Knit Asia Limited

Corrective Action Plan of Kmart

Responsible
SL Findings Finding Picture Root Cause Corrective Action Preventive Action Photo Reference Person/Department
1

1. We Have Discussed the measurement Deviation

with the concern sewing Operator , And Given
> Mr. Ibrahim Khalil
1
Measurement 1. Due to over cut bottom Hamming Operator Act-1> We have thoroughly rechecked all garments Guideline to all qi and supervisor ,They are check
2. Due to Lot of Pulling at Sleeve Join Attatch. of this po and short out all The Measurement. every hour .
4
3 AGM(QAD)
Minus at waist 3. Due To Sprading Time Lay Loose or Pull. 2. Give Awareness at cutting team due to lay
> Mr. Rony
AGM(Production)
spreadingare more carefully Avoid during lay Pull and
Looseness.
 Knit Asia Limited
Corrective Action Plan of Kmart
Responsible
SL Findings Finding Picture Root Cause Corrective Action Preventive Action Photo Reference Person/Department
1

PAP-1>Implement self Trimming for all process.

RC-1> Inadequate trimming or missed trimming
during production PAP-2> awarness create to all production > Mr. Ibrahim Khalil
Act-1> We have thoroughly rechecked all garments
RC-2>. Inconsistent thread cutting manual maintainance and quality team. AGM(QAD)
1 Uncut Thread oversight by operators.
of this po and cut all uncut thread all garments . > Mr. Juyel
RC-3>. End Line and Final qi inspection may PAP-3> Train Quality inspector on handling Uncut 4
3 AGM(Production)
have missed identifying loose threads. Thread, especially around the waist area and inside, to
avoid uncut thread.

RC1. Using fabric from different dye batches PAP-1> Implement additional shade checks after the
without thorough shade matching lead to part- cutting stage to ensure uniformity before sewing.
Shading to-part shade variation. Act-1> We have thoroughly rechecked all garments PAP-2> Implement a protocol to only use fabric from > Mr. Ibrahim Khalil
2 between RC2. pieces are cut from multiple rolls with slight of this po, sort out all garments .
shade differences, they may appear mismatched Act-2> Immediately halt production on the
the same batch for each garment, especially for critical
matching areas like fronts, and backs.
AGM(QAD)
> Mr. Juyel
Garment once sewn. affected po and inspect all garments for part shade
RC2. alteration in some parts of the fabric before issues.
PAP-3> Train teams on recognizing shade variations
and applying corrective actions when discrepancies are
AGM(Production)

boundle assembly. detected.

> Mr. Ibrahim Khalil

CAP-1> We have thoroughly rechecked all garments of this AGM(QAD)
3 Dity Stain 1.Worker neeecklency
po and sort it out all the Oil & Dirty Stain . > Mr. Juyel
AGM(Production)
 Knit Asia Limited
Corrective Action Plan of Kmart
Responsible
SL Findings Finding Picture Root Cause Corrective Action Preventive Action Photo Reference Person/Department
1

PAP-1> aware all the operators about trimming

1.Operator lack of concentration to trim uncut uncut thread from the process and its quality > Mr. Ibrahim Khalil
AGM(QAD)
1 Uncut thread thread from process and 2.poor follow up by Act-1> We have thoroughly rechecked all garments of this style,and re- requirement. Supervisor & roaming inspector make > Mr. Juyel
Quality & production concern. trimming all the un-trim point. regular follow up of the process and ensure threads AGM(Production)
are cut from the process.
4
3

PAP-1> We will make awareness meeting with all

consarn person with fabric supplier regarding
running part shade issues and they are committed to
100% improved the fabric Quality. And we will from
now on 100% inspection of all fabric rolls, and after
cutting. And also we given instruction at cutting
team both side fabric edge must be dropped 8 inc > Mr. Ibrahim Khalil
and make group marker. what ever the fabric that is AGM(QAD)
2 Shading Within Pcs 1.Fabric runing shade & Uneven dyeing Act-1> We have thoroughly rechecked all garments of this po, sort out all garments
dropped will provide fabric supplier. > Mr. Juyel
and consider as rejection. AGM(Production)
PAP-2>we will give Minsell test in our inline QI End
table QI and Finisging QI.
PAP-3> We will check our all Quality Table For light
sourcing lux value 1000 and confIrm D65 Light.
PAP-3> Properly number and track dye lots to
ensure that fabric from the same lot is used during
production.
 Knit Asia Limited
Corrective Action Plan of Kmart
Responsible
SL Findings Finding Picture Root Cause Corrective Action Preventive Action Photo Reference Person/Department
1

PAP-1> We will make awareness meeting with all consarn

person with fabric supplier regarding running part shade
issues and they are committed to 100% improved the
RC1.Fabric runing shade & Uneven dyeing.
fabric Quality. And we will from now on 100% inspection 4
3
of all fabric rolls, and after cutting. And also we given
RC2. Variability in dyeing parameters
instruction at cutting team both side fabric edge must be > Mr. Ibrahim Khalil
(temperature, timing, chemical use) cause color
Act-1> We have thoroughly rechecked all garments of dropped 8 inc and make group marker. what ever the AGM(QAD)
1 Mix shade in a blister inconsistencies.
this po, sort out all garments and pcck shade wise fabric that is dropped will provide fabric supplier. > Mr. Juyel
RC3.A lapse in quality checks during production AGM(Production)
blister. PAP-2>we will give Munsell test in our inline QI End table
and final check may allow mixed shades to pass
QI and Finisging QI.
undetected.
PAP-3> We will check our all Quality Table For light
sourcing lux value 1000 and conform D65 Light.
PAP-3> Properly number and track dye lots to ensure that
fabric from the same lot is used during production.

PAP-1> Set optimal machine parameters (stitch length,

tension, presser foot pressure) for each fabric type and
RC1. Uneven stitching tension can cause the
thickness, especially at critical points like waist belts and
fabric to gather or pucker, especially at seams Act-1> Immediately check and balance thread tension
seams. > Mr. Ibrahim Khalil
Puckring at Waist and side and where multiple layers meet. on affected machines, adjusting as necessary.
PAP-2> Train sewing operators to detect and resolve AGM(QAD)
2 RC2. Issues with stitch length, feed settings, or Act-2> Identify and rework all garments showing
seam presser foot pressure cause the fabric to stretch puckering, particularly at the waist and side seams, to
puckering issues on the spot, focusing on sensitive areas > Mr. Juyel
AGM(Production)
like waist belts and side seams.
or pucker, especially in thicker areas like waist ensure an even, smooth stitch.
PAP-3> Schedule frequent machine checks to ensure
belts and seams. Act-3>
tension, needle sharpness, and presser foot pressure are
all optimal.

PAP-1> Implement additional shade checks after the

RC1. Using fabric from different dye batches without cutting stage to ensure uniformity before sewing.
thorough shade matching lead to part-to-part shade PAP-2> Implement a protocol to only use fabric from the > Mr. Ibrahim Khalil
3
Parts shade within variation. Act-1> We have thoroughly rechecked all garments of this po,
RC2. pieces are cut from multiple rolls with slight shade sort out all garments .
same batch for each garment, especially for critical AGM(QAD)
Garments differences, they may appear mismatched once sewn. Act-2> Immediately halt production on the affected po and matching areas like fronts, and backs. > Mr. Juyel
AGM(Production)
RC2. alteration in some parts of the fabric before inspect all garments for part shade issues. PAP-3> Train teams on recognizing shade variations and
boundle assembly. applying corrective actions when discrepancies are
detected.
 Knit
Corrective

SL Findings Finding Picture

1 Skip Stitch

2 Broken Stitch

5 Mixed shade
 Knit Asia Limited
Corrective Action Plan of Kmart

Root Cause Corrective Action

1. Improper needle thread tension,

worn-out needle and defective feed
mechanism. Act-1> We have thoroughly
2.poor follow up by Quality & rechecked all garments of
production concern. this po,and re-trimming all
3. Lack of regular machine
maintenance and inadequate in-line the un-trim point.
inspection.

1. Lack of thread trimming Act-1>we will do 100% re-

2. Pulling fabric too hard while scanning all the QTY and the
sewing, causing stitch breakage. those garments are found
3. poor follow up by Quality & Broken stitch we will repair
production concern. and re-pack

will do 100% re-check and

Rearrange mixed shade

1. lack of shade qi
2. different shade comes from
cutting
 Preventive Action Photo Reference

1
PAP-1> aware all the operators
about Un-trimming thread from the
process and its quality requirement.
Supervisor & roaming inspector
make regular follow up of the
process and ensure.
PAP2> Checking and adjusting
mahine settings (tension, needle
condition, and feed system).
4
3

PAP-1>Re-stitching affected areas

after correcting machine settings.
PAP-2>given awareness with all
maintenance to set proper tension
adjustment at Sewing machine
PAP-3> Training operators on
proper fabric handling to avoid
unnecessary pulling.

PAP-1>We have discussed the issue

of inspection failure with our
production and quality team, they
have assured us that we will work
towards zero inspection failure.
 Responsible
Person/Department

> Mr. Ibrahim Khalil

AGM(QAD)
> Mr.Juyel
AGM(Production)

> Mr. Ibrahim Khalil

AGM(QAD)
> Mr.Juyel
AGM(Production)

> Mr. Ibrahim Khalil

AGM(QAD)
> Mr.Juyel
AGM(Production)