AQL TRAINING FOR FINISHED GOODS

AQL = Acceptable Quality Level

July 2007

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What is the purpose of this presentation?

CQA cannot visit every manufacturing centre to help with

training of AQL auditors in the time allowed, so we have

put together this presentation to help with the training

locally

The following TI AQL audit procedure should always be

used unless a third party (non Triumph) customer, who may

have their own AQL audit procedures, require us to use

their own procedures

If you have any queries or questions, please do not hesitate

to contact Ms Wong or her staff in TIOL CQA Hong Kong

Contact:-

Ms Wong +852 2797 4094,

email leowfah.wong@triumph.com

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�AQL means ACCEPTABLE QUALITY LEVEL

�This means that we check that the goods inspected do not exceed

the minimum number of rejected garments in a shipment that is

allowed in the AQL rules

�AQL audits only check a small number of garments in a large

shipment, to give an indication of the level of quality of the whole

shipment.

�AQL audits on finished goods should be seen as the last “safety

net” check before shipment

�The number of garments that we need to check are given in a

table of AQL rules called “Double Sampling Plan For Normal

Inspection”.

�AQL finished goods audits should be conducted on totally finished

and packed goods which are ready for our customers to receive.

Some information about AQL audits in

finished goods

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Some information about AQL audits in finished

goods

�AQL audits should be done as close to the manufacturing

as possible, and preferably not in a distant warehouse. It

may be necessary to return a failed shipment to

manufacturing for re-inspection

�The purpose of these AQL audits is to have a final check

on the quality of the products, before they are shipped

so that when our customers receive our products, they

are happy with them and they are to the standard that

they expect.

�AQL audits on finished goods, do not replace end control

or in-line inspections.

�Proper and thorough inspections inline and at end control

MUST take place in addition to AQL audits at Finished

Goods

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What do we need for an AQL audit ?

�Garments boxed and completed, that have passed the final factory

inspection (end control).

�Order Check List (OC) or Product Order (PO) that shows the

quantity ordered by style, size colour and cup for each shipment.

�Tape Measure

�Calculator

�Cotton gloves for handling sensitive fabrics

�Eye Glass, magnifying stitch counter or Triumph Seam Ruler

�Master Garment Sample or Factory Sample, which must be verified

as a proper standard that can be referred to by the AQL inspector

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�AQL report form

�AQL Double Sampling Plan to find out how many garments

to inspect and how many to measure

�Garment Finished Measurement Chart (Size Chart) – see

next slide for more details

�Packaging Specification or Packing Instructions

�Label/tag reference chart or label/tag check list, to

check garment labels, paper tags and box labels against

� Small round green sticker to place on the outside of the

box to denote the box has been AQL inspected

What do we need for an AQL audit ?

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Some of our third party customers, like Marks and Spencer, will

have their own Measurement or Size Charts which TIOL produce and

M&S agree by sign off.

For Triumph styles, SAP will give us a similar chart, but until

Manufacturing Centres are running on SAP, we will have to create

our own.

To ensure that we use the correct information for finished

measurements, each Manufacturing Centre should locate the

finished measurements within the Article Description (AD).

The sections within the AD pages that contains the Finished

Measurements, should be “Copied and Pasted” onto a blank

document page to create your own Measurement (Size) Chart. An

example of this is attached.

This new Measurement (Size) Chart that you have created, should

be signed, dated and verified by the Quality Manager in the Centre,

as being completely accurate before use.

(“What do we need for an AQL audit ?” continued)

Measurement Chart (Size Chart)

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(“What do we need for an AQL audit ?” continued)

Measurement Chart (Size Chart) - Example

MEASUREMENT SHEET

STYLE 40-805 DATE 17TH

JULY 2007

Approved by ………………………………………..

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When should we start the audit ?

�Every shipment or production order should be audited.

�The audit should be started when the whole shipment is boxed and

available, but it is acceptable to start the audit when no less than

80% of the total shipment is finally packed and boxes sealed.

�Shipments or production orders should be audited at least one

complete day before they are planned to load onto the

transport.

Remember, it may be necessary to 100% re-inspect the shipment, if

the audit fails, and time should be allowed for that possibility.

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Procedure…1

Confirm the shipment quantity from the Order Check List (OC) or Product Order (PO)

Find out from the Double Sampling Plan, how many garments you need to inspect out of the shipment and how many of each colour,size and cup you need to inspect

Randomly select these quantities from the shipment, carefully opening the boxes so that they can be used again

Check the outer boxes to make sure that the label details are correct and compare to the shipment or order details

Check the way the garments are packed inside the outer box, to make sure they are packed correctly according to the packaging specification

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Procedure…2

Select the required number of inner packs or boxes that the sample

plan determines you should inspect

Check the inner packs or boxes to ensure that the labelling and

packaging are correct when compared to the packaging specification

Open up the inner packs or boxes to commence examination of the

garments

Check the visual appearance of the garments inside and outside, does

it look creased or stained?

Check all labels and tags to ensure that they are correct

Are all seams correctly aligned?

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Procedure…3

Do any parts of the garment look off shade when compared to the

rest of the garment and when compared to the standard?

Are the seams straight and correct, does the garment look balanced

and equal when comparing one side to the other etc.

Check the make up of the garment, are all the seams secure

Are all the attachments fitting correctly (hook and eyes, rings and

sliders etc)

Do any of the seams crack when reasonably stretched?

Check the wire play on bras to conform to the requirement (some

styles may not require any wire play)

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Procedure…4

As soon as you find a fault, report it on the AQL report sheet

provided and move onto the next part of the garment for inspection

or the next garment to inspect.

All garments that you find a fault with, should have a fault sticker

placed on it and put to one side

In the case of a long thread end, you should continue to find the

possible cause of the thread end and if no subsequent fault is found,

record it as a minor fault

Fault classification (Critical, Major or Minor) is described in further

detail later

Measure the underband (underbust) of every garment checked and

compare to the measurement (size) chart

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Procedure…5

Select the required number of garments to fully measure, according to

the table as given in the “Double Sampling Plan For Normal Inspection –

Measurement”

Commence measuring these garments using the measurements as listed

on the Measurement (Size) Chart, and record on the “Measurement

Sheet”

Fault classification is based upon the severity of the fault and/or the

location of the fault

If a critical fault is found during the audit, the audit automatically fails

If 2 or more major faults are found, the audit automatically fails

If 6 or more minor faults are found, the audit automatically fails (so 3

minor faults counts as 1 major fault)

As soon as the rejection level is reached, there is still necessary to

continue the audit as you are already at the stage that the audit has

“FAIL” (revised 15 Dec 2011)

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Procedure…6

Once you have found a rejectable fault within a garment,

there is no need to continue inspecting the garment, it is now

rejectable

If the audit fails, using the rules described previously, the

shipment MUST be stopped and 100% inspection of the

shipment takes place. Factory Management MUST be informed

of the failure

Once the failed shipment has finished 100% inspection and

Factory Management are confident that the problems have

been identified and resolved or removed from the shipment,

another AQL inspection should take place, exactly as

described previously

All boxes that have been AQL inspected, should be marked

with a small green round sticker, to denote the inspection

The shipment should only be released when a successful AQL

audit has been achieved

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Reporting

Each shipment or Production order should have a separate AQL

report completed

All AQL reports should be completed during the inspection not

after it

Each AQL report should be signed and dated by the AQL auditor,

additionally each failed report should also be signed by the

Quality Manager, the Shipping Manager and the Production

Manager to confirm their knowledge of the failure and the

appropriate actions that are required

Each AQL report should be accompanied by the respective

measurement sheet. All rejections for measurement will be

detailed on this sheet.

A summary of each weeks AQL passes and fails should be emailed

to Ms Wong at CQA TIOL Hong Kong

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Fault Classification

For Classification of faults found, into “CRITICAL”,

“MAJOR” or “MINOR”, please refer to the “TI AQL Audit

Report – Corsetry and Brief”, or the “TI Global Quality

Manual – Product”

For guidance, please see the definitions below:-

“Critical” would be a fault that would cause harm or injury

to the end consumer, or have an adverse effect on Product

Safety

“Major” would be a fault that would result in rejection

and return by the shop/store or end consumer

“Minor” would be a fault that is outside of the quality

standard requirements, but would not necessarily result in

rejection by the end consumer

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AQL report

AQL Audit Report (V1) 7 July 09

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Double Sampling Plan For Normal Inspection

AQL DOUBLE SAMPLING PLAN

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How to use the Double Sampling Plan - Volume

Size of your order

or shipment

First inspection or

second inspection ?How many pieces you

should inspect from the

order or shipment

C = the maximum

number of rejected

pieces acceptable

Between C and D =

Start second inspection

D = the number of

rejected pieces

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Double Sampling Plan For Normal Inspection -

(Measurement)

AQL DOUBLE SAMPLING PLAN - MEASUREMENT

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How to use the Double Sampling Plan - Measurement

Size of your order

or shipment

First inspection or

second inspection ?

How many pieces you should

measure from the order or shipment

C = the maximum

number of rejected

pieces acceptable

Between C and D =

Start second inspection

D = the number of

rejected pieces

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AQL Measurement Sheet

(for recording measurements)

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Weekly reporting of AQL inspections to CQA

Hong Kong

New AQL report format with Example 7 Jul

AQL TRAINING FOR FINISHED GOODS

TIOL CQA Hong Kong July 2007