Quality Control Manual.doc

Updated: 11/11/2008PetEdge, Inc.Quality Control Manual QC Manual 21 of 21Chapter OneQuality Control ProcessPetEdge China Sourcing team is committed to provide top standard merchandisers to customer with full QC system coverage in China manufacturers. A. Factory Evaluation Every new vendor want to develop business with PetEdge, who must go thru Petedge QC audit program, Petedge will rate the vendors with 4 colors ratings to determined if vendors is qualified and reach standard of Petedge required.GREENExcellent VendorYELLOWVendors existing minor issue, Petedge will develop with this vendor and vendor shall continue improving to eliminate the minor shortfallsORANGEVendors existing major issues, Petedge not consider to develop with Orange Vendor until vendor make major improvement followed Petedge within 90 days and waiting next auditREDDisapproval vendor and Petedge will discontinue business with them immediatelyB. QC inspection StepsTo ensure qualified shipment, Petedge QC shall have following steps to supervise production process in factory . Pre-Production Meeting and Introduction ReportAfter factorys PP sample approval, Petedge QC will have a meeting with factory for verifying material, workmanship, production line set up etc. to put it all right before mass production In Line Production CheckingSupervise production and quality status and reported to Office During production ( Dupro) Inspection When factory started packaging and packing of shipment, QC shall be at the factory to check the finished pcs and ensure no mistakes Final random inspection On the basis of 100% production completed and min. 80% shipment packed, QC shall do final random inspection according to AQL2.5Re-Final inspectionIn case of first final inspection failure, re-inspection must be followed up, QC shall work with factory for correct plan and rectify time. C. How to Do QC inspections 1. Prepare file for QC inspectorThe Oder Expeditor will prepare the Order File to be taken along for the QC Inspection, and give it to the Quality Control Coordinator. Sending by Email is preferable. The file shall contain: Purchase Order details Product Spec of shipment Any special instructions Approved PP Sample Email exchange on the PP sample quality comments Packing and packaging instruction Swatch board Inspection booking formThe QC shall inspect the file to ensure that all necessary information and product is included. 2. Carry out QC inspectionThe QC must collect the order file and ensure approved PP samples in factory as well as min.80% shipment was packed before going to do the inspection.The QC Inspection involves the completion of the “Inspection Report Hard goods” or the “Inspection Report Soft goods”.The inspection is based on the AQL 2.5 standard. AQL standard of Quality Assurance is measured as the maximum percent defective that for purposes of sampling inspection can be considered satisfactory as a process average (i.e. the maximum number of defects per sampling size that is deemed acceptable).Defects detected during inspection are classified within 3 categories Critical, Major and Minor.Critical A defect that is likely to result in a hazardous or unsafe condition for an individual using the product or that is contravening mandatory regulations. Any critical defect will result in a failed inspection.Major - A defect that is likely to result in failure, reducing the usability of the product and obvious appearance defects affecting the sale ability of the product.Minor - A defect that does not reduce the usability of the product, but is a workmanship defect beyond the defined quality standard.When defects are identified they need to be marked on the product with a red sticker highlighting where the defect has been identified. The defects are then to be photographed and downloaded in a central QA file under the PO number. The photos can then be utilized by the merchandisers and the buyers as visual representation of the defects identified.3. AQL 2.5AQL 2.5 TableOrder QtySample SizeAcceptRejectInspection %1820125.0%91530120.0%162550120.0%265080116.0%5190131214.4%91150201213.3%151280322311.4%21.2%281500503410.0%18%501120080566.6%16%12013200125783.910.4%32011000020010112%6.2%100013500031514150.9%3500115000050021220.3%15000150000080021220.2%Major defects1 pt.Minor defects0.5pt.Note: Each SKU# must be inspected according to AQL 2.5 on both visual and measurement.4. QC Communication with office for inspection Phone call by QC inspector to keep informed about quality status, defects to QC manager that found in the inspection, A copy of the completed report will be given to the supplier and any required rework will be discussed and documented. The completed report must also include the time the QC Inspector commenced the QC inspection and time of completion.A electronic of inspection report will be emailed to the Quality Control Manager on the date of inspection, the Merchandiser and the Order Expeditor, and The QC Inspector will discuss the outcome with both parties and an action plan for resolution agreed. If the order has failed the inspection, the QC Manager may advise QC that the failure is within the tolerance zone or can be immediately rectified and agree to pass the order once the advised criteria has been met. QC manager will decide QC to see if need another AQL inspections.It is the responsibility of the QC Manager to make the final decision on whether inspection levels are within the tolerance range for approval. Based on the direction of the QC Manager the goods will either be classified as “passed” or “failed”.5. INSPECTION RESULTAfter the random sampling inspection, the QC officer should judge objectively whether the shipment quality meets the customers standard. Under normal conditions, the inspection result would be one of the following.- Passed- Held(Pending)PassedShipment quality meets the required standard. The accumulated numbers of defects for each individual class (i.e. Major and Minor) are below the Acceptance Number of the AQL table.The pass status may include a letter of guarantee by the Supplier. Only Office Manager may approve a letter of guarantee. QC QC Manager to review the hard copies of the QC inspections and is responsible for issuance of Cargo Release Confirmation document. Held (Pending)Due to incomplete reference material, there is a need to further evaluate or communicate the findings with QC manager personnel, related merchandising staff or customer, in some cases, if the product still needs to be verified by a specific laboratory testing, the shipment will be pending for the laboratory result.6. Failed inspectionsIf an order fails it must be repaired, or, if this is not possible, the good must be separated from the rejected batch and the batch that has been rejected remade.When the order is ready for re-inspection, the QC inspection process must be re invoked using the same sample size, and re-inspecting the entire sample.If the number of defects exceeds the allowed number by any amount, the order must be rejected, even if it fails by only one unit.If the order fails its second inspection, the QC coordinator must immediately telephone the QC manager for direction and advice7. Penalty for re-inspectionPetEdge always would not like to see re-inspection happened and prefer all vendors shipment can be passed at one time. Petedge is not going to charge back for re-inspection but In case Vendor have re-inspection over one time, Petedge has right to charge back for QC expense and cost. The penalty will be deducted from the correspondent PO shipment amount. D. Inspection GuidelineQC officers should communicate clearly with the vendors key staff before they execute inspection procedures. Approval sample must be available during the inspection.QC inspection at the factory, normally, will be of the following sequence:.Perform drop test and crush test (to evaluate packaging strength for transport).Draw samples randomly from the shipment.Perform visual inspection including packing, artwork, workmanship and construction.Try the samples from the view angle of an end user;.Measure and weigh merchandise against specifications;.Check UPC number and items number and details on packaging and labeling.Perform other tests, as necessary;.Document all points in the inspection report;.Conclude inspection results and shipment delivery status on the QC report.After the final inspection, QC inspector will ensure the supplier understands the findings.Consolidate defective samples by groups;.Review and discuss the occurrence of the defects and means to prevent them;.Issue QC reports;.Obtain signature confirmation from factory on the report;.Send inspection report back to office;.If inspection result is “held” (means waiting for further information from office), obtain defective samples and the reason for retaining such samples, and make sure factory fully understands the reasons for removing away the said samples;.Where applicable, obtain a tentative re-inspection schedule;.QC inspectors contact the office when they encounter any problem at the factory.E. Product Testing During inspection The method of counting defects follows the International inspection standard, MIL-105D.Drop Test Carton drop test is applicable to all Hardline items Unless otherwise specified, two master cartons randomly selected from the shipment will be drop-tested. Hold the master carton in a horizontal position, pointing the testing panel to the concrete floor .Drop the carton onto the concrete floor at the appropriate height. Repeat the test for each of the 6 faces of the master carton. With an appropriate holding position, the same procedure applies to 3 edges and 1 corner of the same master carton.The appropriate height to drop the carton is:Gross weight of master cartonHeight From bottom of master carton to floor010 kgs1 meter10-18kgs75 cm18-25kgs50 cmAny one item of master carton found broken will be regarded as a failure25Kgs and above stand package upright and push over once only. Weight Warning triangle Advice Yellow and black triangles are required on all retail packs if they meet the 10-20 kgs, 20 + kgs, pack size and uneven weight advice. Black triangles must appear on inner cartons if they also meet the 10-20 kgs, 20 + kgs, pack size and uneven weight advice If product is not contained in a retail pack but meets the 10 20 + kgs weight, then said items should include a peal able yellow weight warning sticker /label. Primary TestAs the scope of the products varies widely, there cannot be any fixed scope of testing for the fast moving products. The most important test to be done is the “AS User Test”. Here the QC officers will transpose their role to that of the end user, attempting to use the product as the end user might. If there are any quality issues, the officers should report to their superiors immediately.Assembly Test for Knock Down ItemsQC must personally perform assembly test for Knock Down Items on at least 2 samples, randomly drawn from the batch. QC should ask vendors to assemble another 10 pieces under supervision.Merchandising staff concerned must alert vendors of this procedure, and have vendors to assign enough personnel at the factory to assist in assembling the drawn samples.QC should review the assembling instruction sheet and assemble the sample according to the steps illustrated in the sheet.Function TestFunction test is applicable for all items.QCs must perform function tests on all of the samples taken for the inspection.Hi Pot test QC must perform Hi-Pot test on the total sample batch for all electrical appliances.Goods must be rejected if any ONE sample failed in a Hi-Pot test. Moisture testAll wooden items must be tested for moisture content with a moisture detector.USA OAK within the range between 8% - 12%CHINA OAK within the range between 8% - 12%RUBBER WOOD within the range between 8% - 12%PINE within the range between 8% - 12%All rawhide items must be tested for moisture content with a moisture detector.PRESS BONE within the range between 10% - 12%TWISTED BONE within the range between 10% - 13%KNOTED BONE within the range between 10% - 13%MUNCHY within the range between 10% - 12% UPC Code ScanItems that are UPC code must be tested with a handy barcode scanner by QC to ensure that the UPC code is correct and consistent with the printed artwork has been scanned at Shanghai office and confirmed it correct.F. Inspection Check ListPetEdge has various of merchandises for shipment inspection, QC shall consider approval PP sample and PP sample specification as standard. Below is the general Defects classification that need QC check completely during inspection.Specific Defects of ClassificationDefective ListCriticalMajorMinorRemarkProduct are out of spec. tolerance on size, weight, coating thickness, Insufficient poly-cotton filling * *Incorrect Material: fabric weight, fabric/yarn contents, fabric color shading; discolors, incorrect texture and printing pattern; wooden moisture percentage; metal content; plastic/rubber content*Hand feeling bad *Weakness, no reinforcement part, accessories/attachment falling off, any accessories with illegal logo; missing accessories or parts*Incorrect/Illegal info on Printing stuff, care label, woven label, size clip, assembly sheet, carton marking, UPC #*Any harmful or dangerous material to health*Dirt, spot, streak, shading, chalk mark, shining mark, dust, rust, scratch surface*Depend on the extent of issue to judge Major or MinorBad /pungent smell*Broken stitch, uneven stitch, open seam, joint stitch, puckering, loose/tight stitch, skip/jump stitch, runoff stitch, SPI uneven, blind stitch, over stitch; needle hole). High/low on left and right parts, Uncut thread, loose thread ,Torn, Crack line, unsecured welding, bubble, spatter, welding beads*Depend on the extent of issue to judge Major or MinorPrinting: Surface not smooth, registration, smudges. Coverage, streaking, dots and Fading *Mal-Function; low battery; motor out of working*Sharp edge on product* Incorrect product construction, improper product shape; incorrect product spec and technology* Products failed at Drop testing* Coating uneven, painting holiday, pinhole, rust *Incorrect packaging and packing: hanger placed wrongly, hangtag/labels misplacement, wrong quantity packing, improper PVC /PE bag packing, wrong carton size*Grommet or other device specified to hang on peg hook; poor alignment Packing and Packaging: Hangtag/cardboard bent or damaged; printing box opened, damaged or crushed; PVC tub/clamshell crushed, PVC bag broken or crushed; master carton or inner damaged or deformed; grommet or other device specified to hang on peg hook; staples poor alignment; products was wrinkle and damaged; products from improper packing, printing card over cutting *Grommet or other device specified to hang on peg hook; poor alignment QC shall refer to below the material, product parts and workmanship for defects description as one of guideline during inspection.DEFECT DESCRIPTIONCRITICALMAJORMINOR1. Shipment Packaging (refer to Section Carton Checking)2. Selling PackagingAccessible sharp point or edge that may injure the user / purchaser *Blood stain*Foreign substance refer to Foreign Substance Table Deformed unit packaging material*Irritating smell*Loose fastening or sealing *Loose packing, insufficient stuffing or fixing inside selling packaging*Missing / Incomplete component*The information on selling packaging does not match actual product*Torn / Damaged / Wet unit packaging material*Unstable / Asymmetric selling packing that will fail to display*3. Labeling, Marking, PrintingMissing / Wrong / Incomplete label or statement of warning / safety marking *Missing required marking such as UL, ETL etc.*Missing country of origin marking if required*Missing Importer / distributor name and address within destination country if required*Color variation of printing within one unit or unit to unit *Label curled, poor adhesion of label*Label peeled off*Missing, incomplete or wrong marking / label / hangtag / instruction sheet / manual*Poor /