TENT / SHELTER / TARPS, GLOBAL DEFECT LIST

Transcription

1 Date Rev. N Modifications tracking 2009/09/08 1 Initial release 2016/07/14 2 Major changes 9/19/ Defects A13, B23 and D39 were added. Defect D9 was modified. 2017/1/23 4 Revision per Coleman design specifications. Defect F15 and F18 modified; New defect photos added 2017/9/17 5 D13(Open Seam)changed to Critical from Major; Added D41 1 PRODUCT DEFINITION The product is defined by the product specifications, drawings and product sample. The product sample is reviewed and accepted by both the COLEMAN and the VENDOR prior to the start of mass production. 2 SAMPLING RULES If Batches size < 50 units => 100% inspection AQL Level Critical Major Minor General Level New supplier / First shipment / Special cause Level DEFECT DEFINITION Critical defect: A product that is hazardous or can potentially be hazardous A product that does not meet a specified engineering performance criteria A product that has diminished or loss of functionality A non-conformity that has a high probability of affecting Customers and Consumers satisfaction Major defect: Aesthetic defects that have a high probability of being noticed by Customers and Consumers A non-conformity that has a low probability of affecting Customers and Consumers satisfaction Minor defect: Aesthetic defects that have a low probability of being noticed by Customers and Consumers

2 4 INSPECTION CRITERIA Defect Code A01 MASTER PACK Carton does not match product spec or PSA sample (dimensions, COO, date code, PO, graphics, logo, color, I2of5, etc) Sampling Plan ANSI/ASQ Z 1.4 Level Sl A02 Moisture content 14%(test with pin mode) Level Sl A03 Barcode label does not scan or is illegible Level l A04 Wrong packaging Level l A05 Wrong assortment or wrong product Level l A06 Incorrect quantity Level l A07 A08 Foreign material inside carton - bugs, trash, gum, mildew, oil, etc Excess material on carton - tape - cardboard and other packaging supplies Level l Level l Defective Classification Critical Major Minor A09 Wrong flute direction Level l A10 Carton is not fully sealed Level l A11 Damage or deformation 6mm x 6mm Level l A12 Stains or other marks 6mm x 6mm Level l A13 Damage or deformation < 6mm x 6mm Level l A14 Stains or other marks < 6mm x 6mm Defect Code B01 B02 B03 UNIT PACKAGING POS / Carry bag does not match product spec or PSA sample (Dimensions, COO, Date code, PO, Graphics, Logo, Shape, Color, UPC, etc) Cardboard box moisture content 14 %(test with pin mode) Carrybag moisture content 9 %(test with induction mode) Sampling Plan ANSI/ASQ Z 1.4 Level Sl Level Sl Level Sl B04 Barcode label does not scan or is illegible Level l B05 B06 B07 Images and text on the box does not match product inside Contamination in carton -- bugs, trash, mildew, etc Missing customer specific packaging requirements B08 Missing or incorrect instruction manual B09 Missing / broken / worn wheels B10 Broken carry handle / lifting grip Excess material in carton -- tape, cardboard B11 and other packaging Defective Classification Critical Major Minor B12 Damage or deformation 6mm x 6mm B13 POS box is not fully sealed

3 B14 Stitching defects: skipped stitches, broken stitches, seam slippage, open seam, incorrect density, crooked, etc B15 Zipper not working properly B16 Missing or loose rivets B17 Holes / cuts in fabric B18 Stains or other marks 6mm x 6mm B19 Stains or other marks < 6mm x 6mm B20 Discoloration or stain visible at 1 meter B21 Discoloration or stain not visible at 1 meter B22 Threads ends not trimmed B23 Fabric not trimmed B24 Damage or deformation < 6mm x 6mm Defect Code FLEIBLE FILM/POLYBAG Sampling Plan ANSI/ASQ Z 1.4 Defective Classification Critical Major Minor C01 Damaged or torn C02 Incorrect size or dimensions Defect Code PRODUCT APPEARANCE Sampling Plan ANSI/ASQ Z 1.4 D01 Tent or fabric does not match product spec or PSA sample (Dimensions, Graphics, Logo, Shape, Color, etc) D02 Logo: Size, incline, position, missing print, shade, clear etc. does not match drawing (refer to printing inspection guide) D03 Hole, rip, or tear on material Hazardous foreign material (blood, needle D04 tips, bugs, waste, etc) D05 Poor/Incorrect seam taping D06 Any repair Silk-screen or heat transfer defects: incline, position, missing print, shade, clear etc D7 does not match drawing (refer to printing inspection guide) Color shading differences within panels or D8 merchandise (> 1/2 step - gray scale) Soil, dirt, oil, or other mark 2.5 cm (1.00 in) D9 in diameter affecting appearance / serviceability Defective Classification Critical Major Minor D10 Rusty poles, stakes, ferrules, or metal rings D11 Non-hazardous foreign material D12 No hot knife edge for end of webbing Broken, looped, or missing stitching which D13 will cause open seam; Open seam D14 Stitching defects: skipped, loose, crooked,

4 not properly tensioned. No back stitching at beginning or end of D15 seams (back stitching 1.5 cm, 0.59 in) D16 More than one pleat per product Poor stitching not affecting performance D17 visible at 1 meter Incorrect stitching density (not between 6-8 D18 stitches per inch) on one piece Scratch / paint skip on poles with exposed D19 metal 0.3 cm (.12 in) in width or 2.54 cm (1 in) in length Seam allowance < 1cm for all major parts D20 and webbing D21 Weld line inside ferrule not smooth or flush D22 Center hole in pole not concentric D23 Missing material on fiber glass pole D24 Visible needle holes Any product deformation or uneven shape D25 without affecting zipper or sales performance All insta-clip loops, quick release buckle loops, toggle loops and stake loops should D26 be sewn into the seam 1.3 cm (.50 in) or more No color variation shall be visible when D27 viewed at 1 m (3ft) distance. D28 Print or dye defect visible at 1 meter Discoloration, color bleeding or stain visible D29 at 1 meter Discoloration, color bleeding or stain not D30 visible at 1 meter Fabric flaws, runs or snags - affecting D31 appearance / serviceability ( 25mm) Fabric flaws, runs or snags - affecting D32 appearance / serviceability (<25mm) D33 Thread ends 0.6 cm (0.25in) in length D34 No hot knife edge for end of guy rope D35 Pleats > 3mm (0.12 in) Sticker defects: not aligned, damaged, poor D36 printing quality, incorrect, wear, etc. Puckered / loose material, not affecting D37 aesthetics D38 Fabric not trimmed D39 Soil, dirt, oil, or other mark < 2.5 cm (1.00 in) in diameter affecting appearance / serviceability Tent fabric moisture content 9 %(test with D40 induction mode) Damage on elastic cords or shock cords D41 which will result in a permanent failure

5 Defect Code F01 FUNCTIONAL DETAILS Difficult to set up (one tent or shelter must be set up by Coleman inspector) Sampling Plan ANSI/ASQ Z 1.4 F02 Non functioning spring clip or push button F03 Incorrectly assembled components F04 Crooked / Missing / Loose rivets or screws. F05 Canting, leaning or crooked structure F06 Broken, split, or cracked poles Defective Classification Critical Major Minor F07 Broken / frayed shock-cords or elastic cords F08 Broken pin housing, clip, hub, corner joint, connector, stake, or any other plastic or metal component F09 Zipper not working properly F10 Broken stake loop / tent corner Pole connector joint, pin housing, ferrule, or F11 plastic end cap poorly attached / unglued Poles not assembled to main hub (Instant F12 tents) F13 Bent, dented, or damaged frames Missing color coding on poles, pole F14 connectors or tent pole sleeves F15 Insufficient coating on fabric F16 Missing binding Rainfly in contact with tent affecting F17 performance when tent is setup Any missing/extra component / material that F18 affects the product performance Any incorrect dimension that affects the F19 product performance Vent support not rigid / vent does not stay F20 open F21 Oversized hinge hole on tent door Any extra component / material that does not F22 affects the product performance Defect Code B.O.M CONFORMITY Sampling Plan ANSI/ASQ Z 1.4 G01 Diameter / thickness / hardness / size not meeting requirements G02 Incorrect material (color, style, etc.) G03 Strong odor emitted from material / chemicals G04 Missing country of origin G05 Final product weight over tolerance Size or dimensions different than advertised G06 (Considering spec tolerance) G07 US product: Missing or incorrect product Defective Classification Critical Major Minor

6 safety & compliance statements or information (CPAI-84 warning, Prop 65 warning, etc) Polybags: Missing safety information with respect to opening perimeter and average G08 thickness + missing holes (FT 310) for EMEA G09 Polybags: Missing safety information Polybags: Wrong / missing language on polybags G10 Polybags: Missing pictograms (FT210 for G11 EMEA) Wrong quantity / missing accessories or G12 components G13 Missing legal label G14 Missing or incorrect instruction manual G15 Missing or incorrect warning information G16 Mildew / mold on product G17 Sharp edges Wrong, missing, illegible composition label, G18 or famous character with copyrights Missing specific requirements from major G19 customers: Shipping units, labels, size US Product: Missing, incorrect or G20 inconsistent fabric tracking lot numbers (US & Canada Wal-Mart & Sam's sku's only) G21 Incorrect fabric weight (variance ± 5%) G22 Incorrect yarn count (variance ± 5%) G23 Missing, incorrect, or illegible logo G24 Missing manufacturing date G25 Missing vendor code number Defect Code PERFORMANCE TESTING Sampling Plan ANSI/ASQ Z 1.4 H01 Fail tent stake loop pull test Level Sl H02 Fail welded corner leakage test H03 Fail pole bending test H04 Fail carry bag handle jerk test H05 Fail rain test H06 Fail vibration test H07 Fail hydrostatic test H08 Fail fire resistance test H09 Fail crocking test H10 Fail gray scale for staining test H11 Fail peel off strength test H12 Fail drop test Defective Classification Critical Major Minor

7 Defect Code LIGHT BLOCKING FABRIC Sampling Plan ANSI/ASQ Z 1.4 I01 Light blockage 99.6 % (DR) I02 Crocking test (Wet and dry per AATC 8): A minimum of class 4 on the grey scale for staining for (BO) I03 Crocking test (only dry per AATC 8): A minimum of class 4 on the grey scale for staining for (DR) Color shading across roll width 4.0, I04 minimum 3.5 (DR) PU coating: Must meet specified fabric I05 pantone color after coatings are applied, class 4.0 min (DR) Light blocking: More than 100 dots per 30 cm round surface of the sample or any light dot I mm. Use a stain scale for dot size validation (BO) 5 VISUAL INSPECTION GUIDELINES Defective Classification Critical Major Minor 1) The items to be inspected shall be placed 50cm in front of inspectors in natural lighting environment to determine those aesthetical defects like oil spots, stains. 6 SPECIFIC REQUIREMENTS EMEA: US and CANADA: 1) When rain fly is assembled to the tent it must overlap all mesh openings (except for windows w/ privacy shades) by a minimum of 6 inches or in such a manner that when the rain fly is fully guyed out, a 30 degree slanted rain shower will not reach the mesh open 2) For U.S & Canada WAL-MART SAM S SKU s, lot numbers must be displayed on both POS packaging and product CPAI-84 labelling. They must be correct and consistent. CPAI-84 Flammability-related test reports and documentations must be complete and accurate for each shipment. JAPAN: AUSTRALIA:

8 6 PICTURES FOR REFERENCE:

9

10

11

12

13

14

15

16

17

18

19

20 7 APENDI