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Accurate Packing

1. Purpose

To ensure accurate packing of finished thread and to double-check them for supplying to customers
without any troubles that could possibly arise from inaccurate packing

2. Definition

2.1. Yarn and Thread

Refer to SBI-2-002 <Tests and Inspections>

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

Refer to SBI-2-002 <Tests and Inspections>

2.3. Cart-Container

It is a carrier shuttling between winding lines and Packing Section to carry finished thread
for packing.

3. Scope

From packing works at Packing Section in winding process up to <Packing-Accuracy Inspection>

on the finished thread to be conducted by the inspector from Marketing Department.
4. Responsibility and Authority

4.1. Production GM

Production GM shall have responsibility for ensuring that accurate works of thread-
packing are carried out.

4.2. Winding Manager

Winding manager shall have direct responsibility to control the works for accurate packing,
and to train packing-related workers in Packing Section regularly and occasionally.

4.3. Marketing GM

Marketing GM shall have responsibility for ensuring <Packing-Accuracy Inspection> as a

final inspection on the finished thread.

4.4. QA Manager

QA manager shall check every day whether or not accurate works of packing and
<Packing-Accuracy Inspection> are being carried out properly.

5. Document Flow

The flows of documents required for <Packing-Accuracy Inspection> are as follows:

(1) ID card: It is an Item Card being used for identification of dyed yarn and finished thread
 during processing. This ID card flows along with Dyed Yarn (semi-product) from the point of
drying machine in Dyeing Process through the point of Packing Section in Winding Process.

P 40/2

(30 TEX)

* Refer to SBI-2-001 <Identification of Goods-in-process>

(2) Winding Card: It is a swatch slip showing brief information of the dyed yarn for winding such
as customer, style no., dyeing no., quantity, etc. This Winding Card flows along with Dyed Yarn
(semi-product) from the point of drying machine in Dyeing Process through the point of
Packing Section in Winding Process.

(3) Winding Request: issued by Marketing Department and forwarded to Winding Process to
have Dyed Yarn wound as finished product.

(4) Packing List: issued by Marketing Department to have the packing workers know about
packing details.

(5) Comprehensive Quality Analysis Report: Quality analysis of thread being analyzed every
day by QA. (Refer to SBI-2-002 Tests and Inspections)
6. Packing and Inspection

6.1. Packing Section

(1) When the Cart-Container filled with finished thread reaches the Packing Section, the
packing-workers shall check the thread in Cart-Container with <Winding Card> and
<Winding Request> and <ID card>.

(2) The packing-workers shall attach <Sticker> on the inner-side of the cones of thread,
and then cover them up with polybag.

(3) The packing-workers shall place the thread into boxes, and write the information on
the surface of each box, such as Style no. Item, Cone size, Quantity, Color.

(4) In case that different colors are to be packed in color assortment into the same box,
assortment list shall be placed inside of the box.

6.2. Final Inspection = Packing-Accuracy Inspection

The packing workers in winding process shall place the boxes on the Inspection Table with
the box top open in order to be available for <Packing-Accuracy Inspection>.

(1) The concept of <Packing-accuracy Inspection> is as follows:

 (2) <Packing-Accuracy Inspection> shall be conducted by the appointed staff of
Marketing Department.

(3) Inspection Items of <Packing-Accuracy Inspection> are as follows:

 Thread Count: Checking whether or not correct count of thread is packed.

 Color: Checking whether or not correct color of thread is packed.
 Sticker: Checking whether or not correct sticker of thread is packed.
 Polybag: Checking whether or not correct polybag is used on the thread.
 Box-marking: Checking whether or not the marks on the box is correct.
 Traverse & Edge Angle: Checking whether or not the thread cone is usable.
 Weight Test: Weighing individual cone of thread, and comparing with standard gross
weight.

6.3. Sample Size and AQL

(1) The inspector shall randomly select the following quantity of samples out of the boxes
displayed on the Inspection Table, and inspect them and make a final decision of pass
or fail

AQL 1.5
Total Cones
Ordered Cones
Accept Reject
to Inspect

0 ~ 150 20 0 1
151 ~ 280 32 1 2
281 ~ 500 50 2 3
501 ~ 1,200 80 3 4
1,201 ~ 3,200 125 5 6
3,201 ~ 10,000 200 7 8
10,001 ~ 35,000 315 10 11
>35,000 500 14 15

* This AQL 1.5 is to be applied only to the  Traverse & Edge Angle and  Weight.
** The AQL for the other inspection items such as Thread Count, Color, Sticker, Polybag,
Box-Marking, is on the Zero-Defect basis with the same samples selected.
 (2) Despite the provision mentioned in (1), QA Manager may request Marketing GM to do
severer inspection with the level of  AQL 1.0 or 0.65 of normal inspection level II,
MIL-STD-105E, or  similar level out of ISO 2859-1.

(3) When a round of final inspection, i.e. <Packing-Accuracy Inspection> is over, the
inspector shall tape up the box top, and send the boxes to <Finished Thread Storage>.

(4) The form of <Packing-accuracy Inspection Report> is attached hereto; the inspector
shall send the inspection reports to QA at the closing hour of the day.

(5) In case that the inspector discovers anything wrong with packing such as wrong thread-
count, wrong color name, etc., the inspector shall immediately set them aside, calling
on QA to take corrective and preventive action against the rejects such as the ones
mentioned in 7.

7. Corrective and Preventive Action

7.1. Inspection on the whole lot

(1) In case of 6.3.(5), QA Manager himself shall perform inspection on the whole lot.

(2) QA Manager shall take actions such as decisions to make on how to address the arisen
issues including additional production to make up for shortage. (Refer to SBI-2-004
Management of Nonconformity Goods)

7.2. Training

In case of 6.3.(5), QA Manager shall train the packing-related workers, including OJT (On
the Job Training).

8. Attachment: Form 41. Packing-Accuracy Inspection Report

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