walmart usa apparel testing manual

80 Pages·2010·1.28 MB·English

WALMART USA
APPAREL TESTING
MANUAL
Revised: July 2010
Issued: May 6th 2008
Table of Contents
1. Introduction.......................................................................................................6

1.1. Color Process Flow Chart ...........................................................................7

1.2. Pre-Production and Production Testing Flow Chart..................................8

1.3. In-Store Quality Audit Flow Chart................................................................9

2. Regulatory Compliance
............................................................................10

3. Testing Process for Apparel
..................................................................11

3.1. National Brands Testing Process...............................................................11

3.2. Private Brands Testing Process.................................................................11

3.3. In-Store Quality Audit Process...................................................................12

3.4. Walmart Exception Orders..........................................................................14

3.5. Test Report Ratings.....................................................................................15

3.6. Defect Classification....................................................................................15

3.7. Quality College.............................................................................................15

3.8. Testing Turn-Around Time..........................................................................16

3.9. What to Submit ............................................................................................16

3.10. When to Submit Pre-Production and Production Samples......................17

3.11. Where to Submit Pre-Production and Production Samples.....................18

3.12. Flammability Test Process for Children’s Sleepwear...............................18

4. Children’s Apparel
.......................................................................................20

4.1. Private Brand Garments..............................................................................20

4.2. Children’s Apparel Mechanical Hazards....................................................20
• Small Parts
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Manual Name: WM USA Apparel
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• Small Parts Labeling
• Sharp Points
• Sharp Edges
• Abuse Testing
• Torque Testing
• Tension Testing

4.3. Apparel Trim/Hardware...............................................................................22

4.3.1 Press Fasteners .......................................................................................22
• Approved Press Fastener Suppliers

4.3.2 Zippers......................................................................................................23
• Invisible Concealed Zippers
• Zipper Pulls
• Zipper Pull Attachments
• Approved Zipper Suppliers

4.3.3 Dungaree Clips (Hasps) and Sliders......................................................26
• Approved Dungaree Clips (Hasps) and Slider Suppliers

4.3.4 D-Rings....................................................................................................27

4.4. Drawstrings, Cords & Ties (Functional and Decorative)..............................27
• Metal Chain Cords/Ties
• Maximum Length Requirements
• Neck Area and Hood
• Below the Ankle and Below the Elbow
• Chest, Leg, Waist, Hip, and Above the Elbow Areas
• Internal Functional Drawstring/Cord

4.5. Adjustable Waistbands...............................................................................31

4.6. Sashes & Thin Ties Tied at Waist Area (Dresses and Tops)....................32

4.7. Belts .............................................................................................................33

4.8. Bath Robes...................................................................................................35

4.9. Fixed Bows...................................................................................................35

4.10. Functional & Decorative Loops..................................................................35
• Belt Loops
• Back Neck (locker) Loops
• Hanger Loops
• Hammer Loops
• Under-Chin Ties on Hats
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Manual Name: WM USA Apparel
Revised: July 2010
• Under-Chin Straps on Hats

4.11. Hats/Caps.....................................................................................................36

4.12. Halter Neck Style Garments and Baby Bibs..............................................38

4.13. Neck Ties......................................................................................................38

4.14. Toggles & Toggle Buttons..........................................................................39
• Toggles
• Toggle Buttons
• Pig Nose Toggles (Cord Lock) / Spring Loaded Toggles
• Decorative Application
• Functional Application

4.15. Button and Buttonsew.................................................................................40
• Buttons
• Buttonsew

4.16. Hook & Loop Fastener Tape.......................................................................41

4.17. Thread Ends & Float Threads.....................................................................41

4.18. Decorative Trims & Embellishments..........................................................41
• Appliqués & Embroidery
• Beads & Jewels
• Sequins
• Diamante (Rhinestones) & Metal Studs
• Pom-Poms & Fringe
• Fake (Faux) Fur
• Natural Feathers

4.19. Miscellaneous Requirements .....................................................................42

4.20. General Wearing Apparel Flammability Requirements............................43

4.21. Children’s Sleepwear/Loungewear Flammability Requirements.............43

4.22. Polyvinyl Chloride in Children’s Bibs........................................................44

5. Performance Specifications
...................................................................45

5.1. General Requirements.................................................................................45

5.2. Colorfastness Properties............................................................................46

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Manual Name: WM USA Apparel
Revised: July 2010
5.3. Woven Fabrics.............................................................................................47
• Woven Natural Cellulosic
• Woven Man-made Cellulosic Origin
• Woven Man-made Synthetic
• Woven Silk, Wool, Animal Hair
• Denim
• Woven Pile Fabrics

5.4. Knit Fabrics..................................................................................................52
• Weft Knits
• Warp Knits
• Knit Undergarments
• Hosiery - Socks and Tights
• Sweaters

5.5. Leather/Suede Apparel................................................................................56

5.6. Accessories..................................................................................................56
• Belts, Caps, Ear Muffs, Gloves, Hair Accessories, Hats, Mittens,
Neckties, Scarves, Ski Headbands, Ski Masks, Stocking Caps,
Suspenders and Pet Accessories

5.7. Products with Special Claims.....................................................................58

5.8. Zipper Performance Standards ..................................................................59

Appendix A
...........................................................................................................60
Defect Type Classifications

Appendix B
...........................................................................................................70
Express Test Exceptions

Appendix C
...........................................................................................................71
Corrective Action Plan (CAP) Process

Appendix D
...........................................................................................................72
Children’s Body Weight Tables

Appendix E
...........................................................................................................73
Standard Fabric Testing Process for Walmart Private Brands

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Manual Name: WM USA Apparel
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Appendix F
...........................................................................................................74
Approved Trim Suppliers

Appendix G
............................................................................................................75
Walmart Designated Independent Testing Facility
Testing Laboratory Locations Information
Communication to Suppliers
Invoicing and Payment Terms
Summary of Testing Charges

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Manual Name: WM USA Apparel
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WALMART Stores, Inc.

1. Introduction and Process Flow Charts

It is our goal to deliver quality products to the Customer in a faster and more cost effective way.
This manual allows us to accomplish this.

In addition to the above objectives this manual outlines the procedures, performance
specifications and regulatory requirements for Walmart Apparel.

Walmart relies on all suppliers to be knowledgeable about the current industry and regulatory
requirements of the products they are supplying. Adherence to these standards is not optional.

It is the suppliers’ responsibility to fully understand and accurately interpret the information in this
manual. If you are in doubt as to the applicability of any law, standard, or regulation that applies
to products that you intend to supply to Walmart, please seek advice from your legal counsel or
Technical Representative.

DO NOT RELY EXCLUSIVELY ON THIS MANUAL AS YOUR ONLY SOURCE FOR
DETERMINING REGULATORY OR INDUSTRY STANDARDS.

Walmart is committed to product safety. Our customers trust us and expect us to provide them
with safe products. Therefore, we expect all suppliers to have the same commitment to this
important aspect of quality.

Changes to the Manual

Supplier Sample Submissions - All suppliers, both Domestic and Direct Import have a choice
to submit Color swatches (Lab Dips, Shade Bands, etc.) and Apparel items to either the
Bentonville or Hong Kong laboratories. However, once a location is chosen, all subsequent
testing for that item and coordinating items, including Color Evaluation, Pre-Production,
Production and Retest must occur in the same facility.

Corrective Action Process (CAP’s) – CAP’s are required for Critical Regulatory Failures.
CAP’s are no longer required for Critical Walmart Failures.

Consumer Testing Laboratories, Inc. (CTL) is the designated independent accredited testing
facility for all Color Evaluation and Apparel items for the USA Retail Division of Walmart Stores,
Inc.

Manual Name: WM USA Apparel 6
Revised: July 2010
1.1 CTL Color Approval Process, Apparel Continue,
Restart SB
Yes
Process
Submit
Requested
1. Electronic Submits are sent to the testing laboratory [email protected]
SB to Test Pass?
or through your DataColor Track Software
Lab
2. Electronic Color Questions or standards
are sent to the testing laboratory [email protected] Yes No
Save LDE as Submit SBE to Restart SBE
Pass?
SBE Standard Test Lab Process
Yes No
After 2 failures, request review
Submit LD to Restart SBE
Pass? through the Test Lab
Test Lab Process
[email protected]
Yes
No
Restart LDE
Submit LDE Pass? Process
to Test Lab

Yes No
After 3 failures, request review
Restart LDE
through the Test Lab
Process
[email protected]
Submit
Substrate to Is Yes Continue,
Electronic
Test Lab Color Restart SB
Required? Process
Submit SB to
Yes
Test Lab Pass?
No Submit LD to
Test Lab Pass?
No
After 2 failures, request review
Restart SB
through the Test Lab
Process
[email protected]
No
Restart LD After 3 failures, request review
Process through the Test Lab
[email protected]
Manual Name: WM USA Apparel
Revised: July 2010 7
1.2 Pre-Production and Production Testing Process, Apparel
Pass/ Marginal Pass
Sample + 2 yds of fabric
Send a memo sent to Test Lab for Garment is Approved to cut
Yes defining the testing testing from Supplier Tested Rating? Garments
needs
Monitor the PO via Is Supplier Improves Supplier sends all
the Host System Testing the Garment and Fail sizes/colors @ 10%
Needed? retests complete point Verify Gold Seal
Approval is done
No Test Lab notes Pre-Production Garment is
compliance in the
Tested
System
Production Pass/ Marginal Pass
SHIP
Rating?
Major & Fail
Critical Regulatory
SHIP Critical Walmart
Pass /Marginal Pass
CAP is written and
Supplier resubmits
submitted to Test Lab.
sample
Rating? for testing Test Lab evaluates CAP
Fail
Is CAP
Supplier and NY approved
Apparel Office for by Test Yes Supplier Good/Marginal Pass
Private Label and Lab resubmits Rating? SHIP
Supplier and sample for
Buyer/DMM for testing
National Brands No Fail
Critical Regulatory
Failures
No WM Compliance
Approved
Order Dept. (only one
for
Cancelled retest may be
shipment?
approved)
Yes No Approved Yes
Order for SHIP
Cancelled shipment?
SHIP
Manual Name: WM USA Apparel
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Revised: July 2010
1.3 In-Store Quality Audit Process, Apparel
Test Lab identifies what
Test Lab researches each in-
styles are needed from the Major Failures Report sent to Supplier and NY
store item via Retail Link to Apparel Office for Private Label
store by using the Walmart
ensure availability of store or Buyer/DMM for National
PO inventory Brands
Recall Product
Test Lab personnel pulls Testing process Critical Regulatory Report sent to Supplier Walmart
identified items from stores (reference production testing process) and Walmart Compliance Compliance
reports Recall to
(Full size/Full color range)
Critical Failures CPSC
Critical Regulatory
Failure generates
Fail immediate High Report sent to Supplier and NY Apparel
Sampling Retest Fail Office for Private Label or to Buyer/DMM
Critical Walmart for National Brands who will notify
Compliance Department for Product
Critical Walmart or withdrawal
Rating?
Major Failures -High
Sampling Retest Rating?
determined by NY
Apparel Office for
Private Brands or High
Pass/Marginal Pass Buyer/DMM for Sampling Retest Pass / Marginal Pass
National Brands required
High Sampling Retest
In-Store Quality Audit complete NOT required
and report sent to supplier
In-Store Quality Audit
Basic replenishment - pulled seasonally and/or quarterly
Fashion - pulled seasonally and/or quarterly
Previous failed samples - pulled as soon as available in the store
Non-compliant suppliers - pulled as soon as available in the store
Special Pulls - as requested by Walmart Management
Manual Name: WM USA Apparel
Revised: July 2010 9