IN-LINE AUDIT
If the production is done in more than one location,each location must be documented with the address of the supplier and the description of the work being done at each location.The In-Line Inspection is to be performed when 10 to 20 % of the production lot is in process,and enough garments are completed to perform the measurements.One or more In-Line Inspection may be required if there are several locations of manufacturing.
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| How to Perform an In-Line Audit and Final Audit |
HOW TO PERFORM AN IN-LINE AUDIT
· Record the factory’s address where the inspection is performed.
· On the sewing floor, randomly select the proper sample size for inspection.The sample size is determined according to the inspection sampling plan and is based on the total production lot size. The production lot is defined as a collection of units of product which,as far as practicable ,includes units of product in a single style and fabrication,manufactured under essentially the same conditions and at essentially the same time.Some of the garments that you inspect will be in complete ,but when you perform the measurement inspection ,these garments need to be completely sewn ,yet may not be trimmed ,pressed or inspected by in-house QC.
· Inspect exactly the number of units called for in the sampling plan.The number of defects must be tallied and the total recorded on the In-Line External Audit Report.
· Examine garments inside and out,
· All reports must be filled out in black ink.
· Inspect the garments using The Defect Tally Sheet to check off the number of defects.As you go through the sample lot measuring.
· If you find a defective unit:
o The garment / piece(s) should be set aside.
o The defect should be recorded using a defect code,with a brief description written on the report and a mark kept on the Defect Tally Sheet and totaled on the line report.
o The factory must be informed of the defect by the auditor.The factory then must explain the defect to the responsible operators and show them the proper method of correction.
o The garments must be 100% inspected and defects must be separated out and repaired or discarded.
o If the defect is not repairable or salvageable, the bundle or group must be sorted and defective pieces discarded.
o To ensure that the problem has been corrected,the inspector will re-audit the corrected garments.
o Rejection of a sample lot can be based on the general quality or measurements Final Audit.
· If an In-LineAudit fails then another inspection must be scheduled to ensure that the problem is resolved.The second inspection should be used the Level 2 sampling plan.If this second inspection fails BUYER must be informed of the issue immediately in order to determine this disposition (Accept or Reject) of the product.
FINAL AUDIT
OBJECTIVE: BUYER requires a Final Audit to ensure we are shipped 1st quality products that meet or exceed BUYER standards.
REQUIREMENTS
· A Final Audit is required for every Purchase Order
· The Final audit is conducted when a minimum of 80% of the shipment is packed, including all colors and sizes, and remaining 20% is complete (sewn, pressed, finished and repairs are complete)
· Initial audits conducted using a 2.5 AQL – Level I Normal Inspection
HOW TO PERFORM A FINAL AUDIT
· At the final pressing and packaging stage, randomly select the proper amount of piecesin the sampling size .The sample size is determined according to the inspection sampling plan and is based on the total production lot size. The production lot is defined as a collection of units of product which,as far as practicable ,includes units of product in a single style and fabrication,manufactured under essentially the same conditions and at essentially the same time.If some garments are being produced for a later shipment at a later time ,then these must be considered a separate production lot.If several small quantity purchase orders are being produced from the same roll of fabric at the same time ,these can be considered one lot.
· Pull from packed garments, randomly from the top, middle and the bottom of the box.
· Examine garments inside and out,
· Inspect exactly the number of units called for in the sampling plan.The number of defects must be tallied and the total recorded on the Final Audit Report.
· All reports must be filled out in black ink.
· A shipment can be rejected based on the general quality and measurements section of the audit.Review any problems from the in-line inspection and be certain that they were corrected.Inspect the garments using the following criteria as a guideline.You may use The Defect Tally Sheet to check off the number of defects as you go.
· If you find a defective unit:
o The garment / piece(s) should be set aside.
o The defect should be recorded using a defect code,with a brief description written on the report and a mark kept on the Defect Tally Sheet and totaled on the Final report.
o The factory must be informed of the defect by the auditor.The factory then must explain the defect to the responsible operators and show them the proper method of correction.
o The garments must be 100% inspected and defects must be separated out and repaired or discarded.
o If the defect is not repairable or salvageable (so that there is no obvious evidence of repair), the bundle or group must be sorted and defective pieces discarded.
o To ensure that the problem has been corrected, the inspector will re-audit the corrected garments.
o Rejection of a sample lot can be based on the general quality or measurements Final Audit
· If a Final Audit fails BUYER must be informed of the issue immediately in order to determine this disposition (Accept or Reject) of the product. Samples must be sent to HQ
BINDING RULE :
BUYER reserves the right to request 100% inspection at any time.If the product fails from second Final Audit BUYER. reserves right to require third party 100% inspecton at manufacturer / agency expense.
MEASURE GARMENTS
1. Measure 1 garment per size for all measurement points
2. Only Critical Points of Measure are required on remaining samples
3. Document measurements on the BUYER QA Page
Inspect every garment in the sample for accurate and consistent stitch,seams and construction.
· Shade Band / Trims Check all sampling plan units against the Approved Shade Band and Trim Card
· Garment Packaging and Labeling Check packaging and labeling of all sampling plan units against Spec Pack
2. Only Critical Points of Measure are required on remaining samples
3. Document measurements on the BUYER QA Page
VISUAL AND CONSTRUCTION INSPECTION
Inspect every garment in the sample for accurate and consistent stitch,seams and construction.
- See Defect Zones for specific product being audited
- Identify any quality defects with colored masking tape or stickers
- Inspection of the garment should not be stopped if a defect is found
- A garment with multiple defects will count as only 1 defect in the total
· Shade Band / Trims Check all sampling plan units against the Approved Shade Band and Trim Card
· Garment Packaging and Labeling Check packaging and labeling of all sampling plan units against Spec Pack
CARTON AUDIT PROCESS
Ensure all cartons meet specifications and have no holes, dents or other damage
Corrugated cardboard
Minimum bursting strength – 45 kgs /sq cm
Maximum weight 20kgs
Protective cardboard top & bottom of carton (if applicable)
Sealed top and bottom with 8cms patterned vinyl or paper reinforced tape
No staples or strapping
Verify total carton count of packed goods against packing list
Check placement, accuracy and legibility of all carton marking
Verify packed count against carton label for 10% of the cartons, selected at random
If a defect is found, increase sample to 20%
If a second defect is found, 100% inspection must be performed
IN-LINE & FINAL AUDIT FORM
Used to document and communicate results of theIn-Line and Final Audit.
REQUIREMENTS
Complete a form for each Audit performed. Submit completed form to Head Quarter Product Group within 24 hours of Final Audit
Buyer business philosophy is based on providing the best possible service, selection, quality and value.The quality has always been a cornerstone of the way we do business. We recognize that providing “quality” is a continuous process that does not end with the shipment of the product to our stores, but must include the customer’s total satisfaction with every purchase.
We support this philosophy by developing private label merchandise with the overall goal of providing superior, exclusive product at the best price. We recognize that our success in accomplishing this goal is based on the strength and quality of the relationship with our supply chain partners. As a result, we seek partners who share our commitment to provide quality and value driven products through continuous collaboration and use of best practice methods.
There are three areas of consideration to ensure product quality meets or exceeds our expectations to provide fit, visual and physical quality merchandise to our customers. These include our Testing Program, Patterns and Quality Manufacturing Process. This Manual has been developed to communicate the requirements of each of these areas. While we understand that processes may vary from supplier to supplier, the information presented, represents Buyer minimum requirements for factory quality processes and further supports our end quality expectation of achieving an Acceptable Quality Level of Final Audit
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