MQP Evaluation Report -...
Transcript of MQP Evaluation Report -...
Performance RatingQuality
83%
MQP Evaluation Report
Mill Registration ID A11689-130234
Mill Name Yeongdeok Industry Co., Ltd
Mill Address 62, Gangbyeon-ro 730beon-gil-
City Dongducheon-si
State Gyeonggi-do
Country South Korea
Meets Expectations : 80-100% Needs Improvement : 60-79% Poor / Insufficient : 0-59%
Quality Excellence
Mill Profile
The mill was established in 1990 originally and the facility being audited was established in the current location in Feb. 2008. It is a dyeing/finishing mill, the main products of the mill are Rayon/Cotton knitted fabrics. There are around 120 workers working in the mill and the total capacity of the mill is around 14.4 million kg per year.
Mill Registration ID A11689-130234
Mill Name Yeongdeok Industry Co., Ltd
Verification Date Jan 05, 2018
Contact Person Ms. Seong-Yeon Roh
Email [email protected]
Telephone 82 31 868 7000
QA Manager Mr. Jung-Ho Lee
Email Address [email protected]
Phone number 82 31 868 7000
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Mill Capabilities
Spinning No Weaving No Color Process Yes
Knitting No Preparation/ Dyeing/ Printing/ Finishing Process Yes Fabric Laboratory Yes
Knitted/woven goods rejection rate after greige inspection -
N/A
Reject rate (%) after preparing the fabric Less than 0.1%
Re-Dye (%) 10%
Re-Dye (%) in yarn dyeing -
Rejection rate after finishing 2%
Rejection rate after final inspection 2.5%
% scrap fabric rejected after inspection 0.1%
Inspection system used 4-Point System
Training for employees conducted N/A
Product Development department Yes
Innovation strengths Dyeing
Certificate Name Expiry Date
ISO9001 22-Dec-2020
ISO14001 22-Dec-2020
Sustainability Certificates
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Quality Excellence | Q2
Participating Mills: 381
I. Mill Quality Excellence Performance Summary
Poor / InsufficientNeeds ImprovementMeets Expectations
Not ApplicableII. Section Rating Summary
Meets Expectations : 80-100% Needs Improvement : 60-79% Poor / Insufficient : 0-59%
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Quality Excellence | Q3
Last Assessment (08-Apr-2016) First Assessment (03-Mar-2011)Current Assessment (05-Jan-2018)
Advancers DeclinerConstant
Section Name Current Last First Change(Current-Last)
Change(Current-First)
General Implementation 63 75 66 -16 % -4 %
Spinning Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable
Knitting Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable
Weaving Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable
Preparation/ Dyeing/ Printing/ Finishing 83 89 88 -6 % -5 %
Color Process 99 100 97 -1 % 2 %
Final Inspection & Testing 81 88 67 -7 % 20 %
Overall Score 83 89 84 -6 % -1 %
III. Performance Trend Analysis
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Quality Excellence | Q4
IV. Mill Comparison Benchmark
Global Mill Average :
South Korea Mill Average : South Korea Mills Average
Global Mills Average
Total Number of Mills : 381 Average Overall Score : 79
Total Number of Mills : 35 Average Overall Score : 81
Total Number of Mills : 178 Average Overall Score : 80
Mill Product Specialty : Knits Knits Specialty Mills Average
Meets Expectations : 80-100% Needs Improvement : 60-79% Poor / Insufficient : 0-59%
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Quality Excellence | Q5
V. Sub Section Performance Analysis Not Applicable
Meets Expectations : 80-100% Needs Improvement : 60-79% Poor / Insufficient : 0-59%
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Quality Excellence | Q6
VI. Mill Quality Capabilities
Preparation / Dyeing / Finishing / Printing
Dyeing Capacity Number of machines/lines Capacity per month
Pressure Jet 15 650,000 kg
Overflow 17 550,000 Kg
Spectrophotometer Brand
Model Number
Serial Number
Illuminant Settings
Color Difference Formula
Specular (included/excluded)
White Tile Serial Number
Black Trap Available (yes/No)
Calibration Frequency (e.g. 4 hrs)
Recent Calibration Record & Date
Datacolor 600 8801082D65, F11, U30, U35, IncA, etc
CIE cmc 2:1 included 8801082 Yes 4 hours Feb. 03,
2017
Color Process
Conditioning Chamber Unit Brand Model Temperature (F) Relative Humidity (%)
BOWOO ENGINEERING BW-161 70 55
Color Process
Type of Dyeing Equipment Sample Size/WeightHow Long are Lab Dips Dried & Method (i.e. Microwave, Convection)
Finishing Chemicals Applied Before Evaluating Color
Copower IR (6 pieces) 5g 8 min / Oven Yes
Daelim Starlet IR (3 pieces) 5g 8 min / Oven Yes
Waerbath shaking (2 pieces) 5g 8 min / Oven Yes
Color Process
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Quality Excellence | Q7
Lightbox Brand
Model Serial Number Illuminants available (e.g. U3000, D65)
Light/Lamp Replacement Hours
Located in the Dark Room
Recent Calibration Record & Date
Gretag Macbeth Spectralight III 603 1705 0400
U3000, D65, Cool White Fluorescent, A, TL84, UV, U35, INCA
2,000 hours Yes Feb. 7, 2017
Gretag Macbeth Spectralight III 603 3732 0102
U3000, D65, Cool White Fluorescent, A, TL84, UV, U35, INCA
2,000 hours Yes Feb. 7, 2017
Color Process
Color ProcessTechnician Name or IDNumber
Nil
Finish Type (Effect)
NA
Specialty Finish
Test Type Ability Test Method Test Frequency
Dimensional Stability to Washing Satisfactory AATCC 135 Every batch
pH value Satisfactory AATCC 81 Every batch
Color Fastness to Accelerated Laundering Only Limited Method AATCC 61 (1A only) Every batch
Color Fastness to Crocking Satisfactory AATCC 8 Every batch
Color Fastness to Washing Satisfactory AATCC 61 Every batch
Fabric Testing Laboratory
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Quality Excellence | Q8
VII. Opportunities for Improvements
1. General Implementation Compliance Opportunity for Improvement NA - Not Applicable
Section Sub Section Question Number
Current(05-Jan-2018)
Last(08-Apr-2016)
Global Freq. of Compliance %
General Implementation General Implementation
14.01 72%
14.02 41%
14.03 67%
14.05 59%
17.00 20%
Question Number Opportunity for Improvement
14.01 There is no documented evidence of management review of the quality program on individual processes for effectiveness and facilitating continual improvement
The mill does not conduct the management review of the quality program.
14.02 There is no documented evidence that recommended actions are followed up
The mill does not follow the recommended actions for management review due to no management review.
14.03 There is no internal audit of the quality program
The mill does not conduct the internal audit of the quality program.
14.05 The mill has no document evidence for the evaluation of the effectiveness of the training program.
The mill does not evaluate the effectiveness of the training program.
17.00 The mill cannot produce product meeting accepted "Organic" Standards (GOTS)
GOTS is not established.
Additional Comments for General Implementation
The mill got the certificate of ISO 9001:2015 and ISO 14001:2015 on 22, Dec, 2017. However, the internal audit and management review are not conducted. The mill has formal quality training program but the effectiveness of the training program is not evaluated. The maintenance of the equipments is handled by the contractor.
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Quality Excellence | Q9
2. Preparation/ Dyeing/ Printing/ Finishing Compliance Opportunity for Improvement NA - Not Applicable
Section Sub Section Question Number
Current(05-Jan-2018)
Last(08-Apr-2016)
Global Freq. of Compliance %
Preparation/ Dyeing/ Printing/ Finishing
Preparation Process 112.00 55%
Dyeing Process
122.00 13%
123.00 26%
127.01 79%
131.00 53%
Question Number Opportunity for Improvement
112.00 Prepared fabric is not tested for tensile and tear (woven) or burst strength (knit)
No test for burst strength
122.00 Chemicals are stored separately but not in a controlled environment
123.00 Dyestuffs are stored separately but not in a controlled environment
127.01 Quality dye tests are not done using visual (lightbox) and spectrophotometer
Dye test was done by spectrophotometer. However, the data was not recorded and maintained.
131.00 Temperature and pressure gauges are not calibrated regularly at dye house
Temperature and pressure gauges are not calibrated regular basis.
Additional Comments for Preparation/ Dyeing/ Printing/ Finishing
The mill performs only commission dyeing & finishing process for the greige fabrics provided by the vendor. All the greige fabric is checked by the vendor. The mill does not test tensile & burst strength prepared fabric. The mill uses the water from the government supply. There is an internal water purifying treatment in the mill with 3,000 tons/day capacity. pH, Hardness and other minerals are tested once a week by a contracted lab.
There is an automatic dispensing system for the dyestuffs from the dye preparation room to the dyeing equipments. However, all the dyestuffs still have to be weighed manually. Dye test was done by spectrophotometer. However, the data was not recorded and maintained. Temperature and pressure gauges are not calibrated regular basis. The percentage of the right-first-time dyeing of the mill is around 90%.
3. Color Process Compliance Opportunity for Improvement NA - Not Applicable
Section Sub Section Question Number
Current(05-Jan-2018)
Last(08-Apr-2016)
Global Freq. of Compliance %
Color Process Color Process 192.00 60%
Question Number Opportunity for Improvement
192.00 No Munsell Hue Color Test is conducted for color technician
The mill's color technicians has not been tested on Munsell Hue Color Test.
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Quality Excellence | Q10
Additional Comments for Color Process
The color lab is equipped with two computer color kitchen machines and one spectrophotometer and two light boxes. The maintenance and calibration of light box are handled by the contractor. The mill's color technicians has not been tested on Munsell Hue Color Test.
4. Final Inspection & Testing Compliance Opportunity for Improvement NA - Not Applicable
Section Sub Section Question Number
Current(05-Jan-2018)
Last(08-Apr-2016)
Global Freq. of Compliance %
Final Inspection & Testing
Final Inspection198.01 82%
201.01 90%
Production Testing Laboratory
213.00 55%
218.00 61%
219.00 24%
220.00 62%
Question Number Opportunity for Improvement
198.01 Finished product is not 100% inspected before final packing
40% inspected
201.01 Inspection frames are available but not with enough capacity to conduct all the final fabric inspection
There are two continuous type inspection frames and one manual type of inspection table in this mill. Not enough if 100% inspection is required.
213.00 The lab is conditioned, but not to the right parameters of 72F and 65% RH
Actual temperature is 73.4F and Relative Humidity is 31%.
218.00 No statistical correlation has been completed in the laboratory
Correlation test is not implemented.
219.00 The laboratory is not certified by any other organizations
220.00 Lab's testing data is not statistically analyzed over time
Additional Comments for Final Inspection & Testing
There is a condition room in the testing lab of the mill. However, the temperature and related humidity inside the condition room is not well controlled. Actual temperature is 73.4F and Relative Humidity is 31%. The lab is running two shifts a day to cover shifts of the production field. Correlation test is not implemented.
The 40% inspection is only performed on the products. There are two continuous type inspection frames and one manual type of inspection table in this mill. Not enough if 100% inspection is required. The inspectors understand the inspection standards, all defects are recorded and shared with other production lines.
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Quality Excellence | Q11
DISCLAIMERThis report is for the exclusive use of the client of Intertek named in this report (“Client”) and is provided pursuant to an agreement for sevices between Intertek and Client (“Client Agreement”).No other person may rely on the terms of this report. This report provides a summary of the findings and other applicable information found/gathered during the audit conducted at the specified facilities on the specified date only. Therefore, this report does not cover, and Intertek accepts no responsibility for, other locations that may be used in the supply chain of the relevant product or service. Further, as the audit process used by Intertek is a sampling exercise only,Intertek accepts no responsibility for any non-compliant issues that may be revealed relating to the operations of the identified facility at any other date.Intertek's responsibility and liability are also limited in accordance to the terms and conditions of the Client Agreement.Intertek assumes no liability to any party, for any loss, expense or damage occasioned by the use of this information other than to the Client and in accordance with the Client Agreement and these disclaimers. In case there is any conflict between the disclaimers stated herein and the applicable terms and conditions of Intertek incorporated into the Client Agreement, then these disclaimers shall prevail.
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Quality Excellence | Q12