GIS QA Process Full Empowerment Refreshment trainingDenim

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QA Standard Operating Procedures

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1. QA Information Package = Manufacturing ready package (MRP)

2. Pre-production meeting3. Pilot run/TOP sampling procedures4. In-process audit5. Shipment audit6. Seconds & Overruns policy

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Manufactory Ready Package (MRP) Objective: To have complete information for

QA to conduct production quality follow up and progress monitoring.

To list out all the monitoring activities and ensure smooth production.

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What were include in MRP folder

1. GSS + BOM2. Fit comment + Line review report3. All Email relate to bulk approval4. Fabric (Shade lots) 5. Trim cards6. Approved sample 7. PP size set sample8. Fabric /Garment test report9. PO & DPO 10. Label positions of all labels.11. Folding method12. Packing material 13. TOP comments

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Who need to involve in MRP program

1) Vendor/Factory merchandisers: - prepare MRP file for DA or in-house factory QA in all

complete information

2) GIS merchant: - Review MRP file and return to vendor with approval stamp

3) GIS & Factory in-house QA : - go through all production information in MRP file before

pre- production meeting - check with all relative parties when some information were found incorrect or missed in the MRP

file

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Sample of trims & document (Phase I)Line review Report

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Sample of trims & document (Phase I) Fabric swatches

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Sample of trims & document (Phase I)Shade Lot Shade blanket

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Sample of trims & document (Phase I) Trims (for phase I) Embroidery sample

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Sample of trims & document (Phase I) Interlining

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Sample of trims & document (Phase I) washing approval standard p. p. sample

Packing related

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QA Information Package

PO/DPO How to read “DPO” Pack type

SGLE - Single MULT – Multiple ASST – Assorted BULK - Bulk

Pre-pack no./unit per pre-pack Full carton:

Y – Goods are packed in “Full Carton” N – Goods in a “Standard Carton”

Unit ordered (Total unit ordered) Ship to (final destination of goods/DC)

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Sample of trims & document (Phase I)Label position Folding method

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Sample of trims & document (Phase II)Packing material

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Sample of trims & document (Phase II)Garment test report TOP comment/e-mail

Vendor Handbook

1. Packing (Chapter VIII)Carton requirement / packing method 2. Trim (Chapter VII)Price ticket / traceability label / polybag3. Delabeling (Chapter X)3.1 Delabeling requirement3.2 Record retention

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Packing

Trim

Delabeling

2. Gap Manual Introduction

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PP meeting 1. Purpose : PP meeting is to ensure all production

related dept review the buyer’s requirement and bulk material quality to set up process and timeline needed.

2. When to start : Buyer’s Approved Sample ready PP size set sample prepared by factory Bulk material inspection and testing done

3. Who to attend: MerchandisersSample room technicianAll Production depts manager/supervisorsQA/QC dept

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PPM – major items for discussion1. Check factory size set PP sample vs. approved fit

sample + wash sample on visual & measurement. 2. Follow up line review – high risk report and see if all

correction made 3. Set critical check point at:

garment production process Laundry mills

4. Check shade blanket, shade band, plan shade segregation for DPO, plan sets of pattern for shrinkage % check in order to meet spec tolerance.

5. Check internal fabric inspection and test result and work out appropriate production planning.

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PPM – major items for discussion5. Product / Production process re-engineer

to enhance quality / efficiency6. Bulk trim check and see if any bulk

control needed on application. (e.g. rivet and buttons)

7. Prototype carton approval8. Check facility production planning and

schedule.9. Complete PP meeting report and

distribute to all related parties for follow up.

10. For repeat styles, MUST have PPM per season

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Raw materials/Materials/Testing/Production Planning

1. Garment factory should request Fabric Mill to provide head ends/lot, 100% inspection report + test report / lot before bulk fabric delivery.

2. There should have a passed fabric test report. If it is failed, check with PI and MR for exception, otherwise, consult PI/Tech for construction that can meet garment test requirement

3. Garment factory should review their internal fabric inspection and testing result of all bulk shipment deliveries. Especially on shrinkage and crocking checking per lot.

4. Garment factory should check all trims quality. For embroidery and printing, grading checking is needed and attachment method should be reviewed to ensure consistency and meet product safety requirement.

Important points in PPM

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Raw materials/Materials/Testing/Production Planning

5. For new wash, vendor should discuss with laundry on the approved wash sample and shade band to see if bulk range is covered. Work together on how to support each other to meet the approved range.

6. Check the production planning of garment and laundry house to see they can align to meet the delivery.

Important points in PPM

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Cutting/ Sewing/Fit/Machinery1. In cutting, ensure the dye lot numbering for shade and

shrinkage is correct and maintained till sending to laundry mill.

2. The technician at sample room should alert production if there is any new construction for the style and how to have bulk control on it. Templates or markings/pressing is needed when set up the sewing line.

3. The tolerance in spec should be reviewed for the last time to determine whether it is manageable.

4. There should be marker assigned to ensure bulk lot can meet measurement tolerance. Check if marker assigned and sewing room can meet the tolerance.

5. There should have before wash and after wash measurement sheet for sewing and finishing dept to follow and check.

6. Critical check point set at sewing line.

Important points in PPM

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Wet and Dry processing1. For light weight fabric with heavy wash or resin finishing,

test the tearing strength in bulk control. 2. For washed spandex garment, fabric pop-up due to the

elastic degraded by high temperature or in heavy bleaching process. Alert laundry house on temperature control.

3. For weak points like belt-loop, pocket opening, buttoning, QA should be alerted to check if fall off or easy tear after washed.

Important points in PPM

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Packing1. When there are 3D whiskers or any special visual effect

that buyer request to have roll pack or any other new packing method, merchant team should demonstrate for packing department. Packing factor and carton size should be studied. Any extended approval should send to GIS MR team and packing@gap.com

2. Crocking hangtag must be added for medium to dark color garment.

3. Even we have approved shade band, alert packing that 1 carton can only allow 1 shade of garment.

Important points in PPM

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Objective of Pilot run : to check the specific high risk area with a manageable quantity to ensure bulk consistency ability and prevent major bulk failure.

Size of pilot run is around 200 pcs per style tentatively and audit size to be 50 for visual and 20/32 for measurement before and after wash.

Brief audit results to facility and provide recommendations for bulk quality enhancement.

Suggested timeline: asap Denim - TWO weeks after cutting

In-house QA to follow up with facility and arrange Pilot Run audit timely.

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Pilot run & TOP sample checking

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Pilot run/TOP sampling procedures (Cont’d)

For small programs ( order qty < 1000 pcs) where a pilot run is not feasible, the facility must demonstrate a process to check and control measurement, construction and workmanship as bulk commences.

TOP samples to be pulled out from pilot run and prepare TOP sample for timely distribution.

TOP samples are checked as being representative of bulk. It is required to sign on the underside of the care label for confirmation.

Pilot Run audit report is copied to both facility and GIS merchants for record. ONE piece of TOP sample to be collected for GIS merchant review.

In-house QA report to GIS merchant of TOP sample review status through weekly WIP report.

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Different scenario for pilot run sampling qty: 1.Check construction consistency –

1 size 1 colorway. 2.Check color combination on colorfastness

1 size + all colorways3.Check grading proportional of solid color

1 color + all sizes or jump sizes4.Check on color combination styling on

grading and colorfastness / shrinkage all size + all colorways

Pilot run design

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1. Follow up the suggestions from PP meeting / high

risk comments to verify their improvement.2. In case of any technical issues that cannot be

corrected & are beyond control. Seek assistance from GIS Tech, WP and QA.

3. If bulk fabric issues, resolve it with mill first. 4. If there is risk of delay shipment or short ship

>5%, bubble up to GIS merchant immediately with qty detail per DPO affected.

Common issues found in Pilot

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1. TOP samples should be representing bulk shipment in correct packing.

2. DA should write name on joker label & to attach the measurement sheet with measurement taken before send out the TOP samples.

3. Submission with MR timeline or at least two weeks prior shipment for GIS merchant & buyer review. If cannot submit in time, please alert the GIS merchant for the late submit date first or any remedy solution needed.

Common issues found in TOP submission

In- process audit

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Production status follow-up Production quality/product safety follow-up Semi product QC or factory QC monitoring Complete in-process audit report

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In-process audit

Production status follow-up Monitor production progress to ensure on-time shipment. Weekly WIP report to GIS - M/R.

Production quality/product safety follow-up On line production quality and finished product inspection Root cause analysis for quality failure. Corrective action plan for quality improvement.

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Frequency of audit Cover all sizes all colors before Final Conduct once per week (minimum requirement)

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In-process audit

In-house QC monitoring End line QC – check 5 pcs visual and measurement

(before wash) per station to see if acceptable. End line QC - check if report in correct and complete

form. Regular meeting with factory management for in-house QC performance review and conduct internal training .

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1. Minor defects and can be rectified – send defects to rectify and also adjust the production floor to avoid further defect produced.

2. Major defects cannot be rectified and sorted out – use the sampling plan and check WIP to see if the sort out will be over 5%. If yes, then send representative data/sample for GIS consideration of buyer approval. Correct production floor to avoid further defects produced.

3. Major and 100% sewn with repeat POs – immediate send photo/sample and call GIS for decision on current PO and repeat PO.

In- process audit – action for various results

Shipment Audit (Final inspection)

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Seconds & Overruns policy Control left-over quantity after shipment.

Overruns, Seconds and Thirds sorting within TWO weeks of last DPO shipped.

Record all information and storage in neat and organized manner.

A shipment audit is done on visual, measurement, OCR and packing according to Gap standard.

Immediate corrective action is taken to rectify and resolve non-compliance quality issues.

Complete shipment audit report.

If outlet accepted offers, NEW PO issue and “S&O” audit before shipment.

Upon receipt of declined offer list, follow-up de-label audit with facility. Close file and keep all QA documents as per Gap requirements.

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1. Passed – remember to put “OK to Ship” in the report for shipment

2. Failed and proceed rectify – check production on rectify timeline, notify GIS if for postpone delivery date.

3. Failed and proceed sorting – check both delivery and shipment qty, notify GIS for postpone delivery and short ship more than 5%.

4. Failed in 100% and cannot rectify nor sort - notify GIS with picture or samples for immediate decision.

Shipment audit – action for various results

QA Reports

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Gap Product Assurance Manual and GuidesGap Source Library (GSL) http://gapsource.gapin

c.com

Check EACH MONTH to get latest information for production Technical Bulletin QA Manual How to Measure Vendor Handbook Fold, Pack & Labeling Standards (Gap, BR and Old Navy) Doing Business with Gap Inc. Outlet Garment Defect Photo Book Gap Inc. Construction Standards Ticket Reference Guide (Gap, BR and Old Navy) Softlines Manual 05/02/2023