PO-1035

QC milestones

1. Stage 1 of 5

   Yarn & Weave Check

   Greige fabric checked against the approved construction.

   Pass

   Date

   12 Aug 2026

   Inspector

   Hamza Iqbal

   • Yarn count

     Target 20 Ne ±3%

     19.7 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

     484 N

     Pass

   Process notes

   Looms 12–18 on this article. Warp sizing recipe adjusted after first beam; pick density verified on 3 rolls.

2. Stage 2 of 5

   Dye & Colour Testing

   Bulk shade and fastness tests against the approved lab dip.

   Pass

   Date

   24 Aug 2026

   Inspector

   Usman Tariq

   • Shade standard

     Target Terracotta Print CL-07

     Terracotta Print CL-07

     —

   • Shade match ΔE (CMC 2:1)

     Target ≤ 1.0

     0.50

     Pass

   • Colour fastness to washing

     Target Grade ≥ 4

     4

     Pass

   • Rubbing fastness (dry)

     Target Grade ≥ 4

     5

     Pass

   • Rubbing fastness (wet)

     Target Grade ≥ 3

     4

     Pass

   Process notes

   Jet dyeing machine 3, liquor ratio 1:8. Recipe from lab dip v2 used without correction.

3. Stage 3 of 5

   DUPRO (mid-production audit)

   During-production inspection of measurements, weights and workmanship.

   Pass

   Date

   17 Sep 2026

   Inspector

   Bilal Ahmed

   • Production complete

     67%

     —

   • Size / measurement checks

     Target ≥ 95% in tolerance

     30/30 (100%)

     Pass

   • Weight checks

     Target ≥ 95% in tolerance

     20/20 (100%)

     Pass

   • Workmanship defects

     Target Majors ≤ 5% of sample

     2 major · 2 minor in 80 pcs

     Pass

   Defects by code

   D08	Misprint		major	2
   D10	Soiling		minor	2

   Process notes

   Two sewing lines on this PO. Inline checker posted at end of each line.

4. Stage 4 of 5

   Final AQL Inspection

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

   Fail

   Date

   11 Oct 2026

   Inspector

   Hamza Iqbal

   • Lot size

     2,400

     —

   • Sample size (Level II)

     125

     —

   • Major defects (AQL 2.5)

     Target Ac 7 / Re 8

     3

     Pass

   • Minor defects (AQL 4.0)

     Target Ac 10 / Re 11

     12

     Fail

   • AQL result

     Target ACCEPT

     REJECT

     Fail

   AQL working: Lot 2,400 → sample 125 → majors 3 (≤7) → minors 12 (≥11) → REJECT

   Defects by code

   D01	Hole		major	1
   D04	Broken stitch		major	2
   D07	Loose thread		minor	8
   D10	Soiling		minor	4

   CAPA-1035-1

   CAPA open

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

   Issue

   Final AQL REJECT: 12 minor defects in a sample of 125 (reject at 11), mainly loose threads and soiling.

   Corrective action

   100% re-inspection and rework of all 2,400 pcs. Lot re-offered for final AQL on 18 Oct 2026.

   Opened 11 Oct 2026Due 18 Oct 2026

   Root cause (internal)

   Thread trimming station on line 2 unmanned for two shifts; finishing area not cleaned between orders.

   Owner (internal)

   Nadia Aslam (finishing supervisor)

   Internal notes

   Mill asked to add a second trimmer. Escalate to mill owner if re-offer slips past 18 Oct.

   Process notes

   Lot offered from finishing hall 2. Trimming station on line 2 was unmanned for two shifts; pieces soiled near the packing table.

5. 5

   Stage 5 of 5

   Packing & Shipment

   Carton, label and shipping-mark verification before loading.

   Pending

   Date

   Not yet inspected

   Inspector

   —

   • Carton count

     —

     Awaiting

   • Labels & shipping marks

     Target Checked

     Not checked

     Fail

   • Ship date

     —

     Awaiting