y Y Y Y Y Y Ah Lian Gap Y Y Y Y Y Y Y Y Y Ah Lian Gap Y Y Y Y Y Y Y Y Y Ah Lian Gap Y Y Y Y Y Y Y Y Y Ah Lian Gap Y Y Y Y Y Y Y Y Y Ah Lian Gap Y Y Y Y Y Y Y Y Y Ah Lian Gap Y Y Y Y Y Y Y Y Y Ah Lian Mar Mar Mar Mar Mar Mar Mar Mar Jen Jen Jen Jen Jen Jen Jen “Y” = the needle detector activated (alarm sounded) when 1.2mm ferrous check card pass through the search head “N” = the needle detector did not react (no alarm) when 1.2mm ferrous check card pass through the search head 41