5/30/2010 1 S.O.P. Final Inspection Certification Program (Training Manual) Prepared By: Technical Service Team Leo Chan Ravi HurPaul Stephen Zhou Prashant Pattam Version:2.0 5/30/2010 2 • Revision History 3/20/2007PAGE 5,16,62S.S.CREVISED 5/30/2010Page 6, add “critical areas” for 2 pointsS.S.CRevised DateSummary Of ChangesAuthorIssue 5/30/2010 3 PART (1) CLASS TRAINING 5/30/2010 4 1. The Flow of “S.O.P. Final Audit” 5/30/2010 5 S.O.P FINAL AUDIT FLOW START CHECK PACKING LIST TTL NUMBER OF EXPORT & ODD CTN PACKING METHOD CHECK TTL UNITS OF SHIPMENT PREPARE SAMPLES & CARTON RANDOM SELECTION COUNT THE TTL NUMBER OF EXPORT CARTON & CHECK SHIPPING MARK CTN SELECTION 8% OF TTL SHIPMENT ACROSS COLOR/SIZE BASED ON AQL CHECK GARMENT FOLDING METHOD & POLYBAG REVIEW AUDIT FILE INFORMATION & P.P. SAMPLE CHECK TECH PACK CHECK TRIM CARD 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. 3. Carry on the inspection even if the information is not up-to-date and not complete. CHECK IN LINE REPORT 5/30/2010 6 CHECK BULK COLOR USE THE APPROVED SHADE BAND(S) LIGHT SOURCE FOLLOW BRANDS REQUIREMENT 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. FOLLOW THE LATEST APPROVED SPEC CHECK FOR THE FITTING (3 SAMPLES) USE APPROPRIATE MANNEQUIN 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. 5/30/2010 7 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. WORKMANSHIP INSPECTION FOLLOW PROPER SEQUENCE OF CHECKING . SHADING WITHIN GARMENT 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. 5/30/2010 8 2. Audit Preparation 5/30/2010 9 • 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. The Light box 5/30/2010 10 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 [...]... factory temporary packing list f/ Upon the completion of 95% of the goods packed into carton , the order can be taken for final inspection 5/30/2010 14 3.2 Q.C inspection file check 3.2.1 VPO 5/30/2010 15 3.2.2 In-line Report Before the final inspection, ensure to go through the inline inspection report in order to know the type of defects that were found 5/30/2010 16 3.2.3 Accessory Card 5/30/2010 17... tape for woven, cut & sew products • 2.3.3 Metal measuring tape for sweater • 2.3.4 Digital camera • 2.3.5 Defect sticker (ensure the sticker does not leave any mark on the garment) • 2.3.6 Inspection report for Final Audit 5/30/2010 12 3 S.O.P Audit Procedures 5/30/2010 13 3.1 Selection of samples and cartons (at least8%) a/ The sample cartons for audit should be randomly selected from different location... 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 5/30/2010 Q.C chair Inspection Table 11 2.3 Audit Tool • . 5/30/2010 1 S.O.P. Final Inspection Certification Program (Training Manual) Prepared By: Technical Service Team Leo Chan Ravi HurPaul Stephen. taken for final inspection. 5/30/2010 15 3.2. Q.C. inspection file check. 3.2.1. VPO 5/30/2010 16 3.2.2. In-line Report Before the final inspection, ensure to go through the inline inspection. pointsS.S.CRevised DateSummary Of ChangesAuthorIssue 5/30/2010 3 PART (1) CLASS TRAINING 5/30/2010 4 1. The Flow of “S.O.P. Final Audit” 5/30/2010 5 S.O.P FINAL AUDIT FLOW START CHECK PACKING LIST TTL NUMBER