Quality Plan at Sample & Development Process

 

1. Purpose

The purpose of this SOP is to define the standard process for sample development to ensure product quality, compliance with buyer requirements, and consistency in execution.

2. Scope

This SOP applies to all personnel involved in sample cutting, pattern making, sewing, washing, finishing, and final approval for buyer review.

3. Responsibilities

- Merchandiser: Provide reference samples, patterns, and requirements.
- Quality Team: Verify accuracy at each stage and record results.
- Production Team: Execute sample cutting, sewing, finishing, and corrections.
- Management: Review failures and implement preventive actions.

4. Procedure

1. Receive File/Pattern/Reference Sample and Requirements from Merchandiser.

2. Cut sample fabric according to the provided reference.

3. Check pattern for correctness:
   - If OK → proceed to panel check.
   - If Not OK → corrective action.

4. Conduct panel check for cutting accuracy:
   - If OK → proceed to sewing.
   - If Not OK → corrective action.

5. Sew sample as per buyer’s construction manual.

6. Check sample for Right First Time (RFT):
   - If OK → proceed to washing decision.
   - If Not OK → corrective action.

7. Determine washing requirement:
   - If Wash Item → send for wash.
   - If Non-Wash Item → proceed to attachment & test.

8. Conduct attachment and relevant tests (e.g., pull test):
   - If OK → proceed to finishing.
   - If Not OK → corrective action.

9. Check finishing and accessories attachment for correctness.

10. Perform pressing, finishing, and metal detection.

11. Conduct dummy fitting check:
   - If OK → proceed to buyer review.
   - If Not OK → corrective action.

12. Submit sample to buyer for review and comments:
   - If Approved → finalize and proceed to next steps.
   - If Not Approved → remake sample, analyze cause of failure, and implement preventive actions.

5. Records

- Pattern & marker accuracy check

- Cutting accuracy records
- RFT check reports
- Washing accuracy check

- Attachment test records

- Finishing accuracy check
- Dummy fitting reports
- Buyer review comments

6. References

SAL/PDC/FO/003 Sample Sample Check Report

7. Definitions

RFT = Right first time