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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.
Triumph-CQA(HK) Page 6 of 15 Issued : June 2010
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.
Triumph-CQA(HK) Page 7 of 15 Issued : June 2010
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)
Triumph-CQA(HK) Page 8 of 15 Issued : June 2010
- Waist for short panty, long panty and brief.
- Leg for short panty, long panty and brief.
Triumph-CQA(HK) Page 9 of 15 Issued : June 2010
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
Triumph-CQA(HK) Page 11 of 15 Issued : June 2010
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.
Triumph-CQA(HK) Page 12 of 15 Issued : June 2010
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
Triumph-CQA(HK) Page 13 of 15 Issued : June 2010
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.
Triumph-CQA(HK) Page 14 of 15 Issued : June 2010
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.
Triumph-CQA(HK) Page 15 of 15 Issued : June 2010
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.