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Tests & Inspections

1. Overview

(1) This SOP is not applicable to mandatory tests and inspections to be conducted by 3rd party
testing provider.

(2) In-house tests and inspections required for quality control are as follows
 (3) Documentation of in-house tests & inspections is as follows:

Test / Inspection
Objectives Scope
(Form: Attached to this SOP)

11. Raw Yarn Inspection Report

Weight, Breaking Strength, Elongation,
Raw Yarn
Yarn Size
12. Yarn Size Report

Dyed Yarn
22. Colorfastness Report Colorfastness to washing
(semi-product)

31. Thread Size & Length Report

Thread Size, Accuracy of Thread
Finished Thread
Length, Breaking Strength, Elongation
32. Thread Strength & Elongation Report

Packing 41. Packing-Accuracy Inspection Report Packing Accuracy as final inspection

Others 51. Comprehensive Quality Analysis Report based on the above reports

2. Definition

2.1. Yarn and Thread

Yarn and Thread are defined as follows, and the following definition is to be applied
generally and commonly to every SOP unless otherwise specified.
 Definition Name by shape Appearance

The products manufactured by

spinning factories, which include the
Yarn ones just before being wound as Cheese
sewing thread regardless of whether
dyed or un-dyed.

The products made of yarns, which

Thread are wound for the use of sewing Cone
works.

2.2. Conversion of English count (Ne) into Tex count

The formula to convert English count (Ne) into Tex count is as follows:

SingleYarn Count 40
Ne ¿ ex: Ne 40/2 ¿ =Ne 20
number of plies 2
591 591
Actual Tex count= ex: Ne 40/2 = =29.55Tex
Ne 20
* The Tex count defined by Kohl’s may differ from the actual Tex count.

3. Purpose

To secure product Quality (quality requirements), and  product Safety (legal requirements).

4. Scope

The following tests and inspections shall be carried out during processing from Raw Yarn through
Finished Thread. (mentioned in 1. (3))

5. Responsibility and Authority

5.1. Production GM

(1) Production GM shall have responsibility to secure tests and inspections to maintain
quality standards of yarn and thread utilizing in-house laboratory equipment.
 (2) Production GM shall work on not only sharing quality information with QA but also
conducting corrective actions in collaboration with QA.

5.2. QA Manager

(1) QA Manager shall govern QC-related activities that include tests and inspections on all
materials from raw yarn through finished thread.

(2) QA Manager shall share all information of test results with Production GM and
Marketing GM to maintain quality standard and customer support.

(3) QA Manager shall convene QA meetings regularly and occasionally to draw solutions
for and against the agenda.

5.3. Marketing GM

(1) Marketing GM shall appoint inspectors to perform Packing-Accuracy Inspection.

(2) Regarding the information on product quality, product safety, packaging, etc., obtained
through Packing-Accuracy Inspection, Marketing GM shall feed them back to QA.

6. Quality Standards of Finished Thread

(1) Our quality standards of finished thread stand on the Protocol 308-8 (Appendix 1).

(2) In case that any buyer demands for higher standards than those in Protocol 308-8, the
upper standards shall become our quality standards of finished thread from then on.

7. Inspection on Raw Yarn

7.1. Inspection guide <Raw Yarn>

(1) Inspection cycle: On every incoming shipment

(2) Inspection item: Weight, Breaking Strength, Elongation at Break, Yarn Size

(3) Lab. equipment: Measuring Reel, Strength Tester, Contrast Board

(4) Primary sampling and AQL: as follows:

 Lot Size Sample Size AQL
Application
(box) (box) Accept/Reject
40 ~ 200 5 1/2 Yarn Size
Breaking Strength
201 ~ 400 10 2/3 Elongation
401 ~ 600 15 3/4 * Average data per each
round must meet the
501 ~ 800 20 5/6 protocol 308-8.

7.2. Weight Test <Raw Yarn>

(1) Weighing: All of the boxes selected shall be weighed.

(2) Standard: -3% (min. 23.77 kgs in gross weight) and up from the standard gross
weight 24.50 kgs/box that equals 22.68 kgs/box in net weight).

(3) In case that weight fails: QA Manager shall inform Marketing GM of the results for
him to bring up adequate claims to suppliers.

7.3. Breaking Strength Test <Raw Yarn>

(1) Sampling: Take one cone out of each box selected, testing 10 times with 500m reeling
and weighing.

(2) Lab. equipment: Strength Tester

(3) Standard: -0%/+10% mentioned in the protocol 308-8 (ASTM D 2256).

7.4. Elongation at Break <Raw Yarn>

(1) Sampling: to use the same cones selected in (2).

(2) Lab. equipment: Strength Tester

(3) Standard: = protocol 308-8 (ASTM D 2256)

7.5. Yarn Size Test <Raw Yarn>

 (1) Sampling: to use the same cones selected in (2).

(2) Lab. equipment: Measuring Reel, Contrast Board

(3) Standard: = protocol 308-8 (ASTM D 1907)

8. Colorfastness Test on Dyed Yarn <Semi-product>

(1) Test cycle: More than 3 times a day

(2) Sampling: one cheese per each dyeing no.

(3) Lab. equipment: Colorfastness Tester

(4) Standard: Shade change shall be graded 4 and up (ASTM D 204). (refer to Appendix
1)

9. Tests on Finished Thread

QA Manager and Laboratory Manager shall conduct the following tests on the finished thread every
day.

9.1. Tests of Thread Size & Length <Finished Thread>

(1) Test Cycle: 3 times a day

(2) Test Equipment: Measuring Reel

(3) Sampling: one or more cones to be randomly selected out of winding spindle(s) when
a certain round of cone-winding is completed.

(4) Standard: ASTM D 1907 (refer to Appendix 1)

9.2. Test of Strength and Elongation <Finished Thread>

(1) Test Cycle: 3 times a day

(2) Test Equipment: Strength Tester

(3) Standard: ASTM D 2256 (refer to Appendix 1)

10. Packing-Accuracy Inspection <Final Inspection>

Please refer to SOP no. SBI-2-005 <Packing-Accuracy Inspection>.

11. Comprehensive Quality Analysis

QA Manager shall regularly analyze the quality of finished thread based on all reports mentioned 1
(overview); and shall record daily the important test results.

11.1. Items of Quality Analysis and Rating Methods

Reference Report Rating Criteria

Analysis Item Standard Rating
no. 5 4 3 0
Colorfastness
22. Colorfastness
1. ≥Grade 4 grade 5 grade 4 x Reject
(Dyed Yarn)
to washing
31. Thread Size &
below below below
2. Thread Size 0%/+10% Length Reject
+3% +5% +10%
(Finished Thread)
Thread
3. ±5% - ditto - ±3% ±4% ±5% Reject
Length
32. Strength &
Breaking ≥protocol
4. Elongation +10% +5% ±0% Reject
Strength 308-8
(Finished Thread)
±2 from
±3 from
=protocol critical
5. Elongation - ditto - median Reject
308-8 median value
value
value
41. Packing-
6. Weight 0%/+10% +5% +8% +10% Reject
Accuracy Inspection

Traverse & un-

7. unwindable - ditto - Excellent Good Reject
Edge Angle windable

11.2. Notes for Rating

(1) Colorfastness to Washing: as the rating criteria mentioned above

(2) Thread Size: to take the data of the 1st round from 31 Thread Size & Length report

(3) Thread Length: to take the data of 1st round from 31. Thread Size & Length report

(4) Breaking Strength: to take the data of 1st round from 32. Strength & Elongation report
 (5) Elongation: to take the data of 1st round from 32. Strength & Elongation report

(6) Weight: Average weight is to be applied to rating.

(7) Traverse & Edge Angle: as the rating criteria mentioned above

12. Feedback of Test/Inspection Results

(1) All results of tests and inspections shall be fed back to QA.

(2) In case that the results turn out to be unsatisfactory, QA Manager shall take proper actions
through QA meetings.

(3) Director shall respect the decisions & resolutions suggested by QA, and assume responsibility
for ensuring further actions such as Corrective Actions, Preventive Actions, Recall, etc.

13. Reference:

SBI-2-001 Identification of Goods-in-process

SBI-2-003 Internal Quality System Audit
SBI-2-005 Accurate Packing
SBI-3-002 Calibration of Measuring Device
SBI-4-001 Purchasing Management

14. Attachment:

Contrast Board (p: 25)

Raw Yarn Inspection Report (p: 26 – 27)
Yarn Size Report (p: 28)
Colorfastness Report (p: 29-30)
Thread Size & Length Report (p: 31)
Thread Strength & Elongation Report (p: 32)
QC Report (Winding) (p: 33)
Packing-Accuracy Inspection Report (p: 34-36)
 Comprehensive Quality Report (p: 37)
Daily Records of Quality Analysis (p: 38-39)

Contrast Board