QC PROCEDURE玩具验货流程英文版

1、INTERNATIONAL INC.QC PROCEDURE (Revised) Dated: Nov. 2013I. General Process For Quality Control A- New Production Preview On QC sample 1. Safety, function and aestheticevaluated by QC & PD China; 2. Estimating main defectsin production &informing suppliersby QC & PD China;3. Data recorde

2、d in file “NEW PRODUCTON PREVIEW” by Q&S and PD China.B- Pre-production Review1. Comparingwith QC samples, especially for color, material and style by PD & Q&S China; 2. Check &confirm suppliers improvement; C- Online check1. New items were produced by about 510%, suppliers and vendo

3、rs will inform us.2. QC will check production quality per specification and check requirements3. If products fails, suppliers will follow up and improvement4. The reworked products rechecked OK and passed for bulk production.5. Lab test result is also necessary.D-Products Quality Control(QC) Pre Ste

4、ps: 1. Per suppliers inspection request and purchasing team liaison to arrange inspection date, inspection schedule made by QS manager ; 2. Prepare all QC tools forinspected items, including factory contact person& address, approvedQCsample , artwork , order requirements, etc.; On Process: AQL L

5、evel II, Critical (unacceptable), Major (2.5), Minor (4.0) 1. Order QTY checking: inspection must be 100% finished, at least 80% are packed, the other 20% are finished under packing; 2. Quantity of package, storage condition checking: be sure the quantity is correct as inspection request, and the st

6、orage place is dry and isolated enough for check quantity;3. Randomly quality checking: included carton chose, pieces chose to guarantee the real level of production is checked; 4. Quality inspection: package inspection for UPC,description ,shipping mark, hangtag, sewing-in- label, polybag(safety ho

7、le and warning words arenecessary on polybag), etc, safety inspection for export carton quality(standard ref chart I-4.1), fabric strength, sewing strength, small parts, sharp edge, metal detector etc, defective inspection for production clearness, production appearance & colors, workmanship, as

8、semblage, finishing etc. Safety checking will be done during lab testing & PPS process. Randomly checking from production; 5. Photo Record: at least one photo with 35pieces(sets) for each item inspected, two photos for critical & major defective recorded in case of future tracking, defective

9、 sample need be collected for mainly major defective or critical defective and sent out on same day of inspection; 6. Data record: handwriting report must be finished & confirmed by supplier in factory, for “RESULT” with detailed “CRITICAL”, “MAJOR”, “MINOR” & “PACKAGE” information, also the

10、 remarks for rectification proposal; 7. Any failed inspection might cause a shipment delayed need be informed to QS manager & purchasing dept. at once.8. If urgent shipment and goods failed at same time, please let factory rework immediately and QC rechecked once more onsite;Next Steps: 1. Repor

11、ts for record: handwriting report & photo for each finished inspection must be transferred to Q&S China coordinator once inspection finished; 2. Summary of each finished inspection must be reported on time to global purchasing dept by Q&S China Coordinator; 3. Defective samples kept for

12、2- 3months is necessary, mainly for major & critical defective; 4. Quarterly assessment & internal sharing. II. Specific Products II-1: Plush Toys l Compare with approved QC sample(signed by PD from USA) for shape, workmanship, size, material, color; l Check the weight: to be sure enough stu

13、ffing inside, also guarantee correctfabric; l Pull the small part such as nose, eyes, tails, ring, etc. to make sure no small part drop off(diameter less than 5mm, 50NT/10seconds, more than 5mm 90NT/10seconds); l Check the seam strength to make sure the stitching is enough strong(70NT), also to make

14、 sure the stitching is enough intensive( 9-10stitches/inch) l Metal detector checking is necessary as the last quality check step before packing into cartons; l Common defective: holes, broken stitching, stain, wrong color, light fabric, fiber falls off etc. l Critical defects: holes(especially afte

15、r pulling force),small parts, blades or other metal parts,etc.Photo For Reference: Quantity Checking: Shipping Mark & Labeling Checking: Item Checking:Safety Checking: II-2: Plastic Toys l Compare with QC approved sample for shape, competent, colors, assortment, etc.; l Check the UPC, package, w

16、arning , recycle signs, sticker etc.; l Pull the small part,; l Check the function if it is a movable item or an electric operated item; l Rub the painting or coating part to check the painting or coating quality; l Drop test to check the items sharp edge, sharp point, function, etc.l Drop height ac

17、cording to different imported nations needs.l Common defective: wrong competent, missing part, poor painting, item or package deformation, leaking etc. l Critical defects: small parts, sharp points, sharp edges, no function, short circuit, battery overheat,Mildew,etc.Photo For Reference: Competent C

18、hecking: Package Checking: Product Drop Test: II-3: Fabric Inspection (International 4 Points Standard) l Check rolls and storage isolated for quantity; If QTY not enough, inspection upon actual QTY; l Packing list check and randomly chose rolls for inspection; l Compare with reference swatch and ch

19、eck the fabric style, color, pile height, weight; l Check cut width, total yards quantity or meters;l Common defective: holes, stain, light weight, less width, less length, loose weft or warp, etc. l Critical defects: mildew spot, missing weft or warp,etc.Remarks: for each holes, stains, added quant

20、ity is 0.2meter per each defective. II-4: Wooden Toys l Compare with approved QC approved sample, check aesthetic ,competent, assortment, etc; l Check the smell of products; l Check the wood humidity between 1112;l Rub the painting or coating part to check the painting or coating quality; l Common d

21、efective: small knock marks, paint rubs, surface burr etc.l Critical defects: Irritating odor, small parts,etc.II-5: Eyes Partsl Compare with technical data and specification, per our QC approved sample also;l Check the color ,structure, material, size, etc.;l Impact test passed by lab testl Calibra

22、te eye dimension, diameter, stem size, etc.III. In-line inspection l Plush toys orders: Fabric inspection for bulk order, plush order quantity > or = 2K during off season, > or = 3K during peak season; l Production in-line for 5-10% production for order quantity > or = 1K pieces during peak

23、 season is needed. l For each in-line inspection, buyer or merchandiser needs work with QC team for inspection arrangement. REMARKS: Buyer or merchandiser has to check in-line when QCs schedule is unavailable.CriticalUnacceptable关键问题不可接受1wrong package(UPC, description, recycle sign, labeling,warning

24、,age grade,etc.包装错误（条形码，描述，环保标识，布标，警示语，年龄标等）2safety issues like small parts,sharp edge,sharp point，strength ,metal detect，etc.安全性，如小物件，利边，尖点，强度，金属物，等。3wrong fabric(wrong color),wrong stuffing material面料用错，填充物用错。4product or accessory mildew.产品或部件霉变。5pungent odor有强烈刺激性气味。6drop test failed，no function跌

25、落测试不通过, 无功能。7foreign object in package or material like insect,etc.产品或包装里有异物。8Battery overheating, short circuit电池过热，短路Main defects(2.5)主要疵点（2.5）1holes,broken seam破洞，爆线2stain污渍3missing part or wrong part部件缺少或部件用错4function (sound，activity, etc.)功能不良。5poor workmanship or shape做工不良或形状不良6coating or pain

26、ting peel off油漆或涂层脱落7color not match色差8Liquid leakage渗漏9joint knot no work关节等功能不良10cord exposed裸露电线11package damaged包装损坏Minor defects(4.0)次要瑕疵（4.0）1Loose thread线头松2less weight克重不足3poor painting喷油差4undersized or oversized尺寸过大或过小5poor glue打胶差或粘度差6light color match轻微色差7sticker peel off贴纸翘起1- Defective

27、List (mainly defective found during inspection or production): 100% minor defective will be a major defective for whole production. It is to make sure our quality is CORRECT for our market. 2-AQL Level II : K&M Inspection Standard: Regular AQL Level IICritical = Unacceptable, Major = 2.5, Minor

28、= 4.0. This standard can be improved & strengthened according to the quality of products.Sample Size CodeSample SizeNormal Sample PlanStrict Sample Plan2.54.0 2.54.0 AcReAcReAcReAcReA2B301C50101D801E1312F20122312G3223341223H5034562334J8056783456K1257810115689L20010111415891213M315141521221213181

29、9N50021221819P800Q1250R2000S31503- For all common defective, whatever major or minor. The production need be re-worked or re-finished, and re-inspection is necessary. 4- Chart I-4.1: CTN Drop Testgross weight (KGS)test height (CM)0975918601827452745304520Export Carton Drop Test: Checking Way: 2 cart

30、ons per PO need be checked for drop test; For example export carton size 60x30x40cm. Step 1: Any one of the corners free falls; Step 2: the shortest edge closed to the corner free falls(should be 30cm edge); Step 3: the shorter edge closed to the corner free falls(should be 40cm edge); Step 4: the long edge closed to the corner free falls(should be 60cm edge); Step 5: the 2 small panel of the export carton free falls(should be 30x40cm side); Step 6: the next 2 bigger panel of th