Standard Operation Process

Shrinkage Risk Mitigation Process

Brand Kmart Major Group KAS Apparel
Effective Date Immediately Last Reviewed Date Jan 24th, 2019
CreatedBy Sherry Wang Version 1

Background:
Wedevelop this process due to below reasons:
 Repeat quality incidents high shrinkage garment returned from unhappy customer
especially for some high shrinkage fabric.
 Frequent shrinkage issue observed late as garment bulk stage, supplier shows poor
process control of different production stage to spot/escalate issue at early time.

High Shrinkage Fabric List (but not limited to):

 Natural fibre with open weave such as linen, cotton voile, cotton gauze& etc.
 Regeneratedcellulosic fibre item: Viscose, Bamboo, Model, Tencel & etc
 Special treatment fabric: crinkle fabric, cheese cloth & etc.
 High % elastane stretch fabric such as 90/10 nylon/elastane

Key Benefits:
 Help to avoid/reduce the risk that customer complaint or return due to shrinkage issue
 Help supplier spot potential issue at early stage, with more time for better solution to
minimize loss
 Provides a practicableguideline for better process control about quality consistency
 Enhance the quality ownership to KAS Garment Vendor/Garment Factory & KAS Sourced
Fabric Mills

Scope:
 Category: For ApparelClothing
 Applicable object: KAS Garment Vendor/Garment Factory & KAS Sourced Fabric Mills

Responsibility
 KAS Sourced Fabric Vendor
 Ensure pre-production test meet Kmart requirement before start master production.
 Ensure pre-production test shall represent bulk quality.
 Conduct 100% batch level testing to during in-line production stage to control the
consistency.
 Ensure bulk fabric with pass results to be allowed shipping to garment factory.
 Ensure Fabric QC File shall meet KAS requirement & send one set to KAS garment
vendor/garment factory before shipment.
 Ensure testing record for Kmart orders must be kept for one year for annually auditing
purpose. Running production testing specimen shall be kept until shipment is released.
 KAS Garment Vendor/Garment Factory
 Ensure fabric pre-production test meet Kmart requirement before start fabric master
production.

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  Ensure pre-production test shall represent bulk quality.
 Ensure require fabric mill/fabric vendor batch level in-house testing report together with
fabric inspection report along with colour continuity card. Only accept fabric that meet
Kmart requirement to be delivered to garment factory.
 Conduct in-house shrinkage checking upon KAS requirement once fabric is arrived in
garment factory. Sampling size chart is listed below & details please refer to Workflow
Chart-Appendix 1
Initial Check-Low Initial Check-High If failed at initial
Shrinkage Risk Shrinkage Risk check stage
Fabric Fabric
Non-garment 5% roll wise to 10% roll wise to Start with 20%, 50%
dye/garment wash cover 100% cover 100% even up to 100%
item batch/lot batch/lot roll wise checking
for the failed batch
Denim & garment 100% roll wise for 100% roll wise for Sort out the
dye/garment wash washing blanket washing blanket rejection roll &
item test test can’t cut in garment

 No garment production can start until pre-production test is pass & PP sample is signed
off by KAS.
 Garment form to translate fabric shrinkage % into pattern.
 Testing record must be kept one year for annually auditing purpose. Running production
testing specimen shall be kept until shipment is released.

 KAS Garment Merchandiser & KAS Fabric Merchandiser

 Follow up with garment vendor/KAS sourced fabric vendor for the pre-production test.

 KAS Fabric Technician/Fabric Technologist

 Batch level testing record to be checked as routine during technical audit.
 Once any shrinkage issue/ concern, all related testing record from fabric mill and
garment vendor to be checked during investigation.
 Reserves the right to require vendor conductverification shrinkage test during in-line
production stage or post production stage in garment form forhigh risk style or big
volume styles & etc.

Effective date
Immediately

Appendix 1 - Workflow

Shrinkage SOP
Workflow -20190124.docx

Appendix 2 – Testing Method& Requirement

1. Testing Method- Dimensional Stability After Washing (AS 2001.5.4)

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 2. Testing procedure Post

KAS Shrinkge
Testing Procedure Post.pdf

3. Testing Requirement- for knit & woven as following table

a) For knit fabric

b) For woven fabric

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Appendix 3 – Best Practice

Pattern correction is normally done according to the following shrinkage ranges, which are shown in
the table. The shrinkage ranges of Warp & Weft percentage combination decide the appropriate
marker.

***when making the pattern correction, technician should understand the proper marker by
considering the Warp & Weft shrinkage. Then the pattern adjustment should be done
according to the Warp or Weft shrinkage, which the measurement belongs.

That is, lengthwise measurement of garment (in seam), we must select Warp shrinkage. If it
is width wise measurement of garment (low hip), the shrinkage range is the Weft one.

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