Workshop - Gap Inspectors Jun 10, 2021

GAP
Inspection
procedure
1 LATAM
June 10th, 2021
Copyrights SgT Group © 2018
MENU
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01 Handwritten Reports
02 Inspection Report
03 Latest Updates

01.
Handwritten Reports

01.
Handwritten Reports
• Inspector is to always use the 3 handwritten reports of GAP for each inspection
final inspection.
• HWR for visual inspection

• HWR for packing audit
• HWR for measurement
Note: For inline HWR packing audit is not needed.

01.
Handwritten Reports
• HWR for visual inspection
Visual inspection HWR including:

1 1. Order information
2. Defective information
3. Packing accuracy
4. Test report information
2 5. Inspection summary
6. Signature
7 7. Additional comments
5 3
4
5
6
01.
Handwritten Reports
1. Order information
You should use DPO Sheet when filling this part.
OCT 10, 2020

MILCO APPAREL EL SALVADOR
486200 6000 LENOR INDUSTRIES
(102) APPAREL GREY HEATHER - NAVY N/A NAME
YOUR
ALTITUTE TIGHT
XS21I-HA 032 4000

XS21I-HA 052 2000

01.
Handwritten Reports
2. Defective information
You should use defect list file to describe defectives.
VS02 Puckering 2
VS05 Open seam 3
1356 Measurement defect 1
1215 Measurement defect 3
Use POM codes from original measurement chart

for each measurement defect

01.
Handwritten Reports
3. Packing accuracy
You should use Pack audit sample plan in GAP Final SOP
65
13 N/A
Example
Total carton quantity is 65 cartons.
Inspector is to select 13 pcs cartons for inspection.
If the 13 selected cartons were not enough to cover all sizes and colors, upgrade sampling to next AQL level, which is 20
8 cartons.
Other eventual sampling out of AQL are NOT aceptable.
01.
Handwritten Reports
4. Test report information
• Test report only valid 6 months from report
date.
TRM-0000506220
• Use DD-MMM-YY date format in the
inspection report.
Example: 07-SEP-20
• Use GAP report number in the inspection

report.
Example: TRM-0000506220
• Product stage shows type of test report.
9
Example: GARMENT
01.
Handwritten Reports
5. Inspection summary Mandatory remarks for Gap
80
0 X • Indicate what is the AQL of sewing tolerance and overall AQL
0 3 X sewing result
X
X
X
Example:
X Sewing Defects VS05 and VS09 AQL 1.5 Ac 2 Re 3 – Result PASS
All mandatory remark here
• Indicate overall result for Combined visual + meas AQL
Example:
1 visual defect and 1 meas defect found = Combined AQL PASS
10

01.
Handwritten Reports
• HWR for packing audit
68 • Add carton number correctly on the report

• Use Pack Audit sample plan
04 XXS 25
15 XS 25
16 XS 25
21 XS 25
23 S 25
36 S 25
42 S 25
43 M 20
52 M 20
60 M 20
62 L 20
65 L 20
67 XL 18
68 0 /1 X
13 0
11

01.
Handwritten Reports
• HWR for measurement
Compare original Measurement Chart (MC) in TP and pre-filled MC on the received inspection report to ensure
specs for inspection are correct.
If you used printed MC from factory as HWR, add next information on top or bottom of the paper sheet:
• Highlight POMs OOT
• Remark Sample Size
• Remark Pass/Fail quantity
• Result: Pass/Fail
Example:
12

01.
How to send e-mail HWR to PQA

• Inspector must e-mail a copy of HWR to the respective PQA + cc PQA director
(hector_ramos@gap.com) and SgT Back office (bahadir.manus@sgtgroup.net,
manuel.torres@sgtgroup.net).
• Send 1 e-mail per inspection performed.
• Attach to the message the next:
HWR for visual inspection

HWR for packing audit
HWR for measurement
13
1 Picture of each visual defective found
01.
How to send e-mail HWR to PQA

• Use next structure for the message send to PQA:
E-mail Subject: SgT HWR_Inspection type_ DPO#_Style #

Example: SgT HWR_Final_YS50Z-YA _503945
E-mail information: Send summary of each AQL result.

Example:
Dear XXX,
Please, find attached the handwritten reports of today inspection at XXX.
Visual audit: Pass

Meas audit: Pass
Combined Visual + Meas: Pass
OCR: Pass
Packing: Pass
14 Overall Result: Pass

02.
Inspection Report
15

02.
Shortage/Excess rule
• Verify each size quantity per color per size between actual packing list and PO sheet.
• Any quantity shortage/excess +/- 5% per size inform Back Office
• Presented order quantity shortage/excess +/- 5% inform Back Office as below example.
Ordered Presented
PO#XX97F-HA style 486200 Difference %
quantity quantity
xxs 162 159 -1.85
xs 703 738 4.98
s 1421 1493 5.07
m 1206 1242 2.99
l 473 494 4.44
xl 178 192 7.87
xxsp 25 23 -8.00
xsp 105 107 1.90
sp 169 153 -9.47
mp 113 115 1.77
lp 51 53 3.92
xst 26 26 0.00
st 101 86 -14.85
16 mt 144 108 -25.00
lt 86 78 -9.30
xlt 37 33 -10.81
5000 5100 2
02.
Mandatory documents to verify for inspection

• DPO sheet
• Packing List
• BOM
• Original Measurements Chart (MC)
• MRP checklist
• Final/Inline SOPs
Factory is instructed to provide the next:
17

02.
Inspection report preparation

Fill empty cell correctly.
• Gender: Man, woman, kids, baby etc.
• Market: USA, Canada, etc.

- You can find proper name on DPO
sheet
• Inspection date format DD/MM/YYYY

- Example: 29/10/2020
18

02.

Examples:
X V Girl X V USA
X V Woman X V CANADA
X V Woman
X V 20/10/2020
X V Man
X V Baby
X V Man
19

02.
• Order and presented quantities should be correct.
• Inspected quantities should be select proportional
• Example:
Order Qty: 3360

Brand:Athleta -> AQL level 1.5 -> sample size:200
Formula: 2472*200/3360=147 incorrect

888*200/3360=53
Black: 2472 -> sample size 147

Bright White: 888 -> sample size 53
20

02.

All cells should be fill correctly.
Should use GAP Final SOP for each Gap

brand induvidually for sample size, AQL
level, max. allowed
21

02.
Information on report portrait must be properly filled in
• Add carton numbers as ascend.

-Example: 1, 5, 8, 16, 32, … Correct
5, 16, 1, 8, 32, ….Incorrect
• FYI → All documents and approved simples are always

provided by FACTORY.
Factory
Factory
22

02.
Add defects per color

First color
• Add all visual defects
• After add measurement defects per color
Second color
• Add all visual defects
• After add measurement defects per color
23

02.

It is suggested that inspector add pictures into final report as per below sequence:
• Packing and labeling section • Conformity section

1. All labels on garment
1. Approved sample view
2. All artworks on garment
2. Product view per color
3. All hangtags
3. Fitting
4. Barcodes on hangtags
4. Color shading among garments
5. All accessories (zipper, snap, cord, …)
5. Color shading between approval and bulk
6. Polybag
6. Grey scale grading
7. All carton labels
7. All trim cards
8. Open carton
8. Fabric and garment test reports
9. Barcode scanning
9. Email update provided by fty about style conformity
10. Cartons in the warehouse
11. Selected cartons
12. Packing list
13. DPO Sheet
14. Email update for shortage/overage
24

02.
Report delivery time
HWR: Send to PQA at the end of inspection before leaving factory
Final report: Same inspection day at nigh or by 10 AM of the morning after

inspection.
Note: Final report is to upload in SgT website.
25

03.
Latest Updates
26

03
Factory tour procedure

• To be conducted when Inspection Sampling is less than or equal to 50 Pieces
• To be performed in either:
➢ 1 Inline Inspection with 1 style only (1 manday)
➢ 1 Final Inspection with max 50 pcs (1 manday)
➢ Or Combined with 125 pcs (2 mandays)
• Inspector to check with CS for any styles in particular to be checked (instruction
given by PQA)
• If no specific styles are mentioned, Inspector to check any GAP running styles,
prioritizing key styles, high risk styles.
• Maximum of 2 Styles can be checked.
27

03

• Process
• Ask factory to provide WIP =>
• Go through whole production process (from cutting to finishing) and check 5 pcs for each
production stage (visual). In finishing area, check 5 pcs for both visual and measurement.
➢ If a defect is spotted on > 50% of the pieces, select another 5pcs for visual and notify in the
report.
• Reminder: Manually check 5 pcs of button/snap/machine attached hardware to ensure the
28
attachment strength.

03

Example of Production Stages:
29

03

• Wherever auditor finds irregularities, e.g. bottleneck in any production stage,
unbalancing between WIP vs. output, he needs to add comments and pictures to
the report.
• Incase Inspector cannot perform Factory Tour => Select any one of the following
reasons
• For any Irregularities Identified => Select any one of the following reasons
30

03

NOTE: Incase Factory DO NOT ALLOW Photo Taking of Production Line, please take
all Defective Pieces found during Factory Tour to the Inspection Room and take
photos accordingly
31

03
DA Correlation procedure
Process:
• Inspector MUST confirm with CS if DA Correlation is requested
• If Yes, proceed as follows
1. Select DA Email
2. Input Inspection Sampling
3. Add Photo of DA
4. Input No. of PASS and FAIL Pieces found by DA
5. Check the PASS and FAIL Pieces and input your findings
6.
• Based on results in 5, DAC Correlation Rate will be automatically calculated
• If DAC > = 90%, DAC Result = PASS
32 7. If there are any comments, please add here

03
New measurement method (As of June 10th)

Step 1: At time of Final Inspection: A target size garment (refer to the next page)
will be selected from the AQL Sample
➢ Any Color Target Size is to be checked against all Measurement Points (Incl. Critical)
➢ This piece MUST be checked also for construction, wash & embellishment standards vs. PP/GTS
➢ Any POM that is OOT = MAJOR DEFECT (1 Garment = 1 Defect)
➢ Even if the Target Piece is within Tolerance => we still need to go to Step 2
Step 2: Perform Measurement on Sampling: 3 Pieces per Size (excluding Target Size)
and for Target Size, select 2 Pieces to cover the sample size required.
➢ All colors should be represented cross size.
➢ Measure only Critical POMs + POMs that were Out of Tolerance in Step 1
➢ If there were no Out of Tolerance points in Step 1 => Measurement only Critical POMS
33 ➢ If there are 2 Garments with the same POM are 1/8” Out of Tolerance = 2 MAJOR DEFECTS (1 Defect = 1
Garment)
03
New measurement method (As of June 10th)

➢ If Two garments with the same POM are OOT => Move to Step 3
➢ If Two garments with the different POM are OOT, e.g. two OOT, one is for body length and the other is for
chest => no need to move to Step 3
NOTE:
1. All colors should be represented within the 3 pcs per size. (If more than 3 Colors, colors can be across sizes.
e.g.: Small Red, Blue, Green: Medium Blue, Orange, Yellow)
2. In some cases, the quantity of 3pcs per size may be greater than the initial sample size, so inspector needs
to stay with the initial sample size and the sample must cover all sizes across colors. If the initial sample size
can´t cover all sizes, auditor must go to the next level of sample size.
Step 3: Perform Measurement on Full AQL Sample Size Quantity

➢ Measurement on all Out of Tolerance points found in Step 1 & 2
➢ Sampling will be the balance pieces (pieces not checked in step 1 & 2)
34 Note: ALL garments of the AQL Sample qty are to be 100% visually inspected

03
New measurement method
35

03
New measurement method

2. Critical POMS
36 Note1: All identified Youth/CPSC POMS must be included

Note2: Gap Inc. (or Brand delegates) may identify critical POMs at any time for Key or High-Risk Styles
Email Manuel.torres@sgtgroup.net
Regional Operations Manager LATAM
37

Workshop - Gap Inspectors Jun 10, 2021

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GAP

Copyrights SgT Group © 2018

Copyrights SgT Group © 2018

• HWR for visual inspection

Note: For inline HWR packing audit is not needed.

Copyrights SgT Group © 2018

Visual inspection HWR including:

OCT 10, 2020

XS21I-HA 032 4000

Copyrights SgT Group © 2018

Use POM codes from original measurement chart

Copyrights SgT Group © 2018

Total carton quantity is 65 cartons.

Inspector is to select 13 pcs cartons for inspection.

• Use GAP report number in the inspection

• Product stage shows type of test report.

Copyrights SgT Group © 2018

68 • Add carton number correctly on the report

Copyrights SgT Group © 2018

Copyrights SgT Group © 2018

How to send e-mail HWR to PQA

• Send 1 e-mail per inspection performed.

• Attach to the message the next:

HWR for visual inspection

How to send e-mail HWR to PQA

E-mail Subject: SgT HWR_Inspection type_ DPO#_Style #

E-mail information: Send summary of each AQL result.

Visual audit: Pass

Copyrights SgT Group © 2018

Copyrights SgT Group © 2018

• Any quantity shortage/excess +/- 5% per size inform Back Office

Mandatory documents to verify for inspection

Factory is instructed to provide the next:

Copyrights SgT Group © 2018

Inspection report preparation

• Gender: Man, woman, kids, baby etc.

• Market: USA, Canada, etc.

• Inspection date format DD/MM/YYYY

Copyrights SgT Group © 2018

Inspection report preparation

Copyrights SgT Group © 2018

Inspection report preparation

• Order and presented quantities should be correct.

• Inspected quantities should be select proportional

Order Qty: 3360

Formula: 2472*200/3360=147 incorrect

Black: 2472 -> sample size 147

Copyrights SgT Group © 2018

Inspection report preparation

Should use GAP Final SOP for each Gap

Copyrights SgT Group © 2018

Inspection report preparation

Information on report portrait must be properly filled in

• Add carton numbers as ascend.

• FYI → All documents and approved simples are always

Copyrights SgT Group © 2018

Inspection report preparation

Add defects per color

Copyrights SgT Group © 2018

Inspection report preparation

• Packing and labeling section • Conformity section

11. Selected cartons

12. Packing list

13. DPO Sheet