PO-1027

QC milestones

1. Stage 1 of 5

   Yarn & Weave Check

   Greige fabric checked against the approved construction.

   Pass

   Date

   2 Jul 2026

   Inspector

   Ayesha Khan

   • Yarn count

     Target 20 Ne ±3%

     20.4 Ne

     Pass

   • Thread count

     Target 120 TC ±3%

     121 TC

     Pass

   • Fabric weight

     Target 220 GSM ±5%

     223 GSM

     Pass

   • Tensile strength (warp)

     Target ≥ 450 N

     474 N

     Pass

   Process notes

   Air-jet looms at reduced RPM for this construction. Greige rolls 4 and 9 checked on the frame.

2. Stage 2 of 5

   Dye & Colour Testing

   Bulk shade and fastness tests against the approved lab dip.

   Pass

   Date

   13 Jul 2026

   Inspector

   Usman Tariq

   • Shade standard

     Target Terracotta 719

     Terracotta 719

     —

   • Shade match ΔE (CMC 2:1)

     Target ≤ 1.0

     0.43

     Pass

   • Colour fastness to washing

     Target Grade ≥ 4

     5

     Pass

   • Rubbing fastness (dry)

     Target Grade ≥ 4

     5

     Pass

   • Rubbing fastness (wet)

     Target Grade ≥ 3

     3

     Pass

   Process notes

   Continuous pad-steam range, second shift. Shade checked at start, middle and end of batch.

3. Stage 3 of 5

   DUPRO (mid-production audit)

   During-production inspection of measurements, weights and workmanship.

   Pass

   Date

   7 Aug 2026

   Inspector

   Sana Malik

   • Production complete

     57%

     —

   • Size / measurement checks

     Target ≥ 95% in tolerance

     29/30 (96.7%)

     Pass

   • Weight checks

     Target ≥ 95% in tolerance

     20/20 (100%)

     Pass

   • Workmanship defects

     Target Majors ≤ 5% of sample

     3 major · 4 minor in 80 pcs

     Pass

   Defects by code

   D05	Measurement out of tolerance		major	1
   D06	Slub		minor	2
   D08	Misprint		major	2
   D10	Soiling		minor	2

   Process notes

   Line 4 and 5 running this style; line 5 operators newer. Hemming folder replaced mid-shift.

4. Stage 4 of 5

   Final AQL Inspection

   ISO 2859-1, General Level II, single sampling. Major AQL 2.5, minor AQL 4.0.

   Pass

   Date

   14 Sep 2026

   Inspector

   Sana Malik

   • Lot size

     8,200

     —

   • Sample size (Level II)

     200

     —

   • Major defects (AQL 2.5)

     Target Ac 10 / Re 11

     7

     Pass

   • Minor defects (AQL 4.0)

     Target Ac 14 / Re 15

     7

     Pass

   • AQL result

     Target ACCEPT

     ACCEPT

     Pass

   AQL working: Lot 8,200 → sample 200 → majors 7 (≤10) → minors 7 (≤14) → ACCEPT

   Defects by code

   D01	Hole		major	2
   D07	Loose thread		minor	4
   D08	Misprint		major	4
   D09	Wrong label		major	1
   D10	Soiling		minor	3

   CAPA-1027-aql

   CAPA closed

   1. Open
   2. In progress
   3. Re-inspected
   4. Closed

   Issue

   Final AQL REJECT: wrong care labels and soiling found in sample.

   Corrective action

   Re-label affected cartons, clean or replace soiled pieces, re-offer full lot.

   Opened 2 Sep 2026Due 9 Sep 2026Re-inspection passed 14 Sep 2026Closed 15 Sep 2026

   Root cause (internal)

   Label roll from another PO loaded on one line; packing area not cleaned between orders.

   Owner (internal)

   Kashif Mehmood (production head)

   Internal notes

   Verified on re-inspection. Mill agreed to add check to its in-line SOP.

   Process notes

   Lot presented in finishing hall. Cartons drawn from all pallets; trimming table under-staffed this week.

5. Stage 5 of 5

   Packing & Shipment

   Carton, label and shipping-mark verification before loading.

   Pass

   Date

   16 Sep 2026

   Inspector

   Sana Malik

   • Carton count

     342

     —

   • Labels & shipping marks

     Target Checked

     Checked

     Pass

   • Ship date

     20 Sep 2026

     —

   Process notes

   Cartons stacked 6 high in warehouse bay 2 pending container. Moisture readings 7–8%.