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PRODUCT GUIDE

FEB. 2007
INTRODUCTION

The Purpose of the Manual :


The purpose of this Quality Procedures Manual is to provide our vendors with a clear understanding
of our manufacturing standards. The manual should answer the majority of your questions.
By better understanding our requirements, you will enable us to more consistently meet consumers need.

How to use the Manual:


The manual should be used as a reference source for answers to questions encountered during
production. The manual specifies procedures and minimum standards that must be met or exceeded.
If a question cannot be answered by the manual or if a standard or procedure is not identified by
the manual then please bring this to our attention.

Our goal in writing this manual was to provide you with a clear concise, user-friendly guide
to Pantaloon Retail India Ltd approved procedures , standards and requirements that will help ensure
our continued success. To ensure our mutual success, these procedures must be followed.

If you find anything in the manual to be unclear it is your responsibility to contact us


immediately for clarification. Please let us know how we can improve future editions to this
manual to make it more useful to you.

Thank You For Your Help.

Rajeev Malhotra
Head ,Sourcing
Pantaloon Retail ( India) Limited
Pantaloon Retail india ltd
Profile

Please type or print nearly and fax to / Email to Head Office

Date : ___________

Section I : Background

Supplier name : ______________________________________ Established : ______________________


Address ______________________________________ Annual sales :_____________________
______________________________________ Phone numbers :___________________
______________________________________ Email to : _________________________

Contact Person ______________________________________

Bank reference : ______________________________________

Are you an agent or do you


own factories ? _______________________________________

Section 2: Product Offering


Product type (e.g.knit tops etc) Department (e.g.men's,etc )

Primary products __________________________________________ ______________________________


__________________________________________ ______________________________
__________________________________________ ______________________________
__________________________________________ ______________________________
others products: __________________________________________ ______________________________
__________________________________________ ______________________________

*Approximate price per unit Fob

What is your competitive advantage?


(e.g Lower cost t-shirts;specialty knit capability;
shortest leadtime trousers)
Section 4: Production Information

Production CapacityIn-house _________________ /month Subcontracted _____________________ / month

Style minimum : ________________________ /dz

Colour minimum : ________________________ /dz

Laundry capacity : In-house _________________ /month Subcontracted _____________________ / month

Laundry capacity : Garment wash :yes/no


stone wash yes /no
Chemical wash :yes/no
Garment dye : yes/no

Production leadtimeBasic _______________________ weeks Fashion _________________________ weeks

Delivery reliability : Excellent ____________________________ Good _________________ acceptable________________

Machinery : Type Brand Quantity


_____________________________________ ___________________________ __________________
_____________________________________ ___________________________ __________________
_____________________________________ ___________________________ __________________
_____________________________________ ___________________________ __________________
_____________________________________ ___________________________ __________________
_____________________________________ ___________________________ __________________
_____________________________________ ___________________________ __________________
_____________________________________ ___________________________ __________________
_____________________________________ ___________________________ __________________
_____________________________________ ___________________________ __________________
_____________________________________ ___________________________ __________________

Printing : Available ?yes/no In-house? Yes/ No

Embroidery : Available ?yes/no In-house? Yes/ No

Type of equipment : __________________

Vertical operations :
Spinning Yes / No
Knitting /weaving : Yes / No
Dyeing : Yes / No
Finishing : Yes / No
Shade controls : Yes / No
Shrinkage control : Yes / No If Yes : Mechanical / Chemical

Cutting : Table width : ________________________


Computer cutting? : Yes / No
Section 5: Primary Customers

Country : Customer: Products :


__________________________ _____________________________ ______________________________
__________________________ _____________________________ ______________________________
__________________________ _____________________________ ______________________________
__________________________ _____________________________ ______________________________
__________________________ _____________________________ ______________________________
__________________________ _____________________________ ______________________________
__________________________ _____________________________ ______________________________
__________________________ _____________________________ ______________________________
__________________________ _____________________________ ______________________________
__________________________ _____________________________ ______________________________

Section 6: Employee Headcount

Production : ____________________________ Shipping /Receiving :____________________


Quality Assurance ____________________________ Clerical : ______________________
Staff Engineer : ____________________________ Admin / Management : _________________
Maintenance : ____________________________ Sale : ____________________
Total personnel : ____________________________

Section 7: Quality Assurance

In-line : Yes / No If yes,number of location ___________________


Full-time quality personnel Yes / No
Final audit : Yes / No If yes,what %
Raw materials inspected : Yes / No If yes,what % __________________________
Raw materials tested : Yes / No If yes,what tests :

Separate raw materials warehouse : Yes / No


Typical seconds fallout: ______________%

Section 8 : Sample /Testing

Do you have a sample room ? Yes / No


Average prototype leadtime :
Pattern maker ? Yes / No
testing : in house / contracted (if so,with )

Section 9 : Miscellany
Systems control Mainframe ____________________Pc ________________________________ Manual ____________

EDI capability : Yes / No

UPC printing capability : Yes / No

Production system : Progressive bundle ____________Modular __________________________ UPS _____________

Signature ___________________ Date ________________


Plant Manager / CONTRACTOR Name

PANTALOON RETAIL ( INDIA ) LTD.


On-site Factory Evaluation

Factory name Address Phone Fax

Factory Sq.Ft /Sq.Mts. ___________________________________________ Numbers of Employees ________________

Piece good Storage: Stored on-end? Y / N


Stored directly on floor? Y / N
Covered to prevent soiling ? Y / N
Storage area cleanliness Hi Med Lo

Piece good Inspection Are rolls monitored for shading? Y / N


Does plant use section spreading Y / N
Are components shade-marked? Y / N
Are flaws marked/cut out? Y / N

Cutting: Spreading : Automated manual


Markers made in-house? Y / N
Computerized markers ? Y / N
Computerized cutting ? Y / N
How long have cutters worked at plant ? (avg.yrs)

Sewing : Label Garment

Garment in production :_____________________________ __________________________


____________________________________________________
____________________________________________________
____________________________________________________

Condition of machine :_____________________________ __________________________

Examine garments :
Do ribs and bodies match the colour ? Y N NA
Are woven collars straight ? Y N NA
Do plaids match on collars /side seams ? Y N NA
Turn garments inside-out to inspect seams Y N NA

What processes are ________________________________

automated __________________________________________
Productivity / Flexibility :

Are workers trained in-house ? Y / N


Can the factory bring in additional workers if necessary ? Y / N
What is capacity utilization ? %
What is the throughput ? days
What is the absentism rate ? %
What is labour turnover rate ? %

QC: Who is in charge of QC ?


Is QC done in-line as well as at end ? Y / N
What is the seconds rate ? %
Look at second pile
What are the problem?
What are the cause?

Who cleans the machine ? operators / staff

Do they have mechanics on staff ? Y / N

Are packers trimming loose threads ? Y / N

Laundry Do they have laundry in house ? Y / N


Machines:

Dryers Type # Total capacity


Type # Total capacity

Do they have sample machines ? Y / N


Do they have do sandblasting ? Y / N
manual ? Y / N
alum.oxide Y / N
extended localized Y / N
Garment dyeing ? Y / N
Enzyme type:
Standard Operating Procedures ( S O P ) for FOB Vendors
No of Days
from delivery Activity
date
Day 120 Handover of style sheet / FINAL Range plan to Sourcing team.

Day 115 Costings to be discussed with respective approved vendors and finalised by sourcing team , costing to be approved in standard format and to be closed
within seven days .

Day 113 Once costings is finalised with the vendor , proto samples to be made by them within 3 working days and if multiple sampling is
involved then the same has to be discussed by the vendor with respective sourcing team member and closed .

Day 110 On finalisation of costings and freezing the delivery dates with the vendor , sourcing to raise PO on the vendor within three days

Day 95-90 After receipt of Approved Pos , vendor to start with the process of artwork approvals , lab shade dips approvals,
desk loom approvals and embroidery approvals with seven days.

Day 90-60 Simultaneously, vendor to start with fit approval , this will be coordinated with sourcing team member and will be approved by the technical team.
Note : Live model fitting and dummy fitting to be discussed with technical team and approved & sealed within thirty days of receipt of final PO.

Day 90-60 Once fit approval is done , size set also to be approved and sealed for msmts .Trims and accessories also to be sealed in this period.

Day 60-55 Fabric to be received in house with all listed fabric test reports within 55 days of receipt of confirmed order.
Fabrics recd to be intimated to the QAD team so that fabric inspection is carried and the same is approved as per ten point system.

Day 55-50 On approval of fabric , vendor to submit PPS for approval through the sourcing team and it has to be approved and sealed by the technical team .

Day 50-45 Vendor can proceed with the cutting of the fabric once above approvals are done .

Day 45-35 Vendor to intimate the QAD for approval of pilot run and /or in line inspection of the order.

Day 45-10 Sourcing team member will be coordinating with the vendor for completion of the order and once confirmation of completion of production
and packing date is received, then requisition for final QC will be given to QAD dept.
Packing to be done as per the set norms by the packaging dept and sealed before inspection .
Delay in delivery from scheduled date by more than a week will attract penalty as per PO terms and conditions .
SOP1
Day10- 7 Once goods are inspected and okayed by the QAD dept., vendor should request for ASN providing complete packing list of the goods.

Day 7-5 On receipt of ASN , SCM to provide for Inbound No. to vendor with CC to sourcing team member.

Day 6-2 Final dispatch to be confirmed by the vendor through approved freight carrier for the region and dispatch details to
be mailed to the sourcing team who will follow up with Whse for inward of the merchandise .

Day 2-0 Inward at Whse to be intimated to all team members

Payment to be made to the vendor as per the agreed terms and conditions.
FABRIC INSPECTION

INTRODUCTION

The role of fabric inspection department is to ensure have better control on the incoming fabric.
Following are the main objectives of fabric inspection.
1. Provide information on length and width.
2. Provide detailed information on the quality aspect of the fabric.
3. Estimate the loss due to defective fabric and to provide evidence to claim indemnity.

Definitions:
The 4 points system:
It is a method of numerically expressing the no of defects per linear mtr or sq mtr.
Fabric fault:
A fabric fault is regarded as an irregularity in the cloth, which in day light is clearly visible from a reasonable
distance (1mtr) and will downgrade a garment.

Procedure:
1. Inspection is based on sampling of 20% incoming fabric for each lot and color.
2. Identify the face of the fabric and load the fabric roll on the machine.
3. Fabric defects will be viewed for weaving, finishing and yarn defects while fabric is running on the
machine.
4. The fabric need to be inspected at a speed of no more than 15 mtrs/min.
The defects are to be marked using appropriate defect point stickers.
i.e.: Points from 1 to 4.

Criteria for assigning points for defects:

Defects Assigned demerit points

Below 3” 1
3 to 6 2
6 to 9 3
Above 9” 4

Following aspects need to be in mind while assigning points for defects.

1. Maximum points to be assigned per meter shall not be more than 4 defective points.
2. The no of faults and points per 100 mtrs are to be calculated and summarized in the fabric inspection report.
3. Fabric hole of any size penalty points would be 4 points.

Following are the criteria to consider the fabric as fresh-150cm finished width-(58-60”)

Maximum defective points 30DP/100 linear meter


Maximum 4 point defects 4/100 linear meter
Maximum 1 point defect 16/100 linear meter
Average no of points 20DP/100 linear meter maximum per delivery
Following are the criteria to consider the fabric as fresh-112cm finished width-(44”)

Maximum defective points 22DP/100 linear meter


Maximum 4 point defects 4/100 linear meter
Maximum 1 point defect 8/100 linear meter
Average no of points 15DP/100 linear meter maximum per delivery

Following are the criteria to consider the fabric as fresh-90 cm finished width-(36 “)

Maximum defective points 18DP/100 linear meter


Maximum 4 point defects 3/100 linear meter
Maximum 1 point defect 08/100 linear meter
Average no of points 12DP/100 linear meter maximum per delivery

Shade Variation:
Frequent shade variation:
1.15 cm of fabric is cut along the width from the beginning of each roll-Mark roll no with permanent marker.
2. Run the roll on fabric inspection machine.
3. On the end of the roll further 15 cm width swatch removed along the width.
Standard Requirement: No variation must exist from beginning to end of roll.

Centre to selvedge/centre to centre shade variation. (Mandatory for all piece dyed fabrics)
1.15 cm fabric is cut along width.
2. Divide the fabric swatch in four equal parts and number them from 1 to 4

1 2 3 4

Cut the fabric swatch in four equal parts and they need to be stitched in the following sequence.

4 1 3 2

Iron the fabric swatch and keep the panel flat on the table under the inspection light.

4-1- To access shade variation between selvedge to selvedge.


1-3 & 3-2 – To access the shade variation between centre to selvedge.
Standard Requirement: No variation must exist from selvedge to selvedge and centre to selvedge.
Fabric Inspection Acceptance Standards for 4 points system

Standard: 20 Points /100 Sq. mtrs. & 30 points / 100 Liner mtrs for 60”
And Average 20 points / 100 liner mtrs per consignments

Meters Width36”/91cms Width 44”/112cms. 58/60”/150cms.


18points/linear 100 22points/linear100mtrs 30points/linear
mtrs 100mtrs
18 22 30
10 2 2 3
15 3 3 5
20 4 4 6
25 5 6 8
30 5 7 9
35 6 8 11
40 7 9 12
45 8 10 14
50 9 11 15
55 10 12 17
60 11 13 18
65 12 14 20
70 13 15 21
75 14 17 23
80 14 18 24
85 15 19 26
90 16 20 27
95 17 21 29
100 18 22 30
105 19 23 32
110 20 24 33
115 21 25 35
120 22 26 36
125 23 28 38
130 23 29 39
135 24 30 41
140 25 31 42
145 26 32 44
150 27 33 45
160 29 35 48
170 31 37 51
180 32 40 54
190 34 42 57
200 36 44 60

Indicative Re Cut percentage based on Index

Width/Index 36”/91cms 44”/112cms 58”/150cms


0.3-0.50 3.5% 3% 2%

0.5-0.7 5% 4% 3%

O.7-0.8 7.5% 6% 4.5%

O.8-1.0 9% 7.5% 5.5%

Note: Above re cut percentage are indicative and may vary from category to category. Suppliers are advised to
work out the exact re cut percentage and work out strategy accordingly.
FABRIC INSPECTION FORMAT-4 POINT SYSTEM
Date:

Supplier: Total Rolls:

Buyer: Total Mtrs:

P.O.No: Roll No/No of pcs:

Style No: Category:

Mtrs: As Marked Width: As per P.O

Mtrs: Actual Width: Actual

Description of Points Points Points Points


Defects
1 2 3 4

Stain

Hole

Slub

Knots

Floats

Neps

Contamination

Broken End

Broken Pick

Missing
End/Pick

Double End/Pick

Weft wise fault

Warp Bar

Weft Bar

Shade Bar

Crease Mark
Fabric Damage

Water Marks

Kitty Marks

Skew

Bow

Printing Fault

Embroidery
Fault

Others

Total
Gr Total

Total Points
Index = ------------------
Total Mtrs

Note: All Suppliers need to have Fabric Inspection Machine as well as in house trained fabric quality
inspectors to ensure all fabrics are been verified as per the required norms of Pantaloon Retail India
Ltd.
Fabric Mills

Fabric Inspection

Fabric Accepted Fabric Rejected

Issue Fabric
Inspection Report Commercially Commercially
acceptable Unacceptable

Fabric release to Negotiate % Reject


cutting discount with
supplier

Inform fabric Mills


If accepted by
supplier.

Return fabric to
supplier with
Issue to cutting with relevant reports
fabric inspection
report clearly
specifying defects
Lab Inspection :

For each lots of fabric,1.5mtrs of fabric is used for conducting lab test.
Following are the tests conducted:

. Colour fastness to home laundering


. Colour fastness to Rubbing
. Dimensional Stability
. Tear Strength for shirts
. Tensile Strength for trousers
. Pilling
. Bowing & Skewing
. Seam Slippage
. GSM
. Center to selvage colour variation in the same roll

The details of the quality parameters across all these categories in mentioned
Quality Requirements

100 % cotton P/C Blends P/V Blends P/W Blends Export Test Method
Parameters Warp Weft Warp Weft Warp Weft Warp Weft Warp Weft
Dimensional Stability +/-3.0% +/-3.0% +/2.5% +/2.5% +/2.5% +/2.5% +/2.5% +/2.5% As required by the buyer AATC_135-1987
Tear strength 1000 gms 700 gms 1136 gms 700 gms 1136 gm700 gms 1136 gm700 gms As per buyer's Standards ASTM-D-1424-83
Pilling Test 4 4 4 4 4 is-10071-83
Colour Fastness to CC SC CC SC CC SC CC SC CC SC IS-764-1992 TEST 3
wash 4 4 4 4 4 4 4 4 As per buyer's Standards
Dry Wet Dry Wet Dry Wet Dry Wet Dry Wet AATC-8-1989

Rubbing Fastness 4 3 4 3 4 3 4 3 As per buyer's Requirement


Parameters Warp Weft Warp Weft Warp Weft Warp Weft Warp Weft Test Method
Crease Recovery 90 deg 90 deg 100 deg 100 deg 120 deg 120 deg 130 deg 130 deg is-4681-93
Tensile strength in kgf As per buyer's Standards
200 to 250 gsm 35 20 35 20 35 20 35 20
Above 250 gsm 40 30 40 30 40 30 40 30 As per buyer's Standards ASTM-D-5034
Crimp % Actuals Actuals Actuals Actuals Actuals Is-3422-90
GSM Actuals Actuals Actuals Actuals Actuals
Fiber composition Actuals Actuals Actuals Actuals Actuals IS-6490-71
Bending Length in cms Actuals Actuals Actuals Actuals Actuals

Martindale Abrasion Visual appearance Visual appearance Visual appearance Visual appearance Visual appearance
Bow & Skew 2% 2% 2% 2% As required ASTM-D-3882-90
Seam Slippage 18 Pound 18 Pound 18 Pound 18 Pound 18 Pound ASTM-D-434

*Piece lengths minimum acceptable is 30 mts and up unless specified


* Colour matching will be done under D65 light unless specified.
* No sulphur dyes to be used.
CC:Change in colour with grey scale.
SC: Staining on cotton with grey scale
DRY/WET : IN Comparison with grey scale
The above values are minimum requirements for acceptance.
In case of 50s,40s cotton plain weave shirtings 900 gms warp tear strength is accepted.
in pill box test (only for synthetic blends):1-very severe,2-severe,3-Moderate,.4-Slight,5-No Pilling
DESCRIPTION

1 Woven Fabric Defects

Defect Explanation

End out Caused by yarn breaking and the loom continues to run.Defects will
appear as a thin line, most always a Major

Burl mark When a slub or extra piece of yarn is woven into the fabric,it is
often removed by "burling tool"The result will usually leave an open
place the fabric and will be a major

Slub usually caused by an extra piece of yarn that is woven into the fabric.
it can be also caused by thick place in the yarn often caused by fly waste
being spun in yarn in the spinning process.Major or MINOR.

Open Reed Result from a bent reed wire causing the warp ends to be held apart
exposing the filling yarn .Will be conspicuous on fabric that use different
colour yarn on warp and shuttle.Major defect

Harness Caused by harness straps breaking on conventional loom.There will


be a definite pattern change in the weave and will be a Major.

Dropped Pick Caused by the filling insertion mechanism on a shutteless loom not
holding the filling yarn resulting yarn to be woven without tension .
The filing yarn then is woven into the yarn appearing as "kindly" There
will also be areas of " end out ." Major.

Soiled Filling or End Dirty ,oily looking spots on the warp or filling yarns ,on package
yarn dyed - Major
Thin place often caused by the filling yarn breaking and the loom continues to run
until the operator notices the problem .Major.

Jerk-in Caused by the filling yarn breaking and the loom continues to run until the
operator notices the problem .Major.

Stop mark when the loom is stopped,the yarn elongates under tension; then when
loom starts again,the slackness is woven into the fabric.major

Mixed filling caused by a bobbin of lightweight yarn used in filling .Will appear as a
distinct shade change.major
Knitting Defects :
Defect Explanation

End Out Warp Knit - results from the knitting machine and the loose end straying
and being knit irregularly into another area. Major

Straying End Warp Knit - caused by an end of yarn breaking and the loose end straying
and being knit irregularly into another area. Major

Mixed Yarn Resulting from wrong fiber yarn ( or wrong size yarn ) placed on wrap.
(Warp Knit ) fabric could appear as thick end or different colour if fibers have different
affinity for dye .Major.

Barre
( Circular Knit ) Caused by mixing yarn on feed into machine. Fabric will appear to have
horizontal streaks. Usually Major.

Missing yarn Caused by one end of yarn missing from feed and the machine continues
( Circular Knit ) to run. Major.

Hole Caused by broken needle. Major.

Broken Colour Usually caused by a coloured yarn out of place on the frame . Major
Pattern

Drop Stitches Resulting from malfunctioning needle or jack .Will appear as holes or
missing stitches . Major.
Garment and Fabric Testing

COTTON DENIM

Examples/End Stability wash (wash, tumble Filling skew (Different between before
Reference Tear Strength Tensile Strength Seam Properties
use Dry) and after wash)

Test Method AATCC 135 ASTM D3882 ASTM D1424 ASTM D168 I-Grab ASTM D434

Seam opens 6mm -


8-10 oz
D1 Fabric-60C Garment-49 c Max 3% In Fabric Inch In Garment Warp 2000gm Weft- Warp- 30 Kg Weft-36 Kg 12kg Strength -
jackets/jeans
1500 gm 17kg
Seam opens 6mm -
10-12 oz
D2 Fabric-60 c Garment-49 c Max 3% In Fabric Inch In Garment Warp 4500gm Weft- Warp- 85 Kg Weft-55 Kg 12kg Strength -
jackets/jeans
3600 gm 17kg
Seam opens 6mm -
D3 12-14 oz or above Fabric-60 c Garment-49 c Max 3% In Fabric Inch In Garment Warp 5500gm Weft- Warp- 55 Kg Weft-36 Kg 12kg Strength -
jackets/jeans 4500 gm 17kg
All Stretch Denim Seam opens 6mm -
D4 (over 10 oz)for All Fabric-60 c Garment-49 c 3% In Fabric Inch In Garment Warp 4500gm Weft- Warp- 55 Kg Weft-36 Kg 12kg Strength -
end use 3600 gm 17kg

Remarks: (A) UPDATE TEST METHOD BEING USED

(B) THE FIGURE ABOVE MINIMUM PERFORMANCE REQUIREMENT.


COTTON BLEND WOVEN

STABILITY WASH STABILITY OF FILLING SKEW PILLING


REFERENCE EXAMPLES/END USE TEAR STRENGTH TENSILE STRENGTH
( 3 WASHES ) DRY CLEAN DIFFERENT BETWEEN SEAM PROPERTIES RESISTANCE
BEFORE & AFTER (BRUSHED ONLY )

TEST METHOD AATCC 135 COMMERCIAL WASH ASTM D3882 ASTM D1424 ASTM D1682 1' GRAB ASTM D 434 ASTM D3512 NON WASH

SEAM OPENS 6MM


FABRIC - 49 C ROOM TEMP SHIRT-800 GM 8 KG STRENGTH II GRADE 2-3
PNO 1 RAYON/RAYON COTTON 3% IN FABRIC WARP - 10 KG , WEFT 12 KG (+/.10% )
GARMENTS - 49 C 12 KG 30 MINIS)
(+/ 5.0 % ) ( +/.2.5 % ) ( +/.10 % ) ( +/.10 % )
POLYESTER/COTTON SHIRT-800 GM SHIRT

POLYESTER FABRIC - 49 C JACKET-1000GM SHIRT SEAM OPENS 6MM GRADE 2-3


GARMENTS - 49 C PANTS-1000GM WARP-12KG 8 KG STRENGTH II 30 MINIS)
ROOM TEMP (+/.2.5
PE 2 3% IN FABRIC
) WEFT-12KG 12 KG
(+/ 3.0 % ) ( +/.10 % )
PANTS/JACKETS PANTS/ JACKETS
WARP-25KG SEAM OPENS 6MM
SHIRT-800 GM
FABRIC - 49 C ROOM TEMP JACKET-1000GM SHIRT SHIRT GRADE 2-3
GARMENTS - 49 C PANTS-1000GM WARP-12KG SEAM OPENS 6MM (30MINIS)
PE 3 RAYON/RAYON COTTON
( + / 2.5 % ) SWIM WEAR 1000GM WEFT-12KG 8 KG STRENGTH II
(+/ 3.0 % ) 12 KG
( +/.10 % ) PANTS/JACKETS

LINEN/LINEN COTTON FABRIC - 30 C SHIRT-800 GM SHIRT SHIRT

RAMIER/RAMIE COTTON GARMENTS - 30 C JACKET-1000GM WARP-12KG SEAM OPENS 6MM


ROOM TEMP ( + / 2.5
LN 4
%) PANTS-1000GM WEFT-12KG 8 KG STRENGTH II
12 KG
PANTS/JACKETS
( +/.10 % ) WEFT-25KG SEAM OPENS 6MM
REMARK: (1) UPDATE TEST METHOD BEING USED
(2) THE FIGURE AB0VE ARE MINIMUM PERFORMANCE EQUIPMENTS
POCKETING PERFORMANCE SPECIFICATION

STABILITY WASH TEAR TENSILE SEAM


REFERENCE EXAMPLES/END USE ( 3 WASHES ) STRENGTH STRENGTH PROPERTIES PILLING
RESISTANCE

TEST METHOD AATCC 135 ASTM D1424 ASTM D1628 ASTM D434 ASTM D3512
T/C POCKETING SEAM POENS 6 MM- 12 KG
P1 COTTON FABRIC MAX 3.0% 2000GM 25 KG STRENGTH - 16 KG
GRADE -2-3 (60 MINIS)
POLYESTER/RAYON (+ / 10% ) (+ / 10% ) (+ / 10% )

REMARK: (1) UPDATE TEST METHOD BEING USED


(2) THE FIGURE AB0VE ARE MINIMUM PERFORMANCE REQUIREMENTS
COTTON WOVEN

STABILITY WASH STABILITY OF FILLING SKEW PILLING


( 3 WASHES ) DRY CLEAN DIFFERENT BETWEE RESISTANCE
REFERENCE EXAMPLES/END USE TEAR STRENGTH II TENSILE STRENGTH II SEAM PROPERTIES
BEFORE & AFTER (BRUSHED ONLY )
WASH
ASTM D 434
TEST METHOD AATCC 135 COMMERCIAL WASH ASTM D3882 ASTM D1424 ASTM D1682 1' GRAB ASTM D351
( SA )
SEAM OPENS 6MM
LADIES SHIRTS/BLOUSE FABRIC - 49 C ROOM TEMP 3% IN FABRIC 700 GM 8 KG STRENGTH II GRADE 2-3
CW 1 WARP - 10 KG , WEFT 12 KG(+ /. 10% )
BOY'S SHIRTS GARMENTS - 49 C (+/2.5%) 12 KG 30 MINIS)
(+3.0%) ( + / .10.% ) ( + / .10.% ) ( + / .10.% )
MEN'S SHIRTS NORMAL - 800GM SEAM OPENS 6MM
MEN'S DENIMS SHIRTS FABRIC - 49 C 3% IN FABRIC PEACH POPLIN WARP - 12 KG , WEFT 12 KG 8KG STRENGTH - 12KG GRADE 2-3
CW 2 GARMENTS - 49 C ROOM TEMP (+/.2.5 ) WARF 800GM 30 MINIS)
WEFT300GM
(+3.0%) ( + / .10.% ) ( + / .10.% ) ( + / .10.% ) ( + / .10.% )
WARP - 25 KG SEAM OPENS 6MM
JACKET TROUSER FABRIC - 49 C ROOM TEMP 3% IN FABRIC AND WEFT - 25 KG 10KG STRENGTH - 15KG GRADE 2-3
CW 3 1000 GM( + /.10%)
(NON DENIM FABRIC) GARMENTS - 49 C (+/2.5%) GARMENT (30MINIS)
(+3.0%) ( + / .10.% ) ( + / .10.% ) ( + / .10.% )

CW 4 COTTON SUPER DENSE POPLIN ORFABRIC-49C(+\.5%) ROOM TEMP (+/2.5 %) WARP - 12KG WEFT - 12KG(+/10%OPENS 6MM -8KG STRENGTH II - 12KG(+OPENS 6MM- 8KG STRENGTH II - 12KG(+

FABRIC - 49 C
GRADE 2-3
OPENS 6MM- 8KG STRENGTH II - 12KG(+
CW 5 TRIMMING/ LINING (+3.0%) ROOM TEMP ( +/.3.0%) 800GM (+/.10%) P - 10 KG , WEFT 12 KG WEFT- 10KG (+/. (60MINIS)

REMARK: (1) UPDATE TEST METHOD BEING USED


(2) THE FIGURE ABOVE ARE MINIMUM PERFORMANCE EQUIPMENTS
Garment and Fabric Testing
KNITTED

Stability Washes
(8 Mins 30 c Stability Washes
ADDITIONAL
Reference Factory/Example Gentle Cycle, (Hand Washes Stability Dry Clean
REQUIREMENTS
Tumble Dry 3 Flat Dry 1 Wash
Wash

Test 10 Mins Hand Commercial Wash


AATCC 135
Method Wash Test
1)Bursting Strength- min
KD1 30-25's Jersey MAX 3-5% 3kg 2)Twisted Body 5% or
JCm

Single Jersey-
KD2 20's/1.20's/2.16's/ Max-9%
1,16's/2 Pique - 1)Bursting Strength- min
20's/1,20s/2,16's/ 3kg 2)Twisted Body 5% or
1,16s/2 JCm
1)Bursting Strength- min
KD3 Max-9% 3kg 2)Twisted Body 5% or
Fleece JCm
1)Stability Washes(8min x
KD4 Max-9% 30 Flat Dry) Max-3%
Polar Fleece
1)Bursting Strength- min
KD5 Max-8% 3kg 2)Twisted Body 5% or
Interlock JCm

Remarks: (A) Update test method being used.

(B) the figures above are the minimum performance requirement.

p.s fty will quote % shrinkage on fancy separately


STABILITY WASH TENSILE COLOUR FASTNESS
REFERENCE EXAMPLES/END USE TEAR STRENGTH II SEAM PROPERTIES
WASHES TUMBLE DRY TEAR STRENGTH II DETERGENT WASHING WATER AT 37 C PERSPIRATION CROCKING (RUBBING))

TEST METHOD ASTM D 1424 ASTM D 434 AATCC 61 AATCC 107 AATCC 15 AATCC 8
AATCC 135 ASTM D 1682 1' GRAB
FABRIC - 30 C
GARMENT - 30 C WARP - 12 KG SEAM OPENS 30 C COLD WATER 3C, 3S 3C, 3S DRY - 3-4
IMF 1 MEN'S SHIRTS 800 GM
(+/4.0%) WEFT - 12 KG 6MM - 8 KG 3C, 3S WET - 2-3
STRENGTH II -12 KG ( FOR REF )

REMARK: (1) UPDATE TEST METHOD BEING USED


(2) THE FIGURE ABOVE ARE MINIMUM PERFORMANCE REQUIREMENTS.
(3) COLOUR FASTNESS STANDARDS APPLY TO GARMENTS. IN ALL CASES FABRICS MUST BE COLOUR FAST AFTER THE FINISH.

VISUAL INSPECTION

METHOD - FOUR POINTS SYSTEMS.

ACCEPTABLE STANDARD AVERAGE POINTS ( FAULTS) 100 SQ YARDS.


Colour Fastness - General Textile Apparel

DETERGENT WATER AT J7C PERSPIRATION CROCKING CHLORINE CHLORINATED


REFERENCE DRY CLEANING LIGHT
WASHING (RUBBING) BLEACH POOL WATER
COMMERCIAL AATCC 61
TEST METHOD AATCC 61 AATCC 107 AATCC 15 AATCC 8 AATCC 132 AATCC 162
LAB TEST ( SA )

DENIM AFTER WASH AFTER WASH SWIM WARE


4C
CHAMBRAY 4C, 3/4S 4C, 4S DRY - 4S 4C
FABRIC WET - 2-JS

INDIA 30C - COLD WATER


3C , 3S 3C , 3S
MADRAS
COTTON ( FOR REF )

PIGMENT AFTER WASH AFTER WASH AFTER WASH 4C (DK COL) SWIM WARE
4C , 4S 4C
DYE 4C , 3/4S 4C , 4S 4C , 4S DRY - 3-4S 3C ( LT & MED COL 4C
PRINT CONTRAST EFFECCONTRAST EFFECTS-4S WET - 2-3S

NYLON/ DRY - 4S SWIM WARE


NYLON/ 30C-4C , 3/4S 4C , 4S 4C , 4S WET - 3S 4C , 4S 4C 4C 4C
BLEND

COTTON 4C , 3/4S 4C , 4S DRY - 4S


FABRIC CONTRAST EFFEC CONTRAST EFFECT WET - 3S SWIM WARE
4C
YARN DYE 4C , 4S 4C , 4S 4C 4C
PIECES DYE COTTON KNITS DARK COLOUR
PRINTING 30C, 4C, 3/4S DRY - 4S
NON DENIM CONTRAST EFFECTS-4S WET -2- 3S

REMARK: (1) UPDATE TEST METHOD BEING USED


(2) COLOUR FASTNESS STANDARDS APPLY TO GARMENTS IN ALL CASES FABRICS/KNITWEAR MUST BE COLOUR FAST AFTER THE FINISH
(3) WHERE CONTRAST COLOURS ARE USED e.g. COLOUR WOVEN, TRIM ON GARMENT, DESIGN EFFECTS e.g. STRIPES

" CHLORINATED WATER FOR SWIM WEAR ( TEST METHOD : JIS L0884 ) - GRADE 4 IN COLOUR CHANGE "

C-COLOUR CHANGE S-COLOUR STAINED


CLASSIFICATION OF DEFECTS.

The major and minor defects as listed are to be used when auditing finished goods. All sewing

MAJOR DEFECT

The major and minor defects as listed are to be used when auditing finished goods. All sewing
may affect the saleability and / Or is a significant deviation from specification.
The only alternatives to " Seconding " a major defect are a " Very neat " repair, repressing, cleaning,
or submitting questionable defects for Quality Assurance approval. ( Example : establishing
acceptable / unacceptable standards for certain problems such as needle chews on the outside
of garment. ) In most cases a major defect which cannot be repaired will be considered a
second. However , before a large number of seconds are made, the defects and alternatives
for repair should be reviewed with our Production and Quality Assurance.

MINOR DEFECT

Any defect which does not render the garment second quality, but does indicate our unsatisfactory
trends and areas requiring improvement to prevent critical defects in the future. Combinations of
three ( 3 ) or more minor defects which seriously detract from the appearance or serviceability shall
be treated as a major defect. ( Example : small material defects when considered individually would
not be serious but when concentrated in one area are distracting. )

JUDGMENT

It is recognized that certain defects may vary in degree of severity to the extent that auditors must
use their best judgment to determine whether a particular defect is major or minor. Any questionable
defect classification should be send immediately to our Technical Director, in the event that a Quality
Manager is not available in order not to delay production or affect quality further.
DEFECT RATING CHART

MAXIMUM DEFECTS ALLOWABLE

DENIM CHAMBRAY OXFORD


INDIGO INDIA FABRIC TWILL
MADRAS POPLIN
KNOTS & NEPS
0
A, B & C A, B & C B&C
1/16" OR LESS
A, B & C A, B & C C

1/16 TO 1/8"
A, B & C B&C B&C
THICK YARNS & SLUBS
A, B & C B&C C

B&C C REJECT
1/16 TO 1/8"
C REJECT REJECT

1/8 TO 1/4"

1/4 TO 1/2"

1/2 TO 1"
Trims Inspection & Lab Testing Procedures

Tests 1 to 5 are mandatory for clearing the lot on priority.


Tests 1 to 5 and 9 are conducted as routine on all lots.
Test 7 is the conducted on trouser fabric in lieu of test 2.
Additional test will be conducted on demand.
For knitted fabric a shrinkage % of +/-5%(stactic method ) on both courses & wales,colour fastness to wash.
CC/SC 4/4 and rub fastness of dry/wet 4/3 is accepted.
For socks texturised yarn needs to have a crimp rigidity>25%.
For indigo fabric wet rub fastness of 2 and dry rub fastness of 3 will be accepted.
For corduroy fabric a shrinkage percentage of 3 & wet rub fastness of 2/3 accepted.

3.Trims Inspection & Lab Testing Procedures


Following are the Trims checked & their standards :

a. Carton boxes
Given in the table below are the varieties of cartons & their inspection standards

Bursting
Strength
cartons Types No of Plies GSM (kgs)
i.Top & Lining Layers -180 gsm
S-24 7 !!.Flatting Layers-150 gsm 19
s-18 7 All Layers -150 gsm 16
s-12 7 All Layers -150 gsm 16
T-25 7 All Layers -150 gsm 16
T-12 7 All Layers -150 gsm 16

Tags & Tissue Papers


Given in the table below are the testing parameters

Product Conformity OK Not OK Comments


Size
Shape/Folding
Letter/Font
Print Quality
Weight
Gauge
Stains/Spots
Scratches
Tissue paper GSM Standard is3.80 & Gauge is0.03

C Polybags & carry bags


Following are the testing standards:

Category GSM Gauge


New shirts 12.5 0.08
Sports 13.5 0.08
T-shirts 14.5 0.08
Trouser Polybag 28.5 0.7
Womenswear Polybag 30 0.7
d. Buttons, Hanger,Gripper,U-Clip, Size Tab & Slug
Following are the testing & Visual inspection parameters
Product Conformity OK Not Ok Comments
Size
Shape
Weight
Ligne ( buttons )
Holes
Breakage
Scratches
Embossing / Engraving

For Buttons - Wash Fastness standards are :


CC-4
SC-4

e. Labels
Following are the visual inspection parameters & testing standards :
Product Conformity OK Not Ok Comments
Size
Shape / Folding
Shade
Lettering
Construction / Weave

Test CC Std SC Std Comments


Wash Fastness 4 4
Crocking 4 .3/4
Shrinking / Elongation

f. Metal Pin & Clips :


Product Conformity OK Not Ok Comments
Size
Coating
Point
Head
Rusting - Distilled Water
Rusting - Soap / Soda Ash
Bending
g. Back Support & Collar Support
Visual Inspection Parameters
Product Conformity OK Not Ok Comments
Size
Shape / Folding
Colour / Shade
Cut
Foam Quality
Print Quality

Test Standards
Category GSM Gauge
Sports 550 0.75
Indigo Nation 850 0.75
Urbana 380 0.54

h. Butterfly, Collar Traveller, Collar Bone


Visual Inspection Parameters
Product Conformity OK Not Ok Comments
Size
Shape / Folding
Colour / Shade
Stiffness
Spots /Scratches
Adhesion

Test Standards
Category GSM Gauge
Sports 12.7 0.52
Indigo Nation 12.7 0.52
Urbana 12.7 0.52

Interlining Construction Standards:


I/L Make Type Number Width (cms )Construction GSM
WENDLER FUSIBLE 3640 112 64 X 58 176
SVIL FUSIBLE SR 504S 113 53 X 47 145
DHJ FUSIBLE 609 113 68 X 56 116
FREUDENBERG FUSIBLE 6616 113 62 X 46 150
FREUDENBERG FUSIBLE 6616H 113 60 X 44 150
FREUDENBERG FUSIBLE 6605R 113 66 X 52 88
DHJ NON - FUSIBLE T-88 113 88
SVIL NON - FUSIBLE MICRODOT 6230 113 88
Interlining Testing Standards

Parameters Standards
Wash Fastness - CC 4
Wash Fastness - SC 4
Crocking - Dry 4
Crocking - Wet 3
Dimensional Stability - Warp +/-3.0%
Dimensional Stability - Weft +/-3.0%
Tearing Strength - Warp 1000 gms
Tearing Strength - Weft 700 gms

4. Spec Sheet Preparation


Depending on the style & collection, the fit of the shirt is decided. We have 4 fits in :

TYPES OF FITS
Classic ( Regular fit )
Contraes fit ( Slim fit )
"VW " Fit ( Evening Wear fit )
Short shirt fit ( Regular )
Short shirt ( new )

The specs for all these fits are different. The specs sheet are standardized & are given in
Annexure

a. Interlining Details: For each style code one set of collar & front placket is fused &
the bond strength is tested with a spring balance. The fusing machine is set to achieve the
standards. A separate file is maintained for future reference. The STANDARDS FOR THE BOND
strength are mentioned in the table below .

I/L MAKE TYPE NUMBERTEMP('C) PRESSURE ( KG ) TIME ( SEC ) BOND STRENGTH ( KG )

DBL LAYER SINGLE LAYER DBL LAYER SINGLE LAYER DBL LAYER SINGLE LAYER
WENDLER FUSIBLE 3640 170 3.5 2.5 40 30 2 1.75
SVIL FUSIBLE SR 5048 170 3.5 2.5 40 30 2 1.75
DHJ FUSIBLE 609 170 3.5 2.5 40 30 2 1.75
FREUDENBERG FUSIBLE 6616 170 3.5 2.5 40 30 2 1.75
FREUDENBERG FUSIBLE 6616H 170 3.5 2.5 40 30 2 1.75
FREUDENBERG FUSIBLE 6605R 170 3.5 2.5 40 30 2 1.75
DHJ NON FUSIBLE T-88 - - - - - - -
SVIL NON FUSIBLE 6230 120 3 3 40 40 - -
MICRODOT
SUBJECT : QC STANDARD

PANTALOON RETAIL INDIA LTD.

CLASSIFICATION OF MAJOR & MINOR DEFECTS

ZONE A ZONE B

FABRIC

1 COARSE YARN & MISWEAVES UP TO 1/4" MAJOR MAJOR


CLEARLY CONTRAST

2 COARSE YARN & MISWEAVES UP TO 1/4" MAJOR MAJOR


GROUND COLOUR

COARSE YARN & MISWEAVES UP TO 1/4" MAJOR MAJOR


ON PRINT / PLAID NOT CONTRAST

COARSE YARN & MISWEAVES NOT OVER 3/4" MAJOR MAJOR

SLUBS MAJOR MAJOR

HOLE OF ANY SIZE MAJOR MAJOR

B. APPEARANCE & COLOUR

1 UNEVEN DYE, STAIN MAJOR MAJOR

2 SERIOUS COLOUR SHADING MAJOR MAJOR

3 COLOUR SHADING FRONT / BACK BETWEEN LEFT & MAJOR


RIGHT SIDE OR OUTSEAM

4 COLOUR SHADING FRONT / BACK AT INSEAM MAJOR

5 MISPRINT SERIOUS MAJOR MAJOR

6 MISPRINT MINOR MAJOR MAJOR

7 OBVIOUS FOREIGN OR COLOUR YARN MAJOR MAJOR

8 NOT OBVIOUS FOREIGN OR COLOUR YARN MAJOR MAJOR

C. SEWING

1 FRAYED EDGE, OPEN SEAM OR LOOSE SEAM MAJOR MAJOR

2 TIGHT STITCH THREAD TENSION MAJOR MAJOR

3 NEEDLE CHEWS UP TO 1 PER INCH MAJOR MAJOR

4 RUN OFF STITCHES UP TO 1/4" MAJOR MAJOR

5 RUN OFF STITCHES OVER 1/4" MAJOR MAJOR

6 SKIP STITCH MORE THAN 1 PER INCH OR ANY SKIP MAJOR MAJOR
CHAIN STITCH

7 STITCHES PER INCH TWO OR MORE LESS THAN MAJOR MAJOR


SPECIFIED
ZONE A ZONE B

8 BROKEN STITCH MORE THAN 1/4" MAJOR MAJOR


9 BROKEN STITCH LESS THAN 1/4" MAJOR MAJOR
10 IMPROPER INTERLINING, EXCESSIVE FULLNESS MAJOR MAJOR
11 PLAID / STRIPE MISMATCH UP TO 1/8" MAJOR MAJOR
12 BARTACK MISSING OR MISPLACED MAJOR MAJOR
13 BUTTON - HOLE BROKEN STITCH MAJOR MAJOR

C1. TOP

1 POCKETS OR FLAPS HI-LOW OVER 3/16" MAJOR -


2 POCKETS OR FLAPS HI-LOW UNDER 3/16" MAJOR -
3 POCKET UNEVEN FROM C . F . UP TO 1/4" MAJOR -
4 POCKET SLANT OVER 3/16" MAJOR -
5 POCKET SLANT UNDER 3/16" MAJOR -
6 MISMATCH POCKET 4 WAY PLAID MATCH OVER 1/8" MAJOR -
7 PLACKET HI - LOW UP TO 1/4" MAJOR -
8 PLACKET HI - LOW LESS THAN 1/4" MAJOR -
9 COLLAR OVERLAP BY 1/4" MAJOR -
10 COLLAR OVERLAP BY 1/8" MAJOR -
11 COLLAR BIAS BY 1/4" MAJOR -
12 UNEVEN COLLAR POINTS BY 1/8" MAJOR -
13 UNBALANCE FRONT / BACK BODY AT SHOULDER YOKE MAJOR -
OVER 3 / 8" ( MEN / BOY )
14 UNBALANCE FRONT / BACK BODY AT SHOULDER YOKE MINOR -
UNDER 3 / 8" ( MEN / BOY )
15 UNBALANCE FRONT / BACK BODY AT SHOULDER YOKE MAJOR -
OVER 1 / 4" ( KID )
16 UNBALANCE FRONT / BACK BODY AT SHOULDER YOKE MINOR
UNDER 1 / 4" ( KID )
17 SLANT PATTERN OF STRIPE / PLAID ON FRONT & BACK MAJOR -
YOKE UP TO 1/4"
18 SLANT PATTERN OF STRIPE / PLAID ON FRONT & BACK MINOR
YOKE LESS THAN 1/4"
19 COLLAR - POINT BUTTON HI - LOW OVER 1/8" MAJOR -
20 COLLAR - POINT BUTTON HI - LOW UP TO 1/8" MAJOR -
21 UNEVEN ELASTIC SETTING MAJOR -
22 SLEEVE LEFT & RIGHT HORIZONTAL STRIPE - MAJOR
UNBALANCE OVER 1/4"

C2 : BOTTOM

1 WAISTBAND HI - LOW UP TO 1/8" MAJOR -


2 UNEVEN WAISTBAND UP TO 1/8" MAJOR -
3 BACK POCKETS HI - LOW UP TO 3/16" MAJOR -
4 BACK POCKETS HI - LOW OVER 3/16" MAJOR -
5 LEG TWISTED OVER 3/4", ( FRONT + BACK ) MAJOR -
6 UNEVEN HEM HEIGHT OVER 1/8" EACH SIDE - MAJOR

C3 : KNIT TOP

1 TWISTED BODY ( FROM BOTTOM OF ARMHOLE ) = 5% - MAJOR


ZONE A ZONE B
D. PRESSING

1 BURN MARKS, SCORCH MARKS, PRESS MARK MAJOR MAJOR


2 UNPRESSED WHEN PRESSING IS SPECIFIED MAJOR MAJOR
3 PRESSED - IN PLEATS MAJOR MAJOR
4 GLARING SHINE MARKS MAJOR MAJOR
5 IMPROPERLY PRESSED ADVERSELY AFFECTING MAJOR MAJOR
6 APPEARANCE MAJOR

D CLEANLINESS

1 STAIN, SOIL, OIL UNDER 1/4" MAJOR MAJOR


2 STAIN, SOIL, OIL OVER 1/4" MAJOR MAJOR
3 RING FROM CLEANING GUN OR RUB SPOTS MAJOR MAJOR
4 ATTACHED SEWING THREADS MAJOR MAJOR
5 ATTACHED THREADS OVER 1 " INSIDE GARMENT MAJOR MAJOR
6 DRILL HOLE OR PENCIL MARK VISIBLE MAJOR MAJOR
7 MILDEW OR GARMENTS WITH HEAVY ODOUR MAJOR MAJOR

E OTHERS

1 PILE DIRECTION NOT AS SPECIFIED MAJOR MAJOR


2 INCORRECT FOLDING MAJOR MAJOR
3 MISSING OR INCORRECT LABEL MAJOR MAJOR
4 INCORRECT THREAD OR ACCESSORIES MAJOR MAJOR

REMARKS :

1 ANY SPECIAL FABRIC CHARACTERISTIC OR NATURE ( LIKE MADRAS,


LINEN ) TO BE UNDER SPECIAL CASE.

2 IF THERE IS A CONSISTENCY MINOR DEFECT FOUND CONCENTRATION


IN A PARTICULAR AREA, IT SHOULD BE COUNTED AS A MAJOR DEFECT.

3 ITEM ZONE AZONE B

TOP FRONT PRESENTATOTHER AREA


BOTTOM FROM WAIST TO HI - OTHER AREA
( FRONT & BACK
GENERAL DEFECT CLASSIFICATION LIST

I. SOIL / GENERAL CLEANLINESS

1 ANY SOILAGE / SPOTS / STAINS ON THE GARMENT AFFECTING MAJOR


APPEARANCE

2 LOOSE THREADS AND DEBRIS IN PACKAGING MAJOR

3 ANY TAPE OR SECONDS STICKERS ON A GARMENT PACKED


FOR SHIPMENT MAJOR

4 ANY ATTACHED THREADS / YARN LONGER THAN 1/4" ON


OUTSIDE OF GARMENT MAJOR

5 MORE THAN THREE ATTACHED THREADS / YARN LONGER


THAN 1/2" EACH ON INSIDE OF GARMENT MAJOR

6 ANY STAPLES, PINS OR SWIFT TACKS LEFT IN THE GARMENT MAJOR


NOT SERVING A USEFUL PURPOSE

7 ANY CHALK MARKS, PEN MARKS ETC… MAJOR

8 CORRODED OR DISCOLOURED HARDWARE OR CLOSURES MAJOR

9 FOREIGN MATTER ( THREADS / FLY YARNS / DEBRIS… ) SEWN IN MAJOR

II. WORKMANSHIP

1 WRONG COLOUR, TYPE, SIZE OF THREAD MAJOR

2 SEAMS TWISTED, PUCKERED, OR PLEATED AFFECTING


APPEARANCE MAJOR

3 SKIPPED STITCHES
A LOCK STITCH - ONE SKIP STITCH MAJOR
B TWO SKIP STITCHES MAJOR

4 CHAIN STITCH - ONE SKIP STITCH MAJOR

5 BROKEN STITCH MAJOR


6 ENDS OF STITCHING NOT PROPERLY SECURED, TIED IN, CAUGHT
IN OTHER SEAMS, BACK STITCHED, OR TACKED MAJOR

7 RAW FABRIC EDGE ANYWHERE IN THE GARMENT MAJOR

8 STITCHES PER INCH DEVIATION OF MORE THAN PLUS TWO PER


INCH OR MINUS ONE PER INCH MAJOR

9 EDGE STITCH MARGIN IRREGULARITY / UNEVENNESS MAJOR

10 TACKS AND OR BACK STAYS MISSING, OR NOT PLACED AS


SPECIFIED MAJOR

11 LOOSE STITCHING CAUSING GRINNING SEAMS MAJOR

12 ANY STITCHING RUN - OFF MAJOR

13 ANY AREA OF FABRIC WITH NEEDLE HOLES ( CHEWS )


AFFECTING APPEARANCE MAJOR

14 ANY AREA ON A SEAM WHERE THE NEEDLE HAS CAUSED


PICKING ( BROKEN YARNS OR YARN FILAMENTS ) MAJOR

15 ANY BROKEN STITCH REPAIR THAT IS NOT SEWN EXACTLY


STITCH ON STITCH WITH AN OVERLAP OF AT LEAST THREE
STITCHES ON EACH END MAJOR

16 ANY REPAIR THAT IS NOT COMPLETE, CLEAN OF THREADS,


OR IF RE - SEWN IN A WAY THAT ADVERSELY AFFECT
APPEARANCE MAJOR

17 IMPROPER / UNEVEN SEAM ALLOWANCE TAKE UP MAJOR

18 CONSTRUCTION NOT CONFORMING TO SPEC.


( I.E. WRONG SEAM TYPE… ) MAJOR

19 INTERLINING OR FUSING CAUSING VISUAL DISTORTION MAJOR

20 PLEATS FACING WRONG WAY MAJOR

21 BAND END NOT FLUSH WITH FRONT ( TOL. 1/8" ) MAJOR


COMPONENT / PARTS CONSTRUCTION

1 ANY DEFECTIVE COMPONENT OR PART THAT AFFECTS THE SERVICEABILITY MAJOR

2 ANY " SPEC'S" COMPONENT OR PART OMITTED FROM THE GARMENT MAJOR

3 ANY REQUIRED OPERATION OMITTED OR IMPROPERLY PERFORMED MAJOR

4 ANY PART CAUGHT IN AN UNRELATED OPERATION MAJOR

5 ANY PART NOT SECURELY ATTACHED MAJOR

6 FAILURE OF SLIDER TO WORK PROPERLY MAJOR

7 COIL / TEETH PULLING AWAY FROM TAPE MAJOR

8 INCONSISTENT ZIPPER SET CAUSING WAVY ZIPPER MAJOR

9 LEFT TO RIGHT ZIPPER SET HIGH / LOW MAJOR


IF FUNCTIONING PROPERLY ( TOL. 1/4" ) MAJOR
OVER 1/4" TOL. REGARDLESS OF FUNCTION

10 WIDE ZIPPER TAPE EDGE MARGIN CAUSING INSUFFICIENT


ZIPPER TAPE COVERAGE BY FRONT FLY PANEL MAJOR

11 FRONT PANEL SEWN TOO CLOSE TO ZIPPER TEETH CAUSING


EXCESSIVE FRICTION ON SLIDER MAJOR

12 ZIPPER PULL TABS OMITTED OR NOT SECURED PROPERLY MAJOR

13 MISSING, MISPLACE OR MISALIGNED CLOSURES MAJOR

14 HIGH / LOW WAIST BAND IN EXCESS OF 1/4" MAJOR

15 POCKET SET INCORRECT ALLOWING POCKET BAG TO SHOW MAJOR

16 POCKET FABRIC RAVELS ON CLEAN FINISHED BAGS


TRIMMED TO 1/4" MAJOR
UN - TRIMMED, OVER 1/4" MAJOR

17 SERGE TAILS ON POCKET BAGS 1/2" TO 1" LONG MAJOR


OVER 1 " LONG MAJOR

18 POCKET SEWN ON SLANT MAJOR


19 HIGH / LOW POCKETS ( TOL 1/8" ) MAJOR

20 SHADED COMPONENT SERIOUSLY AFFECTING APPEARANCE MAJOR

21 LABEL NOT SEWN IN CORRECT LOCATION ( TOL. 1/2") MAJOR

22 CLOSURE SEWN ON UPSIDE DOWN MAJOR

23 BUTTONS NOT SEWN THROUGH ALL EYES MAJOR

24 BUTTONS SEWN ON WITH INCORRECT TENSION MAJOR

25 ONE OR MORE SKIPPED BUTTON HOLE STITCHES MAJOR

26 SIDE EDGE OF POCKET EXPOSED FROM UNDER SIDE OF FLAP MAJOR

DECORATIONS / LOGOS ( EMBROIDERY, SCREEN PRINT, PATCHES, ATTACHMENTS )

1 WRONG COLOUR / TYPE / SIZE THREAD MAJOR

2 WRONG COLOUR / TYPE / SIZE DECORATION MAJOR

3 SLANTED / UNBALANCED CAUSING UNACCEPTABLE APPEARANCE MAJOR

4 INCOMPLETE OR MISSING MAJOR

5 NAPPED APPEARANCE MAJOR

6 INCORRECT OR MISSING BACKING OF DECORATION MAJOR

7 EMBROIDERY WITH INSUFFICIENT STITCH COUNT MAJOR

8 HOOP MARKS VISIBLE IN FABRIC MAJOR

9 LOOSE THREAD OR DEBRIS STITCHED INTO DECORATION MAJOR

10 LOOSE DECORATION THREADS NOT TRIMMED MAJOR

11 CONNECTING THREADS NOT TRIMMED MAJOR


( I.E. THREADS CONNECTING LETTER TO LETTER )
FINISHING

1 ANY BURN, SOURCE OR SHINE MARKS MAJOR

2 FABRIC DE-COLOURISATION / COLOUR CHANGE DUE TO PRESSING MAJOR

3 UN - PRESSED GARMENTS OR SECTIONS OF GARMENTS MAJOR

4 PRESSED IN PLEATS IN FABRIC PANELS WHERE NOT SPECIFIED MAJOR

5 IMPROPER PRESSING, ADVERSELY AFFECTING GARMENT APPEARANCE MAJOR

6 DISTORTED GARMENT FROM EXCESSIVE STRETCHING DURING PRESSING MAJOR

7 FOLDED WITH EXCESSIVE STRETCHING DURING PRESSING MAJOR

8 INCORRECTLY FOLDED MAJOR

9 INCORRECT PACKAGING MAJOR

10 WRONG COLOUR OR OUTSIDE OF ESTABLISHED SHADE RANGE MAJOR

11 MISSING OR INCORRECT TICKETING MAJOR

III. DEFECTS SPECIFIC TO :

TOPS ( WOVEN, KNIT AND OUTERWEAR )

1 EDGE OF FLAP, COLLAR, CUFF, PLACKET CENTER FRONT ROLLED FORWARD MAJOR

2 LENGTH OF COLLAR POINTS UNEVEN MAJOR

3 COLLAR STAY MISSING MAJOR

4 LOCKER LOOP IMPROPERLY SEWN OR MISPLACED ( TOL. 1/8" ) MAJOR

5 MISALIGNED SLEEVE AND SIDE SEAM JUNCTION ( TOL. 1/4" ) MAJOR

6 INCONSISTENT PLEAT DEPTH - RIGHT VS. LEFT MAJOR

7 INCONSISTENT SIDE SEAM LENGTH ( TOL. 3/8" ) MAJOR

8 UNEVEN CUFF WIDTH ( TOL. 1/8" ) MAJOR

9 TWISTED CUFF, COLLAR, TURTLE NECK….AFFECTING APPEARANCE MAJOR


BOTTOMS ( PANTS, SKIRTS, SHORTS )

10 ON LOOPS OR POCKETS ( TOL. 1/8" ) MAJOR

11 LEGS UNEVEN RIGHT TO LEFT ( TOL. 1/8" ) MAJOR

12 UNBALANCED OR MISPLACED LOOPS AFFECTING APPEARANCE MAJOR

13 LOOP OPENING NOT AS SPECIFIED ( TOL. 1/8" ) MAJOR

14 TWISTED LEG IN EXCESS OF 1/2" JEANS MAKE MAJOR


1/2" SLACK MAKE MAJOR

15 UPPER FLY TACK ABOVE TOP OF SLIDER AT IT'S LOWEST POINT MAJOR

16 MISPLACED RIVETS ( TOL. 1/8" ) MAJOR

17 MISALIGNED YOKES AT SEAT SEAM ( TOL 1/8" ) MAJOR

18 MISALIGNED JOIN FRONT AND SEAT SEAM ( TOL. = WIDTH OF SEAM ) MAJOR
METHOD OF TEST
THE WEAR AND PERFORMANCE TRIAL

PURPOSE OF ADMINISTRATION

1. To monitor and assess the performance of new


Fabrics/components/new make-up/assembly
methods during a concentrated period of controlled use.

2. To compare the wear trial performance with


physical/ chemical laboratory test results to confirm or
question their accuracy related to consumer use.
3. To examine wear on fabrics/components where
physical/ chemical laboratory testing would not have been
appropriate.
4. To check the equality of trial or bulk production

PANEL OF USERS
1. A catalogue of people willing to take part in wear
trials should be set up.This should include sufficient
information about them so as to provide a wide range of users
to cover the requirements of any given trial.

For example : for apparel garments, recorded details might include:


Actual measurements
Pantaloon size worn
Age
Height
Occupation ( a sitter for example would be appropriate
for seating or creasing )
Sports activities ( if appropriate )
Any dislikes or preferences
Washing machine type
Drying facilities
Wear characteristics
A Data base which is simple, convenient way to store
the information.
3. As the system builds up it will be useful to grade the
Wearers as per their reliability.
THE WEAR TRIAL FORM
This is the pre-printed standard form for the user to complete during the trial.
A specimen form is shown later in the method.
WEAR TRIAL REQUEST/RECORD
1. Full background information on the articles should be available at the time of
request to enable accurate instruction to be passed on to the user. This should include:
Number of articles with description and size.
The source and quality reference of the articles including all major components
Composition and colour
SKU ( store ) number
Proposed selling price
Proposed care label and instruction for use. Including any intended warnings.
Purpose of trial outlining any specific areas where attention must be paid
Amount of wear/use required
Number of washes/cleans required
2.A complete set of test results on fabrics/components together with any test on
the finished article. For example, durability wash on garments should accompany the
articles. These should be held until examination stage for comparison. It is important that
test results should be as complete as possible and not to be just those relating to the
property under trial. For example, a wear trial to investigate pilling should include
stability and colour fastness results. A failure in these areas could cause the trial to be
halted prematurely. All fabric/component results should relate to the specific batch from
which the article has been produced.

FILING SYSTEM
This should be arranged to hold the background information, test results and a
record sheet listing the users names and contact with any notes o the progress of
the trial.
TEST SPECIMEN

Is necessary to remind the user a few day prior to the return date.
WEAR TRIAL ANALYSIS SUMMARY SHEET
An example of the wear trial analysis/summary sheet is enclosed.

NUMBER OF ARTICLES
A minimum of two articles is required. ( It is desirable to have mare ).
These must be assembled from a single component batch, In the case
where there are two or more pieces to the article to form a set, four
complete sets are required. For example, in two piece garments the tops
and the bottoms will give a different pattern of wear.
Retain one complete article as a reference for comparison with the used
article at the end of the trial, and for further testing, if necessary.
COLOUR, SIZE, STYLING
COLOUR,
There must be a minimum of two articles per colour, with one article of each
colour being retained as a reference.
Finishes
When comparing two or more different finishes, all article should be the
same colour, giving individual users a number or articles each, made
from one of the alternatives under evaluation.
Size
To ensure that all types of covered, it is desirable to
select a range of sizes for the wear trial.
Styling
It is preferable that trial article are made up in the style proposed for
bulk production. Please note that, attractively styled articles are likely to
be used more often and styling details may have an effect on the overall performance.
DURATION The normal trial period is 4 weeks during which the user will be asked
OF TRIAL to use the article at every opportunity to give concentrated wear within
METHOD this period. The minimum usage is 20 hours.

Washable garments:
Underwear, Hosiery - Minimum 6 Washes
All other items - Minimum 4 Washes
The progress of the trial may be monitored by arranging an
intermediates inspection.
Users should be encouraged to return articles early where faults have
developed or changes in performance have become evident.
See note
1. Check each article thoroughly noting any flaws which exist
before issuing the trial.
2. Retain one article per colour as the reference and label with
the identification number of the wear trial.
3. Identify each article (for example A,B,C and so on) using with
indelible laundry marker. For hosiery this is not practical, these items
require tagging.
4. Measurements
Articles should be measured, using a metal ruler or tape for
accuracy, before and after the trial to calculate an approximate
change in dimension. The position of such measurement should
be chosen so that a stability test result can be compared directly
to the article.
Trimmings, collars, stolling, welts and so on should be
measured separately. A record of the exact position of the
measurements should be taken since it is not always practical to
mark the article.
ASSESSMENT & ANALYSIS REPORT

IMPORTANT
Where production will be labelled 'KEEP AWAY FROM FIRE'
For example:nightwear,dressing gowns and cotton knitwear,the wear
trial garment and forms must carry the same warning.
Re-measure and calculate the changes in dimension.Examine each
article comparing the appearance with reference article and note all change on
the analysis sheets.

1. Number of articles examined.


2. Individual hours worn/time used (quote a range,if there is a large variation)
3. Individual numbers of washes/cleans quoting the care
instruction followed (quote a range if there is large variation).
4. Users reference and name.
5. Summarise all appropriate comments.List comments In order
of relevance to the article performance and specific reason for trial
6. Quote percentage change in dimension.
7. The examination should be carried out in conjunction with
the relevant Pantaloon technologist and sourcing personnel

Or in the case of garment maker ,the fabric


technologist / garment technologist and factory manager,and
both should agree any action necessary and sign the summary sheet.
List all observations in order of importance--cross-referencing
the findings with the users comments where applicable. All
points should be carried where necessary.For example, pilling:
"Garment A shows severe localized pilling (bust and hip area)
that is distinct, moderate, etc., as described in the appropriate
test procedure.

RETURN OF GARMENTS
TO USERS NOTE

8. Reports all laboratory test results making a note of any


instance where the test result and wear trial do not agree.

A copy of the summary sheet should be sent to the relevant technologist at


Pantaloon together with the durabilitywash / dry clean pre-seal /cloth buy.
Users should be asked to inform the wear trial department of any further
comments / changes in performance and to be prepared for recall if required.
When garments are assessed for creasing,photographs are often useful.
Wearers should be photographed wearing the garments at different stages
throughout the trial:
I.e.
I. After 1 day's wear
ii. After first wash and wear
iii. At the end of the trial
4 Knitwear must be measured as described :

5 Selection of Users

a Check the suitability of users, for example,size,occupation, uniform, age, group, dislikes,

preferences and so on

b Ensure the user is not currently participating in the trial

c Ask the selected user to carefully view or try on the article to ensure that it is suitable for

constant use during the trial period. Record any initial comments, negative and positive

d Reliability of the user - always get a commitment to carry out the wear trial instruction carefully

e To ensure maximum use during the whole period the selected used must be

6 Fill out the wear trial form with the article description and identification , all essential

instructions, garment reference and return date

7 Keep a record of all user names and contact telephone numbers, garment identification and

measurements.

8 Note in the reminder diary the return date and a date prior to this (usually 3-5 days) when it

will be convenient to issue a reminder to the users.

9 On the return of the trail, ensure the form is filled in correctly and fully. Label each article with

the wearer's

i Available on the day of trial issue to collect the article.

ii Must be available during the full period of the trial to facilitate an early return of the article,

for example - not on holiday


4. WHEN WORN/USED FOR THE FIRST
TIME BEFORE WASHING/CLEANING

a) What did you think of the fit and appearance

b) What did you think of the fabric


or the product material?

c) What did you think of the comfort/suitability?

d) Would you buy it at the stated price? YES NO

5. AFTER THE FIRST WASH/CLEAN

a) Was there any change in fit or appearance? YES NO


if yes ,how did it change?

YES NO
if yes ,how did it change?

c) Comment on comfort and suitability.

d) Comment on the ease of ironing.

6. AT THE END OF TRIAL

a) Comment on any further changes in fit,appearance


fabric,comfort and suitability.

b) Did you consider the label/care instructions satisfactory YES NO


for this merchandise? If not , why?

c) Knowing how the merchandise has performed would


you buy it at the stated price ? If not,state why and
what price you would be prepared to pay YES NO

d) If you had purchased it would you complain to the store? YES NO

e) How do you consider the merchandise could be improved ?

7.Any other comments re styling, design, etc


details of other cleaning methods:-
SPECIMEN WEAR TRIAL FORM
WEAR AND PERFORMANCE TRIAL

DATE ISSUED : TRIAL NO:


WEARER'S NAME: ARTICLE REF:
CONTACT NAME:
MERCHANDISE:
SIZE: COLOUR:
COMPOSITION:
PRICE:

MINIMUM WEAR REQUIRED: HOUR. MINIMUM NUMBER WASHES/CLEANS:

CARE INSTRUCTIONS:

ADDITIONAL INSTRUCTIONS:

PLEASE RETURN WITH THIS FORM


FOR INSPECTION ON :

If you have any queries or strong criticism regarding fit,comfort,make or quality please contact
Tel: Ext:
PLEASE ENSURE THAT THIS FORM IS FILLED IN COMPLETE DETAIL
For mid trial inspection please complete sections 1-6

TRIAL RECORD OF AMOUNT OF USE

Date Worm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
12 hours
7 hours
4 hours
Other Hours
Washed/Cleaned

1. Details of Wash
Method : Hand/Machine Machine Type: Twin tub;automatic;Washer/Dyer
Cold/Medium/Hot Detergent Product Used :___________
Conditioner used :_______________ Other products used:_______________ Soaked: Yes/No
Pre Wash: Yes/No Water extraction : Slow/fast Spin; Drip Dry; Other (specify)
Final Drying: Tumble: Warm/hot: Line ;Hanger ,Supported indoors/outdoors
Ironing:- Yes/No Dry; steamed;damp cool/medium/hot
PROCEDURE FOR FIT AND CONSTRUCTION APPROVAL

All sample garments sent to the Head Office for fit and / or construction approval
should be accompanied by Garment Approval From. This form
should serve to communicate any notations which you want to bring to our attention as
we review the fit and construction upon receipt in our office .Needless to say we will
assume that garments received without any comments have been made to specifications
and that you are unaware of any variances which we might find upon receipt in our office.
The intent of this form is to expedite the approval process to our mutual benefit. Please
see the attached from for bottoms and tops. If you have any further questions or
suggestions please do not hesitate to contact us.
Fit and Construction Approval

PANTALOON RETAIL ( INDIA ) Ltd .


GARMENT APPROVAL
PANTS ( PROTO / P.P / ) SAMPLE

FACTORY :________________________ DATE :_____________ ALL POINTS MUST BE CORRECTED FOR PRODUCTION
PO.NO: __________________________ SIZE :_______________ Factory Comments :
STYLE NO :_______________________

BODY:___________________________________
TRIM:___________________________________

MEASUREMENT SPEC ACTUAL MEASUREMENT SPEC ACTUAL


WAIST CLOSED FRONT POCKET Pantaloon Comments :
WAIST BAND WIDTH FRONT WATCH POCKET
HI HIP FRONT WATCH PKT FM W/B
LOW HIP ( PLEAT OPENED ) BACK POCKET
( PLEAT CLOSED ) BACK PKT PLCMT ( FM W/B )
FRT RISE ( INCL/EXCL W/B ) BK YOKE DEPTH ( FM C.B )
BACK RISE ( INCL/EXCL W/B) ( FM SIDE )
THIGH ( AT/1"BLW CROTCH ) FRONT POCKET BAG
KNEE ( 14"/17" FM CROTCH) APPROVED AS SAMPLE/PROTO
BOTTOM SWEEP REMAKE SAMPLE / PROTO , SEE COMMENTS
INSEAM PROCEED WITH SAMPLES, SEE COMMENTS
ZIPPER LENGTH PROCEED WITH STOCK, SEE COMMENTS
BUTTON FLY

REJECTED BY : DATE
APPROVED BY : DATE
PANTALOON RETAIL ( INDIA ) Ltd .
GARMENT APPROVAL
( PROTO / P.P ) SAMPLE

FACTORY :________________________ DATE :_____________ ALL POINTS MUST BE CORRECTED FOR PRODUCTION
PO.NO: __________________________ SIZE :_______________ Factory Comments :
STYLE NO :_______________________

BODY:___________________________________
TRIM:___________________________________

MEASUREMENT SPEC ACTUAL MEASUREMENT SPEC ACTUAL


BODY LENGTH ( FRONT ) SLEEVE LENGTH Pantaloon Comments :

BODY LENGTH ( BACK ) ARMHOLE


CHEST WIDTH MUSCLE
BOTTOM WIDTH FOREARM
BOTTOM HEIGHT CUFF OPENING
SIDE SLIT ( FRT/BK ) CUFF HEIGHT
SHOULDER WIDTH EMB'Y FM
BK NECK WIDTH STRIPE FM
FRONT NECK DROP LABLE PC (HxW ) APPROVED AS SAMPLE/PROTO
BACK NECK DROP V-INSET (HxW ) REMAKE SAMPLE / PROTO , SEE COMMENTS
NECK HEIGHT POCKET PLCMT ( FM CF ) PROCEED WITH SALES SAMPLES, SEE COMMENTS
COLLAR LENGTH POCKET PLCMT ( FM HPS ) PROCEED WITH STOCK, SEE COMMENTS
COLLAR HEIGHT POCKET ( HxW )
COLLAR BAND HEIGHT NECK STRETCH
COLLAR POINT GMT WEIGHT
PLACKET ( HEIGHT )
PLACKET ( WIDTH )
REJECTED BY : DATE :
APPROVED BY : DATE :Pa
Packaging Strategy

Packaging recoverable by material recycling

- Ensure that the design of the packaging includes consideration for the recycling of
the materials from which it is produced and the selection of the raw materials used is
proper and standardized.

- Ensure that the design of the packaging is compatible with the available recycling
technology and that the enviromental impact caused by the recycling of the packaging
is taken into account and recycling processes are not negatively affected

Test Methods and evaluation criteria for final acceptance of packaging


Establishes test guidelines for packaging materials & Packaging Process

Reduction of waste (prevention by source reduction)

Demonstrate that the minimum adequate amount of packaging has been used,
taking in to account the critical functions of the packaging

Packaging : Re-use
Ensure requirements for packaging to be deemed to be recoverable

Vendor Relationship

Pantaloon is committed to work with our vendor to ensure each product is shipped
to our customers in packaging of such quality that it will arrive safely at the
destination, and in the condition intened by both pantaloon and the original vendor

We expect that each merchandise vendor follow the guidelines as a condition of


doing business with Pantaloon

These standards are a minimum requirement, responsibility for merchandise


damage due to insufficient vendor packaging remains with the vendor.
Five Purposes of packaging

CONTAINER: To hold the product directly; this is PRIMARY packaging . Example include the
1 tube or pump for toothpaste, the can or Jar for food, the bottled beverage, the drum for a cleaning
product.

INFORMATION: To identify the brand any related companies, to explain how it should be used, to
2 warn about the hazard of misuse, and to reveal product contents. Much of this information is also
required according to various laws and regulations.

PROTECT: To prevent spoilage, leakage, breakage, moisture changes, theft and tampering.
3
These packages seal out contaminants in the enviroment like germs, dirt, dust, moisture, etc.

TRANSPORTATION: To easily and safely move the product from the manufacturer, perhaps to a
4
warehouse, then the retail store and finally to the consumer.

DISPLAY: To effectively display, to see ( a marketing tool ). Size, cost, colour, brands,
5
illustrations and shape are all considered for display.

Packaging Definitions
1 Primary Packaging : The container that directly holds the product is the PRIMARY package
Pre-pack : Secondary Packaging - packaging designed in such a manner asto form a group of a
2
certain number of sales units sold as such to the end user or used to fill display stands, any outer
Transport packaging : designed to prevent damage during the handling, transportation and
3 storage of products that ill be used to ship the poduct without further protection or packaging
being added.
Primary Packaging

All merchandise should be labelled with a description, special


handling instructions & barcode for identification clearly visible
for scanning.

Hard goods must be separated/protected within the package


so they do not rub or strike against other items in the same
container.
The supplier must ensure that the package is optimally sized to
suit the contents. Internal dividers should be utilized on fragile
prodcts which are deemed likely to sustain damage during
distribution.
Sharp,narrow,or pointed objects (i.e. table legs, pot handles)
must be wrapped and secured in such a way that prevents that
prevents them from puturing the carton from within

Large or oversized packages must have reinforcement to


prevent collapse under extrene weight conditions.

Pre-pack : Secondary Packaging


Pre-Pack: As per size set/ratio decided by Pantaloon. Special
handling
Packaginginstructions
must have(iappropriate
e fragile Glass
size or
anddirectionel arrows)
strength to protect
the merchandise contained inside
Transport Packaging

.Packaging must have appropriate size and strength

.Large or oversized packages must have reinforcement to prevent collapse


under extreme weight conditions

.Merchandise must be packed in a new box.Recycled cartons should not be


used to ship merchandise.

.The package should comply with BIS:"IS 15526:2004 packaging-


Complete,filled Transport Packages-Stability testing of unit loads"
(refer section 9)
Transport Package specification-Corrugated Fibre board box

1. The package should comply with BIS : “IS 2771(part 1) -1990 Corrugated
fibreboard boxes- Specification part1 General Requirements” (refer Section
9)

a. Maximum weight of Content : 15 kg*

b. Maximum Combined Internal Dimension of the box (L+W+H) : 1275


mm*

Boxes should be made with no single dimension exceeding 50% of the


combined internal dimension

2. Compression strength of CFB box: min 200 kg/sq.cm


3. Moisture Content - 5 % - 8 %
4. Bursting Strength-min 8

* In circumstances where the weight of the case is unavoidably greater


than above specification (e.g. TV's, Furniture like big cabinets/bed) , the
actual weight & size must be printed onto the case itself and must be
authorized by Pantaloon for “Package Design”
Transport package :Bags & Sacks

1.For products which are delivered in poly bags e.g. towels, cushions etc

Minimum bag material thickess:75 micron(300 gauge) HMHDPE is


required.

2. maximum weight of content : 15kg*

*In circumstances where the weight of the case is unavoidably greater


than above specification,the actual weight & size must be printed onto the
pack itself and must be authorized by Pantaloon for "Package Design"

Packaging material Storage & Conditioning for use


.
.Paper based (board) packaging components & Plastic based materials are subject
to deterioration and reduce performance due to environment temperature and
humidity fluctuation.
.The materials should be conditioned to the line environment prior
to use for a minimum of 24 hours.

.All packaging materials should be used on a 'first in - first out'


basis such that components are not stored for unnecessarily
extended periods.
PO Number & Date

Supplier Name

Address

Product Description

BAR CODE

Quantity per Pack (No.)

Supplier Invoice No.

Destination Warehouse

Batch/Lot Code Carton Number

Outer dimension. of Carton (mm)/sack

Net Weight of the Content (kg) Gross Weight (kg)

Storage Conditions, if applicable


Article code Qty

FRAGILE

FRAGILE
Packaging material specification

Corrugated Fiberboard box for Transport


1. CFB boxes -“C type” Tape sealing pattern as shown
2. BOPP tape with Vendor’s logo
3. Individual box to be wrapped with stretch wrap
4. Two Labels preferably one “Lengthwise” & another “Widthwise”
5. Recommended Paper for 15 kg weight carrying capacity : 150 GSM/20 B.F Kraft Paper, 5-ply, A/A Flute.
6. Minimum Compression Strength of box: 200 kg/sq cm

HMHDPE Bags / Sack for Transport:


Specs: 150 g
1. Pack closure: Heat Sealing method
2. Two Labels preferably one “Lengthwise” & another “Widthwise”

BOPP Sealing tape specification


Mode of application: “C” type , as shown in fig.
1. Width – Min. 48 mm ± 1 mm .
2. Thickness : - 25 mic ± 5 % .
3. Breaking Strength : - 3 kgs/10 mm ± 5 %
4. Material : Transparent BOPP tape printed with company logo .
5. Adhesive : PSI based min. 20 gsm .
6. Adhesion : Fibre – tearing during peeling off of tape from the paper substrate .

Stretch film specification


1. Thickness – 23 mic ± 5 % .
2. Film roll width : -10 inch ( 254 mm ) ± 5 %
3. Net wt. of film per roll : - 3 kgs .
4. Material : - Cling LDPE film.
Position of packing slip on the box

Transport Box with stretch wrapping, supplier’s


logo printed tape and packing slips
Packing Guideline- Benefit

.Protection against physical impact object- The objects enclosed in the package may require protection

from among other things, damage caused by physical force, rain heat,cold sunlight, pressure, airborne
contamination, automated handling devices, or any combination of oneor more of these.

.Protection against dust and dirt- Transportation packaging keeps our products clean and neat till the shelf

and so helps cut cleaning costs on the shop floor.

.Pre-Pack- Smallobjects are typically grouped together in one package for reasons of efficiency.

Information transmission- Information on how to use, transport is contained on the package or label

.Marketing- The packaging and labels can be used to encourage potential buyers to purchase the product.

.Reducing theft- These packages are deliberately difficult to open, to hamper thieves from removing their
contents without drawing notice. Packages also provide opportunities to include anti- theft devices, such as
preprinted tape/ strapping & stretch wrapping.

.Prevention of pilferage and tampering- Packaging that cannot be reclosed or gets physically damaged
(shows signs of opening) is very helpful in the prevention of these acts.

Handling & Pallesation


The use of pallets is recommended as a means of
reducing the potential for damage
Standard pallet dim:1200MM x 1000MM (4-WAY ENTRY)
Stack height :1.2 meter (inch pallet)

The maximum pallet weight is 1250 kg (inc.pallet)

reference standard BIS:IS 13823:1993 Guidelines for palletisation-Genral Cargo & IS 9340:1979
for pallet construction (refer section 9)

Introduction of handling equipment is also a recommended method of reducing personnel handling


strains,injuries & incidence of drop

For large packs like furniture,it is recommended to arrange the package on a pallet customized
as per the load with zero overhang
Packaging Reference & Contact

Reference Standards from "Bureau of Indian standards" Contact :

Bis sells Indian standards and other publication through its chain of 17 sales.
centres. Pantaloon Retail (India) Limited

Director (sales)

manak Bhawan Address: Knowledge House,Shyam Nagar,


9,Bahadur Shah Zafar Marg Off Jogeshwari-Vikroli Link Rd.,
New Delhi 110 00291 11 3238821,3233375,3239402 Jogeshwari (East),Mumbai -400060,India
91 11 234062,3239399,3239382 (fax)
sales@bis.org.in
Western Regional Office
Manakaalaya,
E9,Behind Marol Telephone Exchange,
Andheri (East)
Mumbai 400 093,Phone 28253431 For Clarification of technical details contact
Fax 28374231
email saleswro@bis.org.in
Eastern Regional Office Ms.Mrinalini Chavan
5,Chowringhee Approach Sr.Manager-Supply Chain management-Packaging
P.O.Princes Street Mobile-09323138687
Calcutta 700 01291 33 271085
91 33 3377459 (Fax) E-mail-mrinalini.chavan@pantaloon.com
reo@bis.org.in
Northern Regional Office
SCO 335-336,Sector 34-A
Chandigarh 160 02291 172 603843,606083
91 172 602025 (fax)
nro@bis.org.in
Southern Regional Office]
C.I.T.Campus,IV Cross Road
Chennai 600 01391 44 2352315,2351584,2351470
91 44 2350087 (fax)
sco@BIS.ORG.IN

Documentation Instruction
Purchase Order Copy
Invoice Copy
Challan Copy
Packing slip
Qc Report
This form will be used by Factory / Vendor to intimate goods transfer from place of production to the Distribution Centre (DC)

Advance Despatch Notice / Packing List

PO NO Invoice / DC No.

PO Delivery Date Date

Destination / Distribution
Vendor Name
Centre

Transporter Details

Transporter Name LR Date

Mode of transport To be delivered by date:

LR No. No of Boxes

PO Line Item/ line no Article Code /EAN No Article Name/ Article description PO Qty Despatched Qty Carton No.
PO Number & Date
Supplier Name
Address
Product Description

BAR CODE
Quantity per Pack (No.)
Supplier Invoice No.
Destination Warehouse
Batch/Lot Code Carton Number
Outer dimension. of Carton
(mm)/sack

Net Weight of the Content (kg) Gross Weight (kg)


Storage Conditions, if
applicable
Article code Qty

FRAGILE
Packaging Instruction for - Clothing & Fashion and Home furnishing
Category Sub Category Special Instruction General Instruction for this Category

Clothing & 1. With Hanger Appropriate size hanger should be inserted in the 1. Individual/Set of garments should be covered in a clear, protective
Fashion garment. plastic bag.

2. All hangtags should be attached with plastic barbs. All


merchandise should be labelled with a description, special handling
instructions & barcode for identification clearly visible for scanning
3. Metal pins/Safety Pins should not be used.
2. Without Hanger 4. All items should be labelled with the fabric content, country of
origin and care label & should be visible into the garment.

3. Sweater May be folded and Flat Packed in a presentable fashion 5. Barcode as per instruction by Category

Home Furnishing 1. Linens Must be wrapped in protective plastic 1. Individual/Set should be covered in a clear, protective plastic bag-
70 mic PP.

2. 1.Must be wrapped in protective plastic 2. All hangtags should be attached with plastic barbs. All
Pillows/Cushions
merchandise should be labelled with a description, special handling
instructions & barcode for identification and clearly visible for
2.Must be packed individually 3. Metal pins/Safety Pins should not be used.
3. Towels 1.Must be wrapped in protective plastic 4. All items should be labelled with the fabric content, country of
origin and care label & should be visible into the garment.

2. Must be separately packaged by style and colour. 5. Barcode as per instruction by Category

4. Draperies 1.Should be protected with clear plastic/plastic zip bags


2. Rods/Finials should be packed by selling unit.
Specification for Corrugated Fibreboard Box (Transport shipper)
Gross weight of transport pack Up to 15 kg Up to 25 kg

(Content weight + Transport pack


weight)
Clothing & Fashion Formal,Casual,Ocassional Thins, Rolls, Cut pcs.
wear,sportswear,Fashion
Home & Hard Goods Bath accessories, Furnishing, Blankets, Mattresses, Quilts,
Dining accessories
(1) Pack Height should not be more than pack Length dimension

(2) Corrugation Flutes run parallel to the depth of the box so that they are vertical when the box is stacked

(3) Minimum Compression Strength of box: 200 kg/sq cm

(4) Maximum stack height in Storage & Transportation: To be mentioned on the pack. (should not exceed 2100 mm)

(5) For detailed instruction, please refer our ‘Packaging Guideline’


(6) Label containing P.O.No. and date, supplier name & address, product description, quantity per pack, net wt and
gross wt, pack handling instruction, maximum stack height etc as per our labelling instruction should be put on each
transport package.
(7) Any consignment more than 25 kg will stand to be Rejected

Package Handling Instruction


Packaging component supplier list

Description Specification Supplier Contact person and no.


4*50*50 first quality specially
Plastic collar patti Royal Impex Mr. Sameer, 9820763102
shaped
Butterfly no 777 Collar pack sort no 777 gsm 30 Royal Impex

Butterfly no 875 Collar pack sort no 875 gsm 25 Royal Impex


Collar pack sort no B11 Gsm
Old Double Butter fly Royal Impex
30
Collar pack sort no 555 Gsm
New 24* 7 Double Butterfly Royal Impex
30
Pearl Head pins (Crown ) Japanese quality crown Royal Impex
Metal Cuff Clip Brass cross pins Royal Impex
Plastic M and U Clip As per sample Royal Impex

Knight hood Shirt Supporter 360 gsm *2 pasted full


Jay ambe Mr Sainath, 9322262397
With Patti supporter
DJ&C shirt supporter 500 gsm as per sample Jay ambe
400 gsm *2 Pasted I shape
JM shirt Supporter Jay ambe
supporter
Bare Shirt supporter 450gsm as per sample Jay ambe
Butter paper 20*40 ( 7.3 Kg
7.3 kg quality glossy finish Jay ambe
Quality)

Shipper Sai Paper Box Mr Vinod Singh, 9323220770


Jay ambe Mr Sainath, 9322262397
Ami Corp Mr. Jaju, 9819913710

BOPP Tape Mohsin Ent Mr. Usman, 9819610200


Ayush Ent Mr. Shasank, 9869242158
ACME Mr. Mukesh, 23432601

PP Bags ,used only for KH


200 Gauge with Sealking tape Osian Impex Mr. Manoj, 9320222687
Shirts
LDPE Bag For Rest of the
150 Gauge with Sealking Tape Osian Impex
Shirts/Apparels
PP Bags ,used only for
Softgoods
280 Gauge Osian Impex

Stretch Film ITW Signode Mr. Sudarshan, 9820675836


Asmaco Mr. Ali Asgar, 25803070
Mr. Dayanand Shetty,
Kombyne
9322280484

Note: This is list of Packaging supplier recommended by Sourcing Team, HO, Mumbai