Hop Yick (Bangladesh)

Ltd.
IQC Work Flow

Issue Date: 24th September 2017 Version:02

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 Hop Yick (Bangladesh) Ltd.
2nd Process External Parts Work
Flow
Form No: HY-IQC/CQC-HY-001 Issue date: 24th July 2017 Version:01

FLOW CHART FOR-2ND PROCESS EXTERNAT PARTS

MOULDING
Order wise cut pcs Receive

Order wise cut pcs Receive

Collect Approved

Collect Approved

Approved By
Govindan Ravi
General Manager
 Fabric Inspaction Procedure
Packing list wise QC find the materials based on delivery list and review information andfabric whether
they are right materials. The main purpose of this inspection is to assure the quality of received fabrics
before supply in cutting section. To do the inspection we select batch wise 10% roll randomly if 10% is
fail then we communicate with our OAM &Merchandiser as well as Supplier. Based on QAM &
Merchandiser confirmation we release the fabric & go for 100% panel inspection. Or we go for 20% and
100% fabric inspection if necessary. But we are following FOUR POINT SYSTEM as world class
standard.Collect The Buyer Standard Swatch And Compare The Running Material. (Fabric Shade Hand
Feel,Article Color etc.)

point System
Length of Defect Penalty Points
Less Than 3” 1
3"to6" 2
6"to 9" 3
9”to above 4

Total penalty points X 100 X 36=Result

Square Formula:- = Result
Fabric Length (Inspected)X Fabric Width (Inch)

Acceptance Levels-
* Running shade check: Inspection select roll first % yards fabric cut and reject then after 1yard full width
wise cut the fabric 6 (inch) then mention left and right side. Match after 2 yards running shade have or
not.
*Holes defect count always 4 point & defect must be measured lengthwise
*Maximum penalty point per square yard is 4 for fabric .
*Acceptance level up to 30-points /100 square yards for fabric
*Above 30 points/100 square yards lot will be rejected for fabric
*Fabric Length, Width, Roll no, Defect & other information must be recorded properly.
*The passed roll is marked by green tag & reject roll is marked by red tag with all details
*Rejected fabric keep in separate waiting place for Sr-manager Decision
*All Reject roll will be Record and send to non Confirming Area , Record Should be Kept.
Fabric Inspection Procedure
 Fabric Major Running Shading Control Procedure

*Production plan wise we select roll randomly(10%) and go for

fabric inspection.
*During inspection, we check fabric side to center to compare
for fabric running shade after each 3 to 4 yards.
*If our QC findings fabric side to center running shading level is
acceptable as per grey scale then, we pass it.
*If our QC findings fabric side to center running shading level is
not acceptable as per grey scale then we make the running
shading swatch and check it by light box with report.
*After than Our QC comments need to make group/joint or
special marker which to avoid shading.
*QC comments by mail provide to all concern GGT
cutting,sewing and BD Merchandiser team for follow up.
*We also inform sewing line to maintain cut bundle lot wise and
serial to avoid shading.
Fabric Running Shading Control Procedure
The main Purpose of this inspection is to assure the quality of received Lace before Supplying to
thecutting or sewing section. To do the inspection we select 10% quantity out of order total qty,
randomlyif 10% inspection is fail we go to 20% inspection and if 20% is fail, we communicate
with our concernMerchandiser as well as Supplier. Based on Merchandiser confirmation, we
release the lace & go for100% panel inspection. Or we go for 20% and 100% lace inspection if
necessary. But for the Acceptablelevel for Lace we are following FOUR POINT SYSTEM.

4 Point System: Penalty Point

Length of DefectLess than 3” 1
Over 3”but less then 6" 2
over 6” but less then 9" 3
Over 9” 4

Total Penalty Point X 100

Linear Formula:- = Result
Lace Length (lnspected)

Acceptance Level is -
* Only Major defects are considered. Such as Hole, Yarn Contamination,
*Dye/Coating Spot, Stain/ Dirty Spot, Shading, Crease, Streak, Stop Mark, Shade Bar etc.

*Holes all wage 4 point.

*All lace are to be inspected on the face side for defects

*Defect must be measured length wise.

*Maximum penalty points per linear yard is 4.

*Acceptance level up to 40-points per 100 linear yards.

*Above 40 points per 100 linear yards lot will be rejected.

* Defect must marked by arrow sticker.

*Lace length, Width, roll no. defect & other information must be recorded properly.

*Passed roll is marked by green

Lacetag.Inspection Procedure
*The reject roll is marked by red tag.

*All Reject roll will be Record and send to non Confirming Area Record Should be Kept
 ACCESSORIES (ELASTIC,WIRE CASING & RIBBON)INSPECTION

The main Purpose of this inspection is to assure the quality of received

materials before supplying in the sewing section. To do the inspection
we select 10% ctn. randomly if 10% is fail, we go to 20% and if 20% is
fail then we communicate with our concern Merchandiser as well as
Supplier. Based on Merchandiser confirmation, we release the materials
& go for 100%inspection.Or we go for 20% and 100% materials
inspection if necessary.

But, 1st inspection (10%) materials rejection below 1.5% we pass the lot

Elastic inspection: Collect approved swatch & match against received

Elastic Check Width,running shade, Spot. curve Elasticity, Construction
fault, Picot reveres etc.
Wire casing inspection: Collect approved swatch & match against
received Wire casing.Check Width, running shade, Spot, Construction
fault, etc.
Ribbon Inspection: Collect approved swatch & match against received
ribbon Check Width, running shade, Spot, Construction fault, etc.

Procedure:

口 We check 10% quantity if fail, we go to 20% and if 20% is fail then go

to100%inspection.
口 Make defect swatch.
口 Make Quality Report
口 Make Quantity Report (if necessary).
口 Defect Swatch Signature with Quality Officer and Quality Manager
then send to Merchandiser .Merchandisers arrange Replenish if
need.
口 One joint allow within 50 mtr.
口 One defect count 0.25 mtr. For elastic/ribbon/wire casing
 Accessories/Trims Inspection:- Countable

The main purpose of this inspection is to assure the quality of received materials before supplying to Sewing.

To do the inspection we follow AQL- 1.5(Level-l) of our received goods. We are checking the below materials:

口 Label 口 Bow 口 Ring & Slider 口 Hook & Eve 口 Stone 口 Logo 口 Cup wire 口 All packing trims

Check point :

Check all materials against approval trims card and follow below check point:

口 Label :-Collect label layout or CMS sheet to match the Size, Composition, Care instruction, County of
origin,Colour, Check Letter problem, bar code number, UPC number, Stroke number, Department number, Series
number Supplier code number, Date code number, etc.

口 Bow:- Check construction, Width, spot, shade, Open

口 etching & slider: - Check width, spot, shade, etc.

口 Hook & Eye:- Check measurement, color, Hook to Eye shade, Spot, Open etc.

口 Stone:- Check Broken, Placement problem, shading,etc.

口 Logo:- Check Broken, spot, Missing, shading, etc.

口 Cup wire :- Collect size wise wire chart then match the received cup wire.

口 All packing trims :- Packing trims are check as per approval standard.100% inspection to be carried out for any
failure after decision with QA manager

Procedure :
口 We check AQL-1.5(Level-II) system wise. lf pass we make the pass report, if fail we go to check 100% Make defect
swatch.

口 Make Quantity Report

口 Make Quantity Report if necessary

口 Defect Swatch Signature with Quality Officer and Quality Manager & send to concern
Merchandiser.Merchandisers will arrange the Replenishment.

口 All reject item report should be record and send to Non- Confirming Area , Record have to keep
 Mould inspection Procedure

The main purpose of this inspection is to ensure the quality of the mould fabric & cup is up to Buyer
required standard level.

Mould Fabric:
1. As per MO color and size wise collect the packing list and randomly select the cartons.
2. IQC will conduct inspection as per approved standard for mould fabric & plastic shell. Without-
approved standard iQC will not conduct inspection.
3. Collect approve mould fabric and approved plastic cup for size cup reference as per measurement
Chart.
4. Select sample size as per order quantity base on AQL 1.0 Level ll Wise.
5. Fabric cup correct color and fabric quality must be check.
6. lf quality inspection is pass, it will be inform to warehouse for issue to cutting bundling area as per
their system.
7.Any failure inspection discuss to QAM and account Merchandiser for decision.
8. As per decision 100% inspection to be carried out for any failure.
9. Reject sample with inspection report will provide to Merchandiser & MC for replacement.
10. All reject pieces will keep record and send to non-confirming materials area which handover to ware
house for disposal.

Mould Cup:
1. As per MO color and size wise collect the packing list and randomly select the cartons.
2. 2, IOC will conduct inspection as per approved standard for mould cup & plastic shell. Without
approved standard iQC will not conduct inspection.
3. 3. Collect approve mould cup and approved plastic cup for size cup reference as per measurement
Chart
4. Select sample size as per order quantity base on AQL 15 level-ll.
5. 5.Mould cup correct color and fabric quality must be check.
6. 6. If quality inspection is pass, it will be inform to warehouse for issue to cutting bundling area as per
area system.
7.Any failure inspection discuss to QAM and account Merchandiser for decision.
8. As per decision 100% inspection to be carried out for any failure.
9. Reject sample with inspection report will provide to Merchandiser & MC for replacement.
10. All reject pieces will keep record and send to non-confirming materials area which handover to
warehouse for disposal.
 Mould Cup Work Procedure (External part)

External part:
*First to collect receiving status and collect the approved standard.

*Have to select the carton/poly bag by Mo, size and color wise for
inspection.

*Test basis make the mold and send to sample section to check and
confirm.

*Select the sample based on AQL 1.5 level-II wise

*We check and compare with plastic shell.

*lf the quality passed, this will inform to input into the system and send
to cutting section for bundling.

*100% inspection to be carried out for any failure after discussion with
QA manger.

*Have to make report.

*All reject pieces will be recorded and send to Non Conformity area and
record have to keep
*Have to keep all the documents
 Heat Transfer(2nd process) Inspection procedure

*Collect approved sample & pattern, swatch and

supplier machine setting condition, printing art
work.
*Coordinate with all concern to set the quality
standard for bulk approval.
*Conduct wash test (3 times) out from the first bulk
for verification on 2nd process quality issues (if any).
*Second process inspection to be done
100%Inspection pcs to pcs.
*100%Inspection to be carried out for any failure
after discussion with QA manager.
*Any quality issues inform to all concern for
immediate action.
*All reject pieces will be recorded and send to non-
conforming area and record have to keep.
*Have to make the report and send to merchandiser
for replenishments.
Manufacturing Control Plan
 Color Evaluation Procedure

Purpose:
To ensure the right color materials use in the garments making time as per Buyer approval color
swatch or trims card.

Scope:
It is commonly known that natural daylight and specific Buyer wise light source will not destroy
our color judgements. Any well managed color program specifies a form of Buyer requirement
wise light source of choice for making accurate color evaluations.

Procedure:

1.To confirm all receiving bulk materials color quality by compare with Buyer approval
gold seal sample, trims card, packing list and MO sheet.

2.We check lot wise roll to roll keep the swatch fabric for color evaluation by Buyer
Requirement Light Source.

3.Without lot received the fabric 100% cut the swatch & make the shade swatch checked by
Buyer Requirement Light Source. Running shade checking first cut the swatch 6" x 6" from roll
full width & compares the whole roll after 2 or 3 yds.

4.Compare roll side to center & make the shade swatch checked by Light Box Buyer
Requirement Light Source.

5.After color segregate by Light box we will take Approval and comments of our lOC
Manager.

6.If have any running major color shade as per decision our lOC Manager we provide it concern
BD Merchandiser and Production person.

7. Major color shading purpose we also find the MOC report and collect their findings.
8.After final discussion if color shading not acceptable then we attached the red tag on
the rejected roll and keep it selected ware-house area.

9.if our inspection is Pass then roll with approval swatch we release for bulk production.
Lab Test Flow Chart