Nike Product Integrity- Apparel & Equipment Material Quality Manual Nike Product Integrity – Apparel & Equipment Materials Quality Manual © NIKE, Inc 2011 © Nike, Inc Nike Product Integrity- Apparel & Equipment Material Quality Manual This manual is provided to NIKE vendors and factories to understand NIKE process and requirements to deliver the highest possible quality, as well as report all test results as per NIKE requirements Although this manual describes NIKE quality requirements, NIKE also expects its partner suppliers to develop a positive culture of quality This culture must begin with management commitment to prevention-based and continuous improvementbased quality systems including:  Allocating appropriate resources to ensure quality systems are effective  Encouraging active participation of all workers in improvement efforts  Ensuring that processes are stable, capable, and centered through the application of statistical data analysis techniques  Documenting systems, processes, procedures, etc as necessary to maintain effective operations © Nike, Inc Nike Product Integrity- Apparel & Equipment Material Quality Manual Table of Contents Page # Chapter 1: Overview of NIKE Quality Philosophy Introduction, Quality Mission, Philosophy & Prevention System Chapter 2: NIKE Material Quality Process A Quality Policy B Introduction C Vendor Qualification 10 D Material Qualification 11 E Vendor Quality Process 13 F Metrics and Strategic Reporting 20 Chapter 3: Test Requirements, Specifications and Methods A Overview 21 B Material Development Testing Process 21 C NIKE Test Methods 28 D NIKE Vendor Laboratory Accreditation 28 E Regulatory Information 28 Chapter 4: Color Management A Introduction to the NIKE Color Manual 30 B Introduction to the NIKE Production Color Process 30 C Vendor Color Accreditation 31 D Seasonal Color Palette Information 31 Chapter 5: Introduction to Vendor Quality Requirements A Introduction 32 B Fabric Inspection 33 C Inspection Procedure/Execution 35 D Inspection Results 41 E Fabric Defect Classifications 43 F Summary of NIKE Production Fabric Testing & Inspection 48 Appendix: I Acknowledgement & Continuing Product Guarantee II NIKE PPS Generic Specification III Intertek/NIKE Test Lab Site by End-Use IV NIKE/Intertek Test Request Forms V Intertek Global Contact List VI Woven & Knit Test Standards © Nike, Inc Nike Product Integrity- Apparel & Equipment VII NIKE Product Safety Policy: Flammability Material Quality Manual 66 © Nike, Inc Nike Product Integrity- Apparel & Equipment Material Quality Manual Chapter 1: Overview of NIKE Quality Philosophy Introduction This chapter begins by presenting the NIKE quality philosophy, and continues by outlining the NIKE quality system from design and development to production and delivery Quality Mission Statement “Create a culture of quality.” NIKE Quality philosophy is based on the following principles:  Establish clear, consumer-focused requirements  Plan for Defect-Free performance  Quality happens within every Process (each supplier, department, & individual owns quality)  Ensure the Process is capable of meeting the requirements  Control the Process  Continually reduce Variation  Prioritize by isolating the „Vital Few‟ from the „Trivial Many‟ These principles serve as a compass for NIKE They represent the fundamental values we pursue for ourselves, and serve as a basis for selection of and partnership with our supplier base - NIKE defines quality as Conformance to Requirements, where our Consumers and Customers determine the requirements - Our quality standard is Zero Defects and our goal is Zero Variation from the requirements - Quality effort must be applied continuously to achieve this standard in all products and services - Our strategy to achieve Zero Defects with Zero Variation is Prevention Prevention means preparation and planning for an activity so it can be performed without errors or defects, every time, all the time This requires a prevention system On the next page, we will discuss the NIKE prevention system model Nike Product Integrity- Apparel & Equipment Material Quality Manual Model of NIKE Prevention System NIKE Prevention System is designed to deliver the safe, reliable, and quality product our consumers expect of the NIKE brand This system begins with product conception and continues through consumer satisfaction The following figure is a graphic summary of the NIKE Prevention System Each box represents a major phase of apparel design, development, manufacturing, and source selection Within each box are the processes that NIKE finds most critical to successfully meet our consumers‟ quality requirements Prevention System box header definitions: Design Qualification Systems and procedures where NIKE Quality Engineering team works with category design/development groups to help identify and prevent failure modes in product design Supplier Qualification Process of evaluating and approving suppliers to ensure they are capable of achieving NIKE requirements, and include a review of suppliers‟ quality manufacturing and management systems against NIKE requirements and world-class benchmarks Materials Qualification Process of testing, evaluating, and approving raw materials to ensure that the manufacturing process is capable of producing materials that always meet specifications Product Qualification Process of evaluating, and approving finished goods to ensure that the manufacturing process is capable of producing product that always meet specifications Vendor & Factory Quality Process Process of managing vendor and factory performance and driving continuous improvement through evaluation (products & systems), measurement, and reporting Nike Product Integrity- Apparel & Equipment Material Quality Manual Metrics & Strategic Reporting Process of collecting vendor product quality performance data to track performance, rank suppliers, and set priorities for corrective action After reviewing prevention model, next chapter will outline NIKE quality policy and material quality process Nike Product Integrity- Apparel & Equipment Material Quality Manual Chapter 2: NIKE Material Quality Process A Quality Policy Nike Product Integrity- Apparel & Equipment Material Quality Manual B Introduction This Materials Quality Process Manual applies to each vendor that manufactures material for use in NIKE garments (this type of supplier is referred to as a “vendor”) For purposes of this manual, a “vertical” supplier (a supplier who produces their own material and assembles finished product) is both a “vendor” and a “factory” (finished product supplier), and is responsible for all activities required of each, except where noted This Manual is organized according to NIKE Prevention System as it applies to vendors (See diagram below) The processes depicted in bold are described in further detail below These include: Material Quality Process  New Vendor Evaluation  Continuing Product Guaranty  Production Representative Sample  Confirmed Specifications  Production Materials Testing and Inspection  Process Improvement  Strategic Auditing  Vendor Ranking The processes described in the pages that follow are fundamental to ensuring the quality of NIKE apparel product Some NIKE offices/regions may have process requirements additional to these listed, which are covered in detail by the regional Material & PI team on the first meeting with a new vendor after source selection Nike Product Integrity- Apparel & Equipment Material Quality Manual C Continuing Product Guarantee Purpose: The Continuing Product Guarantee is the vendor‟s commitment which assures that NIKE approves the product for production/shipping, no change in design, processing, manufacturing location, or fabric used in production of the product will occur without the vendor obtaining prior written approval from NIKE This guarantee is necessary to validate the materials and garment manufacturing approvals that are given as a course of normal business with a vendor, and greatly reduces the possibility of significant product variation and defective product for both NIKE and the vendor Process: All vendors are required to sign and honor the requirements of the Continuing Product Guarantee 10 Appendix IV: Intertek/NIKE Test Lab Site by End-Use NIKE / Intertek Test Site by End-Use END USE END-USE DESCRIPTION SPEC # SPEC DESCRIPTION WEIGHT (g) MIN MAX ALTERNATIVE SEAM APPLICATION NO SEW SEAM APPLICATIONS/DIE 201,002 CUT LAMINATED SEAMS ALTERNATIVE SEAM APPLICATION BASIC BODY FABRICS KNIT, WOVEN, NON-WOVEN BODY FABRICS 001,001 001,002 001,003 001,004 001,005 001,006 001,007 001,008 001,009 008,001 KNIT-BASIC 010,001 010,002 010,003 010,005 010,006 010,008 010,009 035,001 WOVEN-BASIC 049,004 KNIT-ELASTOMERIC MOISTURE MANAGEMENT SUNSPORT/SWIMWEAR CIRCULAR KNIT MEDIUM DRI-FIT BEACH/POOL WEAR CIRC POWER MOISTURE KNITS WITH 5-15% SPANDEX MANAGEMENT SUNSPORT 120 204 119 204 119 204 NIKE 119 203 100% SYNTHETIC ITS 119 203 CHIEF VALUE SYNTHETIC 119 203 CHIEF VALUE NATURAL 85 153 CHIEF VALUE NATURAL 100% SYNTHETIC ITS ITS ITS ITS ITS ITS ITS 153 CHIEF VALUE SYNTHETIC 153 CHIEF VALUE NATURAL NON-WOVEN-BASIC 049,005 049,006 CIRCULAR KNIT MEDIUM POWER MOISTURE MANAGEMENT DRI-FIT CIRC KNITS WITH 5-15% SPANDEX=ELASTANE 009,007 ELASTOMERIC MOISTURE MANAGEMENT 009,008 009,009 CIRCULAR KNIT MEDIUM POWER STRETCH CIRCULAR KNITS WITH 5-15% SPANDEX=ELASTANE 003,001 KNIT-ELASTOMERIC 003,002 003,003 COMFORT STRETCH RIBS USED AS BODY FABRICS WITH MACHINE WASH WARM/TUMBLE DRY LOW CARE 041,005 LAB SITE NOT APPLICABLE KNIT- CVC BRUSHED FLEECE 85 153 85 153 85 153 CONTENT KNIT COMFORT STRETCH 041,006 041,007 CONSTRUCTED CAPS BASEBALL CAPS, ANY CAP WITH INTERNAL STABILIZER 017,001 WOVEN-CAPS FILL FILL, FIBERFILL, DOWN 030,001 NON-WOVEN, HIGH LOFT HIGH PERFORMANCE WATER RESISTANT BREATHABLE CLIMA-FIT (MIN 900MM SUTERS OR HIGHER) 006,001 KNIT-WATER RESISTANT/ BREATHABLE 013,001 013,002 013,003 HIGH PERFORMANCE WATERPROOF BREATHABLE HIGH POWER MOISTURE STORM-FIT WATERPROOF BREATHABLE 015,001 WOVEN-HIGH 85 PERFORMANCE WATER 85 153 RESISTANT 153 /BREATHABLE WOVEN-WATERPROOF/BREATHABLE DRI-FIT KNITS WITH >15% 009,013 ELASTOMERIC MOISTURE MANAGEMENT 100% SYNTHETIC 100% SYNTHETIC CHIEF VALUE SYNTHETIC CHIEF VALUE NATURAL 100% SYNTHETIC CHIEF VALUE SYNTHETIC CHIEF VALUE NATURAL 100% SYNTHETIC CHIEF VALUE SYNTHETIC CHIEF VALUE NATURAL 100% SYNTHETIC CHIEF VALUE SYNTHETIC CHIEF VALUE NATURAL NOT APPLICABLE 100% SYNTHETIC NOT APPLICABLE ITS ITS ITS ITS ITS ITS ITS NIKE NIKE NIKE NIKE NIKE NIKE NIKE NIKE NIKE NIKE ITS ITS ITS ITS NIKE NIKE NIKE NIKE NIKE NOT APPLICABLE NIKE 100% NIKE 53 NIKE / Intertek Test Site by End-Use END USE MOISTURE MANAGEMENT END-USE DESCRIPTION SPEC # SPEC DESCRIPTION WEIGHT (g) MIN MAX SPANDEX=ELASTANE 009,014 HIGH POWER STRETCH/SUPPORT KNIT-ELASTOMERIC CONTENT SYNTHETIC CHIEF VALUE SYNTHETIC CHIEF VALUE SYNTHETIC 100% SYNTHETIC 100% SYNTHETIC CHIEF VALUE NATURAL LAB SITE ITS KNITS WITH >15% SPANDEX=ELASTANE, SUPPORT BRIEF, RUNNING TIGHT 003,005 INTERNAL COMPONENT INTERFACING, STABILIZER 031,001 NON-WOVEN-THIN WEB JACQUARD KNIT CHIEF VALUE NATURAL JACQUARD KNITS KNIT-BASIC KNIT ACCESSORIES PREMADE KNIT CAPS, SOCKS, GLOVES, SCARVES, HEAD- AND WRISTBANDS 001,020 001,021 001,022 061,001 KNIT CUT & SEW CAPS KNIT MATERIAL USED IN CUT & SEW CAPS 046,001 046,002 046,003 046,004 046,005 046,006 046,007 046,008 046,009 KNIT-CUT & SEW CAPS KNIT/COMPOSITE-WATERP KNIT/COMPOSITE "STORM-FIT" ROOF BREATHABLE WATERPROOF BREATHABLE 052,001 KNIT/COMP-WATERPROOF BREATH NOT APPLICABLE NIKE LEATHER CLEAN ONLY MATERIALS ALL MATERIALS FOR LEATHER CLEAN ONLY GARMENTS 032,003 NON-WOVEN-LEATHER NOT APPLICABLE NIKE LINING-CVC, CVS KNIT POLY/COTTON JERSEY LINING FABRICS 001,017 KNIT-BASIC CHIEF VALUE SYNTHETIC CHIEF VALUE NATURAL 100% SYNTHETIC ITS 003,007 119 204 119 203 KNIT ACCESSORIES NOT APPLICABLE 119 204 119 204 119 204 119 203 100% SYNTHETIC 119 203 CHIEF VALUE SYNTHETIC 119 203 CHIEF VALUE NATURAL 001,018 LOW POWER MOISTURE MANAGEMENT LOW POWER STRETCH NIKE ITS ITS ITS NIKE ITS ITS ITS ITS ITS ITS ITS ITS ITS ITS 009,004 ELASTOMERIC MOISTURE MNGMNT DRI-FIT KNITS WITH 80% submit compliance rate TR vendors must have => 90% submit compliance to their required submit list and => 90% test submit acceptance rate to maintain TR status 66 Updated 2011            Ch Model of NIKE Prevention System Deleted figure graphic summary of the NIKE Prevention System Deleted Ch 2.C Vendor Qualification and Ch 2.C.1 New Vendor Evaluation E.1.1.1 Production Testing Add explanation about Test Rank (TR1), How to get TR1 performance and Criteria of Selecting TR1 list Ch 3.B.1 Update Explanation NIKE Item Number Ch 3.B.2 Additional Explanation Material item Description Ch 5.D Inspection Results Calculation average points / 100 Square Yards Ch 5.D.1 Evaluation Guideline Allowable Points per 100 Square Yards (90 Square Meters) Ch 5.C Fabric Defect Classifications Add defect pictures Deleted Appendix II Material Development Worksheet Appendix V – Updated NIKE/Intertek Test Request Forms Appendix VI – Updated Intertek Global Contact List 67 ... Standards © Nike, Inc Nike Product Integrity- Apparel & Equipment VII NIKE Product Safety Policy: Flammability Material Quality Manual 66 © Nike, Inc Nike Product Integrity- Apparel & Equipment. .. outline NIKE quality policy and material quality process Nike Product Integrity- Apparel & Equipment Material Quality Manual Chapter 2: NIKE Material Quality Process A Quality Policy Nike Product Integrity- ... next page, we will discuss the NIKE prevention system model Nike Product Integrity- Apparel & Equipment Material Quality Manual Model of NIKE Prevention System NIKE Prevention System is designed