SOP: Accessories Inspection Procedure
1.0 Purpose
To provide guidance to all the employees about Trims & Accessories inspection & issuing process from stores to production or other Operation/Process. This is a part of Quality Assurance process.
2.0 Scope
This process applies to all types of accessories.
3.0 Responsibility
3.1 Store Manager responsible from in-house to issue and also information pass to the Merchandiser and Trims & accessories checking person with required document.
3.2 Quality Auditor/ Inspector responsible to check the Quality of Trims & Accessories.
4.0 Process
4.1 Basic Requirements
4.1.1 Customer approved trim card or Merchandiser’s approval for trims & Accessories, Bill of Material (BOM), Order Sheet & accessories received inventory report.
4.2 Procedure
4.2.1 When receiving Trims & Accessories store should keep them at the quarantine area waiting for inspection with yellow sticker. Without Audit no trim & Accessories can store in racks.
4.2.2 After in-house any Trims & Accessories MCD will provide Chelan/received copy & inventory report to Quality Auditor/Inspector (Including actual quantity, packing condition, delivery time, and logistic support). And take the signature of QI person with date & time.
4.2.3 Responsible Quality Auditor/Inspector will choose sample & do the Audit according to the AQL charts & check list. For any color trims need to check in light box against customer approvals.
4.2.4 All the accessories should be checked according to the approved standard. Need to check all the parameters related to that material. (Measurement, Lettering/details, Color Fastness, Strength, Thickness, Adhesive, Logo, Dust/Stain, Color/Shade/Size Mix up, moisture, smell etc.).
4.2.5 After finishing the audit, auditor will issue a copy of audit report to the Store representative and take his/her signature with date & Time.
4.2.6 If the audits pass then Store should store them in the racks allocated for particular items with green QC pass sticker. Trims & Accessories should store FGML wise. At the issuing must be follow first in first out basis with maintaining proper bin card.
4.2.7 If an Audit fail those items should store in the lockable reject item storage rack waiting for return to supplier or pending corrective actions from Merchandiser or supplier end with red rejected sticker.
4.2.8 Store needs to update Merchandiser, Supplier and other respective parties about the audit failure and call for corrective actions.
4.2.9 Without Pass audit report any Trims/Accessories should not issue to production or for any other process in the factory.
4.2.10 Inventory and Audit reports should be maintained to analyze and supplier rating.
AQL-1.5 Acceptance chart.
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|
AQL- 1.5 Countable Item |
|||
|
Lot Size |
Sample Size (L-2) |
Accept |
Sample Size (L-2) |
Accept |
|
2 - 8 |
2 |
0 |
2 |
0 |
|
9 - 15 |
2 |
0 |
3 |
0 |
|
16 - 25 |
3 |
0 |
5 |
0 |
|
26 - 50 |
5 |
0 |
8 |
0 |
|
51 - 90 |
5 |
0 |
13 |
0 |
|
91 - 150 |
8 |
0 |
20 |
1 |
|
151 - 280 |
13 |
0 |
32 |
1 |
|
281 - 500 |
20 |
1 |
50 |
2 |
|
501 - 1200 |
32 |
1 |
80 |
3 |
|
1201 - 3200 |
50 |
2 |
125 |
5 |
|
3201 - 10000 |
80 |
3 |
200 |
7 |
|
10001 - 35000 |
125 |
5 |
315 |
10 |
|
35001 - 150000 |
200 |
7 |
500 |
14 |
|
150001 - 500000 |
315 |
10 |
800 |
21 |
|
500001 - Above |
500 |
14 |
1250 |
21 |
10% Inspection acceptance Chart
|
10% Inspection System for non-countable Item |
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|
Lot Size |
Sample Size |
Accept |
Reject |
|
Any |
10% |
2% |
2% Above |
|
If 1st Inspection (10%) fail |
|||
|
Any |
15% |
2% |
2% Above |
|
If 2nd Inspection (15%) fail |
|||
|
Any |
100% |
2% |
2% Above |
|
If 100% also fail need to contact with merchandising manager, Quality manager & GPQ/QS/CA Account responsible & go for further action. |
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Accessories Inspection Criteria
|
Thread |
Elastic |
Tape |
|
- Color /shade continuity - Thread Count - Thread code - Shade Match with DTM |
- Expiry Date - Measurement - Shrinkage - Stretch ability - Recovery - Latex free test. |
- Lettering or art work - Measurement - Shade/ color - Color fastness check (5time wash) |
|
Label/Price ticket/ Hang tag |
Button |
Bow/ Flower/ Applique/ Patch |
|
- Logo - Information - Layout - Lettering/Font - Measurement - Color - Sharpness |
- Measurement - Color/ Shade - Lettering or art work - Wash test for jeweled/ - decorative button |
- Measurement - Layout - Shade/color - Dimension - Lettering - Sharpness - Construction |
|
Metal Item |
Zipper |
Poly |
|
- Nickel test - Metal detection - Measurement |
-Measurement - Puller - Lettering - Functionality - Color/Shade |
- Logo - Lettering - Measurement - Sharpness - Dust - Air hole - Warning - Recycled sign |
|
Hanger |
Paper Board |
Carton |
|
- Lettering - Information - Measurement - Color
|
- Lettering - Information - Measurement - Color
|
- No of plies - Size - Information - Strength
|
Note:
- All Accessories must be checked for Smell, Moisture & others quality criteria.
- All Accessories must be checked for Actual quantity; it can be one by one or in a calibrated scale.
- Color must be checked in approved light box.
- All trims & Accessories must be check with proper reference/ document & Relevant check point must be followed for any other trims, accessories & materials.
- If any confusion arises need to take advice from GPQ/ RQS/ CA/ Quality Manager
4.0 Reference
4.1 Accessories Inspection report (JEX/QA/F0/039)
5.0 Definitions
6.1 AQL = Acceptable Quality Level.
6.2 BOM = Bill of Materials
AQL- 1.5 (Level-2) for Countable Item
|
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Lot Size
|
Sample Size
|
Accept
|
Reject
|
2 - 8
|
2
|
0
|
1
|
9 - 15
|
3
|
0
|
1
|
16 - 25
|
5
|
0
|
1
|
26 - 50
|
8
|
0
|
1
|
51 - 90
|
13
|
0
|
1
|
91 - 150
|
20
|
1
|
2
|
151 - 280
|
32
|
1
|
2
|
281 - 500
|
50
|
2
|
3
|
501 - 1200
|
80
|
3
|
4
|
1201 - 3200
|
125
|
5
|
6
|
3201 - 10000
|
200
|
7
|
8
|
10001 - 35000
|
315
|
10
|
11
|
35001 - 150000
|
500
|
14
|
15
|
150001 - 500000
|
800
|
21
|
22
|
500001 - Above
|
1250
|
21
|
22
|
10% Inspection System for non-countable Item
|
|||
Lot Size
|
Sample Size
|
Accept
|
Reject
|
Any
|
10%
|
2%
|
2% Above
|
If 1st Inspection (10%) fail
|
|||
Any
|
15%
|
2%
|
2% Above
|
If 2nd Inspection (15%) fail
|
|||
Any
|
100%
|
2%
|
2% Above
|
If 100% also fail need to contact with merchandising manager,
Quality manager & GPQ/QS/CA Account responsible & go for further
action.
|
|||
Thread
|
Elastic
|
Tape
|
-
Color /shade continuity
-
Thread Count
-
Thread code
-
Shade Match with DTM
|
-
Expiry Date
-
Measurement
-
Shrinkage
-
Stretch ability
-
Recovery
-
Latex free test.
|
-
Lettering or art work
-
Measurement
-
Shade/ color
-
Color fastness check (5time wash)
|
Label/Price ticket/ Hang tag
|
Button
|
Bow/ Flower/ Applique/ Patch
|
-
Logo
-
Information
-
Layout
-
Lettering/Font
-
Measurement
-
Color
-
Sharpness
|
-
Measurement
-
Color/ Shade
-
Lettering or art work
-
Wash test for jeweled/
-
decorative button
|
-
Measurement
-
Layout
-
Shade/color
-
Dimension
-
Lettering
-
Sharpness
-
Construction
|
Metal Item
|
Zipper
|
Poly
|
-
Nickel test
-
Metal detection
-
Measurement
|
-Measurement
-
Puller
-
Lettering
-
Functionality
-
Color/Shade
|
-
Logo
-
Lettering
-
Measurement
-
Sharpness
-
Dust
-
Air hole
-
Warning
-
Recycled sign
|
Hanger
|
Paper Board
|
Carton
|
-
Lettering
-
Information
-
Measurement
-
Color
|
-
Lettering
-
Information
-
Measurement
-
Color
|
-
No of plies
-
Size
-
Information
-
Strength
|
