STANDARD OPERATING PROCEDURE

QUALITY DEPARTMENT
The objectives of Quality department is an ensuring the quality requirements of buyer at each and every stage of
production process.

The objectives of Quality department are as follows:

 To ensure the Customer Satisfaction through an acceptable quality
 To ensure the quality of products through First Garment Inspection at all stages of production process
 To achieve First Time Pass in final inspection
 To reduce customer complaints / claims / garment rejections through effective quality monitoring
 To ensure the certification requirements during all stages of quality check
 To ensure the product safety practices at all stages

2.1. Stages of Quality Inspection in JRAJ to ensure Quality:

 Quality verification of goods received at the premises

 Quality verification of fabric / accessories
 Quality verification of all buyer samples, size set & pattern
 Quality verification while sewing
 Quality verification while stitched garment delivery
 Quality verification while printing
 Quality verification while printed goods delivery
 Quality verification while embroidery
 Quality verification while embroidered goods delivery
 Quality verification while finished goods
 Quality verification of packed garments
 Quality verification of Customer Property (items for production)
 Verification of the product safety

1
4.2.1. Manager Quality Assurance

R. No. Roles & Responsibilities Frequency

1 Monitor whether the quality of received items are ensured by respective QA as per
buyer requirement against each order Daily
2 To ensure all inspections are done by QA in various departments Daily
3 To reduce quality complaints and quality claims through regular quality assurance Daily
4 To ensure customer satisfaction in terms of quality Daily
5 Maintain history of identified problems with various solution options and best solution Daily
6 Provide necessary guidelines to QA to reduce garment rejection due to quality in all
stage of production Daily
7 Responsible to deliver the goods without any quality complaints Daily
8 Receive & analyze customer complaints, claims and negative customer feedback
related to quality along with Merchandising and concern HODs and update
Customer Complaint Register and Customer Complaint Corrective &
Preventive Action On required
9 Within 2days
from complaint
received date
Analyzing the customer complaints and send reply to concern Merchandising team
from
Merchandising
dept.
10 to ensure the daily rejections from the production departments are sent to the
Inventory seconds store Daily

4.2.2. Incharge inline sewing

R. No. Roles & Responsibilities Frequency

1 Ensure the top sample are taken from the first day production and handover to the
concern merchandiser Daily
2 Ensure there is no re check happening in the AQL Inspection due to poor quality Daily
3 Ensure that all the checkers are checking clockwise direction which is implemented
in all checking area Daily
4 Regular monitoring in sorting process every day Daily
5 Monitoring all QA responsibility in sewing Daily
6 Ensure the daily oil leakage report Daily
7 Filtering the all types of defects in the line by allocating spot checkers for critical
operations Daily
8 Ensure there are no sewing defects in the end line in order to achieve first time pass
in all inspections Daily
9 Monitoring every one hour the rework / rejection report and take CAPA Daily
10 Monitoring every two hours 7.0 inline report and take effective CAPA Daily
11 Reporting to the manager quality for all quality related issues and steps taken
immediate action On required
12 Every day monitoring the air cleaning of the machines Daily
13 For all cover all styles (with shoe styles) should be reversed after
buttoning process then send to end line checking to ensure that there is no
snap ring inside the garments especially in shoes, which is more critical
to wearer All orders
14 Ensure The FGI Carried Out Effectively by the sewing QA ,In order to avoid
rework and rejection Daily
15 To do effective Pre planning to ensure the Quality of the cut panel Accessories When new style
Before starting the line. taken

2
 16 Ensure the composition of the fabric with respect to the label and tech pack by
applying force on the fabric manually( stretch) All orders

4.2.3. QA - Sewing

R. No. Roles & Responsibilities Frequency

1 Quality issue finding in sewing should be communicated to Merchandising and
quality departments within 20min from the quality issue finding time Daily
2 First garment report (compared with PP Sample) should be done at the time of first
output pieces Daily
3 IPC, Style meeting, Measurement checklist (Style, colour, size) should be done
within 1 hour from line output. Daily
4 Inline checkers should be allocated before starting line as per style Daily
5 Rejection (both cut panel and garments) should be verified and sorted immediately Daily
6 Check list should be followed in daily basis Daily
7 Ensure the 5 min meeting to input, checking, inline Daily
8 Don’t run the line without sample pcs Daily
9 Every line should be displayed the sample pcs & 1st garment pcs Daily
10 All sequence of operations should be ready for ironing Daily
11 Give the instruction to the input about in out of the garment Daily
12 Check & use the clips & guides properly Daily
13 Allocate snap checker for each m/c Daily
14 Rework & rejection analysis to ensure the Quality of the Snap Daily
15 All bundles should be tie tightly. Avoid stain Daily
16 Cross check the Passed pcs hourly once. In the checking Table Daily
17 To check, for any operators change In the line ensure the Quality . Daily
18 All reports should be move to red tag area with red tag card with in one day from the
OC no are dispatched Daily
19 Ensure neck stretch and drawstrings measurements are followed as per buyer
requirements. Every 2 hours
20 Ensure there is no fusing / emb frame impression mark in the garment Daily
21 Ensure there is no recheck happening in the AQL Inspection due to poor quality Daily
22 Ensure that there is no magic pen (Air erasable/ Water erasable) used in production Daily
23 Ensure all the set orders (top &bottom) are matched with size and lot Daily
24 Ensure that all the checkers are checking clockwise direction which is implemented
in all checking area Daily
25 When new style
Style meeting should be conduct with accessories approval card
started
26 Ensure there is no oil leakage in the sewing machine, daily before starting the
production Daily
27 Ensure that all the operations do effective 7.0 system inline report every two hours
and take CAPA
28 Velcro at sharp raw edge , allocated inline checking monitoring every operator at bib
style Daily
29 For all cover all styles (with shoe styles) should be reversed after buttoning process
then send to end line checking to ensure that there is no snap ring inside the
garments especially in shoes, which is more critical to wearer All orders
30 Ensure the composition of the fabric with respect to the label and tech pack by
applying force on the fabric manually( stretch) All orders

3
4.2.4. Senior QA AQL

R. No. Roles & Responsibilities Frequency

1 Receive the DC from sewing department Daily
2 To conduct AQL inspection at normal level 2, limit major-1.5, minor-4. Daily
3 To conduct inspection for accountability of the garments in the selected bundles Daily
4 If AQL inspection pass move to the finishing section. Daily
5 If AQL inspection are fail inform to in charge sewing in line for further action Daily
6 Inform if any critical defects found during inspection to the manager quality for further Daily
action
7 Responsibilities for first time pass in the final in the final inspection. On required

4.2.5. Product safety officer

R. No. Roles & Responsibilities Frequency

1 To ensure all the product safety products are carried out very effectively in all the Daily
stages
2 Monitor and ensure the control of machine needle done effectively in the sewing Daily
3 Monitor and ensure the control of sharp tools done in all the department very Daily
effectively
4 Monitor and ensure the control of small parts are done effectively Daily
5 Monitor and ensure the needle detection procedure done effectively for all the styles Daily
after packing
6 Monitor and ensure the neck stretch and drawstrings procedure done effectively. Daily
7 Monitor and ensure the control of damaged snaps and disposals procedures Daily
followed properly
8 Training program s/d be conducted regarding PSO for all related QA and executives Monthly once

4
4.2.6. Incharge finishing

R. No. Roles & Responsibilities Frequency

1 Before starting the bulk ironing and Packing Ensure that packing is going as per
approved packing Daily
2 While doing the first garment inspection must ensure hand feel(fabric softness) of
bulk garments with as per original sample, especially for garment washing styles Daily
3 Making first garment inspection against the FGI standard and conducting a meeting
with ironing packing staffs to convey and correct the identified comments Daily
4 Daily morning before starting work must conduct a meeting to read and explaining
the daily work & responsibilities to ironing ,packing , accessories and box auditing
staffs Daily
5 Ensure that there is no garments are stocking / dumping in ironing packing area for
any process. If any deviation found in this regard must communicate to ironing
packing in charge, manager Quality and for taking action Also mailing the sorting
details every day Daily
6 Educate and ensure that all styles are packing as per line wise packing system Daily
7 Ensure that packing list are prepared for every order before start the packing and
once after an every carton is completed the carton marking must be filled or carton
stickers must be stuck at the same time with all details are filled.( i.e., carton number,
Po #, Invoice Number, weight, Quantity etc...,) Daily
8 Ensure that all packed garments should be put in to the needle detector machine to
ensure that there is no needle or metal parts in the garments and update the details
in metal contamination record Daily
9 Ensure the metal calibration check as per the given time period and updated details
in the metal calibration record Daily
10 Ensure that there is no embroidery/ fusing impression mark in the garment Daily
11 Ensure that all set orders ( top & bottom) are matched size and color Daily
12 Must ensure that there is no tag shot holes at any part of garment for every order,
also whenever start the packing should give sufficient awareness to all packing
staffs regarding the tag shot holes Daily
13 Ensure the 100% presentation check dune Effectively by the presentation QA in
order achieve first time pass in the final inspection. Daily
14 The 100% Presentation check report should be reported to the manager Quality for
further Action Daily

4.2.7. Incharge inspections

R. No. Roles & Responsibilities Frequency

1 To ensure all the receiving and final inspection are done by QA in all stages in
Various department (sample , fabric , accessories , printing , EMB , cutting ,final
inspection ) Daily
2 To prepare And For word final inspection schedule to the QA Daily
3 Performance evaluation for the Final Random Inspections. Monthly
4 Adopting the updated standards of FRI procedures during the inspection in the
accepted quality level (AQL) Daily
5 To Ensure and confirm all the samples like size set, pre production, reference,
production and shipment samples before sending to buyer Daily
6 To ensure the Box Audit performed by QA Final inspection for all (third party
inspected orders) orders. Daily
7 Before performing the Final Inspection, QA Final Inspection shall submit the samples
to Lab for Final Random Testing. On required
8 Acquire advise from Manager Quality during critical issues and act accordingly On required

5
4.2.8. QA – Accessories

R. No. Roles & Responsibilities Frequency

1 After Accessories In housed , submitting the random Accessories samples through
the trims Approval card to merchandising Department for Approval and lab for testing
purpose. Daily
2 Communicating the daily accessories / general accessories receipt details to all
concern departments Daily
3 Performing the accessories receiving inspection and update the result in FIT ERP Daily
4 Communicating the accessories rejection information to the Manager Quality for
further action and communicate the accessories rejection details to all concern
departments On required
5 Supplier DC's / QC approved trims cards Daily

4.2.9. QA fabric

R. No. Roles & Responsibilities Frequency

1 After fabric In housed, submitting the random fabric samples through the trims
approval card to merchandising department for approval, and lab for testing purpose. Daily
2 To ensure the finished fabric / washed fabric and washed garments quality are as
per original swatch or original garment, especially for all washing
styles should ensure that the hand feel or softness of the fabric and garments Daily
3 To submit the random fabric sample to Lab department for testing Daily
4 To conduct the 4 point Fabric Inspection for in-housed fabric along with lab testing Daily
report and update the result in ERP
5 To analyze the quality issue and report to the Manager Quality Fabric in charge and On required
manager quality with Corrective and Preventive Action
6 To ensure the accountability of the received fabric matches with Order quantity On required
7 Ensure the Fabric are kept for relaxing as per the relaxing standard after the Daily
inspection
8 During the fabric inspection, check the shade, dia, gsm found as per our requirement Daily
9 If inspection is failed, circulate to concern departments (procurement fabric, Daily
inventory fabric, merchandising and ppm depts.) through mail
10 Rejection information pass to fabric task owner to move to next process Daily
11 Pre-shrink lots need to check (shade, dia, gsm, pH, length, width, smell) Daily
12 After complete the fabric inspection, finished fabric inspection reports need to file Daily
13 After AOP fabric in-housed check the print size, design with original swatch or pcs Daily
14 For all the shortage fabric lots fabric inspection lab testing submission should be
completed within an hour from fabric receiving time daily

6
4.2.10. QA cutting

R. No. Roles & Responsibilities Frequency

1 Should not make lay without sample garment. s/d have sample garment for all
Cutted colours and styles Daily
2 To ensure the shade & hand feel of the fabric and garment type as against the
original garment Daily
3 s/d not start cutting without approved seal in the pattern Daily
4 air cleaning in the stickering machine s/d done before start stickering process and
then bundles s/d cross checked if comes any sticker oil Daily
5 To conduct first garment inspection in all stages (Laying , Cutting ) Daily
6 To check cut panels notches, shape and measurements are need to meet as per
pattern Daily
7 s/d ensure whether the rejected cut panel s/d moved to red tag area on the same
day of the rejection date Daily
Daily
8 s/d ensure the job order bundles are covered and tagged properly while issuing to
the Supplier Daily
9 Before start the cutting should check the pattern especially which is joined pattern or
pasted pattern Daily

4.2.11. QA Embroidery

R. No. Roles & Responsibilities Frequency

Performing the random cut panel inspection to ensure the shape and notches are Daily
1
center
2 Ensure the lab result of threads, accessories starting bulk production. Daily
conducting the first garment inspection by using first garment inspection against FGI Daily
3
stander if FGI is passed approve is start bulk production
analysis the daily rejection and ensure that the rejected cut panel or garment are Daily
4
sent to second store with in same day.
5 Ensure there is no emb frame impression mark in the garment Daily
Ensure that there is no frame using for small embroideries for avoiding the frame Daily
6
impression marks

7
4.2.12. QA Printing

R. No. Roles & Responsibilities Frequency

1 Per forming All random cut panel inspection to ensure the shape out notches are
center.
2 Responsible to conduct FGI for all orders Daily
3 Ensure the rejected garments should not be mingled with the good garments through
separate storages Daily
4 Handover the rejected garments to Red tag Area Same day
5 Bring quality related all issues immediately to the knowledge of Manager Quality /
In-charge Printing for timely decision making On required
6 To print the one pcs from bulk and to check the original or approved swatch Daily
7 To compare the original pcs (colour, measurement, print colour, size grading and Daily
positions)
8 After completing the print to check the temperature ,time and speed with help of Daily
curing machine and to conform the fabric and printing shade is not change and then
start the bulk
9 To check the heat, stroke and timing with using fusing. Then to check Daily
the Bed mark and Air point
10 To test the lab for each bulk orders Daily
11 While doing shortage process should follow as like bulk process (should refer the Daily
original pcs and job card)
12 Gumming process should done based on fabric (fleece – 1 time for 2 rounds, jersey / Daily
inter lock – 1 time for 4 rounds)
13 While re-start the process (after found any mistake), should print with available bit. Daily
After verifying the quality only, should print with the original garment
14 Should select and use the pallet size based on the garment / panel size Daily
15 FGI should done against size of the garment and its print size Daily
Before proceeding the bulk printing, should do printing process in waste fabric after Daily
16
that only should proceed the bulk printing
17 Switch on the heater while start the production Daily
18 Switch off the heater after bulk printing completion Daily
Should ensure the sticker placement (inside or outside of the panel) before start bulk Daily
19
printing
Bundle number and continue number should not get changed while printing process. Daily
20
This should be ensured to all bundles (M&R, table and manual)
Print shade should be ensured compare with original garment at every one hour and Daily
21
prepare report

8
4.2.13. QA Sample / sizeset

R. No. Roles & Responsibilities Frequency

To get complete details like mmt chart, tech pack, trims details, original garments if Daily
1
any from concern merchandisers
To ensure the requirements are properly transformed to sample in-charge, pattern Daily
2
master & tailors
Make sure all the tailors have calibrated measuring tape and the mmts are verified Daily
3
at each operation by tailor
To ensure the printed / embroidered panels are correct as per buyer requirement Daily
4
before issue to sewing
5 Make sure all the trims are correctly used as per tech pack Daily
6 Make sure all sleeve hem should be open hem operation Daily
7 Discuss with Manager Quality if any difficult operation to make it easy for production On required
Make sure the sample ironing master having calibrated measuring tape and he Daily
8
verified the mmts during ironing, make him aware DO NOT IRONING styles
Make sure the clips & guides are properly used for the appropriate styles / Daily
9
operations
Any quality rejection, make sure the same will be delivered to seconds store on the Daily
10
same day
11 Make sure only the pre-shrink fabrics are used for size set sample making Daily
12 Approving patterns against buyer specified measurement spec Daily
13 Conduct size set and all samples inspection of all samples against approved pattern Daily
14 Acquire advise from the Manager –Quality during critical issues and act accordingly Daily
15 Ensure inspection carried out within the STS Daily
16 For repeat order, the old and new pattern should be checked for quality Daily
17 The new approved pattern should be issue and old pattern should be destroyed Daily
18 Ensure the quality of all samples sending to the buyer Daily
19 Ensure the pattern measurement before sending to cutting Daily

9
4.2.14. QA Final Inspection

R. No. Roles & Responsibilities Frequency

Every day visit the job work supplier units and make first garment inspection for Daily
1 every process like cutting , sewing , printing and ironing packing then communicate
to the supplier and correct the issues at in process itself.
2 Ensure that submitting random samples to lab testing before final inspection. Daily
3 Before final inspection ensure that the order has completed the box audit Daily
Perform the final inspection as per schedule and submit the reports to In charge Daily
4
Inspection.
Acquire advise from the in charge inspection and Manager quality during critical Daily
5
issues and act accordingly
Collect the daily inspection schedule and co ordinate with third party or buying QC Daily
6
inspection as well
Ensure that all inspected carton ( selected for inspection) boxes for every order are Daily
7
re audited

5.1. Receiving Inspection – Fabric

BP STS (working
Activity Responsibility
No. day)

Receiving the fabric in-housed information from Inventory Fabric Executive process Same day from
1
department and submitting the fabric bit for lab testing control mail date

Inspecting the received fabric by using the “Fabric Receiving Executive process
2
Inspection Report” at random inspection as per 4 point system control

If fabric inspection and lab testing reports are passed, Executive process 3days from mail
3
communicate the result to Inventory Fabric department control received date

If inspection and lab testing results are failed, shall inform to Executive process
4
Manager (PF) / Manger Quality for further action control

Taking the decision regarding to reject / rework the fabric based 1day from
5 Manager Quality
on discussion with MM, Manager – PF to proceed further inspection date

10
5.2. Receiving Inspection – Accessories

BP STS (working
Activity Responsibility
day)
No.
After accessories in-housed, submitting the random accessories
samples (new order accessories only) through the “Trims
Approval Card” to Merchandising department for approval and
Lab for lab testing purpose.
1 QA – Accessories Same day
Note:

Ensuring the quality of repeat order accessories are done by QA

– Accessories in Inventory Accessories department

Inspecting the received accessories by using “Accessories

2 Receiving Inspection Report” for each item as per the QA – Accessories
Standard

If accessories inspection and lab testing reports are passed, 3days from
3 QA – Accessories
update the result in the ERP goods received
date
If inspection and lab testing results are failed, shall inform to
Manager Quality / Manager (PA) for further action and
4 QA – Accessories
communicate the rejection information to all concern
departments

Taking decision regarding to reject / rework the accessories

based on discussion with MM and Manager – Procurement 1day from
5 Manager Quality
Accessories and update the final decision in the Trims inspection date
Approval Card

6 Updating accessories inspection result in ERP QA – Accessories Same day

11
5.3. Receiving Inspection – Printing

BP STS (working
Activity Responsibility
No. day)

Performing the random cut panel inspection to ensure the shape

1 QA – Printing Before printing
and notches are centre

2 Ensuring the lab result of printing before staring bulk production QA – Printing

Conducting the First Garment Inspection by using “First Same day

3 Garment Inspection report” against “FGI Standard”. If FGI QA – Printing
inspection is passed, approve to start bulk production
One day from
Submitting the random samples to Lab testing from bulk
4 QA – Printing samples
production
submission date
If lab test is passed, shall approve to issue the goods to next
5 process and instruct to DEO in Printing dept. to update the result QA – Printing / DEO
in ERP
Same day
If lab test is failed, shall inform to the Manager Quality for further
6 QA – Printing
action

Taking the decision regarding to reject / rework the print based Within one day
7 Manager Quality
on discussion with MM, In-charge Printing to proceed further inspection date
Same of rework
8 After rework, resubmitting the pieces to Lab for retesting QA – Printing
completion date
If re lab tested report is passed, shall approve to move the
10 goods to next process and instruct to DEO in Printing dept. to QA – Printing / DEO Same day
update the result in ERP
If, lab test report is failed, discuss with concern Merchandising
11 Manager Quality Same day
team, MM, In-charge Printing regarding to proceed further
As per details received from QA – Printing, updating the result in
12 DEO Same day
ERP
Hand over the rejected goods to Inventory Seconds store and
13 send mail to Production, Merchandising, Procurement, QA – Printing Same day
Inventory, PPM and Quality departments

12
5.4. Receiving Inspection – Embroidery

BP STS (working
Activity Responsibility
No. day)

Performing the random cut panel inspection to ensure the shape Before
1 QA – Embroidery
and notches are centre embroidery

Ensuring the lab result of embroidery before staring bulk

2 QA – Embroidery
production
Same day
Conducting the First Garment Inspection by using “First
3 Garment Inspection report” against “FGI Standard”. If FGI QA – Embroidery
inspection is passed, approve to start bulk production

Ensuring to hand over the rejected goods to Inventory

4 QA – Embroidery Same day
Seconds store on daily basis before 6 pm

5.6. Size set Inspection

BP STS (working
Activity Responsibility
No. day)

Receiving size sets from Cutting, department and Concern After PP

1 Suppliers and samples from Merchandising and concern QA – Size set meeting (size
Suppliers set only)

Receiving order tech packs with buyer comments from concern

2 Merchandising team and inspect the received samples with QA – Size set Same day
pattern

Approving all samples (size set, pre production, reference,

3 production and shipment samples) before sending them to buyer Manager QA – FI
(both in-house and supplier orders)

Performing the size set inspection for pattern approval by using

Within 1day
4 the “Size set Inspection Report” and sample inspection by QA – Size set
from sample
using the “Sample Inspection Report”
submission date
5 If inspection is passed, shall approve the pattern and samples QA – Size set

If inspection is failed, shall ask to resubmit the pattern and

6 QA – Size set
samples

When re-submit of pattern and samples is done, the above

7 processes shall be constant, until pattern and samples get QA – Size set -
passed

13
5.7. Cutting Inspection

BP STS (working
Activity Responsibility
No. day)

Receiving the approved PPS from concern Merchandising team

After PP
1 during PP Meeting and approved pattern from Quality QA - Cutting
meeting
department

After fabric inward to cutting, conducting the first garment

During laying
2 inspection by using the “First Garment Inspection Report” QA - Cutting
and cutting
against FGI Standard

3 Ensuring the rejected items should not be mixed with good items QA - Cutting Always

5.8. Sewing Inspection – First Garment Inspection (FGI)

STS (working
BP Activity Responsibility
day)
No.
Before starting bulk production, check the approved PPS
1 garment with approved measurement spec to ensure the Floor Manager
measurement
Before starting
If found any deviation, should inform to QA – Size set, concern
2 Floor Manager bulk production
Bulk Merchandiser and Manager Quality for approval

After getting approval, approved PPS garment with approved

3 QA - Sewing
spec will be issued to respective sewing lines

Giving instruction to respective tailors to make one garment only

4 QA - Sewing
to conduct First Garment Inspection

Conducting the “First Garment Inspection” with approved 1st day of

5 QA - Sewing
PPS garment. production start
date
Communicating the comments of First Garment Inspection to all
6 Operators through “Style Meeting” and instruct them to start QA - Sewing
bulk production

5.9. Sewing Inspection – Initial Production Check (IPC)

BP STS (working
Activity Responsibility
No. day)

Conducting the IPC inspection by using the “IPC Report” for

During first
each style (50 garments) and “Measurement Check” for each
1 QA – Sewing output of 50
size (5 garments) and communicating the technical comments to
garments
respective operators

14
5.9. Sewing Inspection – Inline inspection report (7.0 report)

BP STS (working
Activity Responsibility
No. day)

Conducting the inline inspection by using the “7.0 report” for all
1 styles and communicating the technical comments to respective QA – Sewing 4 times per day
operators

5.10. Ironing & Packing Inspection

STS (working
BP Activity Responsibility
No. day)

Conducting the “First Garment Inspection” against FGI After getting

2 QA - Finishing
Standard and communicate the comments to I & P Workers pack approval

Doing calibration in metal detector machine 9 times in a day by

3 QA - Finishing 9 times in a day
using the “Needle Detector Calibration Log”

Before set garments inside the carton box, place the garments
into metal detector machine to ensure no needle parts within the
4 QA - Finishing Always
garments (for children and babies style) and update the
inspected details in the “Metal Contamination Record”

5.11. Needle Management

STS (working
BP Activity Responsibility
No. day)

1 Maintaining the “Needle Stock Register” Needle Controller Daily

Immediately
After verification of the broken and bended needles, provide new
after receiving
2 needle to concern tailors and update them in the “Needle Needle Controller
the damaged
Broken Register” and “Needle Replacement Register”
needle

15
5.12. Box Audit Inspection and Final Inspection

BP STS (working
Activity Responsibility
No. day)
Before Final Inspection, submitting random samples to Lab for Incharge Before Final
1
Final Random Testing workmanship Inspection
Before final inspection, conducting the “Box Audit” for all third Before Final
2 QA – FI
party inspected orders to ensure quantity and packing methods Inspection
If box audit report is passed, approve to send the goods to Final
3 QA – FI After Box Audit
Inspection
If box audit report is failed, the goods are re-checked until get
4 QA – FI After Box Audit
passed
After Box Audit, based on information received from respective
Merchandising team, Scheduling for Final Inspection and Manager QA – FI /
5 After Box Audit
conducting final inspection by using the “Final Inspection QA – FI
Report” and submitting the report to the Manager Quality
If final inspection result is passed, approve to send the goods to
6 Manager QA – FI
buyer Same day
7 If final inspection result is failed, inform to Manager Quality Manager QA – FI
Discussing with Manager Production, Manager Merchandising
8 Manager Quality Within a day
and CMO for further action
from inspection
Based on the discussion with respective merchandising team
9 Manager QA – FI result date
and/or with respective buyers, re-inspection shall be scheduled
If re-inspection is passed, the goods are moved to send to
10 Manager QA – FI
respective buyer Same day of
If re-inspection is failed, based on discussion with MM and CMO inspection date
11 Manager Quality
take further action

NOTE:

All Final Inspections are conducted by BUYING OFFICE team only, except for the buyer who wants to do the Final
Inspection by third parties like SGS, ITS, BVCPS, TUV etc.,

16
S. Format Rev. Retention Mode of the
Format Name Date
No. Number No. Period record

1 Sample Inspection Report FMT/QA/28 00 02/01/2019 6 months hardcopy

2 Size Set Inspection FMT/QA/04 00 02/01/2019 6 months hardcopy

Receiving Inspection
3 Report- Fabric FMT/QA/03 00 08/12/2017 6 months hardcopy

4 Fabric relaxation report FMT/QA/34 00 20/08/2018 6 months hardcopy

5 Trims Approval Card FMT/QA/01 00 20/08/2018 6 months hardcopy

Receiving Inspection
6 Report - Accessories FMT/QA/02 00 20/08/2018 6 months hardcopy
First garment inspection -
7 cutting FMT/QA/22 00 12/10/2018 6 months hardcopy

8 Cut panel check sheet FMT/QA/35 00 12/10/2018 6 months hardcopy

Cut panel inspection report
9 (measurement) FMT/QA/46 00 20/08/2018 6 months hardcopy
First garment inspection -
10 printing FMT/QA/25 00 12/10/2018 6 months hardcopy
First garment inspection -
11 Embroidery FMT/QA/26 00 12/10/2018 6 months hardcopy
Production preplanning
12 check sheet FMT/QA/38 00 08/12/2017 6 months hardcopy
First garment inspection -
13 sewing FMT/QA/23 00 08/12/2017 6 months hardcopy

14 Style Meeting ,PP meeting FMT/QA/06 00 08/12/2017 6 months hardcopy

15 IPC Report FMT/QA/07 00 08/12/2017 6 months hardcopy

16 Measurement Checklist FMT/QA/08 00 08/12/2017 6 months hardcopy

Hourly snap quality check
17 sheet FMT/QA/30 00 08/12/2017 6 months hardcopy

17
S. Format Rev. Retention Mode of the
Format Name Date
No. Number No. Period record

Rework & rejection

18 analysis report FMT/QA/36 00 12/10/2018 6 months hardcopy
100 % cut panel checking
19 report FMT/QA/37 00 12/10/2018 6 months hardcopy

20 Pull test report FMT/QA/31 00 08/12/2017 6 months hardcopy

21 Pull test Calibration report FMT/QA/32 00 08/12/2017 6 months hardcopy

22 Damaged snap qty report FMT/QA/48 00 02/01/2019 6 months hardcopy

23 Snap statistical report FMT/QA/50 00 02/01/2019 6 months hardcopy

Damaged snap disposal
24 record FMT/QA/49 00 02/01/2019 6 months hardcopy
Daily fusing temperature
25 report FMT/QA/33 00 08/12/2017 6 months hardcopy

26 Daily check sheet FMT/QA/43 00 08/12/2017 6 months hardcopy

27 AQL report note FMT/QA/42 00 12/10/2018 6 months hardcopy

First garment inspection -
28 finishing FMT/QA/27 00 12/10/2018 6 months hardcopy

29 100 % quality check report FMT/QA/41 00 12/10/2018 6 months hardcopy

30 Carton box audit report FMT/QA/17 00 02/01/2019 6 months hardcopy

Final inspection report/
31 Measurement Checklist FMT/QA/18 00 12/10/2018 6 months hardcopy
Customer Complaint
Corrective & Preventive
32 Action Report FMT/QA/20 00 12/10/2018 6 months hardcopy
Customer Complaint
33 Register FMT/QA/21 00 12/10/2018 6 months hardcopy

18
S. Format Rev. Retention Mode of the
Format Name Date
No. Number No. Period record

34 Training record FMT/QA/44 00 12/10/2018 6 months hardcopy

Sharp tools
record(trimmers and
35 scissors) FMT/QA/40 00 02/01/2019 6 months hardcopy
Sharp tools record(tag
36 gun and tape dispenser) FMT/QA/45 00 02/01/2019 6 months hardcopy

37 Needle stock register FMT/QA/12 00 08/12/2017 6 months hardcopy

38 Broken needle record FMT/QA/13 00 08/12/2017 6 months hardcopy

Needle replacement
39 record FMT/QA/14 00 08/12/2017 6 months hardcopy
Tag gun needle
40 replacement record FMT/QA/47 00 08/12/2017 6 months hardcopy
Needle detector calibration
41 log FMT/QA/15 00 08/12/2017 6 months hardcopy
Metal detection
42 record(bulk) FMT/QA/16 00 08/12/2017 6 months hardcopy
Metal detection record(in
43 line) FMT/QA/51 00 08/12/2017 6 months hardcopy

44 Fusing bond report FMT/QA/52 00 02/01/2019 6 months hardcopy

45 Neck stretch report FMT/QA/53 00 02/01/2019 6 months hardcopy

46 Drawstrings check report FMT/QA/54 00 02/01/2019 6 months hardcopy

Bobbin thread control
47 report FMT/QA/55 00 02/01/2019 6 months hardcopy

48 7.0 inline report FMT/QA/56 00 02/01/2019 6 months hardcopy

Note:
 After the period of retention, the due documents will be disposed.
 The disposal of other certification related documents will be done against particular certification requirement

S. Annexure Rev. Retention Mode of the

Annexure Name Date
No. Number No. Period record

1 Product safety practice

19
 7.1. Receiving Inspection – Accessories

 After receiving the accessories the QC will prepare the trims card (taking samples from all received) of
accessories).
 Getting approval from concern merchandiser.
 Performing inspection against the approved trims.
 As per the below standard the inspection will be carried.

S. Parameters to be
Item Random sampling Standards
No checked
5% of the received
Thread Colour As per pp sample
quantity
Sewing thread Colour Matching to fabric
1 Colour fastness Rating 4
Visual appearance 5 defect/100mtr
Ply As per requirement
Embroidery thread Colour fastness Rating 4
10% of the received
Label Sewing allowance Visual appearance
quantity
2 Brand label Shade Visual
Wash care label Size As per pp sample
Printing matter As per order sheet
5% of the received
Button Colour fastness Rating 4
quantity
5 nos for color
3 Size Difference not allowed
fastness & pull
Crack Not allowed
Shade Visual
5% of the received
Press button Size Difference not allowed
quantity
5 nos for pull test Shade Visual
4
Crack Not allowed
As per requirement from
Long poll or short poll
QAD
2% of the received
Polygon stone Design Visual appearance
quantity
5 Durability 5 washes

Shade Visual

20
 7.1. Receiving Inspection – Accessories

Random Parameters to
S. No Item Standards
sampling be checked
2% of the
Zipper Length As per requirement
received quantity
6 Fabric shade
Visual appearance rating 3-4
matching
Performance No broken, struck up
10% of the
Elastic and lace Shade Against reference3-4
received quantity
Elasticity 1.5 times - latex
7 1.7 times - lycra
Colour
As per requirement
fastness
Shrinkage +/- 5%
2% of the Visual
Tags and photo card As per requirement
8 received quantity appearance
Printed matter As per requirement
1% of the Breaking
Hangers By usage
received quantity strength
9
Size As per requirement
Model As per requirement
2% of the
Poly bag Length As per order
received quantity
10 Width As per order
Printing matter As per order
Gauge As per order
10% of boxes
Carton box from the received Strength GSM
11 quantity
Ply As per requirement
Appearance As per requirement
5% of the
Size Ring Colour As per requirement
received quantity
12 Model As per requirement
Size As per requirement
Print matter As per requirement

21
 7.2. Receiving Inspection – Fabric
 Check the received fabric quality as per below standard
Parameters to be
S. No Item Standards
checked
COLOUR
Dyed fabric RATING 4
FASTNESS
CHANGE OF
RATING 4
SHADE
RUBBING RATING 4
1 VISUAL
APPERANCE 21 Points/100 yards
(Defects)
SHRINKAGE AS PER BUYER REQUIREMENT
TWIST AS PER BUYER REQUIREMENT
GSM + 5%

7.3 Workmanship Standard

 Check the quality of the garments as per below standard
Random Parameters to be
S. No Inspection type Standards
sampling checked
1 Size set 1 piece / size Measurement As per buyer requirement
100% No. of lays As per standard
As per original size set
2 Cut panel in-line 100% Pattern
pattern
100% Marking As per CAD
5 pieces /
Measurement As per buyer requirement
3 Sewing IPC operator / day
50 pieces / style Workmanship As per PPS

22
 7.4. First garment inspection – Cutting

The first output of the garment from the Cutting is checked against the buyer approved PPS
Sample for any defects / deviations. This checking process is known as FIRST GARMENT
INSPECTION (FGI)

The defect / deviation comments of the FGI are taken to the knowledge of the respective
workers for corrective & preventive action at the beginning stage of the production.

The main objective of the FGI is the garment should reflect the same as the approved PP
Sample & in order to control cost & time wastage due to rework & rejections.

S.No AREA PARAMETERS TO BE CHECKED STANDARD

* Fabric Type As per the P.P.S

* Colour As per the P.P.S

* GSM As per the Requirement

* Dia As per the Requirement

* Lay Length As per the CAD Mark

1 LAY
SPREADING * Within / Roll to Roll
Not Acceptable
Shade variation

* Lay Height As per the Lay standard

* Lot Mixing Not Acceptable

* Fabric Defect As per the 100 % Fabric roll Checking Report

* Pattern As per the Quality approval pattern

* Number of Parts As per the CAD Mark

2 CUTTING
* Cutting Shape As per the Approved Pattern

* Notches As per the Approved Pattern

* Measurement As per the Approved Pattern

23
 7.5. First garment inspection – Sewing

The first output of the garment from the production are checked against the buyer
approved PPS & measurement spec for any defects/deviations. This checking process is known as
The defect / deviation comments of the FGI are taken to the knowledge of the respective
workers for corrective & preventive action at the beginning stage of the production.
The main objective of the FGI are, the garment should reflect the same as the approved
PP sample & in order to control cost & time wastage due to rework & rejections.

S.NO AREA PARAMETERS TO BE CHECKED STANDARDS

* TYPE OF FABRIC AS PER THE PPS

* SHADE AS PER THE PPS

* GRAIN LINE STRAIGHT

1 FABRIC
* GSM AS PER THE REQUIREMENT

* HAND FEEL AS PER THE PPS

* FABRIC DEFECT NOT ACCEPTABLE

* DESIGN AS PER THE PPS

* COLOUR AS PER THE PPS

* GRADING AS PER THE REQUIREMENT

2 PRINTING
* MEASUREMENT AS PER THE REQUIREMENT

* TISSUE PAPER FOR ALL TYPES OF STICKY PRINTS

* PRINTING DEFECT NOT ACCEPTABLE

24
 7.5. First garment inspection – Sewing
S.NO AREA PARAMETERS TO BE CHECKED STANDARDS

3 EMBRIODERY * DESIGN AS PER THE PPS

* COLOUR AS PER THE PPS

* GRADING AS PER THE REQUIREMENT

* MEASUREMENT AS PER THE REQUIREMENT

* LINING AS PER THE REQUIREMENT

* STITCH DENSITY AS PER THE PPS

* EMBRIODERY DEFECT NOT ACCEPTABLE

4 SEWING * STYLE AS PER THE PPS

* SPI AS PER THE PPS / REQUIREMENT

* TYPE OF STITCH AS PER THE PPS

* MEASUREMENT AS PER THE REQUIREMENT

* NEEDLE HOLES NOT ACCEPTABLE

* RUNNING NUMBER STICKER AS PER THE REQUIREMENT

* SEWING DEFECT NOT ACCEPTABLE

25
 7.5. First garment inspection – Sewing

S.NO AREA PARAMETERS TO BE CHECKED STANDARDS

* TYPE OF THE THREAD AS PER THE PPS

5 THREAD * SHADE AS PER THE PPS

* PLY AS PER THE REQUIREMENT

* CONTENT AS PER THE REQUIREMENT

* BARCODE NUMBER AS PER THE REQUIREMENT

6 LABELS * WASHCARE INSTRUCTIONS AS PER THE REQUIREMENT

* PO NUMBER AS PER THE REQUIREMENT

* PLACEMENT AS PER THE REQUIREMENT

* SHADE AS PER THE PPS

* DESIGN AS PER THE PPS

* SIZE AS PER THE PPS

BUTTONING /
7
SNAPPING
* PULL TEST AS PER THE REQUIREMENT

* PLACEMENT AS PER THE REQUIREMENT

* DEFECTS NOT ACCEPTABLE

26
 7.6. First Garment Inspection – Embroidery

The first output of the garment from the embroidery is checked against the buyer approved PPS
Sample for any defects / deviations. This checking process is known as FIRST GARMENT INSPECTION (FGI)

The defect / deviation comments of the FGI are taken to the knowledge of the respective workers for
corrective & preventive action at the beginning stage of the production.

The main objective of the FGI is the garment should reflect the same as the approved PP Sample & in
order to control cost & time wastage due to rework & rejections.

S.No AREA PARAMETERS TO BE CHECKED STANDARD

* Lab Test result (Fastness) As per the Requirement

* Design As per the P.P.S

1 EMBROIDERY * Size grading As per the P.P.S

* Design Color As per the P.P.S

* Foam Quality As per the P.P.S

* Scissor cut Not Acceptable

2 TRIMMING
* Foam removing As per the P.P.S

27
 7.7. First Garment Inspection – Printing

1) Before starting bulk printing for every order should perform the first garment inspection such as color,
size, grading, position and style as required as original garment, approved swatch and tech pack.

2) After completing the printing and before start the curing process or fusing to check and confirm the
temperature, timing, pressure bed mark and speed of the machine according to the requirement.

3) Should check the bulk print shades for every hour against original garment.

4) Should submit 2 pcs per color in every order to lab for testing and testing requirement will be
according to buyer standard.

S.No AREA PARAMETERS TO BE CHECKED STANDARD

* Dyes Recipe As per the Certified Standard

* Design As per the Original Sample

* Color As per the Original Sample

* Placement As per the Requirement

* Size group Grading As per the Requirement

1 PRINTING
* Tissue paper For all Types of Sticky prints

* Testing Report As per the Requirement

* Seating out Defects, Print merged, Stain, Shaking,

Measurement deviation, design changed, Brownish, Pallet &
All are not acceptable.
Scrapper mark, Miss print, Air holes, Overlapping mark, Fabric
ground appearance, Center out

28
 7.7. First Garment Inspection – Printing

AREA PARAMETERS TO BE CHECKED STANDARD

S.No

* Temperature As per the Job Card

2 CURING * Speed As per the Job Card

* Shade As per the P.P.Sample

* Temperature As per the Job Card

* Pressure As per the Job Card

* Second As per the Job Card

FUSHING
3 & * Stroke As per the Job Card
STICKER FUSHING
* Fusing mark Not Acceptable

* Fusing Defects Not Acceptable

* Shade As per the P.P.Sample

29
 7.8. First Garment Inspection – Finishing
The first output of the garment from the Ironing/Packing is checked against the buyer approved PPS
Sample for any defects / deviations. This checking process is known as FIRST GARMENT INSPECTION (FGI)
The defect / deviation comments of the FGI are taken to the knowledge of the respective workers for
corrective & preventive action at the beginning stage of the production.

The main objective of the FGI is the garment should reflect the same as the approved PP Sample & in
order to control cost & time wastage due to rework & rejections.

S.No AREA PARAMETERS TO BE CHECKED STANDARD

* Measurement (Before Ironing) As per the Requirement

* Measurement (After Ironing) As per the Requirement
Dark Color – (Black or Navy)
* Table cloth
Light Color- White
* Shape As per the P.P.Sample
1 IRONING * Steam Leakage Not Acceptable
* Tissue Paper For the sticky print
* Folding Size As per the Requirement
* Impression Mark Not Acceptable
* Defects Not Acceptable
* Packing Method As per the Approved Pack
* Accessories As per the Requirement
* Poly bag size As per the Requirement
* Accessories Defects Not Acceptable
2 PACKING
* Tissue Paper As per the Requirement
* Hand Gloves For light color's
* Packing Ratio As per the Requirement
* Fly, Insects, Hair Not Acceptable

30
7.9. First Garment Inspection – Sampling

S.NO AREA PARAMETERS TO BE CHECKED STANDARDS

* TYPE OF FABRIC AS PER THE REQUIREMENT
* SHADE AS PER THE REQUIREMENT
* GRAIN LINE STRAIGHT
1 FABRIC
* GSM AS PER THE REQUIREMENT
* HAND FEEL AS PER THE REQUIREMENT
* FABRIC DEFECT NOT ACCEPTABLE
* DESIGN AS PER THE REQUIREMENT
* COLOUR AS PER THE REQUIREMENT
2 PRINTING * GRADING AS PER THE REQUIREMENT
* MEASUREMENT AS PER THE REQUIREMENT
* PRINTING DEFECT NOT ACCEPTABLE
* DESIGN AS PER THE REQUIREMENT
* COLOUR AS PER THE REQUIREMENT
* GRADING AS PER THE REQUIREMENT
3 EMBRIODERY * MEASUREMENT AS PER THE REQUIREMENT
* LINING AS PER THE REQUIREMENT
* STITCH DENSITY AS PER THE REQUIREMENT
* EMBRIODERY DEFECT NOT ACCEPTABLE
* STYLE AS PER THE REQUIREMENT
* SPI AS PER THE PPS / REQUIREMENT
* TYPE OF STITCH AS PER THE REQUIREMENT
4 SEWING * MEASUREMENT AS PER THE REQUIREMENT
* NEEDLE HOLES NOT ACCEPTABLE
* SEAM STRETCHABLITY TIGHT / BREAK NOT ACCEPTABLE
* SEWING DEFECT NOT ACCEPTABLE
* TYPE OF THE THREAD AS PER THE REQUIREMENT
5 THREAD * SHADE AS PER THE REQUIREMENT
* PLY AS PER THE REQUIREMENT

7.9. First Garment Inspection – Sampling

S.NO AREA PARAMETERS TO BE CHECKED STANDARDS

6 LABELS * CONTENT AS PER THE REQUIREMENT
* BARCODE NUMBER AS PER THE REQUIREMENT
* WASHCARE INSTRUCTIONS AS PER THE REQUIREMENT
* PO NUMBER AS PER THE REQUIREMENT
* PLACEMENT AS PER THE REQUIREMENT
BUTTONING /
7 * SHADE AS PER THE REQUIREMENT
SNAPPING
* DESIGN AS PER THE REQUIREMENT
* SIZE AS PER THE REQUIREMENT
* PULL TEST AS PER THE REQUIREMENT
* PLACEMENT AS PER THE REQUIREMENT
* DEFECTS NOT ACCEPTABLE

31
32