Triumph-CQA(HK) Page 1 of 15 Issued : June 2010

End Control

(Finished goods

100% inspection)

Training

Triumph-CQA(HK) Page 2 of 15 Issued : June 2010

Contents

Section 1 Introduction

Section 2 End Control (Finished Good 100% Inspection)

Qualification

Section 3 Inspection Tools

Section 4 End Control Process

Appendix I End control process – checking of finished goods

a. Short panty

b. Long panty

c. Brief

d. Bras

e. Long bra with suspender strap and long bras

f. Corselet with gusset and zipper and open corselet

with zipper

Appendix II

a. Visual Defect Reference Guide (Not Acceptable Defect)

b. Quality Catalogue (Table of Mistakes) – using for Repair

Slip and Defects Record Sheet.

c. End Control Form :

- Repair slip

- Preventive & Corrective Action Report

(5D report)

- Daily defect record sheet in sewing line

- Analysis report

- Calibration Record for measuring tape

Triumph-CQA(HK) Page 3 of 15 Issued : June 2010

Section 1 : Introduction

Triumph is a leading brand of quality in intimate apparel – The

End Control (Finished goods 100% inspection) Training is

provided to the finished goods inspector in Production Center to

persuade a guideline for understanding the inspection procedure.

Objective

This End Control (Finished goods 100% inspection) Training has

been created for the following objectives:

1. To release only those finished goods which conform to the

specified standard

2. To ensure that the Finished Goods Inspectors are trained to

meet the required criteria

3. To ensure standardization in all production centers

Triumph-CQA(HK) Page 4 of 15 Issued : June 2010

Section 2: End Control (Finished Goods 100% Inspection)

Qualification

Finished goods 100% inspection is the final stage in production for

inspecting identify the quality standard of the product for

conformance to specification.

Following criteria for finished goods inspectors are required:

1. Eyesight

Famsworth Munsell 100 Hue Color Test

a. Achieve a score of 24 or less on the Famsworth Munsell 100

Hue Color Test.

Ishihara Test for Color Blindness

b. Pass Ishihara Test for Color Blindness.

Triumph-CQA(HK) Page 5 of 15 Issued : June 2010

2. Physically not handicapped to perform task.

3. Good communicator, both oral and written.

4. Appropriate relevant manufacturing experience.

5. Attention to detail.

6. Methodical & consistent reliable above average in integrity

7. Identify issues.

End Control (Finished goods 100% inspection) Supervisor who

must also meet the following criteria :

1. Focusing on corrective and preventive action plans.

2. Organize and manage inspection planning, inspection

preparation, documentation management, communication to

all relevant parties.

3. Has knowledge to use computer (Excel and basic software

package, e-mail)

End Control (Finished Goods 100% inspection) Training should

be used for in-house training in Production Center.

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Section 3 : Inspection Tools

Production Center should have a designated area to perform End

Control (Finished goods 100% inspection). The inspection area

should be equipped with the following:

A. Inspection Table

Preferably size of the table should be 80cm (Depth) X

120cm(Width) with adjustable height.

For Standing Position : The leading edge of the table

should be at elbow height of the finished goods inspector

while standing. Mostly at 36 to 42 inch (90 to 105cm).

For Sitting Position : The leading edge of the table should

be at elbow height of the finished goods inspector while

sitting. Mostly at 29 to 34 inch (74 to 86cm).

Table surface should be slanting at an angle, non reflecting

in white or grey (Preferred) color.

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B. Lighting

Foot-candle rating for lighting should be no less than 700-

750 lux measured at the table surface and the lighting

should be about 25inches (64cm) above the table

(Dependent upon the height of the table is for the finished

goods inspector)

C. Fiber Glass Measuring Tape

- Stainless Steel Ruler with calibration

certificate – In general, the stainless steel

ruler should be calibrated periodically in 1-2

year.

- In general, the measuring tape should be

calibrated by the above stainless steel ruler

periodically in 6 months.

a. Measuring tape should be stuck to the front edge of the

inspection table.

- Under bust (measure straight)

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- Waist for short panty, long panty and brief.

- Leg for short panty, long panty and brief.

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b. Separated approved measuring tape is handled by hand

as per picture for measuring critical point.

- Picture A – as per instruction/chart

(Picture - A)

- Picture B - Under bust (measure along the edge)

(Picture - B)

Triumph-CQA(HK) Page 10 of 15 Issued : June 2010

D. Pencil

E. Repair Slip

F. Fault Sticker

G. Approved Sample

H. Measurement Chart

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Section 4 : End Control Process

A . Flow Chart

Finished Goods

- ready for 100%

inspection

Prepare for inspection

Resp – End Control

-prepare all spec. and info

before conduct 100% inspection

Perform inspection Resp – End Control

- refer to the “checking of finished goods” procedure to perform 100% check quality of the

bundle pieces

- Measurement points checking as per the third party measurement chart or Triumph style

based on finished measurement in AD.

Release for

packing

Defect product Repair Resp. – Sewing operator

- After review the defect garments by

End Control & sewing supervisor, the

repairable garments will be passed to

sewing operator for repair.

- The non repairable garments will be

treated as Second Choice.

Defect Record

Resp – End control supervisor

- collect all defect repair

slip for data record daily.

-

Defect Analysis Report

Resp – End control supervisor

The defect record will be used for defect

analysis. Production Center can set the

quality target, such as the target of

“overall quality level”. It can be used for

further quality improvement purpose.

Preventive & corrective action report

Resp – End Control & sewing supervisor /

QA manager - If the finished goods are failed with a critical

case, such as wrong size label, broken needle on

garment or the whole bundles with same type of

defects etc… The potential defects which will

affect the quality of the whole shipment and

cause any claim from customers, End Control

Supervisor & Line sewing supervisor must hold

a meeting for the defects cause. They will

complete the Preventive and Corrective Action

Report at the same time. And finally

acknowledge by QA manager.

Statistical graph for

management review

Resp – QA manager The defect graph is

plotted for management

review.

Yes

Yes

No

Finished inspection

Resp – End Control & sewing

supervisor - Finished goods passed 100%

inspection will release for

packing.

- Finished goods failed100%

inspection will identify with

stickers and pass on together

with repair slip to be further

follow up and review by End

Control & sewing supervisor

- Incomplete bundle will be kept

Re-inspection Resp – End Contorl & sewing

supervisor

- Sewing supervisor will check and returns the

repaired garments to End control supervisor

for further check.

- Repaired finished goods passed inspection

will put back into the incomplete bundle and

release for packing.

- Repaired finished goods failed inspection will

back into step of repair.

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1. Finished Goods

Bundles with 100% completed sewing operation and paper tags

attaching from sewing line before packing.

2. Prepare for inspection

- Before carrying out end control (finished goods 100%

inspection), product style files need to be prepared

which includes :

a. Approved sample.

b. Sequence of the sewing operation from the AD

c. Measurement chart from the third party style or Triumph

style based on finished measurement in AD.

d. Approved trim card.

e. Repair slip

f. Label checklist

g. Paper tag checklist

And then open and count the bundle pieces.

3. Perform inspection

- Refer to the “Checking of Finished Goods” procedure

to perform 100% check quality of the bundle pieces.

- Measurement points checking as per the third party

measurement chart or Triumph style based on finished

measurement in AD for below item.

a. Bra, long bra

b. Brief, short panty, long panty

c. Corselet

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4. Finished inspection

a. Finished goods passed 100% inspection will release for

packing.

b. Finished goods failed 100% inspection will identify with

stickers and passed on together with repair slip to be further

follow up and review by End Control & Sewing Supervisor.

c. Incomplete bundle will be kept by End Control.

5. Defect product repair

a. After review the defect garments by End Control & Sewing

Supervisor, the repairable garments will be passed to sewing

operator for repair.

b. The non repairable garments will be treated as Second

Choice.

6. Re-inspection

a. Sewing supervisor will check and returns the repaired

garments to End control supervisor for further check

b. Repaired finished goods passed inspection will put back into

the incomplete bundle and release for packing.

c. Repaired finished goods failed inspection will back into step

4 & 5.

7. Preventive & Corrective Action

If the finished goods are failed with a critical case, such as

wrong size label, broken needle on garment or the whole

bundles with same type of defects etc… The potential defects

which will affect the quality of the whole shipment and cause

any claim from customers, End Control Supervisor & Line

Sewing Supervisor must hold a meeting for the defects cause.

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After investigation, if it is came from unskillful of sewing

operator, the sewing operation must be stopped, until sewing

operator fully understanding the sewing skill for handling the

sewing operation.

End Control Supervisor & sewing line supervisor must

complete the Preventive and Corrective Action Report at the

same time. And finally acknowledge by senior manager.

8. Defect Record

End Control Supervisor collect all defect repair slip for data

record daily.

9. Defect Analysis Report

The defect record will be used for defect analysis. Production

Center can set the quality target, such as the target of “Overall

Quality Level”. It can be used for further quality improvement

purpose.

10. Statistical Graph for management review

The defect graph is plotted for management review. It can be

used for quality discussion during in quality meeting.

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B. Workplace Layout

- Finished goods are ready for 100% inspection. The bundles

are placed at left side of the tray.

- Approved sample, AD, Measurement chart from the third

party style or Triumph style based on finished measurement

in AD, Approved trim card, Repair slip, Label checklist and

Paper tag checklist are placed on the right corner of the

inspection table

- The finished goods passed inspection is put on the right side

of the tray.

- The finished goods failed inspection is put on the left corner

of the inspection table. They all will identify with stickers

and passed on together with repair slip to be further follow

up/ review by End Control & Sewing supervisor.