Costco Non-Foods QA Manual Provides Apparel Testing Guidelines

Costco Wholesale Non-Foods QA Manual for Apparel - 1 - Revised 6/09/03
Costco Wholesale
Non-Foods Quality Assurance
Apparel Manual
Revision 4
2/5/07

Not e t o t he vendor
Lab Information
Costco Wholesale uses more than one 3
rd
party testing lab for consumer products testing and
inspections.
Clarification on which lab to use is listed in each test request. You may also contact QA for
clarification.

Costco E-mail Address
Costco QA has set up a general e-mail address, nonfoodsqa@costco.com. This email address is used by the
lab to e-mail all reports to Costco. The vendors can use it to contact QA if the project person is unknown.

Contact Information
To obtain protocols please contact the QA project person or the appropriate testing lab listed on your test
request. To obtain the vendor billing, production schedule and spec forms please contact the buying staff.
For any questions feel free to contact Costco QA for direction.
Please contact the following individuals with any questions.

Jennifer Thompson Becky Berg Aaron Rusnak
Non-Foods QA Manager Non-Foods QA Assistant Manager Non Foods QA
Phone: 425-313-6580 Phone: 425-313-2977 Phone: 425-427-7669
Fax: 425-313-2083 Fax: 425-313-2056 Fax: 425-313-2056
Email: jthompson@costco.com Email: bberg@costco.com Email: arusnak@costco.com
COSTCO WHOLESALE....................................1
NOTE TO THE VENDOR....................................................................2
GENERAL MANUAL.....................................................................................6
PART 1 OVERVIEW.................................................................................................................6
1.1 RESPONSIBLITIES...........................................................................................................................6
1.2 BUYING & NON-FOODS QA DIVISION OF LABOR.................................................................8
1.3 WHAT ITEMS GO THROUGH THE QA PROCESS? .................................................................8
PART 2 THE QA PROCESS: A SUMMARY..............................................................................9
2.1 THE PROCESS: START TO FINISH.............................................................................................9
2.2 QA PROCESS FLOW CHART.......................................................................................................10
PART 3 THE QA PROCESS: A DETAILED EXPLANATION..............................................11
3.1 TEST REQUESTS............................................................................................................................11
3.2 FACTORY EVALUATIONS...........................................................................................................12
3.3 PRODUCT TEST FOR QUALITY AND LABEL ........................................................................13
3.4 SUBMITTING SAMPLES TO THE TESTING LAB...................................................................16
3.5 WAREHOUSE PULL TESTING PROGRAM..............................................................................20
3.6 PRODUCT INSPECTION AT THE FACTORY..........................................................................21
3.7 RANDOM INSPECTION PULL TESTING..................................................................................24
3.8 RECEIVING REPORTS..................................................................................................................24
3.9 RETESTING AND REINSPECTIONS..........................................................................................27
3.10 COMPLETION AND AUTHORIZATION .................................................................................28
PART 4 READING REPORTS..............................................................................................29
4.1 REPORTS FORMATS FOR FACTORY EVALUATIONS ........................................................29
4.2 REPORT FORMATS FOR QUALITY AND LABEL..................................................................29
4.3 REPORT FORMATS FOR 9462 EC..............................................................................................30
4.4 REPORT FORMATS FOR PRODUCT INSPECTION...............................................................30
PART 5 COST AND BILLING..............................................................................................30
5.1 VENDOR RESPONSIBILITY ........................................................................................................30
5.2 TESTING COSTS.............................................................................................................................31
5.3 FREIGHT CHARGES FOR SAMPLE SHIPMENT....................................................................31
5.4 FACTORY EVALUATION & INSPECTION COSTS ................................................................31
5.5 INVOICING PROCEDURES - VENDOR BILLING...................................................................31
5.6 PRE-PAYMENT FOR NEW VENDORS.......................................................................................32
5.7 OVERDUE/ON-HOLD ACCOUNTS.............................................................................................32
PART 6 COSTCO WHOLESALE VENDOR (CV) PROGRAMS ...................................32
6.1 CV DEVELOPMENT TESTING PROGRAM..............................................................................32
6.2 RECEIVING RESULTS ..................................................................................................................33
PART 7 ADDITIONAL REQUIREMENTS FOR CHILDRENS SLEEPWEAR- (USA
ORDERS ONLY) .......................................................................................................................................33
7.1 EXPLANATION..................................................................................................................................33
7.2 COSTCO WHOLESALE REQUIREMENTS FOR NON-TIGHT FITTING SLEEPWEAR....34
7.3 REQUIREMENTS FOR TIGHT FITTING SLEEPWEAR...........................................................34
7.4 REQUIREMENTS FOR NON-TIGHT FITTING SLEEPWEAR.................................................34
7.5 STAGES OF TESTING.......................................................................................................................35
CASHMERE MANUAL...........................................................................37
PART 8 OVERVIEW..............................................................................................................37
8.1 CASHMERE BUYING GUIDELINES ..........................................................................................37
8.2 LAB QUALIFICATIONS FOR CASHMERE TESTING............................................................37
8.3 RESPONSIBILITIES.......................................................................................................................38
PART 9 THE CASHMERE QA PROCESS: A SUMMARY..............................................38
9.1 HOW TO SUBMIT CASHMERE SAMPLES FOR PRODUCTION TESTING..................................................40
PART 10 COSTCO VENDOR (CV) CASHMERE DEVELOPMENT PROGRAM....41
10.1 EXPLANATION.............................................................................................................................41
10.2 CV FORM........................................................................................................................................41
10.3 SAMPLE SUBMISSION PROCEDURES ...................................................................................42
10.4 RECEIVING RESULTS UNDER THE CASHMERE CV PROGRAM...................................43
10.5 CASHMERE TESTING TRACKING SPREADSHEET ...........................................................44
10.6 CASHMERE LAB CONTACT INFORMATION.......................................................................44

GENERAL MANUAL
Nothing in this manual shall be interpreted to relieve vendors from ascertaining and complying with any
and all applicable laws and regulations in their most current form. To the extent that this manual
prescribes steps that are not in compliance with applicable law and regulations, the latter shall govern. In
addition, the fact that a vendor may carry out procedures prescribed in this manual shall not limit Costco
Wholesale in the exercise of its rights to reject or revoke acceptance of merchandise should it determine
that the merchandise is not in conformance with applicable laws, regulations, agreements and/or purchase
orders.
Navigation Hint
To keep track of your place in the manual at all times, and to easily locate all chapter subheadings from
any location, create a Table of Contents sidebar on the left hand side.
Part 1 OVERVIEW
Definitions
Testing Lab: refers to the many different test and inspections offices that provide factory evaluation,
testing and inspection services for the Costco Wholesale Non-Foods Quality Assurance Program.

QA: refers specifically to the Costco Wholesale Non-Foods Quality Assurance Department. QA
coordinates tests, inspections and factory evaluations for non-foods products for Costco Wholesale
buyers worldwide.

QA Process: refers to the QA Factory Evaluation, Test & Inspection Program that is coordinated through
the Non-Foods QA Department.

Test Request: refers specifically to the Testing Lab Apparel Test & Inspection Request Form.

RCDS: refers to the Report Coversheet & Defect Summary Rejection and the Report Coversheet &
Defect Summary Approval forms.

CV Test & Inspection Program: refers to a vendor-run program developed by QA for Costco Wholesale
vendors who want to complete development testing prior to production of an item.

The Costco Wholesale Non-Foods Quality Assurance Manual for Apparel details the procedures and
requirements of the QA Factory Evaluation, Test & Inspection Program for apparel. For questions about
the Costco Wholesale buying process, please contact the respective buying department.
The QA Program supports the commitment of Costco Wholesale to offer quality products to its members.
Costco Wholesale has established a comprehensive factory evaluation, testing and inspection program to
monitor and ensure compliance with all applicable government, industry and Costco Wholesale standards
for safety, quality and performance.
1.1 RESPONSIBLITIES
QA Responsibilities
Create and distribute the Costco Wholesale Non-Foods QA Manual for Apparel to all vendors,
buyers and testing lab.
Advise vendors and testing lab of any changes in procedures or requirements.
At the buyers request, distribute Testing Lab Apparel Test & Inspection Request Form (hereafter
called the Test Request Form) to the vendor and testing lab noting the factory evaluation, and
testing & inspection requirements for each item.
Analyze, interpret and summarize reports for buyers and vendors.
Forward the buyers decision on each report to the vendor and the testing lab, and follow up to
ensure that all necessary corrections are made.
Track each item through the QA process to help ensure on-time shipments.
Issue a QA Letter at the completion of the QA Process to indicate to the buyer and vendor that all
QA requirements have been met. If all required factory evaluations, testing and inspections are not
completed and/or are not approved by the buyer, the QA Letter will not be issued.
Respond promptly to all emails and calls from vendors, buyers and the testing lab.
Assist the testing lab in collecting outstanding payments from vendors.
Vendor Responsibilities
Know, understand and comply with all laws in both the country of origin and the destination
country as they relate to the factory and the product.
Read and abide by all of QAs procedural, performance and quality requirements as laid out in this
manual.
Complete and return each Testing Lab Test & Inspection Request Form Confirmation to QA
within 48 hours.
Test all trim, piece goods, pre-production garments and labeling as needed to ensure that there are
no failures during the production testing and inspection process.
Contact the designated inspector coordinator to arrange factory evaluations and product
inspections 7 days in advance of the specified date on the Test Request to ensure the inspection
can be booked for the day requested.
Submit the correct number of samples, with the proper labeling and the Test Request to the
designated testing lab by the specified date.
Respond promptly to all emails and calls from QA and the buyer regarding needed corrective
action for product.
If re-evaluations, re-tests or re-inspections are needed, the vendor must request and follow through
with these in a timely manner per QAs instructions.
Vendors are responsible for all costs (see Part 5) associated with the QA Process, including
factory evaluation, test and inspection fees and any freight charges incurred in mailing samples to
the testing lab and from the testing lab to QA and/or the inspectors.
Vendors must pay all testing and inspection bills within 30 days of the invoice date.
Vendor shall not ship any product until all evaluations, tests and inspections are completed and
approved and/or the buyer approves shipment.
Testing Lab Responsibilities
Immediately notify QA and/or the vendor with any questions about the Test Request.
Immediately notify QA and vendor if testing is put on-hold for any reason.
Issue clear, accurate reports using the required QA report format including the protocol, charts and
digital photos to explain all defects found.
Send all reports as a single PDF document via email to nonfoodsqa@costco.com and to the vendor
contact(s) noted on the Vendor Billing & Correspondence Information Form.
Meet all quoted turn-around times for factory evaluation, testing and inspection report issuance
(see Section 3.8).
Issue detailed, accurate invoices in the correct format to vendors and/or QA within 30 days of
report issuance. Invoices will by issued by the testing lab no later than 60 days after the report
issuance date.
Communicate any problems to vendors and QA immediately.
Private Label Apparel/Manufacturing Department Responsibilities
Note: Private Label Apparel/Manufacturing is responsible for the following steps when the item is
sourced or coordinated through their department.
Advise vendors in advance that they will be required to go through the QA Process.
Send the Vendor Billing & Correspondence Information Form, Production Schedule Request
Form, and Size Specifications Sheets, Product Specification Sheet to the vendor for completion
Verify the information provided by the vendors after the forms are returned.
Forward the forms with a completed Test and Inspection Request Form -Buyer Use a minimum of
4 weeks prior to the start of production.
To minimize costs to the vendor, complete a single Test and Inspection Request Form-Buyer Use
for all Costco Wholesale buyers in all countries buying the same item (this will allow QA to
coordinate the QA Process to minimize fees and minimize duplicate testing).
Approve or reject reference samples within 24 hours of receipt.
Respond to rejected QA reports within 24 hours of receipt
If Private Label Apparel/Manufacturing disagrees with the QA Rating, both the buyer and the
buyers GMM signatures are necessary for a report override.
Keep QA informed of instructions given to the vendor on how/when to correct product failures.
Buyer Responsibilities
Note: Following are the buyers responsibilities for all products NOT sourced by the Private Label
Apparel/Manufacturing Department.
Advise vendors in advance if they will be required to go through the QA Process.
Send the Vendor Billing & Correspondence Information Form, Production Schedule Request
Form and Size Specifications Sheets, Product Specification Sheet, to the vendor for completion.
Verify the information provided by the vendors when the forms are returned.
Forward the forms with a completed Test and Inspection Request Form -Buyer Use to QA a
minimum of 4 weeks prior to the start of production.
Approve or reject reference samples within 24 hours of receipt.
Respond to rejected QA reports within 24 hours of receipt
If the buyer disagrees with the QA Rating, both the buyer and the buyers GMM signatures are
necessary for a report override.
Keep QA informed of instructions given to the vendor on how/when to correct product failures.
1.2 BUYING & NON-FOODS QA DIVISION OF LABOR
Non-Foods Quality Assurance is a service department within non-foods merchandising. It is our
responsibility to facilitate a quality assurance process that ensures compliance with the quality, safety and
specifications of the products sourced by Costco Wholesale buyers worldwide.
While QA reviews and rates reports based on Costco Wholesales requirements, the QA Report Rating is
only a recommendation to the buyer. The buyer and their GMM ultimately decide whether a report and/or
product will be accepted.
Buyers are also responsible for deciding what items will and will not go through the QA process.
1.3 WHAT ITEMS GO THROUGH THE QA PROCESS?
When a buyer books an item, they must decide if the QA Process coordinated by QA will be required.
Unless otherwise advised by the buyer, all items will go through the QA Process.
If the buyer exempts an item from the QA Process, the vendor may still be encouraged to do their own
factory evaluations, testing and inspections to ensure that their product and factory are in compliance with
all regulatory, voluntary and Costco Wholesale standards.
Part 2 THE QA PROCESS: A SUMMARY
2.1 THE PROCESS: START TO FINISH
The QA Process should proceed in the following chronological order:
1. Costco Vendor (CV) Development Testing Program (optional)
2. Factory Evaluation
3. Product Test for Quality & Labeling
4. 94/62/EC testing for packaging (UK shipments only)
5. Product inspection(s) in the factory(s)
6. QA process is complete and QA Letter is issued by QA
7. Shipment is authorized by the buyer

Note: The vendor should complete each stage and wait for approval from QA before proceeding to the
next stage. However, it is understood that this is not always possible. If the vendor does proceed with
production, the vendor should advise QA.
The QA Factory Evaluation Test & Inspection Program is commonly referred to throughout this
document as the QA Process.
2.2 QA PROCESS FLOW CHART
2. QA issues Test Request Packet to Vendor and BVCPS.
3. Vendor books Factory Evaluation with BV CPS
Inspector.
4. Factory starts production and submits 3 sets of
samples to Testing Lab for processing.
4a. Lab sends
1 set to
Inspector.
4b. Lab sends
1 set to QA or
Buyer.
4c. lab keeps 1
set for testing.
5a. Vendor
books
Inspection
5b. Buyer
reviews against
Buy Sample
5c. Quality &
Label Review
issued by
BV CPS.
8. QA Letter issued and Buyer authorizes shipment.
6b. Approved, continue with production.
6a1. Rejected: Vendor follows
QA instructions on RCDS prior
to the re-Inspection, if no re-
inspection is required return
to 5a (re-inspection).
6a2. Rejected: Testing,
Inspections and Production are
stopped, return to step 4 (QA to
advise details).
6a3. Rejected: Vendor follows
QA instructions on RCDS and
submits retest samples to testing
lab. QA to advise details.
3a. Factory Evaluation
Rejected, for re-evaluation
return to step 3.
3b. Factory Evaluation
Approved.
7. All required QA test and inspections are completed and approved.
1. Buyer sends Product Specification Sheet, Size Specification Sheet, Vendors Billing & Correspondence
Information Form, and Production Schedule Request Formto vendor.

Vendor completes and returns forms to Buyer.

Buyer Reviews and Approves forms.

Buyer sends completed and approved forms with BV CPSTest & Inspection Request Form Buyer Use to QA.

Part 3 THE QA PROCESS: A DETAILED EXPLANATION
3.1 TEST REQUESTS
What is a Test Request?
The term Test Request is commonly used to describe the Testing Lab Apparel Test and Inspection
Request Form. This is a 2-page document issued by QA that explains which tests and inspections are
required for each product.

The Role of the Buyer
To initiate the QA Process, the buyer forwards the following forms to the vendor for completion.
These forms can be found in the Forms section of this manual.
These forms include:
o Production Schedule Request Form
o Product Specification Sheet
o Size Specifications Sheets
o Vendor Billing & Correspondence Information Form
The vendor completes the forms and returns them to the buyer. Once the buyer has received and
approved all forms, they are submitted with a (internal use) Test and Inspection Request Form -
Buyer Use to QA.

The Role of QA
QA completes the Test Request (based on the above documentation from the buyer).
The Test Request and other related QA documents are emailed to both the vendor and the testing
lab.

The Role of the Vendor
The vendor and the testing lab receive the Test Request via email (PDF document).
The vendor signs and returns the Lab Test & Inspection Request Form Confirmation to QA within
24 hours.
The vendor should follow the instructions on the Test Request to arrange factory evaluations and
product inspections, and attach the form when samples are submitted to the testing lab for testing.
Page 1 is detailed information related to
product and the factory (Item #, Dept #, Item
Description, Colors and or patterns, Factory
Name, Production Run, etc.)
Explanation of what is required for item,
Factory Evaluation, Testing and / or
Inspections
Revision of a Test Request: If a Test Request
has to be revised, QA will check this box and
write the reason for revision-QA will then re-
email the forms to the vendor & the testing
Page 2 is the Vendor Instructions for Lab
Testing (Factory Evaluations & Inspections).
3.2 FACTORY EVALUATIONS
What is a Factory Evaluation
A factory evaluation occurs when representatives of the testing lab Inspection division travel to the
factory to review its ability to make product for Costco Wholesale. The factory evaluation protocol can
be obtained by contacting your QA project coordinator. This form lists all questions that will be asked in
the factory evaluation.
Factory Evaluation Ratings
The Factory Evaluation requirements were updated (J une, 2003). As a result the rating structure has also
been updated.
Testing Labs Factory Evaluation Rating System:
GOOD 90% rating with no critical defects
CORRECTIVE ACTION REQUIRED (CAR) 89.9%-75% rating with no critical defects
UNSATISFACTORY 74.9% or less rating and/or any critical defects

Costco Wholesales Factory Evaluation Rating System
Approved QA rating Exemption: Factory is approved for 1 year
90% rating with no critical defects plus all 3 metal detection
Disapproved QA rating Exemption: Factory is approved for that item only
89.9%-75% rating with no critical failures or 2 of 3 methods for controlling metal in products
Rejected QA rating Exemption: Factory must be re-evaluated
74.9% or less with no critical failures or factory with 1 of 3 methods for controlling metal in product
Unsafe/ Misleading QA rating Exemption: Factory must be re-evaluated
Any percentage rating noting no metal detection equipment or policies
Note: Factories making childrens garments are required to have a metal detector. Based on the
production method for adult garments, if the factory does not have a metal detector but they do use needle
guards, have a needle replacement policy or some other means of ensuring no metal is left in the
garments, Costco may approve the factory despite not having a metal detector.
What is a Code of Conduct Audit (Social Compliance)?
The Code of Conduct Audit is different from a factory evaluation. A Code of Conduct Factory Audit,
sometimes referred to as a Social Compliance Audit, verifies whether the factory is in compliance with
the national and local labor, environmental and health & safety laws of the manufacturing country.
Please note that the Code of Conduct Audit is NOT coordinated by QA. For questions regarding this type
of audit, please contact:
Betty Pien
Code of Conduct Compliance
Costco Wholesale Import Department
999 Lake Drive
Issaquah, WA 98027
USA
Email: bpien@costco.com
It is possible for a factory to pass a CSCC audit and fail a factory evaluation or vice versa. This occurs
because the content and purpose of these two audits are different.
When to Arrange a Factory Evaluation
As a general rule, the factory evaluation should always be done as soon as possible after the test request
packet is received from QA.
The factory does not need to be in production at the time of the factory evaluation. The factory evaluation
can be conducted either before production starts or during production. The factory evaluation cannot be
conducted after production is completed.
The test request gives the target date by which the factory evaluation should be completed.
The factory should contact the testing lab to schedule an appointment for the factory evaluation at least 7
days in advance to help ensure the factory receives the date they request.

How to Arrange a Factory Evaluation
When QA issues the Test Request packet, the testing lab logs in the factory evaluation request.
The testing lab then emails the Booking Form to the vendor contact listed on the Vendor Billing &
Correspondence Information Form in the Who Receives Requests section.
The Booking Form must be 100% complete and returned to the testing lab inspection coordinator.
Booking Form: The testing lab inspection coordinator will send the Booking Form to the vendor for
completing. The vendor must complete and return it to the testing lab before they will be given an
inspection or factory evaluation appointment.
Once the testing lab receives back the completed Booking Form, they will call or email the vendor to
book an inspection/evaluation date. The vendor should contact QA if a response is not received from
the testing lab within 48 hours.
If the testing lab receives the Booking Form from the vendor and it is not complete, they will return it
to the vendor for completion.
Once the testing lab receives the completed form, they will book the factory evaluation with the
vendor.

Costco Wholesale does not accept non-communication as a valid reason for a factory
evaluation, testing or inspection delays.
3.3 PRODUCT TEST FOR QUALITY AND LABEL
What is a Product Test for Quality & Label?
A product test for quality and label is a comprehensive test for both the product and labeling for safety,
quality and durability against regulations, voluntary standards and Costco Wholesale requirements.
Testing lab and QA have created a series of testing protocols. A complete set of protocols exists for every
Costco Wholesale region (USA, Canada, Mexico, UK, J apan, Taiwan, Korea). Each protocol is a
The vendor or factory should contact the testing lab 7
days before the target date to schedule their evaluations
The testing lab contact list will be attached to the test
request. On this contact list the factory can find the
testing lab contact information to schedule their factory
evaluation and / or inspection.
If a factory evaluation is required, the test request form
will be checked yes here.
comprehensive checklist of all Costco Wholesale required tests including, but not limited to: fiber
content, care labeling verification, flammability testing, lead in surface coatings and dimensional stability.

If more than one Costco Wholesale region is purchasing the SAME item, all countries can be listed on the
same test request. If this happens, the testing lab will perform the basic testing once. For apparel and
shoes, many countries use the ASTM and AATCC test methods. For this reason, much of the testing for
multiple countries is only actually performed once. The testing lab will then review the test protocol for
each additional country and will perform ONLY the tests that are unique to that specific country.
This procedure for sharing testing saves the lab time in testing the same item for multiple countries, and it
saves the vendors money in testing fees, sample expenses and freight fees as well as improving the
turnaround time for the reports. One report will be issued for each country, and a minimum report charge
will be invoiced for each additional country.
Product Quality & Label Test Ratings
Testing Labs Product Quality & Label Test Rating System:
GOOD No failures or defects
CORRECTIVE ACTION REQUIRED (CAR) Minor product failures/specification non-
conformance
UNSATISFACTORY Labeling violations/major product failures

Costco Wholesales Product Quality & Label Test Rating System
Because the potential failures for a Product Quality & Label Test are many, it is not possible to clearly
identify the Costco Wholesale rating for all types of failures. (Reference Section 3.8 for a general
description of the different Costco Wholesale Report Ratings.)
A Product Quality and Label test report will not be complete unless all sewn in labels, hangtags, care
labeling and fiber content labeling are included with the samples when submitted to the testing lab. If the
final labeling is not yet ready, drafts of all labeling can be submitted.
What is a 94/62/EC Test?
All items shipped to the UK will be required to pass 94/62/EC testing. 94/62/EC is part of the European
Directive that addresses the excessive use of packaging materials that lead to environmental pollution. The
goal of the directive is to address the quantity, quality and labeling of all packaging materials used on an
item.
As part of the QA Program, all packaging materials and components used on an item will be tested to
94/62/EC. 94/62/EC sets limits for the amount of toxic heavy metals that are present in outer and inner
packaging materials and components such as color label, hangtag, master carton, stickers, tape, banding
materials, wrapping papers, banding straps and inks.
The legislation calls for the sum of concentration levels of LEAD, CADMIUM, MERCURY and
HEXAVALENT CHROMIUM present in packaging or packaging components not to exceed 100 parts per
million by weight (0.01%)
These tests will normally take 5-7 working days upon receipt of sufficient test samples. Please attach the
test request with the samples for identification before sending to the testing lab. Although this test
requires that ALL packaging-related materials be tested, the testing lab will choose and test 5 key
materials or components.
If the item being produced is shipping to the United Kingdom the quality testing for this item will
include 94/62/EC testing. This will be indicated on the Test Request here.
Attached to the Test Request will be a 94/62/EC Testing Explanation Form. This explanation page
will list out the required amount of samples that will need to be submitted for testing.
Vendor must indicate on the Test Request that 94/62/EC testing is being requested.

94/62/EC
Attached is a list of the types of packaging components and the number of samples to be sent to the
testing lab. To avoid delays, please be sure ALL packaging-related components are submitted, even if
they are not on the list. Contact the Testing Lab for the required number of samples if the component is
not on the list.

Test Turn Around Time Under normal circumstances, products can be tested against Costco
Wholesales test protocol within seven working days (not including the day the samples are received at
the testing lab).
It is not always possible for the testing lab to complete testing on an item within the established turn-
around time due to conditions inherent to specific tests.
Test results will NOT be issued in 7 working days if the Test Request is not included with the
samples or if insufficient samples are received. Testing will be either delayed or put on-hold until
more samples are received. It is critical that the vendor/factory submit the number of samples
required for full testing. The required number of samples can be found on the Test Request.
Sample Disposal after Testing
Product testing is fully destructive. All samples become the property of Costco Wholesale and are
retained by the testing lab for three months (two months in Hong Kong) from the date of submission.
Vendors can have samples returned to them provided they accept all costs for re-packaging and shipping.
Before the testing lab can return any samples, the vendor must obtain authorization from QA.
Vendors are responsible for all shipping costs associated with the submission and return (by request only)
of test samples.
Master Carton 1 pc
Ink used for printing of Master Carton all colors 50 ml per color
Polybag 10 pcs
Ink used for Printing of Polybag all colors 50 ml per color
Blister (clamshell) 10 pcs
Blister card all designs or styles 5 pcs each
Instruction sheet 3 pcs each
Printed label for different designs or styles 5 pcs each
Adhesive tape for different styles and sizes 1 roll each
Insert card for different designs or styles 16 pcs each
Tissue paper all colors 3 pcs per color
Logo card for different designs or styles 3 pcs each
Window box w/ sheet for different designs or styles 2 pcs each
Plastic screw holder for different color 10 pcs each
Hang Tag 5 pcs
Cable Tie 10 pcs (Approximate 20cm length for one piece)
Plastie wire or Metal wire (twist ties) 50 gm
Plastic Plastie (Banding Strap) 5 feet
Plastic Fastener used to tighten banding straps 12 pcs
3.4 SUBMITTING SAMPLES TO THE TESTING LAB
When to Submit Samples
As soon as the factory starts production, they should pull the first few pieces from the production
line and submit them with the test request to the designated testing lab.
The vendor MUST also provide a UPS or DHL account number that the lab can use for billing
third party courier fees, to be used when the samples are forwarded on to the inspector and QA.
This information should be provided on the Testing Lab Vendor Courier Billing Information For
Costco Wholesale Vendors.
When possible, all colors/patterns should be submitted at one time to the testing lab to minimize
costs and confusion.
If it is not possible to submit all colors/patterns at the same time (due to production), the additional
colors should be submitted as follows:
o Submit the correct number of samples (usually 3 complete sets) of each additional color
with the original Test Request and a copy of the Product Quality & Label Report (if it has
already been issued).
o Attach a note requesting that the samples be tested as additional colors---not full testing.
This will ensure that the testing lab only conducts tests according to the Additional Color
Test Protocol instead of the full test protocol.
o If additional color testing is not requested, the testing lab may conduct a complete test
that will result in higher test costs for the vendor.

Where to Submit Samples
Samples should be submitted to the testing lab location indicated on the test request. The samples should
not be sent to any other testing company or any testing lab other than
the one noted on the test request.

When deciding which testing lab to use, QA takes into consideration
the equipment, the technical expertise for that category of product,
familiarity with QA procedures and proximity to the factory. If the
chosen testing lab is not the most convenient, contact QA to discuss
for approval; however, QA will advise if a change in the designated
testing lab location is possible.

The test request will indicate the lab location that samples
should be submitted to.

The actual address and contact information for that lab location
If lab testing is required it will be indicated on the Test
Request.
Vendor should attach a copy of the Test Request each time
samples are submitted to the lab. Failure to include a copy of
the Test Request will delay testing. Vendor should indicate on
the request what samples are being submitted.
If the vendor already has a complete Product Quality and Label
test and is submitting additional colors for laundry testing
only, the vendor should handwrite additional color testing
only reference report#XXXXXXXXXX. This will ensure
that the lab only conducts tests according to the Additional
Color Test Protocol instead of the full test protocol.

Using a lab other than the one listed on the test request will cause testing delays and in such case the
vendor may be required to pay additional shipping fees to ship the samples to the correct testing lab
location.
How to Submit Samples
The factory should submit 3 complete sets per color/style.
1. One set of samples is for the testing labs testing
2. One set is for QA/buyer approval
3. One set is for use by the testing lab inspector when at the factory.

Each set of samples should be packed separately and clearly marked Test Samples, QA
Samples or Inspector Samples
Testing Labs Test & Inspection Request Form must be included with the samples when they are
submitted to the testing lab.
Upon receiving the samples, the testing lab reviews them to ensure that there are an adequate
number of samples and that all the proper paperwork is included.
The testing lab will match the test request received from the vendor to the test request received
from QA and if there are any differences the testing will be put on-hold and QA will be notified.
If the testing lab receives the correct number of samples, they will lay them out and compare all
the sets to ensure that they are consistent in style, color, hand-feel, finishing and quality.
If the testing lab approves the samples for consistency, the samples are divided and distributed as
noted below.

Test Samples
The vendor must submit the correct number of samples for full quality and label testing.
The needed number of samples per color/pattern is noted on the test request. Sampling requirements
for testing are detailed later in this section.
It is recommended that vendors submit only the largest available sizes for testing to maximize the
amount of material available for testing.
If submitting additional colors the vendor must follow the below procedures to ensure that the
additional color samples are correctly linked to the original report by the testing lab.
1. Submit the correct number of samples for each additional color with the original test request and a
copy of the Product Quality & Label Report (if it has already been issued).
2. A note should be attached requesting that the samples be tested as additional colors---not full
testing. This will ensure that the testing lab only conducts tests according to the Additional Color
Test Protocol instead of the full test protocol.
3. If additional color testing is not requested, the testing lab may conduct a complete test that will
result in higher test fees for the vendor.
Additional samples of trim components such as zippers, buttons will also be requested on the test
request, please disregard if there are no trim components on the garment.
The required number of samples for testing is explained in detail later in this section.
All samples must have final labeling including all sewn in labels, hang tags, etc.
If 94/62/EC testing has been requested, submit additional samples of all packaging and labeling.
If final labeling (labels, hang-tags, etc.) has not been finalized/printed, drafts can be submitted.
Note: 94/62/EC can only be conducted on final production packaging and labeling.
Test results will NOT be issued in 5 working days if the Test Request is not included with the
samples or if insufficient samples are received. Testing will be either delayed or put on-hold until
more samples are received. It is critical that the vendor/factory submit the number of samples
required for full testing. The required number of samples can be found on the Test Request.
QA Samples
The required number of samples needed per color/pattern is noted on the test request.
The number needed for QA approval for garments is usually 1 sample per color/pattern representing
all sizes.
The number needed for QA approval for footwear is usually one shoe each-mens size 9 & womens
size 8.

Testing Lab Inspector Samples
The required number of samples per color pattern is noted on the test request.
The required number of samples needed for use in the inspections is usually 1 sample per color/pattern
plus a 12 x 12 swatch of each additional color/ pattern.
The required number of samples of footwear needed for use in the inspections is usually one shoe-
mens size 9 & womens size 8 unless otherwise noted on the test request.
What Happens While the Testing is in Progress?
The vendor can proceed with production while waiting for the quality results, but this is done at their
own risk.
By this time, the buyer should have already received the samples that were sent by the testing lab via QA.
If the sample is not what was agreed to, the vendor is alerted, production is stopped, testing & inspections
are put on-hold and research needs to be done to determine why there is variation.
If the factory submits insufficient samples, or if the samples are not clearly marked for testing lab, testing
will be put on-hold or delayed resulting in testing that may need to be expedited at the vendors expense.
If shipments are delayed due to these testing delays, the vendor may be responsible for air-shipment, fast
vessel charges and/or late shipment penalties at the buyers sole discretion.

Sampling Requirements for Fabrics & Garments
The required number of samples is noted on the Test Request.
All Product Quality & Label Test samples should be mailed to the testing lab location indicated on your
test request. The test request will indicate what samples must be submitted, Testing Samples, QA
Samples, Inspector samples
The number of samples required for garment & trim testing, QA approval and inspector reference are
clearly noted on the test request.
When submitting samples the test request form must be included with the samples as well as the vendor
must mark on the test request which samples are being submitted.
Failure to submit the correct number of samples will result in the testing being put on-hold and/or testing
delays. Following is information on sample requirements for various types of testing. This is for
reference only (and for CV testing). While we are providing this information here, it is important that the
vendor always send the number of samples noted on the test request.
Fabric (CV Development Testing only):
Knit or Woven 2 yards first color
1 yard each additional color

Trim Testing* (CV Development and/or Garment Testing):
Fabric appliqus 8 per color
Bows 8 per color
Zippers 30 per color or 15 per color +15 pull tabs
Snaps 50 per color
Buttons: 30 per color

Adult Garments (CV Development Testing only):
General 3 garments per color (largest size) +additional trim*
Shorts 4 garments per color (largest size) +additional trim*
Short sleeve shirts 4 garments per color (largest size) +additional trim*
Underwear-general 6 pair +3 pair per each additional color (largest size)
Underwear-thong 10 pair +6 pair per each additional color (largest size)
Bras 4 per each style +2 bras per each additional color (largest size)
Socks 3 pair per color representing all sizes
Pantyhose 4 pair per size +4 pairs per style +1 pair per each additional color
*See Trim testing section for additional button, zipper and other trim sample requirements
Additional Sample Requirements:
If garments have trim components, additional pieces of all trim must be submitted with the garments.
See the trim testing section for sample requirements.
Small garments may also require additional samples because of the limited amount of material in each
sample.
Garments that have prints and/or trims may need additional samples to complete color testing.
If more than one care instruction is indicated on the sewn-in label, then double the number of samples
sent to the lab for testing.
It is not always possible to know if additional samples will be required to complete testing. If the
testing lab requests additional samples, the vendor MUST submit those additional samples ASAP to
avoid testing delays.
If the vendor has questions about the sample requirement for their item, they can email a digital photo
to the testing lab for review.

If the factory submits insufficient samples, or if the samples are not clearly marked for the testing lab,
testing will be put on-hold or delayed resulting in testing that may need to be expedited at the vendors
expense.
If shipments are delayed due to these testing delays, the vendor may be responsible for air-shipment, fast
vessel charges and/or late shipment penalties at the buyers sole discretion.
Zipper Testing
Costco Wholesale specifies that YKK zippers be used on ALL garments.
Below is a guide showing the most commonly used YKK zippers. The YKK Zipper Numbers are
listed under the relevant YKK Fastener Class number in the chart below.
When the testing lab receives samples they must identify the appropriate YKK Fastener Class for the
zipper as the Fastener Class determines the testing that is to be done on the zipper. In order to do this, BV
CPAS will use the following process:
1. The testing lab will look at the back of the zipper slider head for the alphanumeric YKK zipper
number.
2. The testing lab will review the Product Specification Sheet to determine the claimed (if any) YKK
Zipper Number and / or YKK Fastener Class.
3. If the YKK Fastener Class cannot be determined in Steps 1 or 2, the testing lab will look on the
back of the zipper slider for the numeric YKK Fastener Class. This number will be used to
determine the appropriate testing for the zipper.
4. If the Fastener Class is the only available information, and the Fastener Class is between 1-4, the
testing lab will default to the most stringent testing requirements.
5. If the zipper is not marked with an YKK Zipper Number or YKK Fastener Class, and no
information is available on the Product Specification Sheet, the zipper will be measured for closed
chain width and tape width. The measurements will be used to determine the YKK Fastener
Class.
If the determined Fastener Class is between 1-4, the testing lab will default to the most stringent testing
requirements.
YKK Fastener (performance)
Class
1-2 3-4 5-7
Closed Chain Width (in.) .125-.180 .125-.180 .180-.310
Tape Width (in.) 7/16-9/16 7/16-9/16 9/16-3/4
YKK Zipper Number(s) 2CC
3CC 3CF 4YG
3A / 3MA 3ER 5CN
3MA 3FR 5CP
3MB 3LF 5DCN
3MG 3VF 5DG
3MN 3VS 5DVF
3YAN 5MG
3YG 5RB
3YM 5RG
3YN 5RM
5RN
5RNP
5VS
5YAN
5YG
5YN
Note: The list above includes only the most common YKK Zipper Numbers. The list is not complete.
For a complete list of Zipper Numbers, contact YKK directly.
3.5 WAREHOUSE PULL TESTING PROGRAM
Costco Wholesale may pull samples from various Costco Wholesale warehouses and submit them to the
testing lab for testing. The warehouse Pull Testing Program is usually used for one of two purposes:
1. Random spot check for compliance, quality, specifications and consistency with the buyer
approved production sample. This testing is in addition to any testing or inspections conducted
prior to shipment to Costco Wholesale.
2. Full testing for product quality and label for items which are sold year-around. This testing is
usually set up on a monthly or quarterly basis. The product is pulled from multiple warehouses
and submitted to the testing lab for testing. This type of testing is usually used for basic items, as
it is more cost effective than testing and inspecting the product
in the country of origin.

If this testing is required the vendor will receive a copy of a test request advising that Costco
Wholesale will be pulling random samples from its warehouses and submitting them to the
testing lab for testing.

The product is usually keyed out by RTV as a defective. The RA (if required) is usually the
buyers name. This is an indication to the vendor that the samples were pulled and sent to
RTV by QA.
3.6 PRODUCT INSPECTION AT THE FACTORY
What is a Product Inspection?
A product inspection occurs when a representative from the testing lab Inspection Division travels to the
factory to inspect a percentage of the product being made for Costco Wholesale.

The inspection includes a review of the following:
1. Workmanship Inspection
2. Review for color, hand and appearance
3. Review of product against product specification sheet & approval samples
4. Size Specification Verification
5. Labeling Review
1. Inspections are required at different times during production.

The buyer will decide how many inspections are required and at what point in production they are needed.
If inspections are required these will take place for every production run at every factory making the
product.
Most items are required to have two inspections. For small orders, buyers may request only one
inspection.
The number of inspections required will be noted on the test request.
If warehouse pull testing is required, Costco Wholesale will
submit samples for testing from specified warehouse locations.
The vendor will not need to mail samples in from production
If warehouse pull testing is requested it will be indicated on the
test request form here. The request will state that Costco
Wholesale will submit samples for testing.

The vendor should NOT submit any samples to the lab. The
formisbeingsent tothevendor asanFYI only.
Product Inspection Ratings
Testing Labs Product Quality Test Rating System:
CONFORMED The number of non-conforming products found during the inspection and
measurement audit are within the AQL and no additional problems are
noted
NON-CONFORMED The number of non-conforming products found during the inspection and
measurement audit exceed the AQL and/or additional problems are noted

Costco Wholesales Product Inspection Rating System
Because the potential failures for a Product Inspection are many, it is not possible to clearly identify the
Costco Wholesale rating for all types of failures.
Reference Section 3.8 for a general description of the different Costco Wholesale Report Ratings.
Preliminary Inspection Results
Note that the testing lab will leave a copy of the handwritten Preliminary Inspection Results for
the factory after the inspection. All Preliminary Inspection Results are subject to change by the
testing lab Manager that reviews the final inspection reports.
The purpose of the preliminary results is to give the factory a head start in making necessary
product improvements while the final report is written, emailed to the vendor and Costco
Wholesale and processed by QA.
The vendor should remember that not all Non-Conformed results are rejected by Costco
Wholesale. If the vendor is unsure of what defects will and will not be acceptable, they should
wait for the RCDS for QA.
THE VENDOR SHOULD NOT CONTACT THE BUYER UNTIL THE FINAL REPORT IS ISSUED.
The buyer will be unable to comment on the failures without the report. If it is an emergency situation,
the vendor can contact QA for advice on how to proceed with needed corrective action before the final
Inspection Report is issued.
Sampling Method
Sample size for inspection is determined by MIL-STD-105E, Single sampling plan for normal inspection level II.

Acceptable Quality Level (AQL)
The AQL is the maximum percent of defectives considered acceptable for shipments of apparel and
footwear.
Critical (0.0), Major (2.5), Minor (4.0) for Non Private Label items
Critical (0.0), Major (1.0), Minor (2.5) for Private Label items

Critical Defect:
A critical defect is one that could result in a hazardous or unsafe condition for individuals using the
product, a violation of any Federal regulation.
Major Defect:
A major defect is one that would result in the return of a product by the member or that could cause
decreased consumer satisfaction relating to the appearance and/or functionality of the product.
Minor Defect:
A minor defect is one not likely to render the product unserviceable or unsellable yet it does not conform
to Costco Wholesale standards.
Reference Samples Required
The vendor will not be allowed to schedule an appointment with the testing lab for an inspection if the
inspector has not received reference samples from the testing lab. For this reason, it is critical that the
factory submit the correct number of samples with all labeling to the testing lab as early in production as
possible.
The testing lab inspector will go to the factory and conduct the product inspection using the samples they
received from the testing lab. During the inspection, the inspector looks for all defects and compares
production to the samples received from the testing lab.
If the inspector sees any significant variation, the inspector will pull 2 samples per color for variation and
1 sample for consistent defects and sends the samples to QA for buyer review. If there is no significant
variation between what was tested and what was produced, and no consistent defects are found, the testing
lab will not pull any additional samples.
When to Arrange an Inspection
The Test Request (sent to both the testing lab & the vendor) will list target
dates for the 20% inspection, 50% inspection, and 80% inspection. Since
the vendor provides these dates on the Production Schedule Request
Form, they are expected to be reasonably accurate.

The factory is required to have the correct percentage of product available
when the testing lab conducts the product inspection. The Target Date listed on the Test Request is
only a target date. Only the factory will know when it is appropriate to arrange an inspection based on
their production schedule.
An inspection appointment should be requested at least 7 days in advance of the preferred date to ensure
first choice of inspection dates.
If the test samples/reference samples have not yet been submitted to the testing division, the
testing lab will not give the vendor an inspection appointment.
How to Arrange a Product Inspection
The test request issued by QA (sent to both the vendor and the testing lab) lists target dates for the
inspections. When QA issues the test request packet, the testing lab will log the request into their
system.
The testing lab then emails the booking form to the vendor for completion.
The booking form must be 100% completed and then returned to their testing lab inspection
coordinator.
The testing lab will send the booking form to the vendor contact listed on the Vendor Billing &
Correspondence Information Form in the Who Receives Requests? section.
Booking Form: The testing lab inspector coordinator sends the booking form to the vendor for
completion. The vendor must complete and return to the testing lab before they will be given an
inspection or factory evaluation appointment.
If the buyer has requested that the product be inspected at the
factory prior to shipping it will be indicated here on the Test
Request as either an inspection at 20%, 50% or 80%. (or a
combination of 20%,50% and 80%) The vendor will need to
contact BV CPS a minimum of 7 days prior to their estimated
20%, 50% or 80% target date to ensure that an inspector will be
available able to travel to their factory on the desired date.
Once the testing lab receives back the completed booking form, they will call or email the vendor
to book an inspection/evaluation date. The vendor should contact QA if a response is not received
from the testing lab within 48 hours.
If the testing lab receives the booking form from the vendor and it is not complete, it will be
returned to the vendor for completion.
Once the testing lab receives the completed form, they will book the factory evaluation with the
vendor.
If the testing lab receives the completed booking form and the vendor wants to schedule an
inspection, but the Testing Lab Inspection Division has not received reference samples, the testing
lab will put the inspection on-hold and will not contact the vendor to arrange an appointment until
they receive the samples.
Costco Wholesale does not accept non-communication as a valid reason for factory evaluation, testing or
inspection delays.
Multiple Production Runs and/or Multiple Shipments
Every item that goes through the QA Process (coordinated by QA) is required to be tested and inspected
(and approved) before it ships.
If an item is produced in multiple production runs, each of the production runs must be tested and
inspected. Similarly, if multiple shipments are made, and they ship before the 80% inspection, these
goods will need to be inspected separately from the rest of production prior to shipment.
QA will schedule tests and inspections for every production run (at every factory) based on the
information provided by the vendor on the Production Schedule Request Form. QA will issue a separate
Test Request for every factory and every production run.
When QA reviews the Production Schedule Request Form, if the vendor has noted that they have multiple
shipments for a single production run, QA will review the order to determine if each of the multiple
shipments needs to be tested and inspected separately. If this is the case, QA will issue a separate Test
Request for every multiple shipment for every production run.
3.7 RANDOM INSPECTION PULL TESTING
Costco Wholesale may require that the testing lab pull random samples during the product inspection at
the factory. The test samples will be pulled sealed in a box and marked by the inspector.
If this testing is required it will be noted on the test request.
It will be the factorys responsibility to ship the test samples to the designated testing lab for testing.
3.8 RECEIVING REPORTS
Test Reports:
Test reports are issued on the last day of the quoted turn-time for the report. If the turn-time for the item
is unknown, it can be found on the last page of the test protocol.
The turn-time for most apparel items is 5 business days. The report will be emailed out on the fifth day
(not including the day the samples are received at the testing lab).
Inspection Reports:
The testing lab will email product inspection reports within 24 hours of completion of the inspection. If
the factory is in a remote area, it could take up to 48 hours to receive the report, due to travel time.
Factory Evaluation Reports:
The testing lab will email factory evaluation reports within 3 days of completion of the evaluation. If the
factory is in a remote area, it could take up to 5 days to receive the report, due to travel time.
If there are any questions about the status of a report, please contact the testing lab or the appropriate
QA Contact (noted on the test request) for assistance. QA and the testing lab prefer email for
communications regarding the status of testing and inspections
How the Testing Lab distributes Reports?
Reports (protocols, photos, etc) are sent as a single PDF document via email. The report number will
appear in the title of the email.
Only one report is sent per email. The average size of a report is 2 megabytes. The maximum size of
each report cannot exceed 7 megabytes. If a single report is larger than 7 MB, the testing lab will either
zip the file or divide the report into 2 documents and email them separately.

The testing lab has been instructed NOT to give verbal results for quality testing before they actually
issue the report. This is QAs request and is not the testing lab policy.
Who Receives the Reports?
The reports will be sent via email to QA (nonfoodsqa@costco.com) and copied to the designated vendor
recipients. The vendor determines the vendor recipients when they complete the Vendor Billing &
Correspondence Information Form.

Report Processing Procedures
QA completes one of two RCDS.
There is a RCDS for Approved/Disapproved reports and a RCDS for Rejected or Unsafe/Misleading
reports.

Approved and Disapproved QA Reports
RCDS are emailed to the buyer, Private Label Apparel/Manufacturing, International (as applicable)
and the vendor.
The title of the emailed coversheet will be as follows: QA, Vendor Name, Item #, Destination
country, Report #.
Reports that are Approved or Disapproved will not require a Retest or Re-inspection by Costco
Wholesale.
When determining who should receive copies of the reports, it is
recommended to include the names of the factory, manufacturers
representative, and any other party involved in the order. Delays can
result if the correct people in a company do not receive the reports.
List the complete factory address and contact information. The vendors
address cannot be substituted for the actual factory address.
Vendor should provide a separate Vendor Billing and Correspondence
Information Form for each factory producing an item.
The information on the Vendor Billing & Correspondence Information
Form will be used by BV CPS and Costco Wholesale.
Incomplete reports are reports that for a variety of reasons are incomplete. The most common reason
for an Incomplete report is that not all color / patterns were submitted for testing or available at an
inspection. The results in an incomplete report will only reflect the product available at the time of
testing or inspection. The QA Process will not be finished and approved by QA until all reports are
complete.

Rejected QA Reports
RCDS are emailed to the buyer, Private Label Apparel/Manufacturing and International only (as
applicable)not the vendor.
The title of the emailed RCDS will be as follows: QA, REJ , Vendor Name, Item #Destination
country, Report #.
The vendor will not be notified by QA with the RCDS report rating until the buyer replies.
After the buyer has reviewed the RCDS it will be forwarded to the vendor with instructions for the
needed corrective action.
Reports that are Rejected or Unsafe / Misleading will require the Vendor to Retest or complete a Re-
inspection.
Prior to the retest or re-inspection the Vendor will need to correct failures indicated on the Defect
Summary & QA Corrective Action Plan.

Unsafe Misleading QA Reports
RCDS are emailed to the buyer, Private Label Apparel/Manufacturing, International (as applicable)
and the vendor.
The title of the emailed coversheet will be as follows: QA, Unsafe, Vendor Name, Item #,
Destination country, Report #.
Vendor Notification - Interpreting QAs decision (RCDS)
Once the vendor receives the RCDS from QA they will be able to see the overall rating on the report.

The vendor should follow the corrective action plan on the second page of the RCDS. This page explains
QAs corrective action plan and requirements for products.
Approved Rating
An Approved rating means the product/factory is approved. QA will advise if any improvements are
needed.
Disapproved Rating
A Disapproved rating means the product/factory does not meet all of QAs requirements, but the problems
are minor enough that we can accept the problems for the current production. In this case a re-test/re-
inspection is not needed but improvements should be made for future production (if possible) and/or for
future items quoted.
Rejected Rating
A Rejected rating means that QA feels the product/factory is not acceptable until improvements are made.
These required improvements are noted on page 2 of the RCDS. All defects/problems requiring a re-
test/re-inspection or evaluation should be corrected and retested/re-inspected. If a Rejected report is
received, production should be stopped until all products are corrected.
Buyer Override for Rejected Reports
QA is a service department to Costco Wholesales worldwide buyers. It is our job to facilitate the
QA Process and to assist the buyers in ensuring the compliance, quality and specifications of their
products.
While QA makes recommendations to the buyers on the acceptability of reports and product, it is
ultimately the buyers decision as to whether the report and the product will be accepted.
Therefore, it is possible that QA could reject a report/product/factory, but the buyer/GMM could
disagree (for various reasons) and accept the report/product/factory.
If the buyer disagrees with a rejected report (this will be noted on the bottom on the RCDS) it
means that a re-test/re-inspection is NOT needed.
However, the vendor should still make every effort to follow QAs recommendations on the
second page of the RCDS and to improve the quality of the product or factory for future
production and for future items quoted to Costco Wholesale.

Unsafe/Misleading Rating
An Unsafe/Misleading rating means that the product/factory has serious defects or problems which violate
the laws of the destination country or which could result in a hazardous product. The product/factory
must be corrected and a re-test/re-inspection or evaluation conducted as soon as possible.
Only a Senior Vice President or higher can override an Unsafe/Misleading report.
Corrective Action Process
The required corrective action is explained on the second page of the RCDS. It is important that the
vendor begin making the needed improvements as soon as the RCDS is received.
Within 24 hours of receipt, the vendor should confirm receipt and understanding of the document to QA
and advise the timeline for implementing their corrective action plan.
Even if a report is not rejected, if there are defects noted on page 2 of the RCDS, the vendor is required to
proceed according to the above instructions.
In addition to the instructions received from QA, the vendor may also receive phone calls and emails from
the buyer regarding the required corrective action. If the vendor is corresponding with the buyer
regarding their corrective action plan, this correspondence should be copied to the QA contact.
The testing lab is copied on all Rejected or Unsafe/Misleading RCDS so they are informed of QAs
decision and the required corrective action plan for the vendor.
3.9 RETESTING AND REINSPECTIONS
Costco Wholesale reserves the right to require re-testing and or re-inspections when deemed necessary
due to product nonconformities found during the QA Process, or during the distribution or sale of the
merchandise. All costs associated with re-testing and/or re-inspecting will be the vendors responsibility.
If re-tests or re-inspections are required, the vendor is also responsible for all charges incurred as a result
of the original failure(s). This includes but is not limited to the costs associated with removing any non-
conforming product from the selling floor and any freight charges to return the product to the vendor.
When are Re-Tests/Re-Inspections Needed?
A re-test/re-inspection or evaluation is only required if specified by QA on the RCDS.
QA has established very stringent, detailed testing and inspection criteria to ensure that all defects,
no matter how small, are reported to QA in the testing & inspection reports.
At QAs request, the testing lab is very detailed and conservative in their evaluation of product
and factories and as a result, many of the testing labs reports for Costco Wholesale are rated as
Unsatisfactory or Non-Conformed.
A failed report from the testing lab does not necessarily mean that QA or Costco Wholesale will
reject the report.
If the report is received from the testing lab with clearly unacceptable failures, the vendor should
immediately begin corrective action process without waiting for QA to issue the RCDS. The
vendor should email QA and the buyer to advise on the procedures being taken.
If the vendor is unsure as to whether the defects in the report will be acceptable, they should wait
for QAs RCDS before beginning a corrective action plan.

Interpreting an RCDS-Rejected Report that has been overridden by the buyer
Because the Costco Wholesale buyer & GMM can override a QA rejected report, it is
important to read the RCDS carefully.
If a report is rejected, but the buyer has overridden the QA rejected rating, this means that
a re-test or re-inspection is NOT required and that the report has been approved.
If a buyer has chosen to override a QA rejected report, and a retest/re-inspection is not
needed, the vendor should still make every effort to improve the product/factory for future
production or at a minimum for future items quoted.
How to Arrange a Re-Test
When a report is rated as Rejected or Unsafe/Misleading, a copy of the RCDS is sent to the vendor and to
the testing lab. This document tells both the testing lab and the vendor what needs to be retested/re-
inspected or evaluated.

If a vendor needs to retest a product, they should make the needed corrections to the product, attach the
RCDS or original failing report and submit samples to the testing lab for retest. If the vendor is unsure of
how many samples to submit, they should contact the testing lab for clarification
If the vendor has additional questions, or wants additional testing done (in addition to the testing required
by QA), they should include these additional instructions with the sample to the testing lab.
Upon receiving the samples and RCDS, or other testing documents the testing lab will reference the
RCDS they received from QA, verify the two are the same, then proceed with retesting the failures noted
on the RCDS.
How to Arrange a Re-Inspection/Evaluation
When a report is rated as Rejected or Unsafe/Misleading, a copy of the RCDS goes to the vendor and to
the testing lab. This document tells both the testing lab and the vendor what needs to be re-inspected/re-
evaluated.
If a vendor needs to arrange a re-inspection or re-evaluation, all the required changes should be made to
the product and/or factory, then the testing lab should be contacted for an appointment.
When the testing lab receives the vendors request for an appointment, they will reference the RCDS sent
by QA. When doing the re-inspection or re-evaluation, the testing lab will verify that the specified
problems have been corrected.
When the re-inspection report is received, it will be processed according to procedures listed in Section
3.8.
3.10 COMPLETION AND AUTHORIZATION
Non-Foods Quality Assurance Approval Letter Letter of Credit
The Non-Foods Quality Assurance Approval Letter Letter of Credit (QA Letter) is a document
generated by QA at the end of the QA Process. The issuance of this letter indicates to the buyer that all
requested evaluations, testing and inspections have been completed and approved.
This document is required to negotiate all Letters of Credit issued by Costco Wholesale.
When all the required testing and inspections are completed and approved, the QA Letter will be signed
by QA and given to the buyer. The buyer will sign the QA letter and fax it to the vendor.
This letter must be submitted to the bank with all of the other L/C documents in order to negotiate
the Letter of Credit.
QA will issue a QA Letter at the completion of the QA process to indicate to the buyer and vendor
that all QA requirements have been met (If all required factory evaluations, testing and inspections
are not completed and / or are not approved by the buyer, the QA Letter will not be issued).
Once all requested factory evaluations testing and inspections are completed and approved, the
QA Letter will be signed by QA and given to the buyer.
The buyer will sign the QA letter and fax it to the vendor.

If the vendor submits to the bank for payment without the L/C letter there will be an automatic
discrepancy. When Costco Wholesale receives this discrepancy, VP approval will be required to waive
the discrepancy (the buyer cannot waive this).
Non-Foods Quality Assurance Approval Letter Open Account
The Non-Foods Quality Assurance Approval Letter Open Account (QA Letter) is a document generated
by QA at the end of the QA Process. The issuance of this letter indicates to the buyer that all requested
factory evaluations, testing and inspections have been completed and approved.
QA will issue a QA Letter at the completion of the QA process to indicate to the buyer and vendor
that all QA requirements have been met (If all required factory evaluations, testing and inspections
are not completed and / or are not approved by the buyer, the QA Letter will not be issued).
Once all requested factory evaluations testing and inspections are completed and approved, the
QA Open Account Letter will be signed by QA and given to the buyer.
The buyer will sign the QA letter and fax it to the vendor.
Shipping Authorization
All requested factory evaluations, testing and inspections should be completed and the vendor should
receive the QA Letter before any product is shipped.
No documentation is needed from the testing lab in order to ship the product.- Only the buyer can
authorize shipment.

Part 4 READING REPORTS
4.1 REPORTS FORMATS FOR FACTORY EVALUATIONS
Factory Evaluation Report Cover
The Factory Evaluation Protocol is a list of questions the inspector answers related to the factory. Each
question is worth one point toward the factories overall rating score.
Based on the number of points achieved Costco Wholesale will determine if the Factory meets Costco
Wholesale requirements and the length of the time the evaluation is valid for.
If the Inspector finds any critical failures, the testing lab will rate the report as Unsatisfactory. A re-
evaluation will more than likely be required regardless of the number of points achieved.

4.2 REPORT FORMATS FOR QUALITY AND LABEL
Quality and Label Report Cover
The report cover page provides a summary of the item being tested and results. If there are failures, the
report describes each one in detail and includes any comments and/or recommendations for improvement.
Based on the failures found on the quality testing Costco Wholesale will determine if the product meets Costco
Wholesale requirements. QA will issue an RCDS summarizing the failures and providing the corrective action
required.
Quality and Label Protocol Page(s)
The protocols are a line-by-line list of the Costco Wholesale requirements for a type of garment. In the
case of a re-test report where only one or two test property lines from the protocol were used you will see
N/A in all areas not retested.
4.3 REPORT FORMATS FOR 9462 EC
94/62/EC Report Cover
The report cover page provides a summary of the item being tested and results. If there are failures, the
report describes each one in detail and includes any comments and/or recommendations for improvement.
If failures are found for heavy metal requirements for the United Kingdom, Costco Wholesale may require the
vendor to correct failures and retest.
4.4 REPORT FORMATS FOR PRODUCT INSPECTION
Inspection Report Cover
The report cover page provides a summary of the item being tested and the results. If there are failures,
the report describes each one in detail and includes any comments and/or recommendations for
improvement.
Based on the number of defects found during the inspection, Costco Wholesale will determine if the
product meets Costco Wholesale requirements. QA will issue an RCDS summarizing the failures and list
the corrective action required.

Inspection Protocol Page
The protocol is a line-by-line list of the Costco Wholesale requirements for a type of garment. Multiple
protocols will be included for comparison reports, for example, if two items are being tested as a
comparison, a single report will be generated but will contain two protocols, one protocol each for the
results of both samples.
Defects found at the inspection are classified as Critical, Major or Minor. The protocol pre determines the
severity of each possible defect.
Inspection Exhibit Page(s)
Exhibit pages are most often included with a report to show a failure. Exhibit pictures are taken as a
means of documentation such as to show the exact wording and format of a product label.
Part 5 COST AND BILLING
5.1 VENDOR RESPONSIBILITY
Unless otherwise negotiated with the buyer, the vendor is responsible for all fees associated with the QA
process. The fees include test fees and any freight charges associated with mailing test/reference samples,
as well as factory evaluation and inspection fees.
Costco Wholesale makes every effort to keep the fees as low as possible. The rates for testing,
inspections and factory evaluations are extremely competitive against the rates charged by other
independent, global third party labs.
5.2 TESTING COSTS
Contact the testing lab for the cost of testing.
Additional charges (i.e. analytical work) are noted with an asterisk next to the test name in the test
property column and on the bottom of the Basic Test Package in the Pricing Information box under
additional charges.
In addition the testing labs give Costco Wholesale a discount, which will be taken at the time of
invoicing.
Note: **When the Test Request covers more than one Costco Wholesale region (destination country), the
Testing Lab will perform the basic testing once and will then issue a separate report for every country.
The Testing Lab will charge a processing fee for each report that is generated per country, plus any
additional tests required for that specific country.
5.3 FREIGHT CHARGES FOR SAMPLE SHIPMENT
Per the Costco Wholesale Non-Foods Quality Assurance Apparel QA Program, Costco Wholesale
vendors are responsible for shipping and / or courier fees associated with sending samples to
inspectors and Costco Wholesale offices.
The vendor must provide a UPS or DHL account number that the testing lab can use for billing
courier fees.
If an account cannot be set up with UPS or DHL, please provide an alternative billing account
number with a service that operates in the country where the garments will be tested.
Flammability samples or Original Reports: Unless specified by Costco Wholesale All
flammability and/or Original Reports will be sent Fed Ex Ground or the lowest cost courier.
Please charge the vendor when sending flammability samples back to Costco.

5.4 FACTORY EVALUATION & INSPECTION COSTS
For factory evaluation and inspection costs please contact the testing lab noted on your Test Request.
Notes:
A man-day is defined as one person working and/or traveling one normal working day.
The per man-day rates do not include travel, meals, or accommodation expenses.
Overtime rates apply to all work done outside of regularly stated work hours for each particular
region.
Inspections and audits performed on Sundays and public holidays are charged at 1.5 times the
standard rate.
There will be a charge of one full man-day for any inspection or factory evaluation canceled with
less than 48 hours prior notice.
5.5 INVOICING PROCEDURES - VENDOR BILLING
Vendor Billing
The testing lab will generate an invoice within 30 days of completing the test or inspection. This invoice
will be mailed along with a copy of the report to the vendor. The invoice is mailed to the vendor contact
and address listed on the Vendor Billing & Correspondence Information Form which is completed by the
vendor.
.
5.6 PRE-PAYMENT FOR NEW VENDORS
The QA program is a vendor bill program. As such, pre-payment will be required of all vendors testing
with the testing lab for the first time. Once credit has been established through the first test, the testing
lab will invoice, due upon presentation, each vendor upon completion of testing. Each invoice will be
sent by mail along with a copy of the final test report.
5.7 OVERDUE/ON-HOLD ACCOUNTS
The testing lab will not test or inspect product for vendors with past due invoices. This includes past due
invoices through the QA program as well as invoices owed through the program of any other testing lab
client.
If samples are received from a vendor with outstanding invoices, then the new samples will be placed on-
hold until both the outstanding invoices are paid in full and pre-payment is received for the new samples.

As soon as the testing lab receives the test request packet from QA, they should immediately notify both
QA and the vendor that testing will go on-hold when samples are received. The goal is to resolve all
outstanding bills before the samples arrive at the testing lab.

Part 6 COSTCO WHOLESALE VENDOR (CV) PROGRAMS
6.1 CV DEVELOPMENT TESTING PROGRAM
The Costco QA program does not currently require pre-production testing for most items, but Costco
Wholesale expects all product to comply with all Costco Wholesale standards. The CV Development
Testing Program is intended for vendors to use on their own to ensure that their products will not fail
testing during production
It is the vendors responsibility to test piece goods, trim components and label claims as needed in
advance of production to ensure that all materials conform to Costco Wholesale requirements. The
vendor must comply with all Costco Wholesale standards for any product they offer the buyer for sale.
Failures found during production quality testing (coordinated by QA) may jeopardize the program with
the buyer and may result in delays or PO cancellation. This Costco Wholesale Vendor (CV) Testing &
Inspection program will allow the vendor to identify and resolve failures prior to production.
This is a vendor run program created for the purpose of making it easier and more cost effective for the
vendor to test piece goods, trim components, fiber content, care labeling, etc. in the development stages to
avoid failures in production. Development testing under the CV Program is not required by or monitored
by QA. If the vendor chooses to use the CV Program, they must complete the CV Test Request Form
indicating what tests and evaluations they want completed. This can be found from the third party testing
labs.
The CV Program is available to all vendors selling product to Costco Wholesale (regardless of whether
they are required to go through the QA Process coordinated by QA). The testing lab will offer a pre-
negotiated discount on all testing to the Costco Wholesale vendors that use the testing portion of the
program. The man-day rates charged by the testing lab Inspectors will be at the Costco Wholesale rate.
How to Submit Samples
Note that there is a difference between the sample submission procedures for the QA Process coordinated
by QA and the CV Development Testing Program.
The CV Development Testing Program is for pre-production or development samples only. Therefore
additional sets of samples do not need to be submitted to the testing lab for Costco Wholesale or for the
testing lab inspectors.
If the vendor requests piece-goods testing, the testing lab will mark which tests were completed on the
test protocol.
If the vendor does not want all of these tests conducted they should advise the testing lab of this when
filling out the CV Program Request Form.
6.2 RECEIVING RESULTS
The CV reports are for the vendors reference only. The vendor can choose to have the testing lab copy
QA on the results. The vendor can ask the lab to email a copy of the report to nonfoodsqa@costco.com.
QA will forward the report to the buyer but will not process the report.
Any CV report will not take the place of full production testing through QA.
Part 7 ADDITIONAL REQUIREMENTS FOR CHILDRENS
SLEEPWEAR- (USA ORDERS ONLY)

Part 6 of the Costco Wholesale Non-Foods Quality Assurance Manual for Apparel is intended for
informational purposes only. The vendor is responsible both legally and for all Costco Wholesale
agreements for ensuring compliance with all applicable laws including those relating to sleepwear.
7.1 EXPLANATION
Per the Consumer Product Safety Commission (CPSC): Childrens sleepwear is any article of clothing,
such as a nightgown, pajama, robe or loungewear, sized from above 9 months and up to size 14, that is
intended to be worn primarily for sleeping or activities related to sleeping.
There are very stringent requirements for testing childrens sleepwear for sale in the United States (see
test protocols for other country requirements). The regulations can be obtained from the CPSC website
(www.cpsc.gov).
The regulations are published in the Code of Federal Regulations in Title 16, Part 1615 for childrens
sleepwear sized above 9 months and up to 6X, and in Title 16 Part 1616 for childrens sleepwear sized 7
through 14.
The purpose of the regulations is to protect children from burns. According to CPSC guidelines in the
United States, childrens sleepwear must be either tight fitting or flame resistant. If they are tight fitting,
they must match strict criteria for measurements at multiple points within the garment, to ensure the fit is
snug at every size. This is to eliminate airflow between the skin and fabric, so as not to allow a flame to
catch on the fabric. If sleepwear isnt tight fitting, it must be flame resistant and able to meet strict
flammability test requirements.
In addition to the standard QA process (factory evaluation, product test for quality & label and
inspections) all sleepwear must also be thoroughly tested (in accordance with the CPSC) during the
production process to ensure that it is in compliance with all requirements.
Following is an explanation of all requirements that manufacturers must follow when producing
childrens sleepwear. It is the manufacturers responsibility to perform all required testing at each stage
of production, and keep the required samples and documentation to verify the testing was done.
If the manufacturer does not already have an established quality assurance program for testing childrens
sleepwear during the various stages of production, QA suggests that the manufacturer use the CV
Development Testing Program (see Part 7 for details).
For additional information on Childrens sleepwear requirements and size specifications, the vendor can
contact the CPSC, Office of Compliance, Washington, D.C. 20207, telephone: 301-504-0608.
7.2 COSTCO WHOLESALE REQUIREMENTS FOR NON-TIGHT FITTING
SLEEPWEAR

When QA receives the Test Request from the buyer, QA will submit a test request to both the lab and the
vendor. The lab will contact the vendor for copies of all flammability testing documentation.
Documentation from the fabric stage (FPU), prototype seams and trim stage, and from the garment stage
(GPU) will be required. Failure to promptly mail all requested information will result in delays in the QA
Process.
If the vendor is unable to provide this documentation, the purchase orders will be subject to cancellation
by the buyer.
While it is the manufacturers responsibility to test their product at various stages of production
(following CPSC requirements), QA will also coordinate the process on the final garment and labeling to
ensure the product and labeling meet all Costco Wholesale requirements. (See Part 3 for details).
Provided the vendor can produce copies of all testing documents from all stages, QA will not require
garment (GPU) flammability testing to be done during the Product Quality & Label testing. QA will
advise the testing lab (see Test Request) to test ONLY one (1) random color/pattern for flammability.
If the vendor uses the testing lab for their in-house flammability testing, no additional flammability
testing will be required during the Product Quality & Label testing.
It is best to use the same lab that will be performing the production testing. Thus, the lab will have all
reference documents. For questions of which lab to use, please contact the proper QA project person.
Costco Wholesale reserves the right to require flammability testing on all colors/patterns.
7.3 REQUIREMENTS FOR TIGHT FITTING SLEEPWEAR

Tight fitting sleepwear (usually cotton knit) must be manufactured to very tight size specifications, which
generally run small compared to other clothing in the same size range. These garments must not exceed
the maximum dimensions specified in the CFR regulations for the chest, waist, seat, upper arm, thigh,
wrist or ankle.
The vendor is responsible for conducting all necessary tests and inspections during to product to ensure
that all garments meet the size requirements for tight fitting sleepwear.
7.4 REQUIREMENTS FOR NON-TIGHT FITTING SLEEPWEAR
The manufacturer is responsible for maintaining all test reports, burned specimens and samples from each
production stage (fabric, prototype and production garment) for a minimum of three (3) years.
A centralized location for filing and storage is suggested, and should be available within 72 hours to the
CPSC. The manufacturer must be fully capable of interpreting test results issued by the lab. Any
questions about flammability requirements can be answered by checking the CPSCs website.
The link to the 16 CFR 1615 requirements (for sizes 0-6X) is:
http://www.access.gpo.gov/nara/cfr/waisidx_03/16cfr1615_03.html
The link to the 16 CFR 1615 requirements (for sizes 7-14) is:
http://www.access.gpo.gov/nara/cfr/waisidx_03/16cfr1616_03.html
7.5 STAGES OF TESTING
There are three separate stages of flammability testing for childrens sleepwear.
Fabric Stage
Assign an FPU number (Fabric Production Unit) for no more than 5,000 linear yards (or less) of fabric
produced.
Cut a 2 yard sample from the beginning of each FPU and from the end of each FPU. Cut the 2 yard
samples in equal 1 yard segments.
A 1yd piece from the beginning and end of each FPU must be tested for flammability. The other 1 yard
pieces from the beginning and end of each FPU must be kept in sample retention for 3 years.
All samples must be marked with the FPU number and location from the roll (beginning or end.)
Flammability testing is done as the fabric is received in its original state and then again after 50
washings, to make sure the surface isnt altered, or that any flame retardant chemicals have not been
removed during washing in a way that would promote flammability.
Fabrics that do not have any flame-retardant finish (such as 100% nylon or polyester fabric) must also be
tested after 50 washes on the initial FPU only. Subsequent FPUs within the same style do not require
the 50 wash tests, provided that the initial FPU provided acceptable test results after 50 washes.
Fabrics that have a flame-retardant finish must be tested in original state and after 50 washes for each
FPU number in that style. Launder the samples in accordance with AATCC 124, with a water temperature
of 140
o
F and drying temperature of 150
o
F (exhaust temperature). Use an 8 lb. ballast (maximum), when
laundering.
The actual burned specimens from each test must be kept by the vendor and/or manufacturer for a sample
retention period of 3 years. The specimens shall be placed in a plastic bag, and the bag must be marked
clearly with the FPU number, location of roll and lab report number.
The CPSC website has additional information on sample retention procedures and
requirements.
If any FPUs fail, the manufacturer must reference the tightened sampling plan
requirements of the CPSC.
Prototype Seams and Trim Stage
The garment manufacturer must test all seam designs and trim designs prior to garment production.
Trim is defined as a decorative material such as ribbon, lace, embroidery or ornaments. Trim present in
less than 2 square inches of total garment surface area is exempt from this trim classification. Trim does
not include functional items such as zippers, elastic, interlinings or buttons.
It is suggested that if a garment has decorative trim, a sample of that sleepwear style should be submitted
to the lab for evaluation, so it can be determined exactly what should be submitted for the seam/trim
prototype phase.
Prototype testing includes all seam constructions (excluding findings) and trim designs. Actual
production fabric, trims and threads must be used to construct the specimens.
Prototype seams and trim samples must be identical to the production samples. If any changes are made
during the manufacturing process, prototype testing must be conducted on those changes.
For seam testing, prepare fifteen (15) specimens (3.5 wide x 10.0 long) with the seam centered in the
3.5 width. A duplicate set of seams must be kept for sample retention for 3 years. All seams that are
used in the construction of the garment must be submitted.
For trim testing, prepare fifteen (15) specimens with the trim attached as it is constructed in the garment.
A duplicate set of seams must be kept for sample retention for 3 years. If the trim is used in the vertical
position in the garment, including sleeve and neckline trim, it should be placed in the center of the fabric
specimen. If the trim is used in the horizontal position, such as chest piping, it should be attached to the
bottom edge of the fabric.
It is recommended that the vendor submit one sample garment to the testing lab for instruction on what
components need to be tested.
The actual burned specimens from each test must be kept for sample retention for 3 years. The specimens
shall be placed in a plastic bag, and the bag must be marked clearly with the trim or seam design and lab
number.
The CPSC website has additional information on sample retention procedures and
requirements.
50 home launderings is NOT required for prototype seam and trim design.
The manufacturer must be capable of interpreting the test reports to ensure that no rejected prototype
seams or trim designs are used in final production.
If a prototype seam or trim design is rejected, the seams or trim can be reworked to find an alternative
seam construction that passes the flammability test.
Production Garments
The garment manufacturer must assign a GPU number (Garment Production Unit) for up to 500 dozen
(6,000) garments produced.
The GPU number must be clearly marked on each garment label. The label must be permanently attached
and the number must be legible for the life of the garment. Putting the FPU number on the garment is
optional.
Vendor must submit enough samples to complete GPU testing per all CPSC regulations. The vendor must
also retain six (6) duplicate samples of each GPU for sample retention for 3 years.
It is suggested that a sample of the sleepwear (largest size) and/or size specs be submitted to the testing
lab so they can determine the sampling requirements for the garment flammability testing phase.
Note: In cases where smaller infant and toddler sizes are produced (i.e., 12, 18, 24 months), additional
samples may be needed for testing.
The actual burned specimens from each test must be kept for sample retention for 3 years. The specimens
shall be placed in a plastic bag, and the specimens must be marked clearly with the FPU number, GPU
number and lab number.
QA recommends developing a tracking system that illustrates how many garments are being produced
from each FPU number.
For example:
Total Yardage
Purchased
Style FPU No. Color GPU No. Garments
Produced
20,000 yards 73645 1000 Red 001 Small: 2,000
Red 002 Medium: 2,000
Red 003 Large: 2,000
1001 Green 101 Small: 2,000
Green 102 Medium: 2,000
Green 103 Large: 2,000
1002 Blue 201 Small: 2,000
Blue 202 Medium: 2,000
Blue 203 Large: 2,000
1003 Yellow 301 Small: 2,000
Yellow 302 Medium: 2,000
Yellow 303 Large: 2,000

The manufacturer must be capable of interpreting the test reports. Rejected garments cannot be retested,
used or promoted for use in childrens sleepwear in the USA.
The manufacturer is responsible for maintaining all test reports, burned specimens and samples from each
production stage (fabric, prototype and production garment) for a minimum of three (3) years. A
centralized location for filing and storage is suggested.
In conjunction with the tracking system, the manufacturer is also responsible for the disposition of any
rejected units along with specifications and details of all components used in the construction of the
garment such as thread type, trim, garment specifications, fabric specifications, fabric mill location,
garment manufacturer location, purchase orders and date of shipment.

CASHMERE MANUAL
Part 8 OVERVIEW
8.1 CASHMERE BUYING GUIDELINES
The following guidelines were established with and for the buyers to help ensure the quality and
specifications of all cashmere product purchased. These guidelines are specifically for all 100%
Cashmere or the 50/50 cashmere program.
If the vendor has any questions about these buying guidelines, they should contact the Costco Wholesale
buyer for additional information and clarification.
Goods to be purchased FOB Costco Depots (USA orders only).
As Costco Wholesale will not be doing the importing, we will require a copy of all shipping
documents, including the Bill of Lading and the following documents (USA orders only):
Commercial invoice for raw cashmere (white out pricing) Packing List.
Goods should be purchased on Open Account with enough dating to ensure that product is
received and put on the floor long enough to detect any problems before payment is made.
All specs, agreements, purchase orders will state 100% cashmere, or 50% Cashmere/ 50% other
fiber required by the specific buyer.
Vendor must have a USA office from whom an FTC Continuing Guaranty is issued (USA orders
only).
Costco Wholesale must have a copy of the vendors Continuing Guaranty on file. (copies to QA &
buyer)
QA will verify the CG with the FTC.
List of all factories involved in Costco Wholesale production & their background and relationship
to the vendor from whom Costco Wholesale purchased the goods.
Vendor must advise if the factory will be running any other fibers at the same time (i.e., cotton,
wool, silk) as this could pose a potential risk of contamination.
Vendor to provide detailed cashmere specs (see forms section for the Cashmere Specification
Sheet)
Vendor acceptance of purchase orders is acceptance of all terms, conditions, and requirements of
the Costco Wholesale Cashmere Purchasing and QA Program.
8.2 LAB QUALIFICATIONS FOR CASHMERE TESTING
o If shipments for multiple countries are being produced, QA will make every attempt to
coordinate the inspections for each country to take place at the same time.
o All colors / styles will still need to be tested for quality and labeling, fiber ID and
specification verification.
All testing should be done under the CV Cashmere Development Testing Program or under the
QA Cashmere Garment Testing Program ONLY!
Any testing or inspections done outside these two Costco Wholesale programs will NOT be
accepted.
Select testing labs perform all fiber content testing for the Costco Wholesale Cashmere Testing
Program.
In the event there is a failure in the fiber content testing, Costco Wholesale may chose to do
correlation testing with a different testing lab who is approved by the Cashmere & Camel Hair
Manufacturers Institute (CCMI) to identify and test cashmere fibers.
8.3 RESPONSIBILITIES
QA Responsibilities
Track all CV and QA coordinated testing and inspections using the Cashmere Production Tracking
Spreadsheet to ensure that all lots of cashmere are tested and approved at each stage of production.
Submit the Test Request to the vendor and the designated testing labs by the specified dates.
Part 9 THE CASHMERE QA PROCESS: A SUMMARY
50/50 Cashmere Program (KS and Hathaway)

Buyer initiates testing with the proper QA contact
QA keeps all results on a separate spreadsheet on the Costco internal P drive, plus all records, hard
and soft for reference.
The testing lab performs all quality and label tests per Costco protocols except for fiber ID.
The Brachi Cashmere lab performs all fiber ID testing for Costco.
The vendor sends in pre-production samples to the Brachi lab for Raw Fiber
o Raw Fiber tests include: color, fiber content, micron thickness, and fiber length
Raw fiber color must be white..
Fiber length must be a min of 27 mm.
Micron thickness must be below a desired min of 15.5 microns, but an actual
minimum of 15.9.
Once the buyer requests testing and all pre-production testing is approved, the vendor submits 3 sets
of samples to the lab listed on their test request form from Costco QA for all testing.
o 1) QA samples / Brachi fiber ID samples.
o 2) Quality and Label samples.
o 3) Inspector samples.
For quality and label testing. (Vendor sends in 4 samples of one color plus 2 samples of each
additional color for this test)
Inspections are completed per buyers request. Usually 1 inspection per item is done. (Vendor
sends in one sample of any color plus a 12 x 12 swatch of each additional color)
Once all testing (including pre-production tests) requested by the buyer is complete and approved
or overridden, QA will issue a QA approval letter to the buyer.

Buyer Sourced 100% Cashmere Testing Process (Non KS and Hathaway
garments)

Buyer initiates testing with the proper QA contact
The testing lab performs all quality and label tests per Costco protocols except for fiber ID.
The vendor sends in pre-production samples to the Brachi lab for Raw Fiber.
o Raw Fiber tests include: color, fiber content, micron thickness, and fiber length
Raw fiber color may be white or brown.
Fiber length must be a min of 35 mm.
Micron thickness must be below a desired min of 15.5 microns, but an actual
minimum of 15.9.
Inspections are completed per buyers request. Usually 1 inspection per item is done. (Vendor

KS and Hathaway 100% Cashmere Testing Process

The buyer sends a copy of the cashmere tracking spreadsheet to the vendor to be filled out in every
stage of testing.
o Every time a test is complete, the vendor should add the results to the spreadsheet.
o At the end of the month an updated spreadsheet should be sent to QA and the buyer from
the vendor.
The designated testing lab performs all production testing except fiber ID.
The vendor sends in pre-production samples to the Brachi lab for
1) Raw Fiber
o Raw Fiber tests include: color, fiber content, micron thickness, and fiber length (KS and
Hathaway tests needed)
Color must be white.
Fiber length must be a min. 35 mm.
Micron thickness must be a desired max 15.5, but an actual max. 15.9

2) Dyed Fiber
o Dyed fiber tests include: raw fiber color, fiber content, and micron thickness (KS and
Raw fiber color must be white.
Fiber length must be a desired min. 35 mm, but an actual min. 30.0 mm

3) Spun Fibers (knitted panels are for production testing)
o Spun Fiber tests include: raw fiber color, fiber content and micron thickness (KS and
Raw fiber color must be white
Fiber length must be a desired min. 35 mm, but an actual min. 30.0 mm
o Results are combined for all countries except regulatory tests and labeling. A separate
report fee is applied for each additional country.
Inspections are completed per buyers request. Usually 1-2 inspections per item are done. (Vendor
o Most vendors combine multiple countries into one inspection to save cost.

9.1 How to Submit Cashmere Samples for Production Testing

The factory should submit 4 complete sets per color/style.
1. One set of samples is for the testing lab (no fiber ID testing)
2. One set is for QA/buyer approval and Brachi fiber content testing.
3. One set is for use by the testing lab inspector when at the factory.
Each set of samples should be packed separately and clearly marked Test Samples, QA/ Brachi
Samples, and Inspector Samples.
The Testing Lab Request Form must be included with the samples when they are submitted to the
testing lab.
The Brachi Test Request Form must be included with the samples when they are submitted to the
testing lab.

Test Samples
The vendor must submit the correct number of samples for full quality and label testing.
The needed number of samples per color/pattern is noted on the test request. Sampling requirements
for testing are detailed later in this section.
It is recommended that vendors submit only the largest available sizes for testing to maximize the
amount of material available for testing.
Additional samples of trim components such as zippers, buttons will also be requested on the test
request, please disregard if there are no trim components on the garment.
The required number of samples for testing is explained in detail later in this section.
If 94/62/EC testing has been requested, submit additional samples of all packaging and labeling.
Note: 94/62/EC can only be conducted on final production packaging and labeling.
QA and Brachi Fiber Content Samples
The vendor must submit the correct number of samples for QA/ buyer approval and Brachi Cashmere
testing samples.
The required number of samples needed per color/pattern is noted on the test request.
The number needed for QA approval and Brachi testing for garments is usually 1 sample per
color/pattern representing all sizes. (The garment will be cut in half. Half for Brachi testing and half
for Costco QA reference.)

Inspector Samples
The vendor must submit the correct number of samples for use by the inspector during inspections, the
required number of samples per color pattern is noted on the test request.
The required number of samples needed for use in the inspections is usually 1 sample representing all
styles and a 12 x 12 swatch of each additional color/ style unless otherwise noted on the Test
Request.

Part 10 COSTCO VENDOR (CV) CASHMERE DEVELOPMENT
PROGRAM
The CV Cashmere Program is MANDATORY for 100% Cashmere Garments.
10.1 EXPLANATION
This is a vendor initiated and coordinated program for testing cashmere at each stage of production prior
to the assembly of the final garment. This program is NOT to be used for the testing of garments.
All development testing will be conducted by the Brachi Testing Lab. The Brachi Testing Lab is the only
lab approved to test cashmere for the Costco Wholesale program.
At each stage of production the vendor must pull samples of the cashmere and submit them with the
Brachi Costco Vendor (CV) Cashmere Development Test Request Form directly to the Brachi Testing
Lab.
The cashmere testing lab will test the samples primarily for fiber content, micron thickness of the fibers,
length of the fibers, and the raw fiber color. The specific testing required at each stage will be noted
below.
Note this is a mandatory testing program (if claimed 100% cashmere). If any testing required under the
CV Cashmere Testing Program is not completed, the purchase orders are subject to cancellation by the
buyer.
10.2 CV FORM
The vendor must complete the Brachi Costco Vendor (CV) Cashmere Development Test Request
Form.
The vendor must submit this form each time samples are submitted for testing.
Vendor must indicate from what stage of production the samples were pulled Raw Fiber After
Spinning, After Dyeing, After Knitting
The vendor must provide the required specification for the fibers being submitted.
10.3 SAMPLE SUBMISSION PROCEDURES
At each of the below noted stages of production, the vendor must pull samples of cashmere and
submit them to the Brachi Testing Lab.
The samples should be accompanied by a completed copy of the Brachi Costco Vendor (CV)
Cashmere Development Test Request Form (hereafter referred to as the CV Test Request Form) for
each submission to the Cashmere Testing Lab.
The form must include all requested information. If all the required information is not provided to the
Brachi Testing Lab, Costco Wholesale may be unable to link your CV reports to your production.

Raw Fiber Stage
Costco Wholesale will require the vendor to pull 15 grams of raw fibers from each lot of cashmere fibers
and send them directly to the Brachi Cashmere Testing Lab for fiber ID and spec verification for:
Fiber content
Fiber length
Average micron thickness
Raw fiber color
Results & Corrective Action
Failures (less than 100%) will be rejected---additional retests will not be accepted.
The failing lot of raw fibers must NOT be used for Costco Wholesale production.
The vendor must confirm in writing to the buyer and QA that they are sourcing a new lot of
raw fibers. The new lot#must be provided to QA for tracking purposes.

Dyed Fiber Stage
Costco Wholesale will require the vendor to pull 15 grams of dyed fibers in every color from each lot and
send them directly to the Brachi Cashmere Testing Lab for fiber ID and spec verification for:
Fiber content
Raw fiber color

The failing lot of dyed fibers (failing color only) must NOT be used for Costco Wholesale
production.
The vendor must confirm in writing to the buyer and QA their corrective plan.
If a new lot of raw materials is sourced, the new lot#must be provided to QA for tracking
purposes.
The new lot will need to be tested starting at the raw fiber stage.

QA Suggestion (not required)
If the dyed fibers are not going to be spun in the same facility that dyed them, we suggest that the
vendor test the fibers in the dyeing facility before shipment to the spinning facility
The dyed fibers should then be tested again as soon as they are received at the spinning factory to
confirm that there has been no contamination before moving on to the spinning phase of
production

Spun & Dyed Fiber Stage
Costco Wholesale will require the vendor to pull 15 grams of spun & dyed yarn in every color from every
lot and submit them directly to the Brachi Testing Lab for fiber ID & spec verification for:
Fiber content
Raw fiber color

The failing lot of spun & dyed fibers (failing color only) must NOT be used for Costco Wholesale
production.
purposes.

If the spun fibers are not knitted in the same facility that spun them, we suggest that you test in the
spinning facility before shipment to the knitting facility.
The spun fibers should then be tested again as soon as they are received at the knitting factory to
confirm that there has been no contamination before moving on to the knitting phase of
production.

Knitting Stage
This section only applies if the vendor is using separate facilities to knit the panels and assemble the
garments. If the same facility is responsible for both the knitting of the panels and final garment
assembly then the production garment is used for the knitted panel test. The CV Testing is
complete, no additional testing is needed under the CV Program, see Part 3 for Cashmere QA
Process details.
Costco Wholesale will require the vendor to pull 1 knitted panel in each color from each lot of knitted
panels and submit them directly to the Brachi Testing Lab for fiber ID & spec verification for:
Fiber content
Raw fiber color
The failing lot of knitted panels (failing color only) must NOT be used for Costco Wholesale
production.
purposes.

If the knitting is not done in the same facility as the final garment assembly, we suggest that you test
in the knitting facility before shipment to the assembly facility.
The panels should then be tested again as soon as they are received at the assembly factory to confirm
that there has been no contamination before moving to the garment assembly phase of production.
10.4 RECEIVING RESULTS UNDER THE CASHMERE CV PROGRAM
When a report is issued at each of the above stages, the report must be signed off and approved by
the buyer.
While the factory may proceed from one step of production to the next without approval from
Costco Wholesale, we strongly caution you to stop production until each set of reports are
approved.
If a failure is found in the dyeing process for example, but you have already begun spinning the
fibers, Costco Wholesale cannot be held responsible for any financial losses that may result if the
orders are cancelled.
Responsibility for sourcing and producing product that is 100% cashmere is solely the vendors
responsibility.
10.5 CASHMERE TESTING TRACKING SPREADSHEET
This is a document created by QA that is used to track the testing of cashmere through each stage of
production.
The buyer and QA will email the form template to the vendor. Each test result and all information needs
to be filled out by the vendor at each stage.
The vendor should email the form back to the buyer or Private Label Apparel / Manufacturing and the QA
contact for review and approval at the end of each month during testing.
10.6 CASHMERE LAB CONTACT INFORMATION

Brachi
Laboratorio di Analisi
Via Fonda Di Mezzana, 61/L
59100 Prato, Italy
Contacts:
Mr. Primo Brachi and Mr. Giancarlo De Blasi
Phone: 0113-905-7459-1343
Fax: 0113-905-7459-3975
E-Mail: Mr. Primo Brachi: studioprimo@brachi.it
Mr. Giancarlo De Blasi: laboratorio@brachi.it


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Costco Wholesale Non-Foods QA Manual for Apparel - 1 - Revised 6/09/03

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