Quality Systems

End-to-End Lot & Roll Traceability Depth and Recall Exposure

One bale of contaminated cotton reaches 18,000 shirts. Your records decide whether you pull 754 cartons or 5,250.

The Implicated Lot What went wrong, and how much of it survives to finished goods
kg

One cotton bale is roughly 220 kg

%

Fibre to packed garment, after every waste and reject stage

Chain Fan-In How many upstream lots feed each downstream one
lots

Segregated controlled blends run low, commodity laydowns 40 to 90

lots

Count warp and weft supply separately if they differ

lots

One means the dyehouse never combines greige lots

lots

Shade banding usually forces more than one

Records & Recall Window How far back the chain is intact, and what is exposed
links

Counted back from the finished unit, 4 is bale-level identity

kg

A mid-weight shirt is about 0.42 kg

units

Used to size the blind quarantine window

days

Days of production at risk before the problem was caught

units

Cartons, not units, are what the warehouse actually pulls

Units to Quarantine

— units

The traced pull if the chain holds, the whole window if it does not

Dispersion, Exposure & What the Records Are Worth

Finished Units Actually Implicated
— units
Dispersion Factor Across the Chain
— x
Implicated Mass at Finished Goods
— kg
Share of the Original Lot in Each Unit
— ppm
Lots Resolvable from the Records
— lots
Unresolved Fan-In
— x
Implicated Share of the Exposure Window
— %
Cartons to Pull
— cartons

The model assumes each affected lot is fully consumed by the next stage and that blending is complete, which is the conservative reading and the one auditors apply. Where a lot is only partly consumed the true implicated mass is smaller, but you need consumption records at lot level to claim that, and if you had those you would probably not be estimating. Fan-in values should be the maximum the process permits, not the average, because a recall is decided by the worst case in the window rather than the typical one. The chain is treated as a simple sequence: a genuine bill of materials with parallel warp and weft supply, re-dyed seconds re-entering the stream, or leftover fabric returned to stock forms a graph rather than a chain, and each of those paths adds fan-in this calculation will not see. Yield is applied as a single cumulative figure and assumes waste is representative - if the affected material is preferentially removed, by a metal detector or a contamination sorter, the real exposure is lower, and if it is preferentially retained the figure here is optimistic. The quarantine result sizes containment only; it is not a recall decision, which also turns on where the product has already shipped, what the specification actually requires, and the regulatory regime of the destination market. Finally, the window cap means a broken chain and a complete one can return the same quarantine figure when dispersion already exceeds the window - that is not the records working, it is the exposure being larger than the period you asked about.

End-to-End Lot & Roll Traceability Depth and Recall Exposure — free, with the formula and a worked example, at Textile School.