Quality System Audit – Select 5 garments at random from the packed goods and bring them to clean, clear and well-illuminated table.
Check the garments one by one and record nature and number of efects classified under 3 categories :
A – critical
B – major
C – minor
Calculate the DHU (defects per hundred units). Record this.
Enter the Weekly Quality System Audit Summary.
Discuss the quality issues specifically with the production manager.
The auditor is normally the senior-most person in the factory.
The auditor is estimating the defects missed. The efficiency of the quality system is the defects found by the line checkers expressed as a percentage of the total defects (got from the in-line sampler or the sum of the defects found & the defects missed).
There are three types of inspection that must be conducted during
a final inspection-
Workmanship Quality
Spec Measurement
Packing Integrity (which consist of two checks called the Count and Accuracy Quality System Audit )
All three inspections must be conducted when a PO has been packed completely (100%).
A Packing List (P/L) must be available for use by the QA to perform the above inspections, so that appropriate random sample size can be selected for the final inspection.
FORMS TO BE USED FOR EACH INSPECTION
PEI and Vendor QA should use the approved PEI formats globally.
Final Inspection Reports (page-1) which provides a summary
of the result of inspection Final Inspection Check-List (Tops or Bottoms- page-2) used as a guide for the QA to check the product in a systematic manner. Measurement Quality System Audit Report for spec measurements
Using the reports
Report
Usage
Cut quality report
Monitor & target quality by cutter – CS Know in advance which parts have a cutting problem – PM Monitor cutting quality – FM
Roving inspection record sheet
Know trend in operator’s quality over the week and deal with operators who are not improving– QS Check how many operators the sampler has visited – QS
100% inspection
Show which operations are producing defects and require attention –QS Know which are the problem operations and take corrective action – PM
Repair list
Keep track of repairs and ensure that they are returned promptly – QS
Quality audit
Monitor the efficiency of the quality system and provide feedback on the quality being passed – FM
Weekly audit summary
Follow-up on actions arising from the Quality System Audit – FM
Daily quality report
Know which are the problem operations and take corrective action – PM Monitor the quality produced by the lines – FM
Weekly quality report
Know which are the problem operations and take corrective action –PM Monitor the quality produced by the lines – FM
INFORMATION AND GUIDELINES-
Verify the following is available when performing a Final
Inspection-
Ensure FIT, PPS has been approved and PPS available for reference. If PPS has not been approved DO NOT proceed with Final Inspections.
Verify if TOP has been sent prior to conducting Final Inspections. Contact local merchandiser if TOP has not been sent. DO NOT mark ‘PASS’ on Final Inspection report of TOP is not approved.
QC file available with PPS comments from office, complete PDM (tech pack), purchase order sheet with UPC information sheet etc.
Fabric and Hand / Color standard that has been approved.
Shade band in the case of indigo or piece dyed product that has been approved.
Trim card complete with all trims that has been approved including embroidery, printing standards.
Fabric and Garment test reports confirming that the product meets the care label instructions.
Final Packing List.
PACKING MODE
Circle the shipping mode and packing method on the
inspection report-
Verify packing method
Verify if the order is a standard pack (solid size/color) or pre-pack.
Verify if the style should be shipped with individual or master poly bag.
Inspect container for any holes, damages etc.
PACKAGING
Go through the check list against the packaging and place a
check mark against YES, NO or N/A-
Verify if carton quality is good and strong, condition is dry and not damp.
Ensure cartons are taped with approved security tape.
Verify by measuring the carton dimension against what is printed on carton and ensure they are within the requirements.
Ensure carton markings are correct as per requirement of store/customer.
Ensure carton pack ID label is placed in the correct place.
Verify if there are any other extra carton labeling required by specific customer.
Verify if there is no wastage of space within carton while carton size is correct to the size of the stack. Space around garment inside the carton is loose all around.
Verify that the garments are stacked carefully so that there are minimal movements within carton.
Ensure hangers are secured safely within the carton either
to the elastic or hanger grooves (hook holder) made out of corrugated sheets.
Ensure poly bag quality and gauge is correct while the bag
fits to the garment size and that they are not wet or damp, while also
checking if perforation is needed or not.
Ensure hanger and hanger sizer quality is correct while
the color and size is also correct.
If garments are folded and packed flat, ensure they are
folded correctly as per specification and there are no dead creases or
wrinkle marks.
If there are other items for packaging, add the point/s
and mark accordingly.
COUNT AUDIT-
Perform a count audit by counting the number of units within
the box and ensure it matches the carton marking and ID label quantity.
Accuracy Quality System Audit
Verify poly bag sticker size is correct when compared to hang tag size. R emove poly bag.
Verify hang tag/ joker tag & price ticket quality is correct while the placement is as per specification.
Verify hang tag/ joker tag & price ticket information and price is correct.
Verify hang tag / joker tag & price ticket size is correct when compared with size label.
Ensure flasher quality and information is correct while the placement is also correct and secured. If flasher calls for NO IRON or WRINKLE FREE or PERMANENT CREASE etc., then the garments have undergone testing for repeated home laundering and passes PEI or customer standard as per manual
Ensure size strip quality is correct and it sticks on to garment very well while upon pealing the size strip, there are no residues settling on the surface of the fabric. Also verify the color of fabric is not running onto size strip.
Ensure the size on the size strip is correct to hang tag/ joker tag and size label.
If there are any ‘Other’ trims for packaging ensure to add to check-list and mark accordingly of Quality System Audit
How to prepare the roving inspection record sheet:
Obtain a copy of the Roving Inspection manning
Write down which week this sheet will be used for.
Write down, which line this report, is going to be used for.
Write the operation names in the first column, leaving rows for as many operators as have been allocated and 2 more for operators who are moved to this operation for balancing purposes.
Write the names of the operators allocated against their operations.
How to complete the roving inspection record sheet:
Total the number of faults for the week for an operation, excluding clearance checks. Write this under the ‘faults’ column.
Count how many times that operator was visited for that operation, excluding clearance checks. Multiply this by the lot size and write this down under the ‘sample’ column.
Divide the number of faults by the sample, multiply by 100 and enter this for the for the operator.
Add up the number of faults made by all the operators for an operation. Enter this in the ‘faults’ column for the operation.
Total the samples for all the operators who did that operation. Write this number as the sample for the operation.
Divide the number of faults by the sample, multiply by 100 and enter this for the for the operation.
PACKING INTEGRITY INSPECTION
By performing a comprehensive Packing Integrity Roving Inspection either during in-line, pre-final or final inspection stages, we can detect errors caused due to incorrect trims (style, size or color), incorrect garment size/color assortment or incorrect carton marking and labeling, so that the end product reaches the customer efficiently and without the need to perform extra handling thus saving time and money.
TYPES OF PACKING INTEGRITY INSPECTIONS
COUNT- To verify the quantity of units within a size and/or carton is correct to specifications.
ACCURACY- To verify the accuracy of trims and labeling within a garment and that of which is marked/labeled on the carton
HOW TO PERFORM A PACKING INTEGRITY INSPECTION
A packing integrity inspection must be conducted on all
Purchase Orders (PO). During the Packing Integrity Inspection, the entire PO must be completely packed. Packing list must be on hand to perform such Roving Inspection. All carton numbers that have been selected for the random
inspection must be marked on the inspection report
While selecting cartons, ensure to place a signature across the top opening of carton while making sure that the same cartons are brought into inspection area. Have the PO and Final Inspection detail Check-List on hand to perform the Packing Integrity Inspection. After review of performance of the factory, the inspector may be asked to switch back to Reduced Level Sampling Plan.
It is imperative that the factory arrange all cartons in single or double row with carton number facing out, so that QA can view the carton numbers. Factories are not allowed to arrange cartons with carton number facing inwards. Factories are not allowed to arrange cartons in triple or quadruple rows for Roving Inspection.
Mark the defects found on the garment with clearly visible stickers (or a thread if the stickers leave marks).
Record the defect on the 100% Inspection Record
Repeat steps l – lV for the rest of the bundle.
Count the number of defective pieces in the bundle. Note it down in the repair list. Give the pieces to the Quality supervisor. Keep the rest of the bundle aside. Note down the time the pieces were given to the Quality supervisor.
Trace the operator who made the defect.
Give the pieces back to the operators for alteration.
Pieces are altered and given back to the supervisor / repair girl. These are given back to the garment line checker.
Note down the time when the pieces are returned.
Recheck the garments. If there are no defects pass the bundle. If there are defects repeat the procedure from step Vl.
Light control over all operators with increased attention on operators who are unable to meet the Sewing Quality standard.
Identify operators who are unable to meet quality requirements.
Go to the operator indicated by the random number table.
Take a bundle from the operator and draw 5 pieces from the bundle.
Check the selected garments against the specification of the operation concerned.
The number of pieces to be inspected (sample size) from each bundle can be increased.
The number of defects that are acceptable (out of the sample size) can be changed, but zero is the preferred number.
The number of bundles that need to be checked after an operator has been put under clearance can be changed.
The parameters for the sampler should be fixed such that not more than 20% of the operators are under clearance at any time.
Record the number of defects. Write down the number of defects. If there are defects then the number of defects.
If there are no mistakes inform the operator that the bundle seems OK. Repeat from Step I.
If there are one or more defects in the sample put the operator under clearance by placing a blue clip on her workplace and circle the reading on the roving inspection record sheet.
Inform the operator of the problem and ask her to check the remainder of the bundle and correct all mistakes.
Inspect the rest of the bundle and alter all defects.
Come back to this operator after the operator goes through the entire bundle. Select 5 pieces from the bundle and inspect them. If they are OK, note down zero after the circled number against this operator. If there is still a defect, repeat the procedure from step Vl.
Come back and check the subsequent bundle. If this all right enter another zero in the form and remove the blue clip. Repeat the procedure from step l. If a defect is found, repeat the procedure from step Vl.
Check if the fabric/knitting Sewing Quality and hand feel is correct to approved hand standard.
Check if the fabric/knitting color is correct to approved
standard.
In the case of sweaters, knitwear or denims if weight was
checked, verify if the average garment weight correct to specification if
available
Verify if the main label placement is correct to
specification and that the sewing detail if any is nice and clean. Appearance
on the main label is critical to image of the brand.
Ensure size label/country of origin placement and details
are correct including wordings and spellings.
Ensure care label placement, instructions are correct to
specification and does not appear illegible in the case of any washed product
and wording and spellings are correct.
Ensure that the button &/or hook and bar Sewing Quality, color and size are also correct when compared to trim card.
Check zipper quality, size and color to verify they are
correct to trim card and specification.
If there are any ‘Other’ sewing trims used on garment, add
them to the check list and mark accordingly.
Place the pattern on the top ply for the first part. Align the pattern on one edge (reference edge) and check for deviations on other edges.
For each deviation from the pattern that exceeds the tolerance, note a defect for that part under “Top”.
Check the same part (top ply) for position and depth of notches and position of drill holes. Record defects, if any, under corresponding column.
Repeat steps II, III and IV for a ply from the middle of the stack and the bottom ply. Record defects, if any.
Repeat steps II, III, IV and V for the remaining parts.
Show size defects to the cutter and cutting room supervisor. The cutter should rectify the defects immediately.
Compute DHU (defects per hundred units) and record this.
Notes:
Tolerance for straight knife machine is +/- 3 mm and for band saw, +/- 2 mm.
The cut Garment Quality Inspector report is sent to the Factory Manager as a part of the daily Cutting Room performance report (Appendix IX).
The middle ply is taken without disturbing the stack of cut parts so that defects, if any, can be rectified by the cutter.
Parts are inspected based on the requirement of the sewing room. If the sewing room does not require that collars, cuffs etc. is cut exact, inspect these accordingly.
HOW TO CONDUCT A FINAL INSPECTION?
As a practice, a final inspection must be done in the following sequence-
Packing Integrity
Workmanship Garment Quality Inspector
Spec Measurement
FINAL INSPECTION REPORTS-
Below is a guideline for the auditor on how to use the inspection reports.-
Use the approved Final Inspection summary report
Use the detailed check list as a guide to cross check with garment and information on hand
Use the spec measurement report.
All three documents must be sent electronically to the QC dept. for IC issuance purpose by PDF format.
PE QAs must also ensure to verify the factory QA’s performed the compulsory 100% packing inspection and 10% packing integrity audit and all reports are properly recorded and filed prior to accepting a shipment
The Final Inspection Detail Check-List (Tops, Bottoms) must be used as a guide during a Final Inspection.
The inspector must put a check mark against YES only if no issues were found for that area or operation.
A check mark must be placed against NO if issues were found in that area or operation.
If an operation is not applicable, then a check mark should be placed against N/A
