Pack audit
Gap Inc. QA or those designated by Gap Inc. to perform shipment audits, will be responsible
for a 10% assessment of this factory/vendor audit.
Pack Audits Procedures
It must be performed as a separate audit
It is the responsibility of the vendor.
Major Defects for Pack Audits
a) Incorrect quantity
b) Carton labelling errors
c) Carton not as specified (size and construction)
d) Crushed or damaged cartons
When performing this assessment, the Gap Inc. auditor must place a “AA” (Audit
assessment) on each box in the assessment.
When performing the pack audit, the vendor must place an “FA” (Factory audit) on
each box audited. This “FA” must not be covered with tape or other labels because it
will be used by Gap Inc. field personnel and Distribution Centres to verify audits and
assess these cartons.
If the Factory Pack Audit fails, the factory must then take action plan to solve the
problems found in the audit. A re-audit will then be performed and recorded on a
separate Visual Inspection Report.
If problems found create shipping delays, notify the merchandiser/production
representative for corrective action.
Safety procedure
It is mandatory that all trim components, raw materials and actual production garments be
evaluated by a Gap, Inc. approved testing laboratory.
QA procedures when performing a Safety audit:
Check factory Needle Control Procedure Log; sign and date log. procedures. Make
sure log is filled out properly and is up to date.
Check needle detector if factory has one. Check date of machine’s last service
Check for lock-stitch button machines. If there are none, report to merchant as soon
as possible.
Check snap equipment and parts to make sure they are on the approved list of
suppliers.
Broken needle control standard
The following are Needle procedures for vendors when manufacturing garment:
When a needle is broken during sewing, every effort must be made to locate ALL
fragments of the broken needle in the garment(s); machinery must be checked
Operators should not possess any spare needles.
• Replacement needles should be stored in a locked closet.
• Worn needles should be disposed of in a sealed container.
• When needles break, every effort must be made to locate all fragments.
• Broken or used needles should not be around machines or on factory floor.
Needle Replacement Control Procedures
All needles even if needle is not broken must be checked regularly by the supervisor
to ensure that they are in good working condition.
No sewing operator should be in the possession of any spare sewing needles, used
or new, other than the needle installed on the sewing machine.
All replacement / spare sewing needles must be secured in a locked cabinet
accessible only by the plant supervisor, mechanic, or other authorized personnel.
Sewing needles may only be replaced by the plant supervisor, mechanic
orauthorized personnel.
A Quality Manual is a very useful document that not only gives guidance and
direction to an organisation’s own personnel, but gives a potential customer,
inspector or auditor an appreciation of an organisation from the outside.
Quality manual developed by organization ensure that customer receive
quality, reliability and integrity in the product and services.
I will talk about the pack audit procedure, safety procedure , broken needle and
replacement of needle procedure of gap incorporated in detail
The factory is responsible for the pack audit.
The pack audit must be performed as a separate audit and it is the responsibility of
the facility/vendor.
during pack audit, the vendor must place an “Factory audit” on each box audited. This
“FA” must be placed in a one inch by one inch space at the top right- hand corner of
the box information label (the label
containing Purchase Order, style, quantity, etc.). This “FA” must not be covered with
tape or other labels because it will be used as a guide by Gap Inc. field personnel and
Gap Inc. Distribution Centres to verify audits and assess these cartons.
Major defects that founds during pack audits are
Crushed or damaged cartons
Incorrect quantity
Carton labelling errors
The assessment will be performed on 10% of the number of boxes that are audited by the
factory/vendor. If the Factory Pack Audit fails, the factory must then take appropriate action
to correct the problems found. Discuss the results with factory representatives A re-audit
will then be performed (not assessment) to verify the packing errors were corrected.
Safety procedure
The following are QA procedures when performing a Safety audit:
Check needle detector if factory has one. Check date of machine’s last
service. Test machine and it’s sensitivity adjustment.
Check factory Needle Control Procedure Log; sign and date log. Ask factory
management and operators to explain needle control procedures. Make sure
log is filled out properly and is up to date.
Check for lock-stitch button machines. If there are none, report to merchant
as soon as possible. required. If they have lock-stitch, verify they have enough
machines to handle production requirements.
Broken needle procedure
When a needle is broken during sewing, every effort must be made to locate
ALL fragments of the broken needle in the garment(s); machinery must be
checked, including such areas as the sewing machine throat plate, feed dogs
and bobbin case.
Any breakage must be recorded in the broken needle log and the broken
fragments attached(kept) in the Log; entries into the Log must be completed
in full.
Broken or used needles should not be around machines or on factory floor.
Needle Replacement Control Procedures
All new sewing needles may only be replaced by the plant supervisor,
mechanic or authorized personnel. Replacement by the sewing operator is
not permitted.
Used sewing needles must be disposed of in a sealed container in a separate
area form the sewing floor and recorded in the used needle disposal log.
All needles even if needle is not broken must be checked regularly by the
supervisor to ensure that they are in good working condition.
