PRODUCT ZONES

ZONING DEFECTS AND APPEARANCE

PRODUCT ZONING
In product zoning, the company recognizes that some parts of a product are more crucial in terms of appearance than the other parts. Those parts or zones that are more visible are of greater importance than the other parts that are less visible. A definition of each zone or priority area should be included in specifications because terminology and designators for zones are not standard within industry. .

For example, one company might use numbers, such as 1, 2 & 3 or Roman numerals, such as I, II & III to describe the product zones and another company might use letters

such as A, B & C for their Zones.

Zone 1for one company might be the part with the greater demands for appearance, while another company might use Zone C to describe similar requirements

Typically, zones of highest priority are those areas most likely to be viewed during face- to-face conversation with someone or those areas most likely to be seen when using the product.
Thus, the areas of the garment closest to face are of greater importance for apparel. For upholstery furniture, these areas would include backs, armrests and cushions. Areas not as likely to be seen, but remain visible, are assigned to the next zone in terms of priority. Areas that are rarely seen by others, such as under the arms, the crotch, and inside for apparel and areas under the seat cushions and bottom of the upholstered furniture, are assigned lower zone priorities.

In addition to defining the zones, many companies also identify types of defects that would be unacceptable in each area.
For example in mens dress shirts, a company may state that no fabric, construction, or appearance defects are allowed in Zone 1 (the neckline, cuffs, and Centre front placket area). The company may further state that in Zone 1, an absence of thread ends, a button and buttonhole match within + 0.16 cm (+ 1/16 inch), and collar points within + 0.16 cm (+ 1/16 inch), of specified length are required. If a shirt does not meet all requirements for this zone, the shirt has to meet specifications and is not acceptable

EXPLANATION OF ZONES
When a construction flaw or defect occurs in a product, acceptance or rejection of the defective product is prioritized by the area, or zone, in which it occurs. Product zones that are more visible to the customers are more crucial in maintaining higher levels of quality.

Each product has specific zones that are more important than others, and guidelines are defined accordingly.

ZONE 1
Areas with extremely high visibility that is likely to be viewed from a close distance at the time of purchase or receipt. Cosmetic flaws located in these zones would be considered major and would be cause for the rejection of the product.

ZONE 2
Areas that are not visibly dominant, but are visible in normal use. Cosmetic flaws would be evaluated based upon the size of the defect, color, and intended end use of the product to determine acceptability.

ZONE 3
Areas normally hidden in everyday use, but could be visible on occasion. Cosmetic flaws in this zone are more acceptable than in any other location on the garment. Flaws occurring in this zone would be evaluated product by product based upon the intended use of the garment.

PACKAGING

PACKAGING
Packaging is the manner in which a product is prepared for transportation, shipped, and presented to the customer or the ultimate consumer. Packaging standards describe general aspects of how the product is packaged, whereas the packaging specs describes the materials that should be used and the manner in which the garment should be folded, blocked, supported, or manipulated when packaged.

In addition, packaging indicates how many products will be shipped together in the same box or container and the kind of labeling or product information that is to be attached to the outside of the individual product packages and on boxes, cartons, or other containers Companies that ship from a distribution center have very specific requirements for packaging because of their automation systems and the number of items that are processed on a daily basis. Bar-coding is essential in such circumstances. Suppliers who do not meet packaging specs may find orders refused, even though each individual product meets or exceeds the minimum product specs.

APPAREL PACKING MERCHANDISE

Each Master Shipping Carton must contain only one SKU (Stock Keeping Unit). The buyer will not accept any Master Shipping Carton that contains multiple SKUs. Merchandise must be bulk placed without multiple units boxing or bagging inside of the master shipping carton.

The merchandise inside the Master Shipping Carton must not be tied together in bundles with string, bands, ribbons, etc.
Do not ship merchandise on hangers or in hanger packs. The minimum case quantity is 4 selling units per master shipping carton

The buyer encourages its vendors to send full cartons. If you are unable to fill a standard master shipping carton with one SKU, you may choose one of the two options. (1). Reduced Carton Size (Preferred) (2). Quantity Adjustment

(1). REDUCED CARTON SIZE (PREFERRED)

If a shipment is small and a full case of one size and style is not possible, you can reduce the standard carton by no more than 6 inches, thus making the carton dimension 22 in. X 10 in. X 6 in. (minimum carton dimension).

(2). QUANTITY ADJUSTMENT

Discuss order quantity adjustments with inventory control. For example, if you have a request for 20 units and the carton will hold 26 units, you may request increasing the quantity by 6 more units to make a full carton. Another example would be a request for 35 units, and the carton holds only 26. You may request a decrease in the quantity by 9, and include them in a subsequent order.

DIAGRAM FOR PACKAGING A SHIRT

Lay item front down, flat and smooth with the sleeves extended.

Sleeves must be folded flat and smooth with cuffs placed even with the shoulders at top of the package

Shirt must be folded neatly, bulkiness smoothed out by hand.

Clips can be used to secure shirt in position, however pins of any sort are unacceptable

The tail of the shirt must be tightened around the folding template, extend slightly beyond the top of the shoulders and taper in on each side. The shirt tail is then tucked in between the sleeve fold and the sleeve cuffs

Place folded item in an appropriately sized polybag. Seal and label with stock number and country of origin