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FAX: +92-423-5897665

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MANUAL CONTENTS

Quality policy and vision 5 Manual objectives 6 Section I– (Requirements / Responsibilities & Procedures) 7 Requirements / responsibilities of quality control department 7

Audit File 7 o Specifications/Product Development Manual (PDM) 7 o Packaging details 7 o Approved packaging accessories and labels 8 o Purchase order (PO) details 8 o Approved Samples & Swatches 9 o Designer’s / R&D department comments (if any) 9

Quality Assurance monitors 9 Audit Plan 9 Pre-Production meeting to discuss 10

o Yarn Dyeing Inspection 10 o Weaving Inspection/tests 10 o Fabric/Folding Inspection 11 o Product Performance Testing 11 o Packaging Material Testing (Stiffener, Insert, Bag, Carton, etc) 11

Pre-production Samples Inspection 11 Operational Inline Inspection / Pre-Final Audit 11 Final Random Inspection 11 Internal Coordination 11 Acknowledge and monitoring of vendor’s quality assurance procedures 11 Baby/children’s product safety 11 R & D. 11 Sample’s Inspection 12

Quality Team Meeting Prior to Audit 12 Product Evaluation 13

Sample Submission 13 Test Protocols 13 Purposes of Test Protocols 13 Product Testing 16

In-Line Inspection 17 Final Random Inspection 18

Inspection Preparation 18 Inspection Requirements 18 Inspection Procedures 19

o Carton / Bale / Roll Inspection 19 o Product Inspection 20

• Packaging Faults 20 • Making Up Faults 20




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• Fabric Faults 20 • Shipment Samples 21

o Acceptable Quality Level 21 o AQL Chart 23 o General Quality Assurance Sampling Plans 24 o Sampling Plan 25

Defect Definition 25 o Critical Defect 25 o Examples 26 o Major Defect 26 o Examples 26 o Minor Defects 27 o Examples 27 o Classification of Defects 27

• Fabric Defects 27 • Cleanliness Defects 28 • Pressing / Folding Defects 28 • Seam and Stitch Defects 28 • Finished Product Defects 29 • Labeling / Packaging Defects 30 • Some General Fabric Defects Terms 31

Inspection Reports and Records 33 Weekly Order Summary 34

4-Point System of Inspection / Grading 35 Fabric Inspection Policies 35 What is 4-Point System 36 A. Inspection Quantity (Amount to select) 36

o Selection of rolls 36 B. Defeat Evaluation 36 Assigned Points Size of Defects 37 C. Point's calculation 37 Acceptance Criteria and Calculation 37 Inspection Procedure 37 Definition of Major Defects 38 Fabric Sampling Plan 39 Sample Plan Chart 39 Point Calculation 39

o For an Individual Roll 39 o For a Shipment 39

Penalty Point Grading 40 o Running Defects 40 o Full Width Defects 40 o Fabric Width 41 o Shade Matching 41




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o Roll Length 41 o Splices 42 o Bowing 42 o Skewing 42 o Fabric Odors 42 o Holes 42 o Hand / Feel 42

Fabric Weight and Dimension Tolerances 43 o Roll Weight 43 o Fabric Weight 43 o Width 43

• Open-Width Styles 43 Length 44

Piece Length and Seams 44

General Terms of Fabric Defects 44

Documentation 51 Loading Procedures 51

Preparation 51 Container’s expected tolerable conditions 51 Loading 52 Hazardous Material 52

Knowledge & Monitoring of Vendor’s Quality Assurance Procedures 53 Vendor Education 53

Section–II (Job Responsibilities) 54 Job title 54 Department 54 A: Purpose and Scope 54 B. Duties and responsibilities 54 Job Title 55 Department 55 A: Purpose and Scope 55 B. Duties and responsibilities 56 Additional duties 57

Section III (Communication Flow Chart) 58




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QUALITY POLICY AND VISION:

TexCraft Solutions aims to act as true eyes and ears of the buyers at the place of production at all times and for

this purpose we use the latest tools, techniques and procedures available for auditing. We do this with integrity,

following all the ethical and social values that make us a responsible citizen.




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Quality Manual Objectives:

♦ To describe the vendors / buyers our current tests & audit procedures, audit protocols, sample

submission requirements and performance indicators of various product attributes as well as regular

updates of any changes.

♦ To have consistent and accurate working practices for our quality team

♦ To clearly describe and layout the responsibilities of TexCraft Solution’s staff in performing various

tasks.




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Section–I (Requirements / Responsibilities & Procedures) Requirements / Responsibilities of Quality Control Department:

Audit File - To ensure integrity and completeness of Audit File. No auditor should leave the office for

any inspection without the relevant Audit File. Auditor has to ensure that he/she has received the audit file;

it is complete, and duly signed by the relevant merchandiser. The auditor must ensure that the file has been

reviewed by the quality manager and all the concerns have been discussed properly.

Contents of the file should be easily understandable and must be supported by sketches, diagrams, tabulated

presentations, and samples wherever necessary. The contents of typical audit file are as follows:

Specifications/Product Development Manual (PDM) o Size specification along with measurement points

o Stitching details (SPI, hem, binding, cord, frills etc)

o Sew in Label placement

o Direction of the design / fabric to be followed for make ups

o For engineered designs, repeat specifications to be visible on the made up like inner

panel size, border size etc

o Accessories (button, zipper etc) quality, size, color and placement

o Embroidery appliqué and beading specifications, approval lay out, positioning and

colors

o Fabric quality (construction, count, blend, interlining quality/color etc)

o For terry towels, loop density, pile to base ratio, header width, header positioning

Packaging details

o Folding style

o Fold size / pack size

o Inlay / Insert card / belly band / sticker specifications

o Poly bag specifications

o Placement / position of packaging accessories




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o Master carton dimensions

o Inner carton dimensions if required

o Shipping mark

o Master carton net weight / gross weight

o Others (ribbon knot / bow sticker etc)

Approved packaging accessories and labels

o Inlay / Insert card / belly band / labels

o UPC stickers

o Sewn in labels

o Poly bag

o Stiffener

o Master carton quality reference

o Inner carton quality reference if required

o Others (ribbon etc)

Purchase order (PO) details

o Contract number

o PO#

o Factory name

o UPC numbers

o Item # / PID #

o Department #

o Customer name

o Destination

o Size and color wise quantity break down (unit of the quantity to be mentioned like

pack, single made up piece, meter, dozen, yard etc)

o Short description of each item

o Long description of each item

o Quantity per inner pack

o Quantity per master carton




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Approved Samples & Swatches

o Approved yarn skeins for color and count (yarn dyed program only)

o Approved greige fabric swatch (at least one full repeat) for yarn dyed program only

o Color and design fabric swatch approved by customer (at least one full repeat)

o Color and design fabric swatch approved by design department for bulk production

(at least one full repeat)

o Approved shade continuity of previous bulk productions

o Approved accessories and trims

o Approved sample for embroidery, beading, appliqué etc

o Approved sample for make

o Approved sample for packaging reference

o Updated production plan of the relevant design / order

Designer’s / R&D department comments (if any)

Quality Assurance monitors, improves and / or audits; Document Control, Document Change Control,

Calibration, Gage R&R, Corrective Action, Auditing, Systems Interaction Map, Quality Objectives,

Training, Preventive Maintenance, Job Descriptions, Purchase Order Process, Preventive Action, Quality

Plans, New product introduction, Quality Management Reviews, Failure Mode Effect & Analysis, Contract

Reviews and Communication Flow Chart.

Audit Plan - Production plan of all PO’s in hand must be communicated to the quality control manager by

the relevant merchandiser. It should be updated on daily basis. Quality control manager will plan

inspections on the basis of this production plan. Quality control manager must ensure that inspection plan

has been updated and communicated to the relevant QCs on daily basis. All QCs must keep this plan with

them and should monitor production activities accordingly. A typical Inspection Plan should have:

PO Copy

Customer / Label (in case of direct import order must mention ID)

Fabric required in each width/color/design/color way

Quantity required in each Item/size/color/style




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Shipment date

Yarn dyeing start date (for yarn dyed programs only)

Weaving start date

Process start date with complete detail of schedule of different processing stages

Fabric finishing date from processing department

Fabric folding inspection date

Fabric Packing / issuing date

Accessories and trims in house date

Packaging accessories in house date

Cutting start date

1st article inspection date

Stitching start and completion dates

Packing completion date

Final audit date

Pre-Production meeting to discuss:

Pre-manufactured Components (Fastenings, patterns, etc)

Processes (production methods)

Yarn Dyeing Inspection

o Fiber Testing to yarn specifications

Weaving Inspection/tests

o Ends, picks

o Thread count

o Wt/gsm etc.

o Weaving defects

Fabric/Folding Inspection

o With ref to customer’s provided specs.




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Product Performance Testing

o Development Testing

o Fabric Testing

o Made-Up Testing

o Vendor Testing (in house)

o Third party testing (if required.)

Packaging Material Testing (Stiffener, Insert, Bag, Carton, etc)

o Material quality

o Gauge, ply’s etc

o Style, size, special instruction about make up.

o Dimensions

o UPC’s, Shipping Labels, Price codes, tags, other trims.

Pre-production Samples Inspection

Operational Inline Inspection / Pre-Final Audit

Final Random Inspection

o Packaging conformity

o Accessories and trims conformity

o Making up conformity

o Dimensional conformity

o Fabrication and material conformity

o Quantity conformity with ref to packing list and package/roll/bale

o Handling and Loading conformity (Container loading and stuffing)

o Pictures of all specific records

o Inspection Reports and Records

o Weekly order status updates

Internal Coordination

Acknowledge and monitoring of vendor’s quality assurance procedures

Baby/children’s product safety

R & D.




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Sample’s Inspection – Follow up and in time preparation of Samples (either it is proto, pre-

production or production / shipment samples) is the responsibility of TexCraft Solution’s

merchandising team. They ensure the in time arrival of the fabric in folding department and all the

required trims / accessories are in-house by that time.

During fabric / folding inspection quality auditor will take out appropriate yardage of the fabric, as

specified by the merchandising team. Great care should be taken regarding design and colors.

Quality auditor should sign and hand over this fabric to TexCraft Solution’s desk at the factory. A

swatch of the same fabric should be taken as counter reference and an acknowledgement should be

taken from the desk on the same swatch. Also TexCraft Solution’s merchandising team should be

intimated about the fabric inspection.

TexCraft Solutions merchandising team will intimate quality department once the samples are

complete. Quality auditor will check pre-production samples as per:

o Final PDM / Specs Sheet

o Fabric, Design and color standards approved by the customer

o Customer’s approved made up sample if applicable

o Customer’s approved fully packaged sample if applicable

o Samples should be checked for all fabric, processing, make, cleanliness and packaging faults.

No tolerance should be allowed regarding any aspect of the sample as these are meant to be

reviewed by customer’s design and technical team. TexCraft Solution’s merchandising /

quality team should be intimated about the sample readiness so that counter inspection for the

same is done and the result is submitted in the form of “TexCraft Sample Evaluation Form”

to customer (the blank format is attached at the end of this document).

Quality Team Meeting Prior to Audit - Following particulars to be discussed in the meeting:

Key features of the product

Make of the product

Common and well known discrepancies specific to the product

Trims and accessories

Special job other than routine work like embroidery, beading etc

Packaging




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Design / colors; directional / motif / panels etc

Dimensions & measurements

Additions or special instructions

Shipping labels and cartons

Minutes of the meeting should be write down and communicated via e-mail to all concerned personnel for

better understanding and coordination.

Product Evaluation

Sample Submission - Vendors are to submit samples directly to TexCraft Solutions office for testing

along with a completed Request Form. The required number of samples must be sent.

Test Protocols - All samples received by the laboratory are tested in accordance with an established test

protocol which TexCraft Solutions can supply to the vendor for their specific product category.

Test protocols are a compilation of various European / U.S / British regulations and industry standards requirements (i.e. tests) that the product must meet. Test Protocols will be issued by customer’s approved labs and then approved for use by TexCraft Solutions.

Purposes of Test Protocols – These protocols serve two primary purposes:

1. Provide information regarding what tests will be performed so vendors understand the

expectations of TexCraft Solutions for their products prior to testing. As some items may be slightly different. Test Protocols are to be used as a guideline only and are subject to change. A product-specific Test Protocol will be developed at the sample submission stage if necessary.

2. Test Protocols ensure consistency between laboratories around the world by providing

instructions to the approved testing laboratories on what tests are required for specific products.

Our current approved Test Protocols can be found in the ‘Test Protocols’ section of this manual. TexCraft Solutions Test Protocols are updated periodically to reflect changes in products, regulations, industry standards, and quality performance standards.

While the extent of laboratory tests will vary by product category and by specific item, consumer products will be subjected to numerous tests to verify conformance with required federal laws / regulations and industry safety criteria as well as additional TexCraft Solutions requirements. Common regulations to be observed are as follows:




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United States, Europe and par east (partial list)

Flammable Fabric Act

American Society for Test Methods (ASTM)

Poison Prevention Packaging Act

Child Safety Protection Act (CSPA)

Textile Fiber Products Identification Act

Federal Hazardous Substances Act (FHSA)

Toy Safety Amendment to the Hazardous Substances Act

California Safe Drinking and Toxic Enforcement Act (Prop. 65)

Labeling of Hazardous Art Materials Act (LHAMA)

Fair Packaging and Labeling Act (FPLA) Federal

Wool Products Labeling Act

Care Labeling Rule

Physiological properties of textiles

Conditioning atmosphere and physical testing for textile fabrics

REACH Regulations

Rule and Implementation Information for the Fabric Printing, Coating & Dyeing Surface

Coating NESHAP … OAR-2003-0014

Improving environmental performance

Waste and Hazardous substance control

Equal opportunities and deversity for employees

Skills and training for improving staff performance

TexCraft Solutions supports compliance with all government regulatory and labeling requirements. It is

the vendor's responsibility to ensure that merchandise shipped to customer complies with all applicable

regulatory standards. Merchandise in violation of a regulation will not be accepted by the customer.

The types of tests conducted on items will differ depending on the intended use. In most cases,

evaluation of the products will include:

Safety - Could the product cause illness or injury in normal use or in foreseeable abuse?

Instructions - Are they easy to understand and carry out? Are they accurate?




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Packaging - Does it provide all necessary information? Does it comply with labeling regulations?

Actual Use - Will it accomplish satisfactorily the purpose for which it is intended by providing good

performance characteristics and durability?

Standards- The government has issued regulations on many of the items that are tested. Where no

government standards exist, the testing lab will research all reasonably available studies and market

conditions in order to establish practical end-use standards.

Test protocols for new products are developed at the time samples are submitted for testing.

Development of protocols for new items will require research to determine what regulations and

industry standards are applicable for each individual product. The foundation of most test protocols

(methods, procedures and requirements) are developed in reference to a standard(s) or other

information from one or more of the following organizations:

Domestic (partial list) FCC Federal Communication Commission

AATCC American Association of Textile Chemists FDA Federal Food and Drug Administration

& Colorists FED Federal Specifications and Standards AFMA American Furniture Manufacturers Association FTC Federal Trade Commission

ANSI American National Standard Institute IFAI Industrial Fabrics Association International

ASME American Society of Mechanical Engineers ISO International Organization for Standardization

ASQ American Society for Quality ISTA International Safe Transit Association ASTM American Society for Testing and Materials MIL Military Specifications and Standards

BHMA Builders Hardware Manufacturers Association NAHM National Association of Hosiery Manufacturers

BIFMA Business & Institutional Furniture Manufacturers NFPA National Fire Protection Association

Association NIST National Institute of Standards and Technology

CBHF California Bureau of Home Furnishings TAPPI Technical Association of the Pulp and Paper

CFR Code of Federal Regulations Industry

CPAI Industrial Fabrics Association International TMA Toy Manufacturers Association

CPSC Consumer Product Safety Commission UFAC Upholstery Furniture Action Council

DOT Federal Department of Transportation UL Underwriters Laboratories

ETL ETL Testing Laboratories, Inc. USP United States Pharmacopoeia




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OEKO-TEX Association … (Oeko-Tex 100 Standard)

AWTA … Australian Wool Testing Authority

Centro Controllo Tessile … Italy

Codetex srl … Italy

East Thuringian Material Testing Co. Germany

Faseinstitut Bremen eV … Germany

Geospec, Ltd., UK

Hohenstein Instutes, Germany

Q-Tex SA ... Greece

Testex AG., Switzerland

European Geosciences Union

CMA, Hong Kong

CEN … European Committee for Standardization

DIN … Deutsches Institut fur Normung E.V.

BS & EN Standards UK

Product Testing - Under normal circumstances, products will be evaluated in accordance with the Test

Protocols within five to ten working days based on the product type and testing required.

Under certain circumstances it may not be possible to complete testing on an item within the established

timeframe / days due to conditions inherent to specific test requests or due to the product itself. In such

cases, suggested lab will provide an estimated completion time for the required tests.

TexCraft Solutions testing protocols vary by each individual product and can vary by each style. Test

Protocols are subject to change if the product varies from the initial product for which the Test Protocol

was developed. Upon receipt of actual samples, it is at the laboratory’s discretion to determine which, if

any, additional tests are necessary.




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Each test property as well as the overall rating of the final report will be based on the following (The

Client’s established rating system):

Ratings

o Pass - The product meets all the Client’s requirements as outlined in their protocols and provides

good overall consumer serviceability with no improvement required.

o Fail - The product does not meet all the Client’s requirements as outlined in their protocols.

In-Line Inspection - Purpose of inline inspection is to check and verify all specified parameters of the

product during different stages of process from development to finished packed goods. For this purpose,

auditors will perform inline inspections on different stages like weaving, processing, finish folding, cutting,

stitching, packing time to time to improve the quality of the finished product.

This inspection is done to:

Ensure that fabric yarn count, blend and ends picks are ok as well wt/gsm.

Ensure best result of the processing department. Proceed through dyeing or printing or finishing.

Ensure color and design evaluated against approved standard. A very narrow shade band must be

developed and adhered to.

Ensure good packaging quality at finish folding end as well as quantity packed.

Ensure right marking at cutting ends to check dimension of the product.

Ensure correct seams, fabric cut and workmanship when verifying SPI’s. Are the seams secured,

puckering free; grinning, roping and twisting free?

Ensure to check all components of the product labeled properly to avoid any inconsistency.

Ensure consistency of the colors by developing a narrow shade band of each color.

Ensure to inspect the piece for consistency in shade/color, fabric handle, appearance, size etc.

Ensure to handle the goods properly to avoid any unnecessary fabric damage and stains. Do the goods

are soil, stain or glaze free?

Ensure to separate defective goods and to remove from the floor in a documented way.

Ensure that a corrective action plan is developed and carried out to address any problem found and

prevent them from happening again.




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Ensure that product meets AQL. This applies to all fabric, make, packaging and cleanliness faults as

specified in the relevant sections of this manual.

Ensure, do the goods meet retailing standards?

Ensure, is there a correct logo?

Ensure, is there a correct size label?

Ensure, are there barcode tags, or swing tickets incorrect or missing?

Ensure, are the components or trims rusty, tarnishing or broken?

After completion of the inspection a report is made stating the problems in detail. A copy of in line

inspection is given to the concerned personnel of the floor and merchandiser. (A typical in-line

inspection report is attached herewith this quality manual)

Final Random Inspection - A statistical based quality audit is performed on all merchandise prior to ship.

This audit is performed on all production lots. The audit is based on customer’s specified AQL. This

particular section is categorized as follows:

Inspection Preparation:

Audit is started unless all the packages (bales/rolls/cartons etc.) are completely labeled, numbered, marked,

stacked in a sequential order and are accessible. Auditor must make sure availability of followings before

starting the audit:

o Complete audit file / production file including audit plan, and reference samples and swatches.

o All the issues regarding design, making up, and packaging … from development to finish

product, have been discussed and resolved properly.

o AQL table / chart

o Sample evaluation form and Inline Inspection reports

o Appropriate audit area with a flat well lit surface

o Weighing apparatus/scale

o Measuring scale/tape

o Complete packing list with weight details

o Trim card

Inspection Requirements - Auditor must ensure that he/she has check/covered all the below (but not

limited to) areas during final audit:




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o Product must be evaluated by keeping in view the product line, for example quality parameters

for luxury items will be tighter than moderate ones.

o Cartons and shipping labels inspection … marking, pasting, carton dims, material, handling of

packages etc.

o Packaging and labels inspection

o A random sample of merchandise based on the AQL table as advised by the customer.

o Dimensional inspection

o Finished product inspection must be conducted for all fabric, cleanliness,

pressing/folding/lapping, trims, accessories, seams & stitch, finishing and packing faults.

o Baby/Children products to be checked against safety hazards parameters.

All audits must be documented, and appropriate records maintained with clear pictures of faulty product

showing faults prominently.

Inspection Procedures - A statistical based quality audit must be performed on all finished goods. This

audit should be performed on all production lots. When any product fails to pass any inspection, the

failing goods must be separated so that they cannot be used in production and inventories. In addition,

the factory records must indicate the corrective actions taken to avoid the problems happening again.

Below are the standards procedures for various areas of final inspection:

o Carton / Bale / Roll Inspection - Auditor must ensure that total number of packages and units

are as per the requirements of PO. Packing list describes required information as per presented

lot. No tolerance should be allowed for package quality, missing / wrong shipping information or

any other irregularity pertaining to shipping labels and packages. Auditors must check at least

15~20% of the packages (cartons, rolls, bales etc.) for the followings:-

• Master package quality is as per the requirement (material quality, plies, gauges / thickness,

diameter, quantity / yardage packed, specific packaging quality parameters’ dimensions of

the final master package.

• Stacking, sealing, alignments, tapping, pasting to be as per standards.

• Sizes and color assortment as per PO.

• Net weight / Gross weight




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o Product Inspection - Generally following quality parameters are checked:

• Packaging Faults

Quantity / yardage packed

Appearance of package/packet

Dimensions of packed article

Bag quality … gauge, gusset size, zipper, material, flap, sealing, printed instructions

if any

Insert quality, paper gauge/pt/gsm, belt quality, printing quality of the inlay card,

printing instructions

UPCs, SKUs, Bar codes, price stickers, safety stickers, tags, labels with reference to

their placement and scan ability

Wt. of packed article if required

• Making Up Faults:

Cutting margins

Seam / stitch quality

Workmanship

Thread quality used for making up … spun / filament etc.

Labeling placements, directions, workmanship

Dimensional look as well as measurements of the merchandise

Handle / finish / feel of the finished article

Appearance of the finished article

Trims and accessories verification along with placements

Threading and folding

Handling of the article to ensure stain and crease free

• Fabric Faults:

Type of fabric

Yarn quality, blend, thread count, end/pick, dpi/spi

Weave type … plain / dobby / jacquard etc.

Weaving faults like mis-pick, end short, weaving crack, flaws, uncut yarns, ambry

cuts, sizing stains, oil stains etc.




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Spinning faults like contaminations, slubby yarn, smoky yarn, kinks, re-cycled yarn,

carded / combed quality etc.

Weight gram per square meter

textile inspection standards verified by lab reports

Color, design, design versions, color ways, directional views etc

• Shipment Samples: - Shipment sample is an important part of quality control procedures.

Purpose of the shipment samples is to keep record of the product shipped. Shipment samples

serve as a reference:

In case of any complaint from the customer

For next shipments of the same design and product

To develop any other design with same fabrication, make, packaging, reference etc.

Shipment sample must:

Be drawn from each PO after final random inspection

Cover all sizes, colors, and designs in that particular PO

Have PO# and FRI date mentioned on it

Be representative of the product being shipped

Be retained for a period of not less than 6 months from the date of dispatch

A proper record of shipment samples should be maintained having all these information:

PO#

Customer Name

Design/color way/version/color

Date of FRI

Delivered By

Receiver’s acknowledgement

• Acceptable Quality Level - When a continuous series of lots is considered, the AQL is the

quality level for purposes of sampling inspection, is the limit of a satisfactory process

average. NOTE: A sampling plan and an AQL are chosen in accordance with the risk

assumed. Use of a value of AQL for a certain defect or group of defects indicates that the

sampling plan will accept the great majority of the lots or batches provided the process

average level of percent defective (or defects per hundred units) in these lots or batches are




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not greater than the designated value of AQL. Thus, the AQL is a designated value of percent

defective (or defects per hundred units) for which lots will be accepted most of time by the

sampling procedure being used. The sampling plans provided herein are so arranged that the

probability of acceptance at the designated AQL value depends upon the sample size, being

generally higher for large samples than for small ones, for a given AQL. The AQL alone

does not identify the chances of accepting or rejecting individual lots or batches but more

directly relates to what might be expected from a series of lots or batches, provided the steps

indicated in this publication are taken. It is necessary to refer to the operating characteristic

curve of the plan to determine the relative risks. A statistical based quality audit must be

performed on all finished goods. This audit should be performed on all production lots. When

any product fails to pass any inspection, the failing goods must be separated so that they

cannot be used in production and inventories. In addition, the factory records must indicate

the corrective actions taken to avoid the problems happening again. Below are the standards

procedures for various areas of final inspection:




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As per Military Standards, following prescribed acceptable quality levels are used; give below are complete set of quality levels:

AQL CHART Master Table for Single Sampling Plans: Normal Inspection

TABLE-2 ANSI/ASQC Z1.4 & MIL-STD-105E

Sample Size

Code / Letter

Sample Size

Acceptable Quality Levels (Normal Inspection) 0.65 1.0 1.5 2.5 4.0 6.5 10

Ac

Re Ac

Re Ac

Re Ac Re

Ac

Re Ac Re Ac

Re

A 2

0

1 B 3 0 1 C 5 0 1 1 2 D 8 0 1 1 2 2 3 E 13 0 1 1 2 2 3 3 4

F 20 0 1

1 2 3 4 5 6

G 32

1 2 2 3 3 4 5 6 7 8 H 50 1 2 2 3 3 4 5 6 7 8 10 11J 80 1 2 2 3 3 4 5 6 7 8 10 11 14 15

K 125 2 3 3 4 5 6 7 8 10 11 14 15 21

22

L 200 3 4 5 6 7 8 10 11 14 15 21

22

M 315 5 6 7 8 10 11 14 15 21 22

N 500 7 8 10 11 14 15 21 22

P 800 10 11 14 15 21 22

Q 1250 14 15 21

22 R 2000 21 22




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AQL CHART

TABLE 1 ANSI/ASQC Z1.4 & MIL-

STD-105E

Lot or Batch Size

SAMPLE SIZE CODE LETTERS

Inspection Levels

Special General S-3 S-4 I II III

2 to 8 A A A A B 9 to 15 A A A B C

16 to 25 B B B C D 26 to 50 B C C D E 51 to 90 C C C E F 91 to 150 C D D F G

151 to 280 D E E G H 281 to 500 D E F H J 501 to 1,200 E F G J K

1,201 to 3,200 E G H K L 3,201 to 10,000 F G J L M

10,001 to 35,000 F H K M N 35,001 to 150,000 G J L N P

150,001 to 500,000 G J M P Q 500,001 to over H K N Q R

• General Quality Assurance Sampling Plans - AAFES sampling plans are derived from

MIL-STD-105E or ANSI/ASQ Z 1.4, Sampling Procedures and Tables for Inspection by

Attributes. This standard is also known as ISO 2859-1, Sampling procedures for inspection

by attributes - part 1: Sampling schemes indexed by acceptance limit (AQL) for lot-by-lot

inspection. AAFES sampling plans are designed to provide maximum inspection

productivity while maintaining a high degree of random sampling reliability. Plans are

provided for Acceptance Quality Levels (AQL) of 2.5, 4.0, and 6.5 percent defective and are

extracted from Inspection Levels I and II of the above standards. The acceptance criteria for

the smaller (of the two) sample sizes in AAFES sampling plans are based on Level I,

tightened inspection, while acceptance criteria of the larger sample sizes are based on Level

II, normal inspection. The rejection criteria in all sample sizes of AAFES sampling plans are

the same as that of Level II, normal inspection.

An AQL of 2.5 Normal, 2.5 Tightened is used for all hard lines merchandise.




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AQL of 4.0 Normal, 4.0 Tightened and 6.5 Normal, 6.5 Tightened are used for jewelry,

shoes, clothing, soft side luggage and any cut & sewn item.

An AQL of 6.5 Normal, 6.5 Tightened is used for extra value, budget, or entry price

point type of merchandise.

What an AQL mean is that as long as a supplier maintains his/her process average (% defective)

at the assigned AQL or lower, there is a very high probability that shipments from that supplier,

when inspected using AAFES sampling plans, will be accepted. By the same token, there is a

very high probability that shipments, when inspected using AAFES sampling plans, will be

rejected if a supplier's process average (% defective) remains higher than the assigned AQL.

• Sampling Plan - A sampling plan indicates the number of units of product from each lot or

batch which are to be inspected (sample size or series of sample sizes) and the criteria for

determining the acceptability of the lot or batch (acceptance and rejection numbers).

Here is how the random sampling works - Let us say that the shipment or lot size is 2,000 items

or pieces. Then,

(1) Take a sample of 50 pieces at random from this shipment.

(2) Inspect all 50 pieces.

(3) If 2 or less defective pieces are found, accept the shipment.

(4) If 8 or more defective pieces are found, reject the shipment.

(5) If 3 to 7 defective pieces are found, then take additional 75 samples at random.

(6) Inspect all 75 samples.

(7) If a total of 7 or less defective pieces are found, accept the shipment.

(8) If a total of 8 or more defective pieces are found, reject the shipment.

Defect Definition - A classification of defects is the explanation of possible defects of the unit of product according to their intensity; it’s a departure of quality in other words. A defect is any nonconformance of the unit of product with specified requirements. Defects will normally be grouped into one or more of the following classes:

o Critical Defect – A defect which could result in hazardous or unsafe conditions for individuals

using the product as well as defects that violate legal regulations and/or miss-represent the product. A critical defect is a defect that judgment and experience indicate would result in hazardous or unsafe conditions for individuals using, maintaining, or depending upon the product, or a defect that judgment and experience indicate is likely to prevent performance of the tactical function of a major end item such as a ship, aircraft, tank, missile, or space vehicle.




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Examples: • Incorrect fiber content • Missing law labels on merchandise

• Failure to pass textile prescribed standards mentioned in sales contract

• Wrong UPC, bar codes, price stickers, labels etc.

• Wrong size labels or packaging

• Wrong size of component in the product

• Missing component of the product

• Missing trims / accessories

• Wrongly perceived specifications of fabrications

o Major Defect – A defect that is likely to result in failure, or to reduce the usability of the unit for its intended purposes, or making it un-salable. A major defect is a defect, other than critical, that is likely to result in failure, or to reduce materially the usability of the unit of product for its intended purpose.

Examples: • Dirt and soil • Fly or kitty or other contamination

• Dye streaks, miss-prints, off shade

• Poor appearance (pilling, fuzziness etc)

• Poorly sewn seams, open/loose seams

• Many loose threads or long tails from seams ( poor trimming)

• Major puckers or miss-sewn seams

• Missing UPC/Price labels and security labels




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• Incorrectly place labels, missing packaging ( missing hooks, id holes, marks)

o Minor Defects - A minor defect is defect that is not likely to reduce materially the usability of the unit of product for its intended purpose, or is a departure from established standards having little bearing on the effective use of operation of the unit.

Example: • One or two loose threads per sample • Slight shade variation but within the shade band

• Slight variation in size

• Minor contamination < 1 inch

• Minor dirt mark

o Classification of Commonly Found Defects: Fabric Defects

Major Minor 1. All holes x

2. Snags or pulled yarns greater than ¼” x

3. Dirt or oil spots over ¼” x

4. Misprints or faulty print registration

a. If greater than ¼” x

b. If visible when used (depending on location) x

5. Noticeable dye spots and streaks

a. If greater than ¼” x

b. If visible when used (depending on location) x

6. Shading on dye lot

a. within a product x

b. from product to product within shipment x

7. Bowed / biased / slanted fabric over ½” side to side x

8. Weaving defects over ¼” (depending on location) x




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9. Conspicuous pilling x

10. Fabric weight variation greater than +/- 3% x

Cleanliness Defects 1. Spots and stains of a permanent nature

2. Hanging / dead / loose thread clusters that are

‘Not removed from the merchandise at:

a. Out side x

b. Inside x

c. Odor – strong odor that are offensive/pungent x

and/or irritating causing illness or other Complaints

Pressing / Folding Defects 1. Burn or scorch marks x

2. Shine marks on the surface of the merchandise x

3. Press marks resulting from the use of clamps or x

Other holding devices

4. Failure to hang products an adequate amount of x

time after pressing to allow for proper drying and

prior to packaging

5. Poorly pressed products objectionably affecting x

Appearance or look

6. Crease marks … poorly dumped or twisted x

7. Product folds margin more/less than ½” x

Seam and Stitch Defects 1. Seam or bindings that are conspicuously twisted, x

Excessively puckered or containing pleats

2. Open seam or broken stitches x

3. Raw edges showing when should be covered




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a. out side x

b. inside x

4. Openings that are not back-tacked properly x

5. Irregular or uneven top-stitching in any focal area x

6. Run-offs in top-stitching

a. Conspicuous x

b. Slight x

7. Excessively loose stitch tension x

8. Conspicuous irregularities in binding width x

9. Contrast stitching which is conspicuously uneven x

Or not uniformly spaced on any focal are

10. Part of the product caught in any unrelated x

operation or stitching

11. Exposed drill holes used of marking/tracing x

12. Unmatched thread used for sewing purpose x

Finished Product Defects 1. Not squared edges if required x

2. Side to side dimensional variation

a. > 4cms x

b. <1~ 4cms x

3. Size variation more than +/- 2% x

4. Button holes misaligned x

5. Uneven gathering (less gathering margins) x

6. Incompatible interfacing causing cracking, x

Puckering, bubbling (minor if on inside)

7. Fronts and backs uneven in excess or ¼” x

8. Missing trims x

9. Hem is uneven, twisted / poorly sewn x

10. Ties, tassels, trims not fully secure x




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11. Misplaced motif printed / embroidered x

Labeling / Packaging Defects 1. Incorrect label / tag / trim x

2. Incorrect fiber content mentioned x

3. Color shade of ink incorrect major if conspicuous x

4. Adhesive tag failed to adhere x

5. Packaging incorrect size x

6. Gauge variation of bags as per approved x

7. Missing or incorrect hooks x

8. Missing law tags, UPC, SKU, Price, bar code sticker x

9. Missing safety sticker large quantity is major x

10. Item not folded, pressed or packaged according x

to the specifications

11. Insert / Inlays, stiffeners material variation x

12. Carton material variation (liner / craft) x

13. Less plies of cartons / thickness of paper tube x

14. Missing shipping mark x

15. Wrong shipping marks x

16. Less edge crust test strength more than 5% x

17. Damage cartons x

18. Paper tube dia less/greater than required x

19. Poorly sewed rolls or bales polypropylene x

Important Note - This major / minor rating is reformed for any specific customer’s instructions.




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Some General Fabric Defects Terms

Skewed or Bias: condition where filling yarns are not square with warp yarns on woven fabrics

or where courses are not square with wale lines on knits.

Back Fabric Seam Impression: backing fabric is often used to cushion fabric being printed. If

there is a joining seam in the backing fabric, an impression will result on printed fabric.

Barre : Occurs in circular knit. Caused by mixing yarn on feed into machine. Fabric will appear

to have horizontal streaks.

Birdseye: caused by unintentional tucking from malfunctioning needle. Usually two small

distorted stitches, side by side. This term should not be confused with birds eye fabric which is

in fact created intentionally.

Bowing: Usually caused by finishing. Woven filling yarns lien in an arc across fabric width: in

knits the course lines lie in an arc across width of goods. Critical on stripes or patterns and not as

critical on solid color fabrics.

Broken Color Pattern: Usually caused by colored yarn out of place on frame.

Color Out: the result of color running low in reservoir on printing machine.

Color Smear: The result of color being smeared during printing.

Crease Mark: differs from crease streak in that streak will probably appear for an entire roll.

Crease mark appears where creases are caused by fabric folds in the finishing process. On

napped fabric, final pressing may not be able to restore fabric or original condition. Often

discoloration is a problem.

Crease Streak: Occurs in tubular knits. Results from creased fabric passing through squeeze

rollers in the dyeing process.

Drop Stitches: results from malfunctioning needle or jack. Will appear as holes or missing

stitches.




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Dye Streak in Printing: Results from a damaged doctor blade or a blade not cleaned properly.

Usually a long streak until the operator notices the problem.

End Out: Occurs in Warp knit. Results from knitting machine continuing to run with missing

end.

Hole: caused by broken needle.

Jerk-in: caused by an extra piece of filling yarn being jerked part way into the fabric by the

shuttle. The defect will appear at the selvage.

Knots: caused by tying spools of yarn together.

Missing Yarn: Occurs in warp knit. Results from wrong fiber yarn (or wrong size yarn) placed

on warp. Fabric could appear as thick end or different color if fibers have different affinity for

dye.

Mixed End (yarn): Yarn of a different fiber blend used on the warp frame, resulting in a streak

in the fabric.

Mottled: Color applied unevenly during printing.

Needle Line: Caused by bent needle forming distorted stitches. Usually a vertical line.

Open Reed: results from a bent reed wire causing warp ends to be held apart, exposing the

filling yarn. Will be conspicuous on fabrics that use different colored yarns on warp and shuttle.

Pin Holes: Holes along selvage caused by pins holding fabric while it processes through stenter

frame.

Press-Off: results when all or some of the needles on circular knitting fail to function and fabric

either falls off the machine or design is completely disrupted or destroyed. Many knitting

needles are broken and have to be replaced when bad press-off occurs. Bad press-offs usually

start a new roll of fabric.

Printing Machine Stop: Dye or ink smudged along width of fabric as a result of the printing

machine stopping.

Print Out of Repair: Caused by print rollers not being synchronized properly. This results in

various colors of the design not being printed in the proper position.

Puckered Selvage: Usually caused by selvage being stretched in finishing or by uneven wetting

out in sanforization process.




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Runner: caused by broken needle. The runner will appear as vertical line. Most machines have

a stopping device to stop the machine when a needle breaks.

Sanforize Pucker: Results from uneven wetting out on sanforize; usually caused by defective

spray heads. Fabric will appear wavy or puckering when spread on cutting table. Difficult to

detect while inspecting on inspection machine with fabric under roller tension.

Scrimp: the result of fabric being folded or creased when passing through stenter frames.

Slub (woven fabric) : usually caused by an extra piece of yarn that is woven into fabric. It can

also be caused by thick places in the yarn. Often is caused by fly waste being spun in yarn in the

spinning process.

Slub (Knit fabric) : Usually caused by a thick or heavy place in yarn, or by ling getting onto

yarn feeds.

Smash: caused by a number of ruptured warp ends that have been repaired.

Soiled Filling or End: Dirty, oily looking spots on the warp or filling yarns, or on packaged-

dyed yarn.

Stop Mark: when the loom is stopped, the yarn elongates under tension; when the loom starts

again, the slack is woven into the fabric.

Straying End: Warp Knit. Caused when an end of yarn breaks and the loose end strays and is

knit irregularly into another area.

Thin Place: Often caused by the filling yarn breaking and the loom continuing to run until the

operator notices the problem.

Water Spots: Usually caused by wet fabric being allowed to remain too long before drying:

color migrates leaving blotchy spots.

Inspection Reports and Records - All audits are documented, and appropriate record is maintained.

Inspection records are indicated with the style and lot of the fabric or finished product inspected.

Reports are handed over to vendor’s relevant department manager or the desk and the acknowledgement

is taken thereof. Inspection report is made as per the criteria described in the relevant sections of this

SOP. Sample evaluation reports are also attached in the appendix.




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Every inspection report format comprises of followings:

• PO#

• Customer Name

• Style / Design / Color

• Date & Time

• Audit Findings

• Auditor’s Signatures

• Vendor’s Authorized Personnel Signatures

• Photo record

A copy of the report is handed over to the relevant merchandiser and the logistics manager after it

has been reviewed by the quality head. An acknowledgement is taken from the merchandiser and the

logistics manager mentioning time and date.

Records (inspection data, certifications) that provide evidence that the product was inspected will be

kept by the quality assurance department for a period of not less than one year (minimum retention

time). The records must clearly show that the product has passed or failed the inspections specified

in the acceptance criteria.

(The format of Final Random Inspection (FRI) is attached at the end of this document)

Weekly Order Summary - Weekly order summary is required for internal record keeping.

It is useful to determine:

• Final audit record, when and at what time the audit of a specific PO/order was conducted

• What were the audit findings, did it get through in the first audit? If not, what were the

reasons? Were these problems due to weaker inline inspections?

• Inline record, if sufficient inline inspections were conducted for a specific PO/Order.

• To assess work load and efficiency of the quality people

This summary should include following information:

Customer

Store

PO#




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Design / Color way / Version

Color

Product / Item

Quantity

Ship date

No. of inline inspections conducted for mentioned PO

Final Audit Date

Final Audit Time

Inspector’s Name

Inspection Result

Remark

4-Point System of Inspection / Grading

FABRIC INSPECTION POLICIES - The purpose of fabric inspection is to determine the quality and

acceptability for our merchandise. It also allows us to prevent loss of material and time during the

manufacturing process. Fabric inspection, mapping or marking defects is important prior to spreading

and cutting because:

Spreading can be done more quickly because the spreader is not also inspecting the fabric.

A cutter’s productivity will increase because the defects are already marked.

TexCraft Solutions requires that all production fabric to be inspected according to the 4-Point

System.

Fabric inspection is conducted at the mill, and the cutting and sewing facility.

Fabric inspection focuses on fault/defect rate, color, end to end and edge to middle shading,

hand/handle and appearance. The client will select the appropriate fault rate and standard to

determine the acceptance of each shipment. This will minimize the quantity of panels or made up

item rejected for fabric faults, thereby ensuring the quality of the finished goods.

Fabric inspection is also considered as preproduction inspection for made ups or other textile

products.




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The following aspects are assessed:

Color

Fabric faults

Shading

Length

Usable width

Fabric hand/handle

Appearance

Packaging

Quantity

Basic difference between American and Japanese 4 point system is points per defects. Japanese 4 point

system was introduced earlier and this system contains some soft attitude for the seller. American 4

point system was introduced after the Japanese system and it is more strict than any other inspection

system.

What is 4-Point System - This is issued by The American Society for Testing and Materials with reference to

the designation: ASTM D5430-93.

A. Inspection Quantity (Amount to select)

Inspect at least 10% of the total rolls of the shipment.

Selection of rolls - Select at least one roll of each color. If more than one role must be selected, then choose the

additional roles in proportion to the total number of roles per color received.

1. If inspecting on the base of total yardage, inspection quantity: total yardage 1/2 x 8

2. If inspection on total package: inspection quantity = total packages ½

B. Defeat Evaluation:

Point

Defect is 3 inches or less than deduct one point

Defect between 3 inches and 6 inches deduct 2 points

Defect between 6 inches and 9 inches deduct 3 points

Defect exceeds 9 inches, deduct 4 points

Continuing defect, deduct 4 points for every yard




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Bigger defect (hole, etc., however big) deduct 4 points for every yard

Continuing Slub mark, crease mark, uneven dye, less width, barer, etc. deduct 4 points for every yard.

Assigned Points Size of Defects

1 <3" or <8 cm

2 >3" < 6" or >8 cm < 15 cm

3 > 6" < 9" or > 15 cm < 23 cm

4 > 9" or >23 cm

C. Points calculation

1. Evaluation grade = total points x 36 x 100/ inspection yardage valid width (inch)

<40 for every 100 square yards' defect equal or less than 40: qualified (the fabric is acceptable)

2. Reject

>40 reject (the fabric is rejected)

(OR)

Acceptance Criteria and Calculation:

· 40 points per 100 yards is the acceptable defect rate

· # of Points per 100 yds = # of penalty points x 100

Yds inspected

Inspection Procedure:

o Determine the amount to inspect (10%).

o Select the rolls to inspect.

o Put the rolls on the inspection machine or other viewing device.

o Cut off a 6 inch piece across the width off the end of the roll. Mark the right and left side of the

strip. Stop the inspection process every 50 yards and use the strip to check for any shading

problems. Also make sure to check the end of the role.




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o Inspect for visual defects with the light on at a speed slow enough to find the defects. (The fabric

must be checked at a slow rate in order to effectively find flaws). Sometimes you may have to

turn the light off to see how a flaw will affect the appearance of a garment.

o Check that the roll contains the correct yardage as stated by the piece goods source.

o Check for skewed, biased, and bowed fabric.

o Mark any defects to the side with colored tape so that they can be easily found and noted.

o Record any defects.

o No more than 4 penalty points can be assigned for any single defect.

o No linear yard or meter can contain more than 4 points, regardless of the number of defects

within that yard or meter.

o A continuous running defect which exceeds 9 inches (23 cm) should be assigned 4-points. In the

event there is an additional defects within the same linear yard or meter it should be considered

as a separate defect and assigned defect point accordingly.

o Any continuous defect (i.e., roll to roll shading, narrow or irregular width, creasing, uneven

finish, barre’, skew, etc.) should be assigned a maximum of 4 points for every yard or meter

within a shipment. Any defect of a continuous nature shall be assigned four points for each yard

in which it occurs.

o Each full width defect should assign 4 points.

o Obvious, noticeable and severe defects are to be assigned 4 points for each yard or meter in

which they occur, regardless of size.

o Severe defects are assigned the maximum four points for each yard in which they occur.

Example: Regardless of size, hole would be penalized four points. Continuing conditions such as

barre, side center side shading, roll to roll shading, narrow or irregular width, creasing, uneven

finish shall be counted four points for every yard within the roll that is found to contain these

conditions.

o The maximum penalty for any one yard shall not be more than four points.

Definition of Major Defects:

Major woven fabric defects include but are not limited to slubs, holes, missing yarns, yarn variation, end

out, soiled yarns, and wrong yarn.




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Major dye or printing defects are out of register, dye spots, machine stop, color out, color smear, or

shading.

Fabric Sampling Plan - The following sampling plan lists the minimum quantity of fabric for each

pattern, color way, or print, which must be inspected. All rolls to be sampled will be randomly selected

by the inspector. Once a roll has been selected, no adjustments will be made.

SAMPLE PLAN CHART

Lot Size Inspection Lot Size Inspection %age of

Yards Yards Meters Meters Total lot

0 - 2,500 not less than 500 0 - 2,300 not less than 460 20%

2,501 - 5,000 251 – 500 2,301 - 4500 230 - 450 10%

5,001 - 20,000 400 - 1,600 4,501 – 18,300 360 - 1465 8%

20,001 - 30,000 1,200 - 1,800 18,301 – 27,400 1,100 – 1,645 6%

All inspected rolls will be identified with an inspection tag. This tag may not be removed by anyone

prior to the production cutting.

POINT CALCULATION

o For an Individual Roll:

Points per 100 Square Yards = Total Points for the roll x 3600 / {(Inspected Yards x Cut able

Fabric Width (inch))]

Points per 100 Square Meters = Total Points for the roll x 100,000 / [Inspected Meters x Cut

able Fabric Width (MM)]

o For a Shipment:

Total Shipment Points per 100 Sq. Yards = Total Average Points per Linear Yard x 3600 /

[Shipment Inspected Yards x Cut able Fabric Width (inch)]

Total Shipment Points per 100 Sq. Meters = Total Average Points per Linear Meter x 10,000 /

[Shipment Inspected Meters x Cut able Fabric Width (MM)]

OR

All inspections are based on a sq. yards computation. The following formula is used to determine

the point of each roll.




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Total Points x 36 x 100

---------------------------------------------------------- = points per 100 sq. yards.

Inspected yards x Cut-able fabric width

The total defects shall be multiplied by 3600 and then divided by the product of the total yardage

multiplied by the overall width including selvage.

The average point count per shipment is calculated by totaling the number of penalty points per

100 sq. yards per roll and then dividing by the number of rolls inspected.

Total penalty points per 100 sq. yds. of all rolls

--------------------------------------------------------------------- = Average Points Per Shipment

Total number of rolls inspected

Penalty Point Grading:

Running Defects:

1. Any defect found to repeat and /or run in a continuous manner will constitute a running defect. All

running defects must be assigned four to every yard in the roll that the running defect occurs.

2. Any roll having a running or repeating defect through more than three continuous yards shall be

rejected regardless of point count.

Full Width Defects:

3. No roll that contains more than four full width defects per one hundred linear yards, shall be accepted

as first quality.

4. Any roll found to contain defects, in any increment of one hundred yards, with an average of more

than one major defect per ten linear yards will be rejected.

5. No roll shall be accepted that contains a major defect in the first or last three yards of the rolls. A

major defect is considered to be any three or four point defect.

6. No roll shall be accepted as first quality that exhibits a noticeable degree of lose or tightness along

either or both selvedges, or ripples, puckers, folds or creases in the body of the fabric that would prevent

the fabric from lying flat when being spread in a conventional manner.




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Fabric Width:

7. Fabric width will be checked a minimum of three times during the inspection of a roll, beginning,

middle and end. The roll width will be checked more often if the fabric is close to the specified

minimum width of if the fabric width is uneven.

8. Rolls having a measurement of less than the specified purchased width will not be accepted.

9. For woven fabric, rolls having a measurement of 1" wider than the specified purchased width will not

be accepted. But for the stretched woven fabric, it can be accepted 2"wider than the specified purchased

width.

For knit fabric, rolls having a measurement of 2" wider than the specified purchased width will not be

accepted. But for the Lycra knitted fabric, it can be accepted 3"wider than the specified purchased width.

10. Overall fabric width is measured from the outside of the selvage to the outside of the opposite

selvage.

The cut able fabric width is measured by excluding the fabric selvages and/or stenter pin marks, bare,

unprinted, uncoated or otherwise untreated surface portions of the base fabric.

Shade Matching:

11. Roll to roll and lot to lot shading must be no less than 4, on the AATCC Grey Scale.

12. Full width (6" - 10" wide) shade bands will be taken from each roll during the fabric inspection

process. The inspector will use these bands to compare shading within a roll and roll to roll.

13. Rolls with side to side, side center side, or end to end shading, must be no less than 4 Grey Scale

rating according to the AATCC Grey Scale. Four points shall be assigned to each yard of the inspected

roll that contains this type of shading defect.

14. If the shade of the raw materials being inspected does not match the provided approval sample must

be no less than 4-5 Grey Scale rating, the shipment will fail the inspection. No penalty points will be

assigned to the rolls for the off shade condition. The inspection of the raw material will continue, all

rolls will be graded accordingly.

Roll Length:

15. Rolls found to deviate more than 2% from the length of the roll ticket shall be rejected. Penalty

points will not be assigned for roll length variation, but shall be noted on the inspection report.

16. The entire shipment shall be rejected if the total measured yards in the sample audit deviates 1% or

more from the ticketed yards.




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Splices:

17. For woven fabric, rolls can be composed of several spliced parts. No roll shall be accepted that

contains a splice less than forty (40) yards in length unless otherwise stated in the purchasing agreement.

For knit fabric, Rolls can be composed of 1 spliced part. No roll shall be accepted that contains a splice

less than thirty (30) lbs in weight unless otherwise stated in the purchasing agreement

Bowing:

18. For both woven & knit fabric, no rolls shall be accepted as first quality that exhibit bow or bias or

more than 2% for print or stripe fabric & 3% for solid fabric.

Skewing:

19. For woven fabric, no rolls shall be accepted as first quality that exhibit skewing more than 2% for

print or stripe fabric & 3% for solid fabric.

20. For knit fabric, no rolls shall be accepted as first quality that exhibits skewing more than 5% for

solid, print or stripe fabric.

Fabric Odors:

21. No roll shall be accepted that exhibits objectionable odors.

Holes:

22. All defects that break the fabric, regardless of size, shall be penalized a maximum of four points. A

hole consists of two or more broken yarns.

Hand / Feel:

23. The hand /feel will be checked between rolls and to a reference sample. If there is a noticeable

difference, the roll will be classified as second quality and 4 points assigned to every yard. If all rolls do

not match the reference, the inspection will be put on hold and no points will be assigned.




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FABRIC WEIGHT AND DIMENSION TOLERANCES

ROLL WEIGHT - Weight of individual rolls measured on a calibrated scale with accuracy to the

nearest tenth of a pound.

a. Core weight (tare weight) to be considered ½ pound unless otherwise agreed.

b. Maximum rolls weights to be stated in contract and/or purchase order. They can vary by program,

cutting facility, etc.

c. The weight of the fabric roll will not vary more than +/- 5% from the style specification weight.

d. Shipping weights are based on lot or batch averages.

FABRIC WEIGHT

o Fabric weight is quoted in terms of ounces per square yard, ounces per linear yard, grams per

square meter and fabric yield. In the case of open-width fabrics, the standard weight is based on

the overall width of the fabric.

o Ounces per Square Yard or Grams per square meter is the area weight of the fabric. The oz/yd2

or gsm is taken by weighing the known area of a test fabric and calculating the ratio of weight in

ounces to one square yard or grams to one square meter of the same fabric.

o The fabric weight for most styles is guaranteed to be within plus or minus five percent (+/- 5%)

of the standard ounces/square yard (oz/yd2) or grams/square meter. Ex: If the standard ounces

per square yard or grams per square meter is 5.5, the tolerance would be 5.22 to 5.78 oz/yd2 or

gsm.

o Yield is the actual number of yards or meters shipped divided by the total pounds or Kgs.

shipped. Tolerance on yield is also +/- 5% of total lot or shipment.

WIDTH

o Open-Width Styles - The cut-able width is guaranteed to be within one inch (1”). The cut-able

width is quoted as the minimum cut-able width plus two inches. For example, a quoted cut-able

width of 60-62 inches means that 60 inches is the minimum cut-able width and that 62 inches is

the maximum cut-able width.




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LENGTH

o Yards are recorded as measured using a machine with a calibrated yardage meter. Measuring the

yards on a cutting table is not an acceptable means of measuring fabric yardage.

o Reasonable consideration will be given to consistent shortages or deviations.

PIECE LENGTH AND SEAMS

o Individual roll pieces may be lapped rather than re-sewn. The pieces must be sewn together on

jumbo rolls and Prepared-For-Print (PFP) rolls.

o The number of splices or seams per roll are as follows:

o Fleece or Terry Fabrics - Two splices or seams per roll. Each spliced piece must be at least five

yards.

o Prepare-For-Print (PFP) Fabrics - All splices will be sewn. Two seams per 100 yards. Each

piece will be at least 25 or 40 yards between seams depending on the greige roll size for that

style.

o All Other Fabrics - Three splices or seams per roll. Each spliced piece must be at least 40 yards.

Prefer no splices, but will accept one splice per roll.

General Terms of Fabric Defects :

Barre - In knits, a condition generally characterized by a somewhat patterned unevenness-of-appearance

in the course or widthwise direction of a fabric. Some causes are uneven yarn, uneven tension and yarns

having different dye affinities

Bad Place - A term convenient to use for defects that sometimes defy description. Usually used to

describe localized places where the weave has been severely disrupted.

Bias (also skew) - In woven, where the filling yarns are off-square to the warp ends; in knits, where the

course are off-square to the Wales.

Birdseye Defect - In knits, the occasional and erratic appearance of tucked stitched contrary to the

design of the fabric.

Bow - In woven, where the filling yarns lie in arc across the width of the fabric; in knits, where the

courses lie in an arc across the width of the fabric.




FAX: +92-423-5897665

45

Broken End - Where a warp yarn has ruptured and been repaired - often characterized by the broken end

being woven into the fabric.

Broken Color Pattern - In woven, a break in the continuity of design, caused either by a mistake in the

drawing of the color pattern through the loom harness, or improper resetting of the filling pattern chain

after servicing the loom for a filling break. In knits, the result of a mistake in creeling

Broken pick - Where a filling break leaves a pick missing for a portion of the width of the fabric.

Bruise -(see also temple bruise) - A condition where the yarn while being woven, or the fabric after

being woven, has been scuffed so as to disorient the fibers and result in a fuzzy appearance.

Burl mark - A distortion resulting from some superfluous material such as a thick slub, waste, or wild

yarn being removed with a burling tool.

Buttonhole selvage - A selvage defect caused by excessive tension buildup in the shuttle just before

filling change. This tension tends to restrict the selvage yarns from proper shedding and interlacing,

resulting in a defect resembling a buttonhole.

Chafed Yarn - Yarn that has been scuffed by abrasion, disorienting the fibers and leaving the yarn

fuzzy. This will affect the dye-ability and often result in warp streaks or filling bands.

Chopped Filling - An unevenness in the filling direction characterized by a distinct or measured pattern

resulting from the eccentric behavior of a drafting roll.

Clip mark - An un-dyed place resulting from a metal clip being used on the edge of a fabric to prevent

or correct a selvage turndown during dyeing.

Coarse End - An end whose diameter is noticeably greater than that normal to the fabric.

Coarse Pick - A pick of filling whose diameter is noticeably greater than that normal to the fabric.

Coarse Yarn - A yarn whose diameter is noticeably greater than that normal to the fabric.

Cockled Fabric - In knits, crinkled, shriveled or ridgy fabric that will not lie flat on the cutting table.

May be caused by irregular twist in the yarns, uneven tension during knitting or varying degrees of

reaction by the yarns within the fabric to the finishing processes.

Cockled Yarn - A yarn in which some fibers appear wild or tightly curled and disoriented. This is the

result of some fibers being too long for draft roll settings so that the succeeding roll grips the fiber

before the preceding roll releases it, causing the fiber to snap and curl. Cockled yarn often appears as

tiny slubs in the fabric.

Color Fly - Fibers of a different color appearing in a yarn or fabric as contamination.




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46

Color Misdraw - In woven, the drawing of colored yarns through the loom harness contrary to the color

pattern and/or weave design. In warp knits, the drawing of colored yarns through the guide bars contrary

to the pattern design.

Color Out - In printing, when the color paste runs low in the reservoir resulting in blank skips in the

print pattern.

Color Smear - In printing, when the color is smeared, distorting the pattern.

Compactor Crease - In knits, hard-set creases resulting from the introduction of wrinkled fabric into the

shrinkage control and stabilization process.

Corrugation (also sanforize corrugation) - A washboard effect resulting from a malfunctioning

sanforizer blanket.

Cover - A term used to describe the face of a fabric in relation to the amount of a warp of filling-show,

prominence of design, or other desired characteristic achievable by varying the influence of one or the

other of the two yarn systems.

Crease - A place where a fabric has been folded on itself under pressure.

Crease Streak - The visual after-effect of a crease occurring the dyeing or finishing processes.

Damaged - The condition of a fabric rendered unusable for its intended use.

Doctor Streak - In prints, a narrow, oscillating length-wise streak resulting from a damaged doctor

blade.

Double End - Two ends where only one is called for by the design of the fabric.

Double Pick - Two picks in a single shed where only one is called for by the design of the fabric.

Doubling - A filling yarn twice the normal size due to two ends of roving running together into a single

end of spinning. The same occurrence in warp yarn would result in a coarse end.

Dragging End - In warp knits, an end being knit under erratic tension due to its being entangled and/or

trapped on the warp beam.

Drawback - A defect resulting from excessive tension gradually applied to a number of warp yarns by

some abnormal restriction; when the restriction is removed, the excess slack is woven gradually into the

fabric.

Dropped Pick - This is the result of the filling insertion mechanism on a shuttle-less loom not holding

and releasing the filling yarn too soon. This allows the yarn to snap into the body, leaving a missing pick




FAX: +92-423-5897665

47

part-way across the width of the fabric. The released pick is then woven into the fabric. The released

pick is then woven into the fabric in a somewhat tangled mass.

Dye Streak - Streaks related to dyestuff, its application to, or absorption by the fabric.

End Out - A missing warp yarn.

Filling band - A visually perceptible band across the width of the fabric directly attributable to a

difference in the chemical or physical characteristics of the filling.

Filling Floats (see also shed-splitting, under shots and over shots) - Picks of filling extending unbound

over or under warp ends with which they should have been interlaced.

Fine End - An end whose diameter is noticeably smaller than that normal to the fabric.

Fine Yarn - In knits, a yarn whose diameter is noticeably smaller than that normal to the fabric, usually

resulting in fine lined cracks in the course or widthwise direction.

Flat - A miss-draw in a plain weave resulting in two ends weaving as one and opposing two other ends

weaving as one.

Float (see warp float, filling float and skip stitch) - A thread extending unbound over or under threads

of the opposite yarn system with which it should have been interlaced.

Foreign Fiber - Fiber, other than that common to a fabric, existing as contamination; it may be confined

to a single yarn or be distributed randomly.

Foreign Matter - Contamination by some substance other than fiber.

Fuzz Balls - Balls of fiber encircling the warp yarn formed by the abrasion of the loom. These usually

result from the lack of sufficient sizing material on the warp yarns, causing what generally is referred to

as a "soft warp".

Gout - An accumulation of short fiber or fly spun into the yarn or drawn into the loom shed. This defect

differs from slubs in that slubs generally are symmetrical in shape while gouts appear as un-drafted

lumps.

Halo - A light place encircling a defect resulting from dye migration to the defect during drying.

Hang Pick (also loopy filling) - A pick of filling hanging for a split second on a warp knot or other

protrusion until freed by the stroke of the reed. This results in a short loop of filling appearing on the

face of the fabric.




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48

Hanging Thread - A thread left hanging on the face of a fabric. The most common cause is the failure

of a weaver to clip the excess yarn after repairing a broken end and/or the cloth inspector's failure to

remove the excess yarn.

Hard Size - A place in a fabric characterizes by a harsh, stiff hand and cloudy, uneven appearance. This

is most common in mill-finished yarn-dyes and is the result of a slasher stop that allows excessive

amounts of sizing material to harden onto the yarn. This generally appears in bands across the width of

the fabric.

Harness Balk - An isolated failure of a loom harness to move in its prescribed sequence, causing a pick

of filling to float over certain warp ends with which it should have interlaced.

Harness Breakdown - A place where a harness ceases to function, resulting in the ends drawn through

that harness floating either to the face or back of the fabric.

Harness Misdraw - Where one or more ends are drawn through the harness contrary to the design of the

weave.

Hole - Self descriptive.

Jerk-in - An extra piece of filling yarn jerked by the shuttle into the fabric along with a regular pick of

filling. On conventional looms they generally are confined to the battery side, the most common cause

being the failure of the thread-holding mechanism to hold the filling from the out-going bobbin long

enough for the temple thread cutter to cut the yarn after a filling change.

Kinky Filling - A place in a fabric where a pick of filling has been given enough slack to twist on itself

for a short distance. Causes are: shuttle not boxing properly, a malfunctioning filling fork, too much

power on the picker stick , excessive twist in yarn, inadequate setting of filling twist, etc.

Knot - A place where two ends of yarn have been tied together.

Loom Bar - A change in shade across the width of a fabric, resulting from a buildup of tension in the

shuttle before a filling change. This is most common on yarn-dyed fabrics.

Loom Waste - A place in a fabric where accumulated waste off the loom has found its way into the

fabric either by air current or loom shuttle.

Loopy Filling (also hang pick) - A pick of filling hanging for a split second on a warp knot or other

protrusion until freed by the stroke of the reed. This results in a short loop of filling appearing on the

face of the fabric.




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49

Loose Course - In knits, a course whose loops are more extended than normal, due to a lack of correct

tension on the yarn.

Machine Stop - A term used to describe the visible evidence of a fabric having been stopped in some

machine during the dyeing and finishing process. Generally it appears as glaring shade changes across

the width of the fabric.

Mat-up - A place where the warp yarns have become entangled so as to disrupt the proper interlacing of

warp and filling. This can be caused by a loom failing to stop when an end breaks, or the introduction of

a piece of wild yarn from some other source. Mat-ups may range in severity from minor to very

damaging.

Misdraw (Harness) - Where one or more ends are drawn through the reed contrary to the design.

Misdraw (Reed) - Where one or more ends are drawn through the reed contrary to the design.

Misdraw (Color) - In woven, the drawing of colored yarns through the loom harness contrary to the

color pattern and/or weave design. In warp knits, the drawing of colored yarns through the guide bars

contrary to the pattern design.

Mis-pick - Where the weave design is broken by the absence of a pick of filling.

Missing Yarn - In knits, the absence of a yarn, often resulting from a machine continuing to run after a

yarn breaks.

Miss-selection - In knits, where the design is corrupted by the random dropping of stitches. This can

result from sticking jacks or the erratic behavior of a yarn feed.

Mixed Filling - A visible widthwise band resulting from filling.

Mixed Yarn - Yarn that is alien to a fabric because of its peculiar chemical or physical characteristics.

Mottled - A term used to describe a blotchy or spotty appearance resulting from the uneven application

of color to a fabric, or the uneven acceptance of color by a fabric.

Needle Line - In knits, a vertical crack resulting from a bent needle. The design is intact but the uniform

placement of wales is distorted.

Neppiness - An excessive amount of tangled masses of fiber (neps) appearing on the face of a fabric.

Open Reed (also reed mark) - A defect resulting from a bent reed wire, characterized by a fine-lined

thin place in the warp direction.

Out Of Register - In printing, pattern distortion due to lack of synchronization of the printing rolls.




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50

Overshot - A pick of filling deflected from its normal path through the shed and extending unbound over

warp ends with which it should have interlaced. This condition is most common within twelve to fifteen

inches of the selvage and results from improper loom setting.

Pattern Defect - In woven, the formation of interlaces or the insertion of color contrary to the design of

the fabric, resulting from a machine malfunction or the incorrect placement of colored yarn in the

harness of the loom. In knits, the formation of stitches or the insertion of color contrary to the design of

the fabric, resulting from a machine malfunction or the incorrect placement of colored yarn in the creel.

Pin Holes - These are holes common to a fabric run over a pin-tenter and become a defect when they

venture too far in from the selvage and enlarge or tear.

Press Off - In knits, a condition where the fabric fails to knit and either falls off the machine or the

design is completely disrupted and destroyed.

Pucker (also sanforize pucker) - A warp wise distortion resulting from uneven wetting-out during

sanforization, generally due to faulty spray heads. It may appear as a wavy selvage or affect any other

area of the fabric. Confined to one spray head, the pucker generally is eight to ten inches wide.

Reed Misdraw - Where one or more ends are drawn through the reed contrary to design.

Reed mark (also open reed) - A defect resulting from a bent reed wire, characterized by a fine-lined thin

place in the warp direction.

Reed Streak - A warp-wise defect attributable to a bad reed. It may appear as light and heavy streaks

due to uneven placement of the yarn, or it may scuff the yarn varying its affinity for dye.

Reedy - A condition characterized by open streaks following the pattern of the reed wires. This can be

the result of a too-coarse reed, wrong reed-draw arrangement or improper setting of the loom.

Rough - A term used to describe a rough or crinkled appearance resulting from a broken needle or jack.

Sanforize Corrugation (also corrugation) -A washboard effect resulting from a malfunctioning

sanforizer blanket.

Sanforize Pucker (also pucker) - A warp-wise distortion resulting from uneven wetting-out during sanforization,

generally due to faulty spray heads. It may appear as a wavy selvage or affect any other area of the fabric.

Confined to one spray head, the pucker generally is eight to ten inches wide. Sanforize Roughness - A term used to describe a rough or crinkled appearance resulting from over-sanforization.

Scrimp - A defect resulting from a fabric being printed in a folded or creased condition so that the pattern is

destroyed when the fold or crease is opened or stretched out.




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51

DOCUMENTATION - To ensure proper documentation on the Inspection report the following should be

correctly recorded.

Mill Name

Fabric P.O. Number

Mill / Supplier roll number

Roll length

Ticketed

Actual

Difference between ticketed and actual

Recorded cut-able width

1st Measurement – At the start of the roll at least 2 meters or yards into the roll

2nd Measurement – At the middle of the roll

3rd Measurement – At the end of the roll at least 2 meters or yards before the end

Number of defect points per roll by 4 point system

Defect result calculated by roll in points/ 100 Sq Yards/Meters

Inspector comments if any per roll.

(A typical fabric inspection report is attached t the end of this document)

Loading Procedures –

Preparation – The preparation includes to:

o Ensure that a memorandum is filled out and sent through the proper channels requesting the use of a

container

o Ensure that proper material handling equipment (MHE) is available for use and if not request proper

MHE

o Ensure that proper blocking and bracing materials are available for use

Container’s expected tolerable conditions

o Sides, tops and bottoms cannot be dented more than ¾ of an inch

o Welds should not be cracked, broken, or damaged in any way

o Identification of the container must remain visible and legible at all times

o Top and bottom rails and tie down points must not be dented, crushed, torn, or twisted




FAX: +92-423-5897665

52

Loading

o Ensure that load is distributed evenly across the floor of the container

o Ensure that heavier items are on the bottom

o Ensure that all proper procedures are observed at all times.

o Ensure that load is with in rated capacity for that container

o Ensure that proper center of balance (C/B) of containers is maintained * if C/B is any where other

than in the center Notify the carrier of the container immediately

o Container is properly weighed and marked with the weight and C/B

o Container is properly sealed with the seal number written on the container and packing list

o Ensure that inner of container is clean, corrosive particles free, rust free, and explosives free too.

o Stuffing should be made as per maximum utilization of internal space.

o Container’s specifications should be clear and visible.

o Ensure container is properly sealed.

o Pictures of starting, middle and closing of stuffing should be captured along with sealing digits.

Hazardous Materials - These are classes of hazardous material which should be check at all:

o Class 1 Explosives - Munitions, Trainer Missiles

o Class 2 Compressed Gas - Compressed Gases, Oxygen Cylinders, Acetylene Cylinders, Propane,

Butane, Fire Extinguishers

o Class 3 Flammable & Combustible Liquids - Mono gas, Diesel Fuel, Jerry Cans – Empty and

Full, Fuel Tankers – Empty and Full, Denatured Alcohol, Mineral Spirits, Paint, Paint Thinner




FAX: +92-423-5897665

53

o Class 4 Flammable Solids - Meal, Ready-to-Eat (MRE) Heat Tabs

o Class 7 Radioactive Material - Electronic Tools with Radio Active Components, Radioactive

alarms

o Class 8 Corrosives - Alkaline Batteries, Vehicle Batteries, Battery Acids

Knowledge & Monitoring of Vendor’s Quality Assurance Procedures - Each division and subsidiary

must adopt, implement and adhere to these policies. The sourcing procedures of each affected business unit of the

Company will reflect the policies set forth in this policy statement and also contain such procedures, protocols and

standardized forms as are necessary to implement these policies fully and effectively in the context of each business

unit's business and operations. Independent Production Services and the Company's attorneys, auditors and

accountants are available to the business units as resources to assist in the production of such procedures, protocols

and forms.

Vendor Education - As the Company continues to develop strategic relationships with vendors and

otherwise reduces the size of its vendor base, it will continue to intensify its commitment to vendor

education. The sourcing procedures of each affected business unit will provide for such education that

may include:

o Distribution of written summaries of our policies to all vendors, translated where appropriate into local

languages, and requiring vendors to further distribute such materials to their subcontractors and suppliers.

Acknowledgment of receipt of and a commitment to compliance with, our policies will also be required.

o Development of purchase agreements, letters of credit and other appropriate transaction documentation that

fixes responsibility within vendor organizations for adherence to the Company's policies and procedures that

requires clear and conspicuous display of a summary of our policies in all facilities where work is done.

o Commits vendors to refrain from interfering with, discouraging or punishing efforts by employees to

communicate with us or to otherwise assert their concerns or grievances.

o Requires maintenance of records of the names, ages, and hours worked and wages and benefits paid for each

employee, the making of such records immediately available to us and our agents upon request, and allowing

us or our agents to conduct confidential interviews with employees.

o While we recognize that local customs and values profoundly influence individual judgments in many areas

covered by these standards, we support the work of international agencies and organizations that seek to

develop internationally recognized standards for labor practices and business conduct.




FAX: +92-423-5897665

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Section–II (Job Responsibilities): JOB TITLE: Quality Auditor

DEPARTMENT: Quality Assurance

A: Purpose and Scope - The Internal Auditor is responsible for conducting internal audit activities of assigned

Tex Craft Solution’s major field service operations and assist in providing oversight and continual improvement

to quality system. These internal auditing activities are used to assess and ensure quality assurance compliance,

both internally and externally per the requirements of global perspective.

Quality Auditor:

Audits work activities of processing production workers to verify conformance of activities to quality assurance

standards, applying knowledge of job performance requirements, equipment operation standards, and product

processing specifications.

Obtains quality assurance personnel check list.

Observes and asks worker questions pertaining to job functions.

Reads processing information, such as worker logs, product processing sheets, and specification sheets, to

verify that records adhere to quality assurance specifications.

Observes worker using equipment to verify that equipment is being operated and maintained according to

quality assurance standards, applying knowledge of equipment operation.

Writes audit information on quality assurance form and keys information into computer, using keyboard.

Submits audit report to supervisory personnel.

B. DUTIES AND RESPONSIBILITIES

• Responsible for execution of internal audits. Plan audit, execute and prepare audit report. Formally

document findings. Work with the departments audited to resolve compliance issues, provide

recommendation, communication on status of action resolution and bringing to management issues that

require attention tracking corrective actions. Maintain data base, files generated from each audit.

• Responsible for on-site audit of supplier quality systems. Plan audit, execute and prepare audit report.

Formally document findings. Maintain data base, files generated from each audit. Perform necessary

follow-up which include communicating with auditee(s) on status of action resolution.




FAX: +92-423-5897665

55

• Provides internal communication regarding compliance issues and applicable regulation changes. Aids

in the creation of gap analysis to any new/changed regulations.

• Assist inspections, preparations and corrective actions as needed.

• Collaborate with different members of the QA/RA department working in special projects. Perform

additional assignments as directed by Manager Quality Assurance. Assist in maintaining various quality

systems and programs, as needed.

JOB TITLE: Quality Assurance Manager

DEPARTMENT: Quality Assurance

The Quality Assurance Manager is responsible for all operational aspects of the Quality Assurance & Quality

Control Departments related to the manufacturer of products in strict accordance with all Standard Operating

Procedures, current Good Manufacturing Practices, Company policies and procedures.

A: Purpose and Scope

Overall day-to-day management of the QA activities

Scheduling of all audits

Database audits

Vendor audits for vendors contracted for associated studies

Statistical and Reporting audits

Work with the operational heads to develop strategies, processes, and quality systems; programs for data

management.

QA review of protocols, case report forms, plans, statistical analysis plans etc

With the operational heads determine SOP requirements and provide QA review of SOPs for the group

Assist with organizational and coordination of sponsor and regulatory audits.

Participate in training sessions

Execute other duties as may be required by the Directors.




FAX: +92-423-5897665

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B: DUTIES AND RESPONSIBILITIES:

• Oversees, manages, coordinates and prioritizes the daily activities of the Quality Assurance & Quality

Control Departments and assigned staff.

• Provides QA input during design and development phases to ensure all requirements are properly

documented.

• Provides continuous QA oversight to all phases of production.

• Provides oversight and manages quality and product performance at all suppliers.

• Maintains approved supplier list, including appropriate rating and quality improvement plans for

suppliers.

• Conducts, coordinates and documents investigations, corrective and preventative actions; tracking;

trending; and maintenance of historical files.

• Oversees Material Review Board; manages the identification, investigation, and closeout of

manufacturing non-conformances.

• Oversees customer complaint handling program.

• Oversees configuration control program as related to processes, equipment, systems.

• Oversees change implementation.

• Participates in design and safety reviews and failure analyses.

• Carries out managerial responsibilities in accordance with the organization's policies, procedures, and

state, federal and local laws.

• Reviews and approves manufacturing deviations.

• Ensures that all personnel are adequately trained, and where required, certified. Ensures that training is

appropriately documented. Maintains training records in an orderly manner that facilitates easy retrieval

and review.

• Ensures that production materials are tested for acceptability in accordance with written procedures.

Performs all quality audits.

• Reviews and approves production and process control Standard Operating Procedures (SOPs) that are

drafted, reviewed and approved by other organizational units.

• Coordinates with the Director of Operations to ensure compliance with and understanding of company

policies and practices, and safety procedures.




FAX: +92-423-5897665

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• Prepares periodic reports for CEO and executive management.

• Oversees, participates and approves the interviewing, hiring, and training of departmental employees;

conducts performance evaluations for direct reports.

• Provides support, direction and coaching to subordinate employees in the areas of hiring, training,

disciplinary action, problem resolution, planning, and work assignment delegation.

Additional duties

• Responds to Quality Assurance-related inquiries from management, employees and regulatory agencies.

• Prepares, presents and administers department budgets. Manages department expenses, evaluates new

equipment and other capital expenditures and submits purchase recommendations.

• Manages multiple projects, duties and assignments. Ensures project deadlines and performance

standards are established and met.

• Directs, coordinates, delegate's assignments and reviews work of assigned department personnel.

• Establishes and maintains cooperative working relationships.




FAX: +92-423-5897665

58

Section–III (Communication Flow Chart) – Below diagram outlines how the communication

should flow within the organization. The purpose of this chart is to make it clear to all concerned how the

communication needs to flow between various concerns.

Director

Merchandiser

Inspector

(team Leader)

Inspectors

Buyers

Suppliers

KEY Two way communication channel One way communication channel (Discretion of Director)


Approved Lab dip Yes No Packing List Yes No Shade Band Yes No Trim Card Yes No Product Specification Sheet Yes No Other References Yes No

38-XX, 2ND FLOOR, COMMERCIAL ZONE PHASE 4 DHA, LAHORE, PAKISTANTEL:+92-423-5896438, 5746442, 5743413-4

FAX:+92-423-5897665

PRODUCT DESCRIPTION, STYLE & CONFORMITY (iii)

LAB TEST REPORT FROM SUPPLIER (vi)

NOT APPLICABLE

Factory Contact . Person

Factory Name

Factory / Manufacturing ..Location

SKU# Presented for Inspection

Audit Details - Section (i) Personnel Involved / Contact Details

Audit Report Pages

1 OF 8

TEXCRAFT SOLUTIONS (PVT) LTD

MADE UPS AUDIT REPORT

Inspection Reference# Fax #: Email:

Copy to: Inspector ..Name(s):

Contact Person:

Email: 0092 423 5897665 [email protected]

Telephone #: Mr. Ali Imran Iqbal

Fax #:

Service Performed

Customer Name: Contact Person: 0092 423 5746442, 5896438, 5743413-4 Telephone #:

Rec date Color / PatternApproved By

Approved Standard (Customer)

Additional References submitted for Inspection

Inspection Summary / ResultSPECIFICATION / SUMMARY

WORKMANSHIP (ii)

PASS PENDINGFAIL

ACCESSORIES CONFORMITY (vii)

PACKING DETAILS (ix)

MEASUREMENT CHART (viii)

BARCODES (iv)

READY TO SHIP CARTON MEASUREMENT & WEIGHT (v)

REMARKS

OVERALL RESULT

Customer PO# Product Description


Sr#123456789

10111213141516171819

CommentsResults

FAX:+92-423-5897665

4.02.5 (ii) WORKMANSHIP

OF

Audit Report Pages

2 8 MADE UPS AUDIT REPORT

Number of Defects Found

Major MinorCriticalDefects Found With Detail


1

2

Product Description

Total Defects Found Total Defects Allowed

Product Specification

(iii) Product Description, Style/Specification, Color Conformity

Result

Product Color(s) conformity as per Approved Standard

SAMPLING PLAN

GENERAL COMMENTS / REMARKS:


Maximum Allowed INSPECTION LEVEL SAMPLE SIZE

NormalII

3

AQL Defects Found


Comments / Remarks

HeightLength

COMMENTS / REMARKS

(v) READY TO SHIP CARTON SPECIFICATION AND WEIGHT CONFORMITY

Height

Barcode / UPC Placement Found

8

Gross Req

Item Weight

CTN Weight

TTL Carton Weight

Carton Put-up

Length

3MADE UPS AUDIT REPORT

Scan-ability

Overall Barcode / UPC Sticker Conformity

Comments

Width

Product Weight

Bar - Code Digits Found

(iv) Barcodes / UPC Sticker Conformity Barcode / UPC Placement required

Size / Item Bar - Code Digits Required

OF

TEXCRAFT SOLUTIONS (PVT) LTDAudit Report Pages

Width

Carton Dimension (Required) Carton Dimension (Found)

Sizes / Item Req (PCS)

Found (PCS)


FAX:+92-423-5897665

RESULT .

Sample Checked Pattern / Color

Pass Fail


Care Instructions RequiredLabel Dimensions Found

Length

PCS Number of CARTONS CHECKED

COMMENTS / REMARKS:

Label Dimensions Approved

PCS

TEL:+92-423-5896438, 5746442, 5743413-4FAX:+92-423-5897665

Width

38-XX, 2ND FLOOR, COMMERCIAL ZONE PHASE 4 DHA, LAHORE, PAKISTAN

RESULT ..

RESULT ..

Length Width

Audit Report Pages


MADE UPS AUDIT REPORT4 8

Care Instructions Found

(vii) ACCESSORIES CONFORMITY (WASH / CARE LABEL)

RESULT ..

INSERT / INLAY CARD

Result . Comments / Remarks

OF

Sizes / Items

Number of Insert Card / In-lays ...Checked

SHIPPING MARKS PRINTED ON CARTON

sets

CARTON LABEL

Number of CARTONS CHECKED

Comments / Remarks


FAX:+92-423-5897665

(vi) LAB REPORT


Audit Report Pages


MADE UPS AUDIT REPORT5 OF 8


(viii) MEASUREMENT CHART

TOL (+ / -)

Item / SpecsSKU # SKU # SKU # SKU #

Color / Pattern Color / Pattern

Color / Pattern

Color / Pattern

POINT OF MEASURE Specs 1 2 3 4 Specs 1 2 3 4 Specs 1 2 3 4 Specs 1 2 3 4

PILLOW..CASE

LENGTH

WIDTH

TOP HEM

SIDE HEM

BOTTOM.HEM

BOX /POCKET

TOP HEM

GENERAL COMMENTS / REMARKS

2nd Floor 38-XX, Commercial Area Phase 4 Khayaban-e-Iqbal Road, DHA, Lahore - PakistanPh: +92-423-5896438, 5746442, 5743413-4 Fax: +92-423-5897665

Website: http://www.tex-craft.com

Audit Report Pages

6 OF 8

HEM


MADE UPS AUDIT REPORT

WIDTH

WIDTH

FLAT SHEET

LENGTH

FITTED SHEET

LENGTH

Number Of ..Samples Measured


CTNS

Put-up

Qty / Bal %age

(ix) Packing Details / Shipment DetailsQty presented for Inspection

CTNSPattern / Color Item / Sizes

Audit Report Pages

Units

units under stitching not packed

Units/PCS

Packed Units in Cartons

%ageQtyPO #

CTNSSKU #

Quantity Required


MADE UPS AUDIT REPORT7 8OF


FAX:+92-423-5897665TEL:+92-423-5896438, 5746442, 5743413-4


Audit Report Pages


MADE UPS AUDIT REPORT8 OF 8

Photo Record


TEL:+92-423-5896438, 5746442, 5743413-4

FAX:+92-423-5897665


Documents

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