Quality Assurance Manual

Transcription

Cost Plus Management Services, Inc.
Quality Assurance
Manual
Furniture and Lighting Vendors ONLY
NOTE: This manual was updated July 22, 2013
Shaded sections highlight significant additions or changes from the previous
version.
* Non-Furniture & Lighting Vendors should refer to the version titled:
Quality Assurance Manual – Excluding Furniture, Lighting, Food, and Beverage
Vendors
INTRODUCTION
All products sold at Cost Plus World Market, hereafter referred to as CPWM, must be produced in accordance with all
United States Federal, State, and local regulations1. This manual is a general guide only and may not be complete. It is
the vendor’s2 responsibility to thoroughly understand and comply with all applicable regulations to ensure that all
manufactured products meet the necessary requirements. It is also the vendor/agent’s ultimate responsibility to stay
current with any updates and changes to all laws and regulations as well as our quality standards.
CPWM has partnered with Bureau Veritas3, hereafter known as BV, and SGS to evaluate product samples prior to
shipment in order to guarantee that these standards are met.
This Quality Assurance Manual, hereafter known as QA Manual, was created as a reference tool to ensure that all
vendors adhere to CPWM quality testing and verification/inspection processes. Regulations are product specific and
divided by product category. To ensure complete compliance of all of the requirements, please review this manual
carefully, referring to the appropriate sections and appendices for details.
This manual is divided into 4 sections:
1. General Overview (applicable to all vendors)
2. Softlines (pillow labels)
3. Furniture section (vendor specific)
4. Appendices (applicable to all vendors)
Because each vendor typically specializes in one product category, vendors should ONLY refer to the specific
section designated for their product category. The General Overview and Appendices are applicable to all
vendors.
Amendments to this manual can be found on our Vendor Relations website. The link to the website and vendor
ID/passwords are located at the bottom of every page of the QA manual. We reserve the right to amend the terms of this
QA Manual as needed. Therefore, all vendors should regularly check the Vendor Relations website for updates. Contact
[email protected] if you have questions after reading this document.
This manual contains color coded information. Viewing this manual through electronic or printed media will
require color output capability.
1
For a list and description of these regulations, refer to Appendix C.
Throughout this document, vendor will be used unless agent is applicable.
3
For more information about Bureau Veritas, refer to www.bureauveritas.com. For more info about SGS, refer to www.sgs.com.
2
TABLE OF CONTENTS
I. OVERVIEW
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
New Item QA Process Flow……………………………………………….............................. ..1-1
Sample Approval ....................................................................................................................... 1-2
Purchase Order (P.O.) Creation ................................................................................................. 1-2
QA Requirements ...................................................................................................................... 1-2
Retail Packaging ........................................................................................................................ 1-2
Warning Statements and Law Labels ......................................................................................... 1-4
1.6.1 Suffocation Warning for Plastic Bags…………………………… ......................... ….. 1-4
1.6.2
Law Labels…………………………………………… ........................................ ….. 1-4
1.6.3
Flammability CA 117……………………………………………… .......................... .1-5
1.6.4
Formaldehyde Emissions from Composite Wood Products..........................................1-5
Label Ordering ................................................................................................................. .... ….1-6
Vendor In-House Product Testing ............................................................................................. 1-6
Third Party Testing ................................................................................................................... 1-7
Assembly Instructions...................................................................................................................1-8
Load Plans.....................................................................................................................................1-8
Vendor Inspection ...................................................................................................................... 1-8
1.12.1 Defect vs. Defective ................................................................................................... 1-8
1.12.2 Evaluating Inspection Result ....................................................................................... 1-8
1.12.3 Defect Classifications ................................................................................................. 1-8
1.12.4 Inspection Types ........................................................................................................ 1-11
1.12.5 Monthly Inspection Summary ................................................................................... 1-16
Transit Testing ......................................................................................................................... 1-19
DC Receiving Inspection ......................................................................................................... 1-21
Product Inspection by Third Party Services ............................................................................. 1-23
III. SOFTLINES
3.1 Development/Bulk Production Submission Process .................................................................. 3-1
3.2 Pillow Label Attachment ........................................................................................................... 3-1
IV. FURNITURE
4.1 Product Labeling ........................................................................................................................ 4-1
4.2 Defects Classification ................................................................................................................ 4-3
4.3 Furniture Standards .................................................................................................................... 4-3
APPENDICES
Appendix A: Vendor Contact List .........................................................................................................A1
Appendix B: CPWM Testing Protocol List ........................................................................................... B1
Appendix C: Federal and State Requirements ....................................................................................... C1
Appendix D: Warranty / Care Template ...............................................................................................D1
OVERVIEW
1.1 NEW ITEM QA PROCESS FLOW
•
Figure 1-1 illustrates CPWM’s new item QA process flow.
New Item
Vendor
Vendor submits sample
to buyer
(Refer to Vendor Guide
section 2)
Vendor performs in-house
product testing (according
to Protocol) and transit
drop testing (if applicable)
Buyer and Product
Engineer review and
approve
Vendor submits samples
for quality testing and
additional over-packed
samples for transit testing
(if applicable) to testing lab
Testing lab sends test
result to vendor/agent
and CPWM
Planner generates P.O.
(Refer to Vendor Guide
section 1)
Packaging and carton
markings are
completed per CPWM
requirements
Domestic vendors refer to
Vendor Guide section 4 for
domestic shipping procedures
International vendors refer to
Vendor Guide section 3 for
international shipping procedures
DC Incoming inspection uses
2.5 AQL - ANSI ASQ Z1.4
Special Inspection Level I as
standard to evaluate products
Figure 1-1 New Item QA Process Flow
1.2 SAMPLE APPROVAL
I. OVERVIEW
•
Figure 1-2 illustrates CPWM’s sample approval procedure. All new items are required to undergo a sample
approval.
Vendor submits sample to buyer
(Refer to Vendor Guide Section 2)
Sample reviewed & approved by
the buyer and Product Engineer
(if applicable)
Revision to product
specification
requested?
Yes
Vendor completes
the revision needed
No
Final Approval
.
Approved sample must be signed
and dated by the buyer and vendor
Contact your buyer for specific SOP
Provide 1 copy of the
sample, color swatch
and shade band to
4
CPWM
4
Keep 1 copy of the
sample, color swatch
and shade band at the
vendor’s site
Figure 1-2 Sample Approval Procedure
Sample must be kept in an environmentally controlled area to preserve the original condition.
1.3 PURCHASE ORDER (P.O.) CREATION
•
•
Once the sample is approved, the Buyer/planner will create a P.O.
For more details about P.O. creation, refer to CPWM Vendor Guide section 1.
1.4 QA REQUIREMENTS
•
•
•
•
•
Items must meet all Federal, State, and local requirements. It is the vendor’s responsibility to be aware of and to
meet all legal requirements as well as CPWM quality expectations.
Quality testing is required for all new products and reorders with expired test results (test results are valid
for 12 months). Refer to sections 1.10.1 and 1.10.2 for more information.
Vendors who are required to conduct quality tests are required to utilize our approved testing partner BV or
SGS. (See CPWM Vendor Guide section 2 for more details).
Unless an exemption is granted from [email protected], all vendors should contact the closest BV or SGS testing lab
(See CPWM Vendor Guide section 2 for more details).
In addition to product testing, see sections 1.9 - 1.12 for further requirements.
1.5 RETAIL PACKAGING
•
Assembly Instructions (if applicable).
o Assembly instructions must be included with all products which require assembly.
o The assembly instructions must contain the following (see template located on our Vendor Relations website)
QA Manual CONFIDENTIAL
Date: July 22, 2013
1-2
For updates to this manual, go to
www.worldmarketcorp.com/vendor-relations/
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I. OVERVIEW
o
o
World Market logo.
A picture of the finished product (after assembly).
The tools required for the assembly.
A picture of each component, the tools provided in the hardware package, and the quantity of each. The
vendor must ensure that all tools provided are appropriate for easy assembly.
The assembly instructions (step by step procedure) must be written in English in a clear and understandable
manner. The written instructions must be followed by an action diagram illustrating the instructions.
All furniture and lighting assembly instructions must be approved by both CPWM Engineering and the
appropriate buyer. Vendors will be issued an Expense Offset Fee for non-compliance (See CPWM Vendor
Guide section 6 for more details).
As product experts, Vendors are responsible for the accuracy of the final included version of their assembly
instructions. Any errors that require reprinting or redistribution will be done at the vendor’s cost.
•
Important! Assembly instructions MUST be included with the final sample. All product assembly instructions
must be approved by CPWM Engineering prior to shipping.
•
Story Cards
o Contact the Buyer/Assistant to determine if a story card is required.
o If a story card is required, consult with the Buyer/Assistant regarding the content of the card. The design and
content of the story card must be sent to [email protected] and must be approved before printing.
o Vendors are responsible for printing story cards and may utilize their printer of choice.
o Prior to re-printing story cards, please contact your Buyer/Assistant for approval as changes may be required
from the original version.
•
Fiber Content and Care Labels
o Fiber content and care labels must use the CPWM design. See below for the templates required by product
category.
o Care labels and law labels must be Tyvek, Valeron Vellum cloth, or a material of comparable quality that will
not flake when abraded.
o The official World Market logo must be used, REPRODUCTIONS ARE NOT ACCEPTABLE. The logo is
available on the Vendor Relations website.
o For more details about fiber content and care labels, refer to www.ftc.gov/os/statutes/textile/rr-textl.htm#303.10
o Care labels created by the vendor should not be printed until a passing test report is issued and/or a testing
waiver form (TWF) has been issued by QA.
o To ensure that our approved testing lab reviews your label, please make sure to include them with the samples
sent for testing. Please note that labs will accept a proof/draft of your care label. The label does not need to be
printed in order for the lab to review it.
o Testing labs have been instructed to perform a fiber content analysis and laundering tests even though a care
label has not been submitted. To ensure that the item does not receive a failure for lack of a care label, please
make sure to include it with your sample sent to the lab.
o Labels of any kind (i.e. Content or Care) must never be sewn on top of the law label as a penalty/fine could be
received by CPWM from the various states we sell in. Vendors will be responsible for any and all
penalties/fines CPWM incurs due to this issue.
o For questions regarding the labels, contact [email protected]
•
Care and Cleaning Instructions
o If special care is needed either before use and/or for maintenance purposes, then care instructions must be
provided with the product.
o Care and Cleaning Instructions should be included in the Assembly Instructions (if assembly instructions are
applicable). If assembly instructions are not applicable, the care and cleaning instructions and the warranty (if
applicable) should be printed on the same paper (see Appendix D).
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I. OVERVIEW
Figure 1-5 Care Labels
1.6 WARNING STATEMENTS AND LAW LABELS
•
Warning statements should be in all CAPITAL letters and worded exactly as indicated below.
o Warning statements and law labels created by the vendor should not be printed until a passing product test
report is issued by one or our approved testing partners and/or a testing waiver form (TWF) has been issued by
QA.
o To ensure that the testing lab reviews your label, please make sure to include them with the samples sent to the
lab for testing. Please note that labs will accept a proof/draft of your label. The label does not need to be printed
in order for the lab to review it.
1.6.1 SUFFOCATION WARNING FOR PLASTIC BAGS
•
Applies to plastic bags with a thickness of less than 1 mil (0.0010 inch) and an opening size of 5 inches or more.
o The following wording must be stated on the bag: WARNING: KEEP THIS BAG AWAY FROM BABIES
AND CHILDREN. DO NOT USE IN CRIBS, BEDS, CARRIAGES, OR PLAYPENS. THE THIN FILM
MAY CLING TO NOSE AND MOUTH AND PREVENT BREATHING.
o Refer to www.plasticbag.com/industry/warning.html for the font type and size requirement of the warning
statement.
1.6.2 LAW LABELS
•
Applies to anything that contains filler.
o For more details about Law Labels, including size requirements, refer to International Association of Bedding
and Furniture Law Officials (ABFLO) at www.abflo.info
o Not all Law Labels require the CA 116 and/or CA 117 Flammability Warning. Check the testing protocol
specific to your product for this requirement and refer to section 1.7.11 for more information.
o Figures 1-9 and 1-10 show the label format as of January 1, 2005. Since this format may change, the vendor
is responsible for checking the ABFLO website for the most updated format.
o If your company has not been issued a valid filler registration number contact [email protected] ASAP for
further details. It can take 4 to 6 weeks before new applicants are issued a number.
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I. OVERVIEW
•
Important!
o The Red areas are input fields. Fill in the information where it is shown in the Red boxes with the appropriate
information. The red boxes shown here are for reference only; therefore the final label will be all white with
black print only. Insert correctly: Filler Material, Registration Number, Finished Size in Inches (in) and
Centimeters (cm), Net Weight of Filling Mat in Grams (gms) and Ounces (ozs), Federal RN #, and Country of
Origin.
Example
Insert
100% POLYESTER
FIBER
Here
IMPORTED BY
ADDRESS MUST
BE LISTED AS
SHOWN
Figure 1-10 Law Label without Flammability Warning
NOTE: LABELS ARE NOT SHOWN TO SCALE
Figure 1-9 Law Label with Flammability Warning
1.6.3 FLAMMABILITY CA 117
•
Applies to all upholstered furniture with filler and any cushions which are deemed to be sat upon.
o The following wording must be attached to the law label:
THIS ARTICLE MEETS THE FLAMMABILITY REQUIREMENTS OF CALIFORNIA BUREAU OF
HOME FURNISHINGS TECHNICAL BULLETIN 117. CARE SHOULD BE EXERCISED NEAR
OPEN FLAME OR WITH BURNING CIGARETTES.
o For more details about the Flammability Warning CA 117, refer to the California Bureau of Home Furnishings
and Thermal Insulation www.bearhfti.ca.gov/, and to the International Association of Bedding and Furniture
Law Officials www.abflo.info
1.6.4 FORMALDEHYDE EMISSIONS FROM COMPOSITE WOOD PRODUCTS
•
The California Air Resources Board (CARB) introduced a measure in 2009 to reduce Formaldehyde Emissions from
Composite Wood Products. If you do not manufacture items with composite wood products you may disregard
this section.
o Beginning January 1, 2009 you cannot purchase and or manufacture composite wood products that do not
comply with these standards. Standards can be found at: www.arb.ca.gov/toxics/compwood/compwood.htm
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I. OVERVIEW
o
o
o
o
All shipments to CPWM must be in compliance with this requirement. You cannot ship non-compliant
composite wood products.
All applicable products must have affixed (to the master carton and the finished good) our approved CARB
sticker. The template is located on our vendor relations website under CARB Label Template.
Vendors must also include a statement of compliance on all bills of lading or invoices, which serves as a record
of the sale of compliant products for downstream customers. The GTN commercial invoice (Import Vendors
Only) includes the applicable CARB statement as an option to be included on the invoice. Domestic vendors are
required to add a statement of compliance on to their existing company invoice for every shipment.
Vendor will be issued an Expense Offset Fee (Refer to the CPWM Vendor Guide section 6 for more details) for
non-compliance.
1.7 LABEL ORDERING
•
•
Once the vendor confirms the labeling requirements, the vendor must order the labels. Labels such as care, content,
product warnings and law labels may be ordered through a supplier of your choice. Avery Dennison or Fineline
Technologies are available to print these types of labels. (Refer to the CPWM Vendor Guide section 2, for contact
information).
Labels such as care, content, product warnings and law labels must be included with your samples submitted to the
lab for product testing.
1.8 VENDOR IN-HOUSE PRODUCT TESTING
•
We require all vendors perform in-house product pre-testing prior to submitting a fresh sample to the testing lab
(refer to Figure 1-11). If failures or damages occur, most can be easily analyzed and fixed in-house within a short
amount of time. Failure to do so may result in:
o Extra cost of producing another test sample
o Extra lab fees due to retesting
o Time delays (shipping transit time and 1 week testing turnaround)
Figure 1-11 In-House Product Pre-Testing Procedure
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I. OVERVIEW
1.9 THIRD PARTY TESTING
•
Figure 1-12 illustrates the testing lab Product/Transit Testing Procedure.
Vendor submits approved samples to testing lab
If a product also requires transit testing,
additional samples must be submitted in final
production packaging
Testing lab sends
test results to the
vendor/agent and
CPWM
Pass
Third Party
Testing
Fail
Vendor improves the product
and/or packaging design as
necessary
For furniture only, CPWM
Engineering advises corrective
action and provides final
approval for the revised sample
and/or packaging design
Testing lab sends
test results to the
vendor/agent and
CPWM
Vendor proceeds
with production
Figure 1-12 Product/Transit Testing Procedure
IMPORTANT:
• Vendors must use the CPWM Test Request Form which is available on our Vendor Relations website. CPWM
has partnership with BV, which provides a 30% discount off of the total invoice price. Our partnership with SGS
provides a 25% discount off invoice price. Refer to CPWM Vendor Guide section 2 for complete details.
• Samples for Furniture: Due to the high cost of producing furniture samples, it is acceptable to send one sample for
both product and transit testing. However, the vendor should be aware that in the event of a transit test failure, the
product sample may be damaged and therefore not useable for product testing. We recommend sending separate
samples for transit and product testing to avoid this issue. If the vendor chooses to submit one sample for both tests
and additional samples are then required for product testing, the vendor is responsible to adhere to the ship date as
scheduled.
• Vendors shipping product from multiple factories (sub-contracting) must submit a representative production run
sample for quality testing and transit testing from each of the factories as required. The sample has to be clearly
identified from which factory it is manufactured.
• It is not acceptable for vendors to expand or move the production to another facility without prior approval from
CPWM.
• Vendors are responsible for all costs associated with additional quality tests if CPWM finds any quality issues (at
point of receipt or at any other time).
• Artwork/ care labels/ law labels
o Artwork created by CPWM should not be printed until the final approval has been given by the buyer.
o Artwork/ care labels/ law labels created by the vendor should not be printed until a passing test report is issued
by BV/ SGS and/ or a testing waiver form (TWF) has been issued by QA.
o To ensure that BV/ SGS reviews your labels, please make sure to include them with the samples sent to BV/
SGS for testing. Please note that BV/ SGS will accept proofs of artwork/ care labels/ law labels. The labels do
not need to be printed in order for BV/ SGS to review them.
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I. OVERVIEW
1.10 ASSEMBLY INSTRUCTIONS
•
All furniture vendors are required to submit assembly instructions for review and approval after final sample is
approved buyer and QA and PRIOR to final printing. Submit your draft to CPWM Engineering. Appropriate buyer
must be copied on your request for review and approval. There are no exceptions.
1.11 LOAD PLANS
•
•
All furniture vendors loading full containers at their factory are required to submit load plans for review and
approval PRIOR to shipping. Load plans should be submitted after passing transit testing and carton dimensions are
confirmed, with sufficient time to implement any changes to PO quantity. Production packaging should be final.
Appropriate buyer/planner must be copied on your request for review and approval. There are no exceptions.
Vendors using L-shaped cartons must perform stack tests to ensure packaging materials are sufficient and cartons
will withstand transit duration to DCs and stores. Product should be inspected after stack test to ensure no
indentations due to loading orientation or packaging materials.
1.12 VENDOR INSPECTION
•
The main objective of an inspection is to find all non-conforming items (defective) based on the established defects
classifications. The acceptance or rejection of an inspection is based upon the accumulation of critical, major or
minor defect(s) on each unit, turning each unit with defects into defective units using a given AQL chart.
1.12.1 DEFECT VS. DEFECTIVE
•
•
A defect is any nonconformance of the unit of product with the specified requirements. There are 3 types of defects:
critical, major and minor.
A defective is a unit of product which may contain one or more critical, major or minor defects. There are 3 types of
defective units:
o A critical defective unit contains one critical defect.
o A major defective unit contains one or more major defect; 1 or more major defect and 1 or 2 minor defects OR
3 or more minor defects.
o A minor defective unit contains no more than 2 minor defects.
1.12.2 EVALUATING INSPECTION RESULT
•
•
•
•
One critical defective will automatically fail the inspection.
Major defective will be counted and evaluate based on the AQL chart for Major Defective.
Minor defective will be counted and evaluated based on the AQL chart for minor defective. Since minor defects are
less serious than critical or major, a lower AQL level is used to determine the outcome of the inspection with more
tolerance.
Vendor must perform regularly scheduled inspections. This includes Defects Classifications, Inspection Types, and
the Monthly Inspection Summary.
1.12.3 DEFECT CLASSIFICATIONS
There are 3 types of Defects Classifications:
1 - Critical Defects
A critical defect is likely to result in a hazardous or unsafe condition for use, a violation of U.S. regulations, and/or a
litigious situation. Critical defects include, but are not limited to, the following:
o Violation of any U.S. regulation (e.g. labels incorrectly positioned on the entire shipment, missing country of origin
label, incorrect care label).
o Hazardous or unsafe for use by consumer (e.g. needle fragment in textile item, nail protruding from wood item, box
knife left inside package).
o Evidence of insect infestation or mold growth (visual or odor presence).
Zero Tolerance (1 critical defect = 1 critical defective = failed audit). Detection of one critical defect, regardless
of location on the item, will result in a cancellation of the shipment.
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•
•
I. OVERVIEW
•
•
2 - Major Defects
A major defect is likely to result in failure, or to reduce the functionality of the product for its intended purpose.
o Cannot be sold as First Quality.
o Major defects will result in the customer rejecting and returning the product.
o Major defects include, but are not limited to, the following:
Affects appearance (e.g. not representative of final sample, does not function as intended, cracked glass, pattern
distortion, color smear).
Affects durability (e.g. warped, inadequate cabinet joints, inadequate/lack of glue, brittle natural fiber in weaved
items, inadequate textile tear strength).
Affects performance (e.g. lighting fixture will not light, candle won’t burn, container lid does not seal as
intended, folding chair will not close, dining chair that rocks when placed on a level surface).
Non-compliance with approved sample or specifications (e.g. wrong item, wrong color, or measurements out of
tolerance).
Moisture content of a wooden item not in compliance with CPWM standards.
If the number of defectives found is equal to or greater than the allowable limit (Reject Number), the audit
will fail.
3 - Minor Defects
Minor defects do not significantly compromise the durability, appearance, or performance of the item.
o
o
o
Not likely to cause customer return.
May be sold as First Quality.
Examples: color variation on candles, small dents on the candle base.
Three minor defects on the same unit are equal to one major defect. In addition, 3 minor defects on 3
separate units will be considered as 3 minor defects. The number of minor defectives shall be used to rate the
inspection based on a lower AQL level. At the lower AQL level, each unit with one or 2 minor defects will be
counted as one minor defective.
•
General Defects Classifications
o Table 1-1 is only a general list of defects classifications for all product categories. Refer to the specific Defects
Classifications list for your product category (Softlines, Hardlines, and Furniture).
Table 1-1 General Defects Classifications
Description
Critical
Label
Incorrect or missing country of origin label
Other incorrect or missing label components in entire shipment
Labels incorrectly positioned on entire shipment
Comparison to Approved Sample and/or Specification
Non-compliance (incorrect or missing):
General appearance
Color
Size/capacity/weight
Stem does not support vessel or separates
Protective covering
Shade
Decoration or distressed standard
Finish
Shape
Components/attachments, including assembly instruction
Incorrect pack for multiple item
Containers
Display box
Multiple item packs
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Major
Minor
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
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Finish
Material/Surface Defects
Incorrect materials
Infestation
Oxidation/mold
Contamination within or on surface
Surface blemishes
Flaking of exterior coating
Other cosmetic issues-dents/marks/paint
Very small surface blemishes
Removable finger prints
Small dents on wooden item
Workmanship Defects
Sharp or broken edges, cracked, sharp spikes, wire ends, wood or glass splinters
Loose or broken knobs, handles, or ornaments
Deformation of shape
Uneven/unstable base
Lid and/or other components misfit
Cosmetic defects-dents/marks/paint
Excessive bubbles in glass
Excessive seam marks
Crazing
Poor surface detail
Unsightly and/or inconsistent seam molding
Incomplete buffing/ irregular plating
Threads hanging in excess of ½ inch
Manufacturing by product
Broken/cracked
Excessive, unpleasant odor
Dusty or unclean item
Minor mill flaws (small stubs and knots) on hand loomed fabric
Assembly Instructions (Assembly of 1 unit is required)
Product does not assemble and/or assembly instructions are incorrect
Product does not assemble easily and/or instructions are unclear
Textile
Not pressed as specified
Not folded as specified
Not packed as specified
Fabric flaws-holes, broken ends, drop stitches, vertical or horizontal lines, not cut
on grain lines, snags, slugs, mis-weave
Conspicuous piling
Printing defects, wrong and/or missing color, incomplete coverage of color, misregistration, wrong pattern
Mismatched stripe or plaid
Nap not as specified
Skewed pattern or fabric
Trims missing or incorrect
Mis-matched color within a set
Stitch overlaps unattractively
Seams puckered, twisted or not aligned
Uneven closures/zipper
Conspicuous pressing defects
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x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
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Excess threads-over
Bottom hem uneven
Label
Not readily visible
Not legible
Master Carton Marking (missing or incorrect)
The country of origin
P.O. #
SKU description
SKU#
TTL/SPs (total units of inner cartons in each master carton)
TTL/PCS (total amount of units in the master carton)
Net weight
Gross weight
CTN NO (carton number)
Inner Carton Marking (missing or incorrect)
SKU#
SKU description
Number of pieces per inner carton
Packaging
Non-compliance with the specified CPWM packaging rules6 and published
specifications
Protective Packaging Design
Void areas not filled as required
Multiple items not properly separated (exception for flatware e.g. fork, spoon, and
knives)
Excessive internal movement
Inadequate surface protection
Inadequate edge protection
Inadequate corner protection
Sharp items not adequately wrapped, suspended or isolated
Loose hardware not bagged/contained
Difficult to unpack/repack
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
1.12.4 INSPECTION TYPES
Inspections are conducted at the vendor’s website and must be performed in a well-lit area appropriate for inspection
activity7. The 3 types of inspections required are Pre-Production Inspection, In-Line Inspection, and Final
Inspection. Refer to Figure 1-13 for the diagram detailing these inspections.
• Inspections must be recorded on an Inspection Summary Report. The vendor (or CPWM agent where applicable) is
responsible for updating and maintaining this monthly, and must provide this report to CPWM upon request. The
format of the report is chosen by the vendor/QA inspector.
Pre-Production Inspection
• The Pre-Production Inspection is an inspection of raw material prior to the start of production. The objective is to
ensure that all materials are in accordance with the sample approved by the Buyer. Identifying any issues with the
material quality as early as possible will reduce the number of defective products.
Procedure
• The Pre-Production Inspection Report must contain the following:
o SKU number (CPWM product SKU number)
•
6
7
For packaging details, refer to Vendor Guide section 2.
The vendor assumes the role of the inspector unless there is an agent, in which case the agent acts as the inspector.
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•
•
•
•
o Description of the item
o PO #
o Lot number
o Date of inspection
o Date of production
o Vendor / Factory
o Factory Address
o Country of Origin
o Units to be inspected, AQL, Acceptance and Reject number
o Production Status at time of inspection
The Pre-Production Inspection is a useful method for alerting and working with the vendor to rectify problems as
early as possible in the production process. Any problems or discrepancies found with the raw materials,
construction, measurement, color, workmanship and/or hardware that are observed during the Initial Inspection must
immediately be brought to the attention of the Vendor Management and their own QA so that immediate action can
be taken to rectify the problems or discrepancies.
A Pre-Production Inspection report must be completed for every inspection performed and the vendor must be
prepared to show this report to CPWM upon request. As much of what is recorded on the report will also require a
verbal explanation, forms should be completed when both the factory QA and the vendor’s representative are
together.
The frequency of Pre-Production Inspections required will depend upon the type of merchandise being produced, the
vendor’s past performance, and the order quantity.
A minimum of one Pre-Production Inspection for each shipment must be performed.
Inspection Schedule
• In order to schedule Pre-Production Inspections properly and effectively, the vendor/agent’s QA Department must
be kept well informed of the progress of the bulk production. The approximate completion dates for the
manufacturing of the program should be recorded by the merchandiser and passed to the vendor/agent’s QA
Manager to plan the inspection schedule. Merchandising must follow up with the relevant vendor and notify the QA
Manager promptly of any changes in production schedules so that vendor/agent’s QA inspection schedules can be
adjusted accordingly.
In-Line Inspection
• The In-line Inspection includes rechecking the raw material’s quality, construction, measurement, color, hardware,
labels, tags, bags, and workmanship with special attention to finish, paint, polish, moisture content, durability, and
instructions. Inspect the above criteria against the approved sample. Packaging, inner boxes and markings should
also be inspected if available.
Procedure:
• The In-Line Inspection Report must contain the following:
o SKU number (CPWM product SKU number)
o PO #
o Lot number
o Date of production
o Date of inspection
o Vendor / Factory
o Factory Address
o Country of Origin
o Units to be inspected, AQL, Acceptance and Reject number
o Production Status at time of inspection (e.g. sanding, finishing, packing, etc)
•
Any problems or discrepancies found must be brought to the attention of the vendor management and their own
Q.A. so that action can be taken to rectify the problems or discrepancies immediately. Every time an In-line
Inspection is performed at a factory, an inspection report must be completed and the vendor must be prepared to
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provide this report to CPWM upon request. Since much of what is recorded on the report will also require a verbal
explanation, the forms should be completed when the factory Q.A. and the vendor’s representatives are together.
The frequency of the In-line Inspection will depend upon the type of product being produced, the production quality
as perceived, the vendor’s past performance, and the order quantity. If the In-Line Inspection passes, production can
be continued. If the In-Line Inspection fails, the vendor must take corrective action, and the inspector must perform
a re-inspection until the material is deemed acceptable or until it is determined that it cannot meet standards.
Final Inspection
• The Final Inspection should only be carried out when at least 80% of the shipment lot has been packed, with the
balance cleared from the production lines. Depending on the quality history of the production factory, the QA
inspector might demand for the shipment to be 100% packed before conducting the Final Inspection. For some
items (e.g. very bulky items such as furniture), it is permitted to conduct the Final Inspection after the shipment is
50% packed.
• The Final Inspection procedure consists of a series of checks to ensure the accuracy of the color, hardware, material,
labels, measurements, workmanship and packaging.
• The AQL inspection system, based on the MIL-STD-105E, should be used. Different AQL levels are used for
different product categories (refer to Table 1-2)
o Use 2.5 AQL MIL-STD-105E- Normal Level II Single Sampling Plan (refer to Table 1-3).
• It is important that the QA inspector determines the Sample Lot Levels required before carrying out the inspection.
It is the vendor’s responsibility to provide a clean, well lit, and spacious work area to carry out the inspection. It is
the QA Inspector’s responsibility to ensure that the area provided is adequate for the purpose of inspection; any
inadequacies should be communicated to the vendor/agent’s senior management as soon as possible so that issue
could be rectified. Each separate shipment and SKU will require a Final Inspection conducted by a QA
Inspector.
•
If the Final Inspection fails, the QA Inspector must perform a re-inspection of the failed P.O. after the factory has
taken steps to correct (rework/replace) the rejected (defective) units. The subsequent Level II Single Sampling Plan
inspection for that same P.O. should be carried out at a lower AQL of 1.5. If the same shipment fails the reinspection, the following subsequent inspection for the same P.O. shipment shall be at Level III (100%) also at an
AQL of 1.5.
•
In addition, if a shipment has failed, the factory must begin their final inspection on the next 5 P.O. shipments at a
Level II Single Sampling plan with an AQL of 1.5.
Final Inspection Date
• The QA Manager/Supervisor should plan the inspection schedules in accordance with the P.O. ship date. The Final
Inspection schedule is arranged and carried out on each separate P.O. prior to shipment so as not to adversely impact
the ship date.
•
The Final Inspection consists of 6 different checks/verifications:
1.
•
Packaging
Inspection consists of checking the following:
o Size and Construction of Outer Carton being used
o Carton Marking
o Contents of Carton, including size/color assortment and quantity
o Individual item packaging inside the carton is correct and the packaging labeling is correct
•
The QA inspector should record all findings in the sections provided on the Final Inspection Report. The QA
Inspector should use the appropriate AQL 2.5 Level II, Single Sampling Plan table to determine the number of
cartons to be opened for each shipment. As a general rule, regardless of the number of cartons packaged, a minimum
of 3 cartons should be selected. The shipment will be rejected if one or more cartons are found with packaging
mistakes or other non-compliance
2.
Quality
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•
Inspection shall be carried out by randomly select samples from the entire lot (shipment). The sample selected shall
be representative of the entire lot/shipment and must include sizes and different colors/color combinations
proportionately as applicable.
3.
Responsibility
•
It is the vendor’s responsibility to ensure the final inspection at the established AQL is 100% compliant. In the event
that CPWM fails a shipment at an AQL 2.5 Level II, Single Sampling Plan during a CPWM inspection, vendor will
be responsible for all costs associated with the CPWM inspection.
•
Vendor is required to document all defects and maintain a record of the factory’s corrective action plan (CAP).
These documents must be readily accessible if requested by CPWM.
Table 1-2 General AQL MIL-STD-105E- Normal Level II Single Sampling Plan
Use for
Major defective all categories
Minor defective all categories
•
General AQL
Level 2
1.5
2.5
4.0
Level 3
100% inspection(Sorting)
Major defective all categories
Minor defective all categories.
Table 1-3 represents the sample size required per SKU order quantity and the Accept and Reject Number per tested
sample for Major defects only
Table 1-3 2.5 AQL MIL-STD-105E- Normal Level II Single Sampling Plan
SKU Order Quantity
2-50
51-150
151-280
281-500
501-1200
1201-3200
3201-10,000
2.5 AQL
Normal Level II Single Sampling Plan
Sample Size
Accept
5
0
20
1
32
2
50
3
80
5
125
7
200
10
Reject
1
2
3
4
6
8
11
•
Example (refer to Table 1-3):
o If the P.O. calls for 300 units of SKU 12345 to be shipped, then it falls into the category of 281-500 units and the
required sample size for the vendor to inspect would be 50 units. If no more than 3 major defectives are found, the
shipment is acceptable. If 4 or more major defectives are found, the shipment is subjected to a 100% inspection by
the vendor. Please note that the above only lists the number of Major defectives.
•
Table 1-4 represents the sample size required per SKU order quantity and the Accept and Reject Number per tested
sample for Furniture Minor Defects only.
Table 1-4 4.0 AQL MIL-STD-105E- Normal Level II Single Sampling Plan
SKU Order Quantity
2-50
51-150
151-280
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4.0 AQL
Normal Level II Single Sampling Plan
Sample Size
Accept
5
0
20
2
32
3
1-14
Reject
1
3
4
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281-500
501-1200
1201-3200
50
80
125
5
7
10
6
8
11
Procedure
• Once selected, the samples should be taken to the designated inspection area for evaluation. Proper visual inspection
is very important. The QA Inspector must ensure that the reference sample or photo he/she has recorded has been
approved by CPWM. It is necessary to inspect every single selected sample in the lot. It cannot be assumed that the
selected sample lot is either good or bad after inspecting a few samples; therefore every sample must be thoroughly
inspected.
o
•
Verify that all outside carton labeling details on the item match the labeling details on the package (e.g. size,
SKU, etc). Check that the other labels details are also correct (e.g. country of origin etc). The QA Inspector will
conduct the drop test as well as check the packaging method in accordance with the approved transit/packaging
laboratory report.
o Examine the item: If applicable, check the materials for quality, color, and shading. Check for dampness (take
moisture reading as applicable), biological presence, and (offensive) odor. Review the available raw material,
swatches, labels and accessories, and compare them to the approved samples and the CPWM Furniture
Standards. Record the comments and findings on the Material Inspection Report.
Review the production (or components) for the following (as applicable):
o Accuracy of design against the approval sample
o Accuracy of construction against the technical specifications
o Material quality and colors
o Workmanship
o Color shade
o Assembly
o Function
o Secure joining
o Measurements
o Sharp edges/Sharp points
o Finish→ Holes/Scratches/Pit marks/Dents
o Dirt/Oil stains
o Moisture Content/Mold/Cracks/Odor (offensive)
o Color differences within one piece
o Packaging components are correct
o AI instructions (as applicable) are eligible and have a country of origin marking/label
•
All findings should be recorded on the Inspection Report and contain the following:
o P.O. number
o SKU number
o SKU order quantity
o Merchant/Buyer
o Vendor
o Country of Origin
o Units inspected, Acceptance Number, and Rejection Number
4.
•
Moisture Content (M.C.) Monitoring
CPWM will check the M.C. of wood and cellulose derived products, including packaging, for acceptability and
compliance. The M.C. of 10% upon product receipt is the accepted standard. Vendors should be knowledgeable
about M.C., and should always consider temperature and humidity and their affect on the product in the United
States climate.
Any critical defects resulting from dimensional movement, mold, offensive odor, or fracture will be considered
unacceptable regardless of the measured M.C. at production time.
•
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•
The MC limit for indoor product is 8-12%. A target of 8-10% is preferred. For outdoor items CPWM will advise as
necessary.
5. Assembly Test
• Assemble 3 samples according to the provided assembly instructions. The shipment cannot be released if the
assembly test fails to meet the below criteria:
o
o
o
The assembly instructions are correct, easily understood, and clean
The provided tools are of the correct size for the hardware
The hardware pack (components and special tools) required for assembly are provided and are the correct size
and qty as required by the AI
o The components fit together properly after assembly
o Assembled items function as intended (drawers move smoothly, doors close without catching, magnetic clasps
close and hold doors, tables and chairs are leveled, etc)
6. Drop Test
• All Furniture products and select fragile Hard-line items require transit testing. Products which have previously
passed transit testing for other retailers within the last 24 months will be granted a waiver. However, these products
must be identical to the ones which were tested, and the passing results will need to be verified by way of vendor inhouse drop testing. The transit test report must be available for reference upon demand. The vendor must conduct
drop testing of 3 unit samples (refer to section 1.12). All tested samples must pass the in-house drop test or the
initial shipment cannot be released. In the event of failure, the vendor shall inspect, document, correct the issue, and
repeat the in-house drop test. If all three revised samples pass, the packaging revision must be implemented for the
entire shipment. The vendor/agent must clearly document the packaging revision, notify CPWM Engineering of the
change, and proceed to ship without delay. The vendor/agent must also follow up with BV transit testing with the
revised packaging (if required).
7. Final Inspection Report:
• The inspector must complete and file a Final Inspection Report, and be prepared to provide this report to CPWM
upon request. The format of the report is chosen by the vendor/QA inspector.
o If the Final Inspection passes, the inspector issues the authorization to proceed with shipment.
o If the P.O. passes the re-inspection, the inspector issues the authorization to proceed with shipment.
o If the P.O. fails the re-inspection, the shipment is held at the vendor’s warehouse. The inspector must send a
copy of the inspection result to CPWM (or agent where applicable) for further instruction. To release the
shipment, a written authorization from CPWM (DMM or Senior Buyer) must be obtained and signed off by the
agent office (DMM).
o
Furniture Vendors ONLY. You are required to submit all FINAL inspection reports by sku/PO to CPWM no
later than 24 hours prior to the ship date noted on the PO. Key points to remember:
Inspections (all three levels) are required for every sku/PO shipment. Only the FINAL inspection report is
to be sent to CPWM.
If the sku/PO is manufactured in multiple factories, final inspection documents must be submitted to
CPWM from each factory.
If the Final Inspection passes, the inspector issues the authorization to proceed with shipment.
If the P.O. fails the re-inspection, the shipment is held at the vendor’s warehouse. Vendor/agent must
communicate failures to the CPWM buyer ASAP. Please copy [email protected] on your communication.
Skus with failed inspection results cannot be released for shipment without the approval of CPWM.
Inspection documents must be submitted in English.
Final Furniture inspection documents must be submitted to [email protected].
• Please use the following applicable statement in the subject line:
• SKU#: XXXXXX PO: XXXXXXXXX Final Inspection Document – Passing Results
• SKU#: XXXXXX PO: XXXXXXXXX Final Inspection Document – Failing Results
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1.12.5 MONTHLY INSPECTION SUMMARY
•
•
Each Final Inspection must be recorded on an Inspection Summary Report. The inspector is responsible for updating
and maintaining this monthly, and must provide this report to CPWM upon request.
The Monthly Inspection Summary must contain the following:
o Vendor name
o Agent name (if applicable)
o Country
o Inspection date
o PO#
o Department number
o SKU#
o Item’s description
o Quantity Unit Available
o Quantity Unit Inspected
o Quantity Unit Rejected
o Result (Pass/Fail)
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Figure 1-13 Vendor Inspection Procedure
8
Or agent where applicable.
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1.13
•
•
•
TRANSIT TESTING
All furniture and lamp items are required to be transit tested. Please consult with [email protected] if any
assistance is needed. (See the CPWM Vendor Guide for more details).
CPWM Packaging Engineering has the final authority on all transit test results from BV. For questions regarding
shipping fragile products and the ISTA transit testing requirements, contact [email protected].
All vendors are strongly encouraged to conduct in-house drop testing. It is strongly recommended that you achieve
successful results prior to submitting a fresh (un-tested) packaged sample to BV for transit testing (refer to Figure 114).
Figure 1-14 In-House Transit Pre-Testing Procedure
•
ISTA Transit Test Protocol
o
The ISTA test performed will be dependent on your carton physical characteristics as detailed in the table
below. Tests consist of vibration, compression and drop tests:
IF YOUR PACKAGE IS
AND
6 sided carton ( like a cube)
Less than 150 lbs (68 Kg)
6 sided carton ( like a cube)
More than 150 lbs (68 Kg)
Flat carton (e.g. mirror)
Elongated carton (e.g.
side Rail)
Furniture attached on a custom pallet
o
•
9
SELECT
ISTA -1C
ISTA -1D
ISTA - 2D
ISTA - 2E
CPWM Protocol
CP-9029-US
CP-9029-US
CP-9057-US
CP-9058-US
Palletize
CP-9052-US
This policy does not apply to cartons with a gross weight of more than 150 lbs (68 kg). Contact
[email protected] if your package gross weight is more than 150 lbs (68 kg).
Loose Load Vibration Test - (for vendor reference only)
This portion of the test consists of a 45 minutes package vibration test:
o 15 minutes in the base down
o 15 minutes in the side down
o 15 minutes in the back down orientations
The frequency of the test platform shall be adjusted until the package just leaves the platform surface.
For BV Protocols, refer to Appendix B.
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•
Free Fall Drop Test – (required for in-house drop testing)
o This portion of the test consists of a series of ten (10) free-fall drops from a height that varies with the carton
gross weight as outlined in Table 1-5:
Table 1-5 Drop Height
Carton/Package Gross Weight
Drop Height
English (lbs)
Metric (Kg)
English (inch)
Metric (cm)
1 – 20
1–9
30
76
21 – 40
9.5 – 18.2
24
61
41 – 100
18.63 – 45.5
18
45.7
101 – 150
46 – 68.2
12
30.5
•
Test surface
o When performing the in-house free fall drop test, select an even, smooth, and rigid surface such as a concrete
floor. No uneven, carpeted, wooden or dirt floor surfaces are allowed.
•
Identify the critical corners
o Pick the most fragile corner of the packaged item, marking that corner as 1st. If you do not know where the most
fragile corner of the item is located, select the corner where the carton-manufacturing joint (vertical seam of the
carton) is located (refer to Figure 1-15).
1st corner
Critical corner
(Manufacturer joint)
Figure 1-15 Identifying Critical Corners
•
Drop Testing Technique
o When performing the drop, especially on critical corners and edges, the orientation of the carton must be such
that the entire weight of the carton is concentrated onto one point the critical corner or edge being tested.
Refer to figure 1-16 for the diagram illustrating this procedure.
Figure 1-16 Drop Testing Technique
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•
Drop Sequence
Orientations of the impacts are as follows and must be
performed in the following order, as illustrated in Figure 117:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Most fragile corner (manufacturer’s corner)
Shortest edge radiating from that corner
Medium edge radiating from that corner
Longest edge radiating from that corner
Flat on one of the smallest faces
Flat on the opposite small face
Flat on one of the medium faces
Flat on the opposite medium face
Flat on one of the largest faces
Flat on the opposite largest face
8
3
1
9
4
6
5
7
2
10
Figure 1-17 Drop Sequence
•
Carefully inspect for damage after the in-house drop test is completed. If no damage is found, pack and send a
fresh (untested) sample to the BV test lab to avoid inherent stress from previous drops. Failing to send a fresh
sample to BV may result in loss of time and additional cost due to a potential test failure.
1.14 DC RECEIVING INSPECTION
•
DC Receiving Inspection uses 2.5 AQL ANSI ASQ Z1.4 MIL-105E- Special Level 1 Inspection as standard.
Table 1-6 represents the sample size required per P.O. order quantity and the Accept and Reject number per tested
sample.
Table 1-6 2.5 AQL ANSI ASQ Z1.4 MIL-105E- Special Level 1 Inspection
P.O. Quantity
2 to 50
51 to 500
501 to 35,000
Over 35,000
•
•
•
Sample
Size
2
3
5
8
Major Defective
Accept
Major Defective
Reject
0
1
Please note: This standard receiving inspection shall be performed internally at CPWM at our discretion. It is a
cursory inspection to determine the likelihood that a PO shipment will meet our quality standard. In the event that
the Special Level I Inspection fails, a Normal Level II Inspection (refer to Table 1-4), will be performed.
Example: A PO shipment of 520 units is inspected upon arrival at the CPWM DC. Five (5) units are randomly
selected and inspected. If one (1) or more major defective(s) is/are found, the shipment fails the Receiving
Inspection. This failure warrants CPWM to consider a Level II Inspection.
Refer to Figure 1-18 for the diagram illustrating this procedure.
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Figure 1-18 DC Incoming Inspection Procedure
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1.15 INSPECTION BY THIRD PARTY SERVICES PRODUCT
•
•
•
•
•
•
Third party inspections are typically conducted for a new vendor and/or a new program, or for prior persistent
quality issues.
Only the Buyer or the CPWM QA department can initiate third party inspections.
Inspection Appointment Scheduling Procedure
o QA forwards the form to both the vendor10 and the inspection service via e-mail.
o Inspection service confirms the receipt of the request.
o Inspection scheduling occurs between the inspection service and the vendor (CPWM plays no role in this
process).
o Six days notice is required for all scheduling changes. It is the vendor’s responsibility to contact the inspection
service directly for any appointment changes.
Vendor’s Role in the Inspection Process
o POs flagged for inspection may not ship without authorization from the inspection service or CPWM.
o POs must have already passed vendor final inspections.
o The entire PO must be 100% complete; minimum 50% packed (large items such as furniture need only 10 units
packed).
o Approved samples should be available to resolve potential defect disputes.
o A clean, well-lit area appropriate for the product inspection must be available for the inspector’s use.
Sampling Method
o ANSI ASQ Z1.4 Normal Level II Single Sampling Plan→2.5 AQL for Softlines, Non-Furniture Hardlines
lighting and 4.0 AQL for Furniture Major defects only.
o Critical defective Zero tolerance (if 1 critical defect is found, the lot fail the inspection)
o Major defective see Defects Classifications for example and definitions.
o Minor defective 3 minor defects on the same unit will be treated as 1 Major defective.
o In general, minor defectives are treated at a lower tolerance than Major defectives (Non-Furniture 4.0 AQL and
Furniture 6.5 AQL).
Inspection Conclusions
Table 1-7 Inspection Conclusions
Conclusion
Abort
•
•
•
•
10
Pass
Fail
Circumstance
Inspector attempts the inspection but the entire
P.O. is not ready
Shipment conforms to CPWM standards
Shipment does not conform to CPWM standards
Hold
Requires decision from CPWM
Action
No Shipment
Reschedule the inspection
Ship
No Shipment
100% inspection
Reschedule the inspection
No Shipment
Wait for CPWM decision
Payment for Inspections
o CPWM pays for the first completed inspection (regardless of Pass/Fail/Hold conclusion).
o The vendor pays for Aborted (shipment not ready for inspection) and all re-inspections.
Reports
o The inspector is required to leave a copy of the inspection report with the vendor before leaving the premises.
o The inspector is required to review all rejected units and reasons for rejection with the vendor.
Samples and Photos
o Failed and On Hold inspections require samples and/or photos to substantiate conclusion.
o The inspector forwards samples immediately to CPWM QA Department at [email protected] using the CPWM
shipping account number. Contact the Buyer for this account number.
Disputes
o Contact CPWM QA Department at [email protected] immediately.
o Do not ship until the dispute is resolved in writing.
Or agent where applicable.
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II. HARDLINES
HARDLINES
•
The CPWM QA Manual is separated into two versions. There is a version dedicated solely to non-furniture
(hardlines and softlines) vendors titled: Quality Assurance Manual - Excluding Furniture, Lighting, Food, and
Beverage Vendors. This manual can be found on our Vendor Relations website.
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III. SOFTLINES
SOFTLINES
•
The CPWM QA Manual is separated into two versions. There is a version dedicated solely to non-furniture
(hardlines and softlines) vendors titled: Quality Assurance Manual - Excluding Furniture, Lighting, Food, and
Beverage Vendors. This manual can be found on our Vendor Relations website
3.1 DEVELOPMENT/BULK PRODUCTION SUBMISSION PROCESS
All fabrics must be submitted for review and approval to the applicable buyer. Refer to the documents titled CPWM
Bulk Production Submission Process and CPWM Textile Development Submission Process. Refer to the forms titled
CPWM Development Form - Bulk Submission for Yarn Dye – Prints, and CPWM Submission Form – Lab Dip – Bulk
Submission. Documents and forms are available on our Vendor Relations Website.
3.2 PILLOW LABEL ATTACHMENT
•
Zippered Pillow Labeling Requirements
o Zippered pillows should be labeled per the following:
o
o
•
Care instructions and fabric content:
o Attach a care label to the inside of the shell itself.
o You must follow the care label format shown in section 1.5 of this
manual.
o PLEASE NOTE: CARE AND FABRIC CONTENT CANNOT BE
PRINTED ON THE LAW LABEL. Care and content labels must
never be placed on top of the law label.
o
o
o
Date: July 22, 2013
The law label must be attached to the filler/insert.
A second law label must also be attached to the outer shell if it has a
zipper as required by ABFLO.
The law label attached to the filler and care labels must be tucked
inside the shell and the pillow shipped to us fully zipped.
You must contact the Buyer to discuss vacuum packing. If the pillow
can be vacuum packed, we should consider this option as the freight/
cube savings are dramatic.
A "hangtag" ticket must be attached to the outside of the pillow. The
ticket attachment must be run through the seam.
3-1
III. SOFTLINES
•
o Sticky tickets must never be used.
o Pillows without a zipper, "hangtag" ticket must be placed on the bottom, left hand-side of the pillow.
Pillow Zippers
o Zippers must be located on the bottom seam, hidden and dyed to match the pillow unless otherwise specified by
the Buyer.
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3-2
IV. FURNITURE
FURNITURE
•
Living, Outdoor, Dining
4.1 PRODUCT LABELING
•
TICKETING - NO RETAIL
o The vendor must affix a P.O. ticket (refer to Figure 4-1) to the product.
o The P.O. ticket must be placed on the underside of the furniture item and on the outer master carton (refer to
Furniture Carton Printing Requirements found on our Vendor Relations website).
o Note for Furniture Vendors: Furniture price tickets should not include a retail price on them. This is a
mandatory requirement unless directed otherwise by the buyer.
Figure 4-1 Example PO Ticket
•
LABELING – NOT FOR COMMERCIAL USE
o The vendor must affix a label on the underside of ALL furniture items with the following statement:
Not For Commercial Use
4.2 WARRANTY
•
•
The warranty statement must include all parts of the item. For example, if the furniture contains frame, springs and
webbing, foam, leather, and all other parts, then the warranty statement must cover all of the above (refer to figure
4-2). Warranty's must be reviewed and approved by the Buyer/Assistant.
The warranty statement and care and cleaning instructions can be printed on the same paper (see Appendix D).
Date: July 22, 2013
4-1
IV. FURNITURE
Frame – Limited 5 Year Warranty
The X collection frame is warranted for 5 years that against manufacturing defects in material and workmanship.
Springs and Webbing – Limited 5 Year Warranty
The springs and webbing used in the X collection are warranted for 5 years against breakage due to defective material or workmanship.
Foam – Limited 5 Year Warranty
The foam in the X Collection is warranted 5 years against loss of resiliency and free from defect in material and workmanship. Loss of resiliency
should not be confused with softening and flattening of fiber that will occur as a result of normal use and aging, and is not a manufacturer defect.
Leather – Limited 5 Year Warranty
The X Collection is guaranteed to be upholstered in 100% leather, which is warranted for a period of 5 years from the date of delivery against
tearing and splitting under normal household usage. This warranty does not include coverage for wrinkling or natural markings, variation in
grain, or color variations because they are typical of authentic cowhide leather. In addition, the warranty does not include coverage for tears due to
poor maintenance.
All Other Parts – 1 Year Warranty
All other parts not specifically listed as being warranted are covered under a one year limited warranty against defective material or workmanship.
This warranty is limited to repair or replacement of the defective part.
This warranty also does not cover damages occurred during transportation or due to misuse, abuse, negligence such as cuts, burns, pet damages,
treating the leather with any chemical product, exposing the leather to sunlight, high heat, or bright lights both artificial and natural. This warranty
does not cover spills such as acids, solvents, dyes, or other corrosive chemicals, ink, paint or body fluids.
Warranty Service
All claims for service must be accompanied by proof of purchase (bill of sale). Any claim for service under the warranty must be through Cost
Plus World Market. This warranty is valid to original consumers’ purchaser.
Figure 4-2 Example of Furniture Warranty
Date: July 22, 2013
4-2
IV. FURNITURE
4.3 FURNITURE DEFECTS CLASSIFICATIONS
•
•
•
•
•
Location of the defect on the product will dictate the defect severity.
Example: A defect on class A zone (show) surface is classified as Major. The same defect on class B or C zone
surfaces may be classified as minor.
Definitions of surface zone are as follow:
o Class A zone surface – all surfaces on the item that are either readily visible or will be visible with no effort
required during the course of normal use or observation. (e.g. standing, bending at the waist, opening doors or
drawers)
o Class B zone surface - all surfaces on the item that are occasionally visible or will require bodily effort to be
visible (e.g. bending down at the knees, kneeling, or moving components for observation).
o Class C zone surfaces - all surfaces on the item that are rarely visible or will require extraordinary bodily effort
to be visible (e.g. flipping over, detaching, disassembling, or requiring a flashlight for observation).
Refer to Table 4-1 for Furniture Defects Classifications and Table 4-2 for Furniture Packaging and Labeling Defects
Classifications.
DEFECT LOCATIONS
o This section is a reference guide to assist quality inspectors in defining the severity of defect found on specific
furniture items. Some items may specify a higher quality level, in which certain areas may be upgraded. For
example, a class C zone area may be upgraded to a class B zone.
4.4 FURNITURE STANDARDS
•
General Furniture Standards
o Listed below are the furniture standards for Cost Plus World Market. I have listed construction as well as
material standards that need to be adhered to in order to insure good quality product for our customers.
Changes and or substitutions may be made in certain situations but only after review and approval by the
product engineer and the merchant.
A) Joinery:
1) Dowel or tenon construction requires adequate, not excessive gluing of both components, if an
excessive amount is applied then the joint must be wiped clean, sanded if needed to avoid finishing
issues.
2) Joints are to be flush unless an offset is specified in the technical drawing.
3) Pin nails may be used to secure joint until glue sets up, but not as a method of joining two components.
4) If pin nails are used in exposed areas, then the holes must be filled and sanded so they will not stand
out after finish is applied unless distressed finish is specified as part of the design intent/aesthetic.
5) All KD/RTA fasteners must be hidden if at all possible. In situations where the fastener cannot be
completely hidden the finish/color of the fastener must compliment the finish/color of the item not
contrast to the point of drawing attention. Wooden plugs or in some cases plastic caps may be used if
approved by CPWM.
B) Sanding:
1) All exposed areas must be properly and evenly sanded. Sand through on
veneer or burnishing (over sanding with fine grit sand paper) of solid wood is not acceptable as it will
cause the finish to run excessively.
2) Cross grain marks on veneer or solid wood is not acceptable unless part of the design intent.
3) Distressing should take place after sanding not during the sanding process.
C) Finish:
1) Finish must match approved color panel and be consistent over the entire
product. All finished surface areas must be within the shade band.
2) Lacquer runs, trash (dust, or other particulate) in the top coat on exposed.
Surfaces are not acceptable.
3) Stain must be applied evenly so that all components have consistent color.
4) Adhesion tests must be performed on a regular basis to insure that flaking or peeling will not occur.
Date: July 22, 2013
4-3
IV. FURNITURE
5) Distressed or antiqued finishes must appear random not uniform so that it has an aged appearance by
normal wear.
D) Materials:
1) Wood specie/s should be as specified or indigenous equal, if vendor
wants to suggest a substitution for cost or availability, it must first be approved by the merchant and
product engineer. This should be submitted as first sample option at vendor’s expense.
2) Moisture content goal is 8-10%, however 12% is acceptable but must be
maintained throughout the product to prevent excessive movement of components.
3) Veneered components must be (3) or (5) ply construction to achieve
balance and stability of panels and components.
4) Substrate material for veneered components should be MDF (medium density fiberboard) in most
cases if particleboard is used it should be a minimum of 40 lbs/ft2. Particleboard can not be used on
panels with exposed edges. In cases where particleboard is used the edges must be banded to keep
moisture out especially on the bottom edge where it could be exposed to liquids or damp/wet floors.
E) Hardware:
1) Specified hardware may be substituted if approved by CPWM merchant
And design.
2) Structural or functional hardware must be tested by a reputable testing lab,
and the results presented to CPWM for approval.
3) Connection hardware for KD/RTA product should be standardized whenever possible to help lessen
confusion when assembling the product.
•
•
•
In General:
o As a general standard all edges must be broken, 1mm radius, unless chamfer or shape is specified. No sharp
edges on tops, posts or other areas that may splinter or cause injury.
o All cabinets with doors and tables should have adjustable levelers, chairs should be checked for level before
being packaged and have screw in nylon floor glides on the bottom of each leg.
Leg attachment:
o Legs on dining tables and chairs in general should have leg bolts as opposed to inserts whenever possible. The
strength of the leg bolt is much better than the insert and insert screw. There are situations where the leg bolt
can’t be used due to space constraints but in most cases the leg bolt can and should be used. See photo below:
CONSTRUCTION STANDARDS
o Refer to the CPWM Vendor Relations website to view our furniture construction standards. For example,
if you manufacture dining tables, you are required to follow the construction standards posted on our website.
New standards are being added regularly. Please refer to our website periodically to ensure you are up to date
on all CPWM standards. For questions regarding CPWM standards, contact CPWM Engineering.
Date: July 22, 2013
4-4
IV. FURNITURE
CASE-GOODS
Zone A
Top, Molding
Zone A
All visible areas of front
view
Zone A
Side panels, moldings
Zone C
Rear edges of top and side
panels
Zone C
Back panel view
Date: July 22, 2013
4-5
IV. FURNITURE
Zone A
Top and side edges of
opened doors
Zone C
Under side edges of
opened doors
Zone B
Rear half of all shelves
on case goods with doors
30” high or less
Zone A
Front half of all
shelves or 7” deep
from front edge
Zone A
Inside surface of door and
side panels
Date: July 22, 2013
4-6
IV. FURNITURE
Zone B
Lower edge of top rail,
ceiling of case goods
Zone B
Inside surface of back
panel
Zone A
Front rails
Zone B
Inside surface of back and
side panels
Zone C
Bottom side of case-good
excluding door edges.
Date: July 22, 2013
4-7
IV. FURNITURE
Zone A
Outside legs surfaces
Zone C
Bottom side of leg
Zone B
Inside legs’ surfaces
Zone C
Interior of cabinet
of drawer case goods
Zone B
Inside side panels
Inside back panels and
interior rails
Zone B
Inside ceiling
Underside of top
front rail
Date: July 22, 2013
4-8
IV. FURNITURE
Zone A
All double sided,
non-handed
adjustable
shelves
Zone B
Top panel on case
goods 72” tall or
taller
Zone A
All carved or
raised details
Zone B
Entire perimeter
of turned legs,
less than 6” Ht.
Date: July 22, 2013
4-9
IV. FURNITURE
Zone A
Door Glass
Inside & Out
and metal
hardware.
DRAWER
Zone B
All inside surfaces of
drawer including top
edges
Zone A
Front surface drawer
including drawer pull
Zone A
All 4 edges of drawer
face panel
Zone B
Side panel outer surfaces of
drawer, except back side
Date: July 22, 2013
4-10
IV. FURNITURE
Zone B
Bottom surface drawer
pull and bottom edge of
front panel
Zone C
Bottom surface and rear
of back panel
UPHOLSTERY
Zone A
All front and top
touch surfaces
Zone A
All front and top
touch surfaces
Zone B
Side, top, and
back surfaces
Date: July 22, 2013
4-11
IV. FURNITURE
Zone A
Front foot rest,
visible front leg
Zone B
Back and Rear
Surfaces
Zone C
Underside
surfaces
Date: July 22, 2013
4-12
IV. FURNITURE
Zone A
Top and front
surfaces
Zone A
Both sides of
reversible cushion
Zone B
Backside of
Living seating
Date: July 22, 2013
4-13
IV. FURNITURE
Zone A & C
Non-reversible
cushions. Top is A,
Bottom is C
Zone C
Underside liner
Zone B
Seating base &
bottom of side
panels
Date: July 22, 2013
4-14
IV. FURNITURE
Zone A
All upholstered
areas of dining
chair
Zone A
All outside sides of
legs; zone B for all
inside sides of legs
Zone C
underside liner
Date: July 22, 2013
4-15
IV. FURNITURE
DINING
Zone A
Top surface and all of
outside apron
Zone B
Upper 1/2 of
column base
Zone C
Underside of
table surface
Zone A
Visible area of legs
and/or base
Zone C
Interior of apron
Zone C
Underside of
Base
Date: July 22, 2013
4-16
Zone A
Entire perimeter o
turned dining table
legs
IV. FURNITURE
Zone A
Back rest,
seat, apron,
front leg face
Zone B
Back side of
legs
Date: July 22, 2013
4-17
IV. FURNITURE
Zone A
Back surface,
back rest
supports
Zone C
underside of
seat and legs
OCCASIONAL TABLES
Zone A
Top, Face, Legs,
Shelf, Side
Date: July 22, 2013
4-18
IV. FURNITURE
Zone B
Back side of unit
`
Zone C
Underside
surfaces
Zone A Shelf surface;
Zone B Side Apron
Date: July 22, 2013
4-19
IV. FURNITURE
SCREENS
Zone A
All faces including
edges
Zone C
Bottom of feet
Zone B
Top edge
Date: July 22, 2013
4-20
IV. FURNITURE
Beds & Headboards
Zone A
front faces,
aprons, legs
Zone C
Behind
headboard, under
frame
Zone B
Headboard area
obscured by
mattress
Date: July 22, 2013
4-21
IV. FURNITURE
FURNITURE
• ZONE KEY (Corresponds to Defect Location Guide)
o A = Primary visual surface (always in view by customer)
o B = Secondary visual surface (occasionally in view by customer)
o C = Non-Visual surface (rarely in view by customer)
• DEFECT KEY
o C = Critical*
o M = Major
o m = minor
o  = Not Applicable
*Critical Defect – Hazardous/unsafe for use, violation of U.S. regulation, item cannot be sold due to condition.
Table 4-1 Furniture Defects Classifications
Description
Code
A
B
C
Compliance
In violation of any US/CAN regulation for specific product
C-1
C
C
C
Missing or incorrect Country of Origin label
C-2
C
C
C
Missing or incorrect other required labels in the entire shipment
C-3
C
C
C
Size / Capacity / Weight other than labeled
C-4
C
C
C
Incorrect position of label in the entire shipment
C-5
C
C
C
Comparison to Approved Sample and/or Specification
Non approved material or wood species
S-1
C
C
C
Color / Shade
S-2
M
m
m
General Appearance
S-3
M
m
m
Failed to complete 3 samples of testing cycle
S-4
M


Decoration, texture or distress standard
S-5
M
M
m
Visual discoloration compared to surrounding area
S-6
M
M
m
Material and Wood Defects
Insect Infestation
M-1
C
C
C
Mold or mildew growth
M-2
C
C
C
Wood knot within 2in (5cm) from joint or on structural member.
M-2b
C
C
C
Holes or other material void (non-specified)
M-3
M
M
M
De-lamination greater than 25 mm2
M-4
M
M
m
Crack with visible gap
M-5
M
M
m
Knot split with visible gap, unfilled > 25 mm
M-6
M
M
m
Knot split filled and matched < 25 mm
M-7
m
m

Moisture Content 10% (+/- 2%) at center of wood member
M-8
M
M
M
Offensive Odor
M-9
M
M
M
Warp, bowing, bow, twist of surfaces or members >3mm/mtr
M-10
m
M
M
Veneer split, checking
M-11
M
M
M
Workmanship and Construction Defects
Structural failure – component separation/broken/loose
W-1
C
C
C
Post operation repair of component, repair visible
W-2
M
M
m
Visible crack, split, gap, failure on any connection or support (load bearing)
W-3
C
C
C
Hairline crack
W-4
M
m

Excessive glue squeeze out, or insufficient glue
W-5
M
m
m
Glue failure, or glue used was not as specified
W-6
M
M
M
Damage or dent that fractures and exposes bare wood
W-7
m
C
C
Non fracture indentation does not penetrate finish
W-8
M
m

Joinery, hardware, or joint not as specified
W-9
M
M
M
Joint expansion/contraction due to wood movement
W-10
M
m
m
Construction loose, assembly wobbly and or racking
W-11
M
m
m
Misalignment of components > 2 mm, product assembles in stable condition
W-12
M
M
m
4-22
Date: July 22, 2013
IV. FURNITURE
Description
Code
A
B
C
Drawers not even, level, or square
W-13
M
M
m
Drawer operation binding or not function smoothly
W-14
M
M
m
Split >5mm long caused by assembly or hardware installation
W-15
M
m

Exposed nails or protrusion of nail heads
W-16
M
C
C
Sharp or broken edges, cracks, protrusions, or splinters
W-17
M
M
m
Loose or broken handles, adornments, or ornamental items
W-18
M
m
m
Visual details, reveals, u-grooves, missing or wrong
W-19
M
m
m
Poor putty repair, not smooth, not color matched
W-20
M
M
m
Finishing Defects
Discoloration or visible defect on surface
F-1
M
M
m
Color, stain, sheen, or shade mis-match (within single unit)
F-2
M
m

Color, stain, sheen, shade mis-match (between multiple units)
F-3
M
m

Multiple drip stain spills or built up stain surface
F-4
M
m

Bubbling
F-5
M
m

Blushing
F-6
M
m

Checking or crazing
F-7
M
m

Overspray onto hardware or adjacent panel
F-8
M
m

Flecking of any exterior surface coating
F-9
M
m

Cracked finish (along joints or panel surface)
F-10
M
m

Debris embedded inside finish layer, dirt, insects, leaves, etc.
F-11
M
m

Uneven/inconsistent finishing application, (ex: bare spots)
F-12
M
m

Resin bleed through
F-13
M
m

Clear lacquer only on floor contact surface
F-14
m


Raised grain, rough surface texture, poor scuffing pass
F-15
M
m

Handling marks, or finger prints embedded into finish
F-16
M
m

Bad finish repair (filler/color) not blended, defect still visible
F-17
M
m

Scratch or scuff that penetrates to substrate
F-18
M
M
m
Scratch or scuff that does not penetrate substrate
F-19
m
m

Excessive finish (paint or lacquer) along the groove joints
F-20
M
m

Upholstery (In addition to all other defects)
Collapsed seat pan or back rest (no rebound)
U-1


C
Open seam more than 50mm long (exposed foam)
U-2
M
M
m
Split seam less than 50mm long
U-3
M
m

Skipped or broken stitch
U-4
m
m

Hanging threads
U-5
m
m

Hole or tear in fabric exposing foam or construction
U-6
m
M
M
Crushed corner, frame material is damaged
U-7
M
M
m
Corner abrasion, surface leather/fabric damage
U-8
M
m

Loose buttons or adornments
U-9
M
m

Curves and seams do not match specified locations
U-10
M
m

Pinhole or cut < 1mm no exposure of inside
U-11
m
m

Cloth fold or rumple sewn into a seam
U-12
M
m
m
Stain, dirt, marks, or soil
U-13
M
m
m
Exposed staple heads
U-14
M
M
m
Permanent scuff or abrasion on material
U-15
M
M
m
Cloth indentation, lumps, or puckering
U-16
M
m

Non-penetrating scratch or line abrasion > 25 mm long
U-17
M
m

Crushed or worn pile in velvet or microfiber
U-18
M
m

Loose upholstery or puddling of fabric without rebound
U-19
M
M
m
Polyurethane/adhesive failure on leather products
U-20
M
M
M
Shading difference between components within single unit
U-21
M
m

4-23
Date: July 22, 2013
IV. FURNITURE
Description
Shading difference between lots among all PO’s
Assembly and Hardware Defects
Rust on hardware or metal parts
Burred/sharp edges on metal hardware or parts
Damaged (bent, scratched, broken) but usable hardware
Discoloration on hardware other than specified
Hardware bags not secured or consolidated
Hardware mechanisms do not operate smoothly
Missing or damaged installed hardware required for assembly
Incorrect tool(s) supplied with the hardware
Missing holes/inserts as required for assembly (KD products)
Difficult to assemble, but possible with box contents
Missing and/or illegible assembly instructions
Mislabeled components and/or incorrect assembly instructions
Damaged torn/marred assembly instructions
Blurred or unclear printed assembly instruction – hard to read
Date: July 22, 2013
4-24
Code
U-22
A
M
B
m
C

H-1
H-2
H-3
H-4
H-5
H-6
H-7
A-2
A-3
A-4
A-5
A-6
A-7
A-8
M
M
M
m
m
M
M
M
M
M
M
M
M
m




























IV. FURNITURE
Examples of furniture defects
Oil and grease on finish surface not removable
Dents and nick from internal handling prior to packing
Unfilled knots
Wood Movement
Excessive moisture dissolved stain coat
Dried adhesive on wood and glass
Date: July 22, 2013
4-25
IV. FURNITURE
Uneven finishing – Staining operation
Greasy hardware
Lower shelf gap more than 5 mm wide
Abrasion damage – incomplete stain coverage
Internal dents and nicks on components
Hairline crack on entire length of leg
Date: July 22, 2013
4-26
IV. FURNITURE
Bubbles from lacquer > 25 mm2
End split
Stain runs
Marring of finished surface
Oily hand prints prevents staining
Clogged spray nozzle
Date: July 22, 2013
4-27
IV. FURNITURE
Dulled saw blade – edge tear out
Poor staining
Hole mis-alignment
Poor panel alignment with other parts
Zipper handle installed backwards.
Hairline crack more than 50 mm
Date: July 22, 2013
4-28
IV. FURNITURE
Poor stain application
Missing hardware, connecting screw
Missing leveler glide
Internal handling damage pre-finishing
Scratch on class A surface
Stain drips on edge – class A surface
Date: July 22, 2013
4-29
IV. FURNITURE
Dowel pins plugs – non matching stain
Poor finish sanding
Dulled drill bit – wood tear out
In-complete staining
Clear crack penetrate all way though the piece
In-correct tool supplied with hardware
Date: July 22, 2013
4-30
IV. FURNITURE
Interior checks more than 10cm
End crack on class A surface
Wood chipped at bottom of leg
Lacquering drips – finger prints
Wood split at hinge location.
Door clasp mis-aligned with catch
Date: July 22, 2013
4-31
IV. FURNITURE
Shelf gap more than 0.25in (6 mm)
Nail protrusion to surface of panel
Wood edge band separation
Staple/nail exiting wood
Shelf pin hole
Rusty strike plate
Date: July 22, 2013
4-32
IV. FURNITURE
Rusty connector bolts
End crack on Class A surface
Exposed metal connector – staple
Exposed metal connector - Staple
Excessive and poor putty application
Finish runs and drip
Date: July 22, 2013
4-33
IV. FURNITURE
Wood filler shrinkage
Improperly filled wood void
Filler putty color mis-match
Stain puddle
Hardware pullout
Date: July 22, 2013
Glue seam failure
4-34
IV. FURNITURE
Leather gouge
Leather rip
Seam rip
Collapsed seat pan
Boring beetle infestation
Date: July 22, 2013
Termite infestation
4-35
IV. FURNITURE
Table 4-2 Furniture Packaging and Labeling Defects Classification
Description
Critical
Label
Not readily visible
Not legible
Master Carton Marking (Non-compliance – missing or incorrect)
The country of origin
P.O. #
SKU description
SKU#
TTL/SP’s (total units of inner cartons in master carton)
TTL/PCS (total amount of units in the master carton)
Net weight
Gross weight
CTN NO (carton number)
Carton graphic smears, blur or unevenly printed
Non approved carton graphic on furniture items
Inner Carton Marking (if not floor ready)–(Non-compliance – missing or incorrect)
SKU#
SKU description
Number of pieces per inner carton
Packaging
Missing or incorrect incomplete components packed
x
Use of restricted material (saw dust, printed newsprint, popcorn, straw, etc)
x
Not in compliance with the specified Cost Plus packaging rules11 and published
specifications
Void areas not filled as required
Inadequate corner protection (foam collapsed, loose corners, etc)
Drop test failed
Multiple items not properly separated and secured (exception for flatware e.g. fork,
spoon, and knife.)
Excessive internal movement
Inadequate surface protection (incomplete coverage, use < 2 mm thick foam-sheet;
plastic bag < .0015 in. thick).
Inadequate edge protection (gap > 30 cm not supported)
Sharp items inadequately wrapped, suspended or isolated
Use of staples to seal carton
Tape applied directly to any class A or B surfaces
Water marking on carton or damp to touch
De-lamination of corrugated carton material affect the structure of carton
Not consistently packed between units or as tested and approved sample
Loose hardware not bagged/contained
Use of staples to seal plastic bag, hardware bag
Difficult to unpack/repack
Loading
Side void larger than 2 cm not properly blocked/braced
Unauthorized stacking with disregard to the UP Arrow orientation
Unstable load lacks proper constraint to prevent shifting
11
Major
Minor
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
For packaging details, refer to Vendor Guide section 2.
Date: July 22, 2013
4-36
IV. FURNITURE
•
Examples of Packaging Defects
Inadequate use of foam thickness and density
Foam bottoming out
Unsecured hardware bag inside carton
Improper wrapping coverage of components
Cosmetic finished exposed to corrugated
Tape adhere directly on product
Unsecured foam pads inside carton
Date: July 22, 2013
4-37
IV. FURNITURE
Inadequate components separation
Debris inside the wrapped product
Dirty or excessive dust on item
Packaging material impression – lacquer not dried
Date: July 22, 2013
4-38
APPENDIX A: VENDOR CONTACT LIST
APPENDIX A: VENDOR CONTACT LIST
Contact
Phone
Fax
Email
Corporate Office
200 Fourth Street
Oakland, CA 94607
510-893-7300
510-893-3681
[email protected]
Sample House
201 Second Street
Oakland, CA 94607
510-893-7300 x3470
510-893-6418
N/A
Stockton, CA
Distribution Center
(SDC #901)
1735 Zephyr Street
Stockton, CA 95206
209-982-1244
209-234-6515
N/A
Windsor, VA
Distribution Center
(VDC #909)
Shirley T. Holland Industrial Parkway
12300 Dominion Way
Windsor, VA 23487
757-242-9930
757-242-6992
N/A
Domestic Logistics Dept.
Inbound Manager
California Inbound Scheduler
Out-of-state Inbound Scheduler
Director of Transportation
209-982-1244
209-982-1244
209-982-1244
209-982-1244
Import Logistics Dept.
Manager, International Logistics
Manager, Customs
Manager, C-TPAT Compliance
510-893-7300 x3156
510-893-7300 x3273
510-893-7300 x3354
510-893-3776
510-893-3776
510-893-3776
[email protected]
[email protected]
[email protected]
510-893-7300 x 3065
510-763-5564
[email protected]
Invoices / Accounting
Manager, Accounts Payable
x7038
x7040
x7025
x7062
[email protected]
[email protected]
[email protected]
[email protected]
[email protected]
[email protected]
[email protected]
[email protected]
[email protected]
GT Nexus / EDI
Vendor Compliance
Quality Assurance
Protective Packaging
Product Labeling
Not sure who to contact? Email [email protected]
Date: July 22, 2013
A-1
APPENDIX B: CPWM TESTING PROTOCOLS
APPENDIX B: CPWM TESTING PROTOCOLS
NOTE: Vendors may obtain copies of all CPWM testing protocols at:
•
BV
https://docushare.cps.bureauveritas.com/docushare/dsweb/Login
Username: cvendor660
Password: co660vendo
•
SGS
https://share.sgs.com/sites/cn-cts-costplus
Username: b2b\quincy_albert
Password: aswish21
Date: July 22, 2013
B-1
APPENDIX C: LINKS FOR FEDERAL AND STATE REQUIREMENTS
•
Disclaimer: We require that all merchandise meet all Federal, State, and Local U.S. laws and regulations, as
well as our expectations for product quality and packaging. The below list of Federal and State regulations is a
general guide only and may not be complete. It is the vendor/agent’s ultimate responsibility to be aware of
all laws and regulations and to stay current with any updates and changes to all of the above.
FEDERAL REGULATIONS
Topic
Consumer Product Safety Act
Regulations
Country of Origin Labeling
Regulations
Fair Packaging and Labeling Act
Regulations
Federal Hazardous Substances Act
Regulations
Regulations
Regulations
Regulations
Regulations
Regulations
Food, Drug and Cosmetic Act
Food, Drug and Cosmetic Act
Regulations
Labeling of Hazardous Art Material
Act (LHAMA) Regulations
Poison Prevention Packaging Act
Regulations
Toxic Substances Control Act
Regulations
Date: July 22, 2013
Requirement Reference
16 CFR 1303
www.cpsc.gov/businfo/cpsa.html
www.access.gpo.gov/nara/cfr/waisidx_99
/16cfr1303_99.html
19 CFR 134.11
/19cfr134_04.html
16 CFR 500
www.ftc.gov/os/statutes/fpla/part500.htm
16 CFR 1500.3 and 1500.40-46
/16cfr1500_00.htm
16 CFR 1500.48-53
/16cfr1500_00.html
16 CFR 1501
/16cfr1501_02.html
16 CFR 1505
www.gpo.gov/nara/cfr/waisidx_04/16cfr
1505_04.html
16 CFR 1510
/16cfr1510_03.html
16 CFR 1511
/16cfr1511_03.html
Food and Drug Administration’s
Compliance Policy Guidelines (CPG)
21 CFR 170
/21cfrv3_00.html
16 CFR 1500.14
/16cfr1500_00.html
16 CFR 1700
/16cfr1700_03.html
40 CFR 700-799
C-1
Description
Regulates lead content in paint, surface coatings,
materials on furniture and toys and articles
intended for children.
Provides labeling requirements for articles of
foreign origin (or their containers).
Provides labeling requirements for consumer
commodities.
Addresses toxicity, irritants, sensitizer, corrosive
items, volatile flammable materials, flammability
of solids, and flammability of self-pressurized
containers.
Addresses sharp points, sharp edges, and use and
abuse testing for toys and other articles for
children.
Addresses small parts for toys or other articles
intended for children under three years of age
that present choking hazards.
Regulates electrically-operated toys or other
articles intended for use by children.
Establishes requirements for baby rattles
including structural integrity, size, and
protrusions.
Establishes requirements for pacifiers including
structural integrity, size and protrusions.
Establishes requirements for lead and cadmium
content of ceramic-ware and silver-plated food
contact articles.
Provides requirements for materials which are
used for food contact (e.g. plastic, paper and
coatings, etc).
Provides labeling and evaluation requirements
for materials embodied or used in the creation of
graphic or visual works.
Requires child-resistant packaging for a number
of household substances.
Establishes requirements for products which
contain releasable chemicals.
STATE REGULATIONS
Topic
California Proposition 65
http://www.oehha.ca.gov/prop65/back
ground/p65plain.html
California Tableware Safety Program
Mercury in Consumer Products
Texas Hazardous Substances Act
Requirement Reference
California Health and Safety Code,
Division 20 Miscellaneous Health and
Safety Provisions, Chapter 6.6,
“Safe Drinking Water and Toxic
Enforcement Act of 1986”,
Sec 25249.13
California Health and Safety Code,
Division 104 Environmental Health, Part
3 Product Safety, Chapter 9, “Control of
Lead Release from Tableware”, Sec
108850-108915
Individual state statutes in VT, ME, RI,
NH, and CT
Texas Health and Safety Code, Chapter
501
Toxic in Packaging
Model Toxic in Packaging Legislation
Suffocation Warning for Plastic Bags
www.plasticbag.com/industry/warning.ht
ml
www.bearhfti.ca.gov/
www.abflo.info
Law Label and Flammability Warning
Date: July 22, 2013
C-2
Description
Establishes rule requiring warning labels for
products containing lead, cadmium, or other
listed substances.
Legislates marking of tableware containing lead
or cadmium by manufactures or importers.
Requires ceramic-ware, enamel metalware and
pewter to comply with the FDA ceramic-ware
leachable lead and cadmium limits.
Requires notification and labeling of products
containing mercury.
Requires manufacturers, importers, and private
label distributors of hazardous consumer product
sold in Texas to register their companies with the
Texas Department of Health.
Regulates the heavy metals content (lead,
cadmium, mercury and hexavalent chromium) of
packaging materials, including cartons,
wrapping, and tape.
APPENDIX D: WARRANTY AND CARE TEMPLATE
Care Instructions
Type in the care instruction (if applicable)
Warranty
Type in the warranty (if applicable)
Refer to the Upholstered Furniture Limited Warranty template found on our Vendor Relations
website.
Date: July 22, 2013
D-1

Quality Assurance Manual

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