J

QAD-FR-196
I NTE R ,,.)ll,,.lli;P DOCI]MENT APPROVAI, I'ORM
Ilo'ision No. 07
lssue/Revision Date: 30 Nov, 2021

Department: QAD f)ocument Name: SOP FOIT QAKNITTING INSPECTION

(PROCESS BASED APPROACII)
Document Code: I Type Code
OP
Document #

051
{
Description: -
Changes (Required in case of Revision):
Initial Released / Revised Revision # 12

0. Deleted Description
1. Added
0/1. Modified

2. Scope

This procedure encompasses the inspection activities within the process & process and is
0lt applicable to al1 customer orders.

3.Definitions / Abbreviations

ADS Automated Dispensing System

5. Procedure
'l'he incoming QA GL r'vill resumc responsibility from the and engage in discussions regarding
any hightighted issues from the previous shift. These di topics such as maior or recurring 1'aults
in specific orders, the introduction ofnerv orders, and problems. T'he QA GL will then suppty
provi de the rclevanlQualityAuditor with " Dai ly Form," to PRODCUT INSPEC'IOR and he
whiel+rvi11 automatically gencrates all the QMAS system.
The Qualifl\uditor PROCESS the assigned knitting lines and obtain r.recessary
essential information such as Order Nun.rber. . Pattern Number, Machine Size, and Base Color
'Ihis information will be sourced Production (as a Knitting Plan)" report as tvell as the
'WSS/BSS l"older" accorrpanied by Trial Report, Knitting Work Order, and Yarn Path, u,hich ale
provided by Knitting Opelations. The PROCESS AUDITOR u'il1 then verifv this intbrmation on
all the machines currently being
n
a. Process A
l.
1) To at knitting level; Quatity-Audi{sr PROCESS AUDITOI{ rvill conduct the
PROCESS AUDIT of 33
0tl
all knitting machines
3% in each shift) and will perfonn pair code u,isc yarn verification (Physicalll'yarn verilication
of one machinc i,vith work order/WSS/BSS).
2) QA GL will be responsible for data feeding of last shift, Daily Ituitting Process Audit (QAD-
FR-223-Rev.01) findings at shift start up.
u. Change Ot,er Process Atrdit
l) To ensure Article change over on Right First Time;Quality-eudi{ers PRODCIUl'INSPIrCTOIl
lvillconducttlreChangeoverProcessAuditinbelowtrvophases@
a) Velification of changeover pre requisites availabili+1fur+hange€ver+nde++he-subieet-of
Proeess-Based4udi+ (Trial Run report/Risk Assessment/ Yarn & yarn path detail / etc.).
b) Soeks {ns-eetion under the sehieet ofProduet Audit Physical Socks Inspection
2) When neu, orders will induct on knitting machine or any chturge ivill take place in the running
orders. then shilt supervisor operations will send the DAIL,Y ARTICLE CFIANGE OVER
BOOK Form to aA+M PRODCUT INSPECTOI{ after getting it confimrecl by hi+n+rid i<nitting
technician.QATA.4,will-ved-fy+he$ulkp+oduetion asper+he+equi+e+nentsle1m+ges nientioned
inllAltY-A{
 QAD-FR-196
INTER[j.,,P DOCUMENT APPROVAI, F'ORM Revision No. 07
Issue/Revision Date: 30 Nov, 2021

3) Q{-Team-++embet- PRODCUT INSPECTOR i,vill perform the inspection of 5 pieces after

Machine Change Over (Change Over include Size, Yarn, and Article). Break up of inspection
of 5 pieces as
a) 01 Piece lbr Greige measurement, stretoh, Yarn verification and WSS/BSS veriflcation
b) 01 Pair tbr Greige Weight (lncluding fir'st piece)
c) Workman Ship (Fabric Defects) of all Five Pieces
fn €ese ofNeR durifl io"-alr+ill,beisllov*
4) a++eani-m€mb€r PRODCUT INSPECTOR will recold Change over Process Audit Findings
on his/her KNITTING MACHINE CIFIANGE OVER AUDIT (QAD-FI{-224-Rev.0t). In case
of variation from deoided parameters in Process Audit and Product Audit. Auditor u,ill declar"e
the Changeover Process Fail and advice to operation supelvisor measures
accordingly.
5) QA GL will be responsible for data feeding of last shill KNI CHANGE
OVER PROCESS AIJDIT findings at shift star1 up.
i ii. CTO_Gritk sLtagxpliy) Pr@e;;-4!d
1) To ensure standardized practices in 2417, QA FC will CTQ (Clritical to
Quality) Process (QAD-FR-222) audit and share the findings accordingl-'-
2) Kr.ritting QA FC will be responsible for ofall Process audits on nced
basis (Daily and Monthly) with all operation i,vill clernand corrective actions
tlom concern teams.
b, Product Inspection
i. Daillt KnittingProdttct Inspection
l) ageam+*emUer-PRoDCUT perform the one rclund machine wise at ADS
structure of knitting ONE Fresh piece for
a) Greige measurem
b) wss/BSS & Shade)
c) Irabric oating ( Workmanship of three pieces including one
fresh piece)
2) To ensure stretch requirements of socks, the Quality--4udi+or PRODCIJ1'
rstretches of specific sections of the socks (one machine Ibr. each
machineJhe.4udiber PRODCUT INSPECTOR will maintain a record
of this "Daily Gleige Stretch lnspection F-ol'm."
3) requirement of socks fbr TARGEI' and AMAZON customers across all
rnachines, the Quaiitl,4udifor PRODCUT INSPEC'|OR rnill conducr
33% ofthetotal operational machines during each shift. By follolving this approach.
will be covered on a daily basis.
4 the above-mentioned inspections, if the-Quali+y--\rdi€or PRODCUT INSPECTOR
identifies a single defective piece due to measurement variations, stretch issues. WSS/BSS
r
verification discrepancies, or fabric defects, auditer PRODCUT INSPECTOR will stop the
knitting machine and plovide feedback to Line crerv to hang a Q-Tag tei+ on the relevant knitting
machine.
;
.1?.j
5) The Quafi$ Auditor PRODCUT INSPECTOR will mark a Non-Confbrmance Report (NCR)
on the Knitting Inspection Form and deliver the dei'ective sarnple to the respective line
technician or shift in-charge ofoperations for necessary corrective measures.
6) The current production on the machine will be removed by the line technician ol shili supcrvisor
ofopelations for sorting the defectivc quantity.
7) Once the knitting machine has been rectifled, the line technici an or shift supervi sor o1'operations
rvill infbrn.r the Qualitl-4u.di+er PRODCIiT INSPECTOR for a re-inspection of the machine.
8) 'lhe Quali+y Audi+or PRODCUT INSPECTOR rvill le-inspect three sample pieces liom the
Q-
Tagged machir.re. One piece will be I'rom fi'esh production, and two pieces will be fiom rer.vorked
productior.r. If the lesults are satisfactory, then aua+iqi-,4udito+' PRODCUT INSPECTOR
 QAD-trR-196
INTEP[':r'i''P DOCUMENT APPROVAL FORM
llevision No. 07
Issue/Revision Date: 30 Nov. 2021

coordinate with Line crew to t'emove the Q-'Iag and authorize the resumption of production or.r

the machine.

ii. l,tiar BtLlr_BLueh

1) After the completion of Trial Run and the cleveloprnent o1' the yarn path through the eftbrts of
NPI and the Preproduction meeting conductecl by PPC rvith all stakeholders, the QA F'C will
ensure the smooth transition of neu, inductions.
2) During the neu, induction process, the QA I(nitting FC will oversee the inspection of a quantity
of 5 dozens by the l,ine Foleman and eemplete verity the Mini Bulk Machine Induction
Checklist for Line Tech (KNT-FR-137) lilled by Line'l'ech.
3) QA FC Knitting r'r,ill ensure that OPS supervisttl is leeding the data of Waste and thc
actual knitted quantity. in comparison to the planned quantity at ne lcrr the
Mini Bulk Batch.
4) The QA FC Knitting r.vill maintain close coordination with shing. ensuling the
prompt sharing of results for the Mini Bulk Batch.
5) The QA FC Ituitting holds the lesponsibility for actions based on the
feedback provided by the QA FC Finishing, speci knitting process.
iii. Yarn Complaint Card

1) During the production, if rnaiol yarn faults knitting operations statT rvill raise
Yarn Complaint Card to
2) a+-fn++nf+ne+arge |C QA rvill by takir-rg the samples liorlr yarn bags /
cartons lying in knitting and then QAseetiefl+neha€e he r,vill hll Yarn
Verification Column on send it to QA - Drl lab sc€+bn for further
proceedings.
lt.
1) Pre-requisites for
Beforc startinq of ofan order, the Shift Supervisor toe closing u,ill ensure
availability of sites on toe closing maohine
a) / WSS)
b) order
2) Toe
rvill induct on stitching machine; shift superr"isor operations tvill otl'er
e batch
to PRODCU'| INSPECTOR. He/She r.vill inspect the 5 Pcs and will verily
as per Standard & work order and will endorse signature on Daily Stitching Plan
No. TOC-FR-003-Rev.05). In case of any discrepancy, PRODCUT INSPECI'OR
feedback to shift supervisor for preventive measures for bulk production.
Linking Yarns
b) Linking Type
c) Stitching Faults (Sewn in Waste, Wavy Seam, Puckering etc.)

7 Related Documents
0lt
Stitching plan Toe Closing TOC-FR-OO3

End

Prepared by: Reviewed

Designation Functional Lead .^

Date 4Aru A/V1/V
-
 QAD-FR-196
ewwwwwa% "k Revision No. 07
Wffi W W'ffi,#^ 4w DOCUMENT APPROVAL FORM Issue/Revision Date: 30 Nov,2021

,/\PI)RoVED NO I API'ROVI;D

Comrlernts (iI'an)," b1'Approval Autholity):

Approved by:
Va-\
,^,
Designation VP OPS
:r,a;
wwewwww%,ffi "w SOP FOR QA KNITTING INSPECTION (PROCESS [-oP-051
WW-WWWW^ *# BASED APPROACH)

TABLE OF CONTEI{TS

2
1. PURPOSE
2
2. SCOPE.....

-1. DEFINITIONS / ABBREVIATIONS

t,,,,
.,'liij..i.......
1
2
4. ACCOUNTABILITY
,...'2
5. PROCEDURE

TOLERANCE LEVEL FOR MEASUREMENTS, STRETCHES AND WEIGHT......,.'

5
6.
5
1. RELATED DOCUMENTS
5
B DOCUMENT HISTORY..

Tliis document is...

Prepared by: by: Approved by:

Y*a
.--
FUNCTIONAL PLANT HEAD VP OPS
LEAD

Effective Date: 2S.lnrzrlzi

lssue / Revisiorr No. 12 lssue Date Jan 03,2024 Page 1/6

 SOP FOR QA KNTTTING IF{SPECTEON (PROCESS
INTERUOI BASBD APPROACH)
rLoP-051

1. Purpose
The objectil'e of this procedure is to establistr and rccord the inspeotion process for qualrty assuranoe in Knitting, with a
shift in mindset from product inspection to Proocss audit in alignment rvith the BIQ Concept theme. It encomlxsses the
development of a systematio approach, detailed inskuctions for oonJucting the process, and the allocation of
responsibilities to ensure a thorough understanding of crutomer requiremurts witlrin the knitting inspeotion process.

2. Scope
fhis prooedre encompasses the inspeclion aotiviiix wilhin th-e Knitting llrsccss & Toc Clo;ing process and is applicablc
to all customer orders.

3. Definitions / Abbreviations
GL Group Leader
TM TeamMember
QA Quahty Assu,rance
wss White Seal Sample
BSS Blue SeaI Sample
BIQ Builtin Qalit_v
CTQ Criticalto Q*lity
ADS Aulomated Dspensing System

4. Accountability
"QA is accountablc for th: applioation of {ris proce.l.rt:.

5. Procedure
The incoming QA GL will resume QA e: and engage in discussiorn regarding any
highlighte.l issues from the previous will cover trpios such as majoi or recuiiing lh'.rlts in specific
orders, tlrc introduotiour of new prcLi;r.,,-,. The QA GL will lhen poride the "Daily
Knitting Inspcotion Fe,rn1 " to andl-r,: rvill auton:at,xi7y generates all inspeclion pirameters fronr
the QMAS syqtem.
lhe PRoCESS AtiDITOn assignc.l Lnittfurg lines anrl oblain necessary essential information such as
Order ltiqmber, Delir.ery lrda:hine Size, arll Bss; Color. Thisinformation wili be sourced from
f.e "Da.ly Achieved Plan)" report es rnell as the i.iVSSiBSS Folder" accompanied by the Trial
Ilrn Pcpprt,ICrittirry Yarn Patl,, *hich are provided by li"r:"ling Operations. The PROCESS AUDITOR
rill {harwrify all thc machirres curcltly h-'i.rg utilizeli.
&. ' .i,

BIQ Process at.kuitung lercl; PROIESS AUTJITOR will condrct +Jle DAII,Y KNITTL'.IG
AUDIT ol all knittL ', r,rachinc: r33Y i.- eec'. i''.ri:t) rnd til! pcrfL\rm pal' c:de u'isc 1'ar:r
r ril.h u.ork ortLr/WS S/B SS)
2) QA Gl-r,rill be IJr:111, Knitting l)occss Audit iqap-';'R-223-
Rev.01) findings at
n.
1) To enswe Article change o\,Er on Righi First Time I'>RODCUT INSPECTOR vill conduot the
Changeover Process Audit ih Lelorvtwo ph;,ses
a) Verifrcation of ohangcover pre requisites Qrial, Itun repcrt/Risk Assessment/ Yam & ya"n path
Co{;ril / ctc.).
t) r'}hysi.:al Sccl:.i i:rspecr,i:

Issuc / Revisi'r,i Nc. 12

' IssueDale Jan 03,2024 Page 2/6

I
 KNITTING INSPECTION (PROCESS
INTERIGP SOP FOR QA
R,|SED APPROACH)
rLoP-051

2) When new orders wjII nduot on knilting macktne or any ahange will takc plaoe in the nuling orders,
then shift sq)ervisor operations will send the DAILY ARTICLE CHANGE OVER BOOK Form to
PRODCUT INSPECTOR after getting it confinned by knitting teohnioian.
3) PRODCUT INSPECTOR vrill perforrn the inspeotion of 5 pieoes after lvlachine Change Over (Change
Over inclrrde Size, \'am, and Arlicle). Break up of iuryecti<xr of 5 pieces as
a) 01 Piece for Greigo measurernent, stetoh, Yarn verifrcation and WSS/BSS verification
b) 01 Pair for Greige Weight (noluding frrst pia:e)
c) Workrnan Ship @abrio Defeots) of all Fire Pieces
4) PP.ODCUT INSPECTOR lrih recorcl Change over Pic;crs Audit Findings on his/her KNIITING
MACHINE CI{ANGE OVER AUDIT (QAD-FR-22;|-Re:.' 0l). h case of decided
parametcrs in Process Audit a-rd Prodr,rct Audit, .r\u'"tritor t'ill declare the Changewer Fail and
advice to opcmtiou supsrr"isor for con'eotive meas.rbs acoordingly.
5) QA GL will be responsible tbr data feeding of last shifl'KNITTING OVER
AUDIT findings at strift start up.
iii. CTO (Citical to Oralit! Proce,ss Audit
1) To ensr:re standardized practioes it 24/7, QA FC will conduct the to Qualif)
Process (QAD-FR-222) audit aad shmelho CTQ hocess Audit
2) Knitting QA FC will be reqponsible for sumtrarized data audits on need basis
@aily and Monlhly) with all opration staketolders and actions from concem
teams.
b. .,,]roduct Inspection
i. Daillt Kniitine Product Inspection
1) PRODCTIT INSPBCTOR wiII -uerforrn wise at ADS structure oilnitting lines
and wifl check the ONB Fresh piece
a) Grcige measurement
b) WSS/BSS vcritloation &
o) Fabric faults& Trimming ( ofthree pieces including one fresh piece)
2) To ensure the weigtf and of socks, 1he PRODCI-IT INSPECTOR rvill assess the
sh'etches of'speoifio (one maohinr: tbi each pair code) using a stretch machfulc
PRODCUT a record ofthis data on the "I)aily Greige Stretch lnspection
Fofm:"
3) To enir:re flre socks for TARGE I anC AIr{AZON ctstomers across all operaticnal
knitting iI.ISIEETOI{ r,,ill con';uCi slretehes cn 33o/o of the total operational
B5r foilowing this appqoach, al, rnachines rvill be covered on a dcily basis.
inspections, if tlre pnoDCUT'iNSpBcfon identifies a singlc defectivc
.4) virtiations, stretch verifrcation discreprurcies, or fatnic

anC
riece ssary corrective measurgs:
The currort producton on dr,e,t,,,achine witl be rsrnoved b1-.ihe line technician or shift supervisor of
operations for sorting the d;fctiye rtrandly
1) Once the knitting rnrchine has bcm rectifred, thc line leci; or shift supervisor cf opcrations rvill
',:iarr
inforrn the PRODCUI INSP.ECI'OR lbr a re-inspcction oflhe machine.
8) Thc PRODCUI INSPECTOR r-'ill re-:nspo;t tlree sample pieces from the Q-Tagged maclil,re. Onc
piece will be from fre sh profuc'tion, and two pjeces will be from reu,orked production. If the regults are
satisfactory, then PRO.DCIUI I.ISPECTOR coontnatc vuith Line crel to remove tl:e Q-Tag and
aulhoize the reswnption of podr:ctj.on on tlre maohine.

Issue / Ilevisic,l lrlo. 12 Issuc Date lan 03,2024 Page3l6

 SOP FOR QA KNITTING INSPECTION (PROCESS ILOP-051
INTERKHP BASED APPROACH)

ii. L!!r,@!t na,xn

l) After the completion of Trial Ru.r and the da,elopment of the yam palh through the efforts of NPI ancl
the Preproductionmeeting con{ucted by PPCvrith all stakeholders, the QAFC will ensure the snocth
tansition of new inductioirs.
2) During the new irrduoticn process, the QA Knitting FC witl oversec the inspection of a quantity of 5
dozens by the Line Foreman 4'nl verifu the Mhi Bulk lvlachine Induction Checklist 0(NT-FR-137)
frlled by Line Tech.
3) QA FC Knitting uill ensure tl.ct OPS supervrsoi is feeding the data of C Grade Wzrste and the aotual
knilted quantity, in compmisontl the planned quantif nt designated machine for the Batch.
4) The QA FC Knittlr45 will mairlaiir olose oobrdination wiCr ttre QA FC Finishing the promp
sharing of rezults for the lrdr.i-E:lk Bd.aL
5) The QA FC Knitting holds the responsibility for inrplemorting oorrective feedbaok
proviCed by the QA FC Finishini, speoifioally within the knitting prooess.

iii. Ycnt Comrtlaint Card

1) During the production, if major yam foults will obsen'e, then stcff will raise Yam.
Complaint Card to FC QA.
'crtons lying in knitting and if
2) FC QA will verify Jre problem Ly taking the samples
the problem confirms, then he wili fill Yam V complaint card and sord it to QA -
Dry lab for firthcr proceedirgs.

iv. Tpe Closins Chaase Over

1) Prrc-requisites for Toc Closing

Before starting of tde elosing of order, the Shift Supcvisor toe closing will ensure
availabili ty of following machlne
Appror,rcdtrim
")
b) Toe Closing
2) Toe Closing
When any new induot on stitching maohine; shift supcrvisor operations will offer
machine for INSPECIOR. I{eiShe will inspect the 5 Pcs and will veri& the
below & work order and will sndorse signature on Daily Stitching Plan (Document
No. 05). In oase of any discrepaucy, PRODCUT INSPECTORTvilI give feeCback to
shift measures for bulk prodrction
a) arns
Type
Faults (Ser,ur in Wasto, Wary Ssarn, Puckering etc.)

Lsae / tlevisionNo. 12 Issip Date Jan03,2024 Page 116

 sop FoR QA KNTTTING TNSPECTION (PROCESS
INTERISP BASED APPROACH)
ILOP-o51

6.' Tolerance Level for Measurcments, Stretches and Weiglrt

Size Welt Rib+ Welt Rib High Foot Welt Stretch Foot
lYeiglrt
Heig[t widrh Length Hcel Length Stretch Stretch
(Gram$ Clip
l.-
I

,
1

# d
3
*1 om
+ 0.00 Nil 10.5 cm
,l .
-F0.5 cm * 0.5 om _o5cm
cm Nil

*#'
5
{
6

Standard (where applicablo in thc lcritting

d*J-
at welt 0 Cn1 Exhayarnat Heel and toc I.5 om, cmandmaximum3 cm

7. Related Docurnents
Daily Knitting [rspeC,ion Form KNT-FR-OO3'
Daily Greige Stretch Inqpection Form System Generated
Knitting Stetch Report KNT-FR.125
CTQ (Criticalto Qtahty) Process QAD-FR-222
Daily Knitting Process Audit QAD-FR-223
K-nitting Change Over QAD-FR-224
Mihi Bulk ]vfrchine Line'Iech KNT-FR-137
Daily Stitching Plan TCC TR.OJ3

8.

Revision Approved By
Revicfufate Description of Chqnges Revised By
-W
l No.
Proccdure
ft) hr orda to ensurq strctch requirernent
of sooks all operational knitting machines
on TARGET & AMAZON customers
tflli115,2021 l0 ody, Q*hty Auditor rvill petform N4anager QAD President
strelches of
33Yo machines of total
opor'ational lvlrchines in eaoh s]rift .By
following it lN % machines v{tl be
covered on daily bosis.

Issue / Rcvision No. 12 Issuc Dats 03,2024 Page 5/6

 sop Fon QA KNTTTING TNSPECTTGN (PROCESS
INTERIGP ASED APPROACH)
ILOP-051

7. Rclated Docrrrents
Knittine StetohReport KNT-FR-12.5
IL logo has changecl Water mark added VP OPS
July 19,2023 I1 Functional Lead
and Docurnerrt History
Increase inspeotior pieoes from one to Funotional Lead VP OPS
Jan03,2024 12
three and add Toe closrng ch44ggqrer-

Issue / RevisionNo. 12 Issr.o Date Jan03,2024 Page 616