Quality Assurance Procedure

Incoming Material:

1. Fabric:

(a) 100% inspection of Fabric is performed on all types of fabrics.
(b) Pass/Fail criteria is based on 4 point system.
(c) Only passed fabric is sent to the subcontractor.
(d) Minor defects are pointed out, which are later removed in the dyeing & cutting section.
(e) Major defective rolls/fabrics are immediately returned to the suppliers after complete inspection.
(f) Fabric lots are clearly marked and segregated.
(g) Lot approval is always taken from the QC/Merchandiser in charge.
(h) Record of Fabric Inspection (passed & rejected qty) is maintained in the specified register.
(i) Supplier Performance is also evaluated.

2. Trims and Closures (Accessories):

(a) As per AQL 2.5, qty is of the total quantity received.
(b) AQL 2.5 is used for acceptance criteria of Trims and Closures.
(c) Minimum 10 pcs are checked randomly (for Bar Codes min. 5 pcs will be checked).
(d) If minor defects are found, the criteria of acceptance of minor defects are 1 major defect is equal to 3 minor defects.
(e) In case excessive defects are noticed in a particular lot, the lot is rejected.
(f) Inspection is conducted against the specifications or approved sample.
(g) Record of Inspection is maintained in the incoming checking report.
(h) Supplier Performance is also evaluated.

3. Cartons Drop test (Carton strength/Transit strength)

(a) The height of the packed carton from the ground for drop test is selected, 24 inches and up to shoulder height.
(b) The shortage edge is selected first then medium then largest for drop test.
(c) The carton is dropped from the corner edge.
(d) Carton damage & damage of packaging are checked.
(e) The responsibility of Drop test is under packaging/ finishing in charge.

4. Semi Finished Goods

(i) AQL 2.5 is followed for initial inspection of goods received.
100% inspection of semi finished goods is performed on all types of products.
(iii) Only passed Pcs are sent to the Packing/Finishing Section.
Minor defects are pointed, which are later removed in the Finishing section.
Major defective Pcs are immediately returned to the suppliers after inspection.
All lots are clearly marked and segregated.
Lot approval is always taken by the Production in charge.
Record of goods Inspection (passed & rejected qty) is maintained in the specified register.
Supplier/sub-contractor Performance is also evaluated
II Process Quality Control

5. Field Inspection

In this, the Field inspector goes to the Fabric checking area at Nimri (production area) of the Sub contractors and carries out inspection as per the laid down standards. For non standard products, sample is carried by the field inspector and documents & his report is filled in the Field inspection Form. He also advises the vendor for corrective and preventive action to ensure improvements in the products.

6. Inline Inspection

(a) In process, Quality Control is carried out by Independent QC at all stages of Production and is reported in the specified format.
(b) AQL 2.5 based inspection of all incoming goods is done.
Inline inspection is carried out for all products by randomly selecting the products (20, in case the qty is less than 500 & 5% if qty is more than 500 Pcs) by the inline QC in the initial stage of production and documents his report in the Inline Inspection Form.
(c) 100% Inspection (Finishing & Checking):
All products undergo 100% inspection as per the approved sample. Rejected products are immediately segregated. Daily checking reports are forwarded and rejected product is recorded as per the rejection report.
(d) Final Random Inspection:
Product is not released or delivery is not preceded until the planned arrangements are satisfactorily completed and is approved by relevant authorized person, where applicable by the customer, Evidence of conformity with acceptance criteria is maintained. Records indicate the authorization for the release of the products. Final AQL 2.5, G II based Quality Audit is performed by the Quality In charge as per the Buyer’s Requirements.
All records are maintained in specified formats

7. Agent / Buyers Inspection:

If required the goods are inspected by outside agencies like buying house, buyers as per AQL 4.0 or AQL 2.5.
III. Lab testing:
a. Lab test is conducted for all Processing activities. In process Quality Control is carried out by Independent Lab (Nimri) which is segregated from the production and reported in the specified format.
Incoming material is checked as per the given specifications.
All color fastness testing is checked as per the required minimum standards.
Testing is performed on both yarn Dyed & Piece dyed fabrics.
All testing results are recorded in specified formats.

Following tests are performed in the lab:

1. Colorfastness to Crocking / Rubbing
2. Colorfastness to washing/Laundering
3. Shade Matching
4. GSM - Weight
5. Shrinkage
6. Yarn count
7. GSM

Testing by Customer Certified Lab

If required the samples will go for testing to customer certified labs for different tests required by the buyer.

Information and Specification Flow

(i) A technical file is maintained by the QA-Head, who circulates the relevant information to the concerned departments.
(ii) Factory is provided with all the relevant information and the approved sample.
(iii) Inspection Reports for all orders are reviewed by respective merchandiser before dispatch of the goods.

Equipment Calibration

(i) Measuring Tapes: All measuring Tapes are numbered and calibrated at an interval of three months with the Master Tape, which is obtained from an independent agency. Numbered measuring Tapes are issued to the checkers.
(ii) Weighing Machine: approved supplier performs the weighing machine calibration on an annual basis.
(iii) Barcode Scanner
(iv) Needle Detector

Other important issues

(i) All purchasing is centralized and all purchase orders are mention in the required specifications.
(ii) A separate job order is issued to Sub-contractors and vendors listing all the requirements.
(iii) Separate Rejection Record is maintained
(iv) All the cutters issued in the factory are numbered and controlled.
All the incoming material (raw-material and finished goods) are stored in such a manner that “Received Reject” and “Passed” are segregated at each stage.