2007-8-22 Full_Factory_Evaluation

FACTORY EV ALUATIONAPPROVED□ RECOMMENDATION □HOLD FOR INSTRUCTION □DISAPPROVED□(Recommendation is For Technical Evaluation only)Customer:Factory Name&address:1.0FACTORY DETAILS: order product:_____________1.1 QUICK OVERVIEW:Total Factory Area :Production Area: Office Area: Dormitory:Total No. of Employees: Turnover Rate: % Local: Other Provinces:Overseas:No. of Operators In:Processing: Design:Assembly: Office:Inspection:Packing: Quality Assurance:No. of workers in factory during visit:No. of workers in factory during peak season:Production Capacity: doz/mth Product produced: Minimum Order Quantity:Production Leadtime: days for an order of 1,5000-2,0000 pcs. Utilities:Electric Power: □self sufficient □power station □bothWater Supply: □self sufficient □town water □bothGoods Made During Plant Evaluation:Brands: Type:Quallity of The Goods Made:Randomly select and inspect 20 pieces of the goods made,□Good Quality – no major found□Acceptable Quality – 1 major found□Unsatisfactory Quality – 2 or more majors found□Unsatisfactory Quality – 5 or more minors foundDeseription of The Manufacturing Processing:1.2 NATURE OF BUSINESSThe manufacturing facility can do the following processing and can make the following products ( Tick the appropriate box)Product/Process Specific Type Product/Process Specific Type Screws□Plastic Molds □Bolts□Machined Metal Parts □Nuts□Machined Plastic Parts □Washers□Extruded Metal □Nylon Fasteners□Wire / Wire harnesses □Rubber Seals / O-Rings□Electronic Components □Stampings□Heat Treating □Wire Forms□Light Assembly □Raw Metal Casting□Heavy Assembly □Plating□Welding □Painting□□Powder coating□□□□□□1.3 EXPORT MARKETThe market(s) of the factory is / are : (Tick the apppropriate box and□give percentage ) USA□%Canada□% Europe□%Australia□% South America□%Japan□% China□%Others(Please Specify)□%1.4 MAJOR CUSTOMERSThe five main customers in descending order are:1.5 TYPE(S) OF MANUFACTURING(Tick the appropriate box□and give percentage)OEM (Original Equip □%Assembly Line System □% Manufacturing)ODM (Own Design □%Product Line System □% Manufacturing)Module (self contained □%Others(Please specify)□% Manufacturing units)2.MANAGEMENT / HOUSEKEEPING2.1 PLANT LAYOUTYes No 2.1.1Is there a written plant layout?□□□□2.1.2Does the written plant layout include all the departments in thefactory?□□2.1.3Are all manufacturing equipment / machines drawn in the writtenplant layout?2.1.4Was the written plant layout look to be effective?□□2.1.5Does the actual plant layout look to be effective?□□Remarks:2.2 GENERAL HOUSEKEEPINGYes No N/A 2.2.1 Were the warehouse(s) clean and well organized? □□□2.2.1 Were the workshop(s) clean and well organized? □□□□□□2.2.3 Were the machine(s) & production equipment clean and wellorganized?2.2.4 Were the tool / jig & fixture storage(s) clean and well organized? □□□2.2.5 Were the open area(s) clean and well organized? □□□2.2.6 Were the maintenance room(s) clean and well organized? □□□Remark:2.3 MAINTENANCE OF THE PREMISES Yes No N/A□□□2.3.1 Does the factory maintain a plan for maintaining the facilities(e.g. lighting, lift, electrical supply, computer network, walls,water supply, windows)?□□□2.3.2 Does the factory maintain a checklist for the inspection thefacilities in the premises?2.3.3 Is the data in the premises inspection checklist valid? □□□□□□2.3.4 Does the factory maintain a maintenance record for inspectionof premises?2.3.5 Are the records maintained and organized well? □□□Remark:2.4 MANAGEMENT AND MAINTENANCE OF THE PRODUCTIONEQUIPMENT AND MACHINES Yes No□□2.4.1 Does the factory maintain procedures / plan for managing andmaintaining production equipment and machinery?□□2.4.2 Does the factory possess a master list for all production equipment andmachines?□□2.4.3 Does the factory identify the critical production equipmentand machines?□□2.4.4 Does the factory possess the work instructions or specificationsfor inspecting and maintaining the critical production equipmentand machinery?□□2.4.5 Does the factory maintain a checklist showing the schedulefor inspecting each critical production equipment and machinery?□□2.4.6 Does each of the critical production equipment and machinerypossess a maintenance record?Remark:2.5 MANAGEMENT OF TOOLS / JIGS & FIXTURES Yes No N/A□□□2.5.1 Does the factory designate a special area for storage of tools /jigs & fixtures?2.5.2 Are the tools / jigs & fixtures stored well in this area? □□□□□□2.5.3 Does the factory maintain a master list recording all its tools /jigs & fixtures□□□2.5.4 Do the tools / jigs & fixtures have any identification (i.e. the toolnumber / tool name)□□□2.5.5 Does the factory record the position of the tool / jigs & fixturesStorage in the designated area?□□□2.5.6 Are the tools / jigs & fixtures put in the right place as stated inthe record?□□□2.5.7 Can the factory trace where the tool / jigs & fixtures has beenstored?□□□2.5.8 Does the factory maintain receive and release records of itstools / jigs & fixtures?□□□2.5.9 Does the factory have adequate resources to repair tooling ordics and molds?□□□2.5.10 In cases where tooling management is not an in-house capability,is the factory capable to monitor its tooling subcontractors?Remark:2.6 MANAGEMENT OF WAREHOUSES Yes No N/A□□□2.6.1Does each material / each batch of finished producthave any label or tag with QC approval for identification inthe warehouse(s)?2.6.2 Are materials handled to prevent damage or deterioration? □□□2.6.3 Are materials stored and recorded in designated areas? □□□□□□2.6.4 Are there formal procedures to control inventorytransactions to and from these areas?□□□2.6.5 Are materials preserved and segregated while underthe factory’s control?□□□2.6.6Is the product (material and end product) suitablyprotected after test / final inspection?Remark:3.1 PURCHASING Yes No□□3.1.1 Are procedures documented and maintained to ensurethe specified requirements for all purchased products andservices are fully met?□□3.1.2 Are purchase orders completed with sufficient data toclearly describe the product ordered?□□3.1.3 Are there any procedures to describe the selection andevaluation of all suppliers?□□3.1.4 Does purchasing or other departments maintain a SupplierHistory in terms of quality, quantity and time of delivery?□□3.1.5 Are there any provisions for the factory to verify purchasedproducts at their supplier’s premises when necessary?Remark:3.2 MATERIAL CONTROL Yes No□□3.2.1 Has the factory assigned special personnel(s) to deal withmaterial control?□□3.2.2 Are procedures documented for controlling the materialsin/out of the storage?3.2.3 Are materials in / out records maintained?□□3.2.4 Was the data in the records valid and accurate?□□□□3.2.5Does the factory have any computer system / programhandling the material control?3.2.6 Does the factory record the data manually?□□3.2.7 How often does the factory update the material in / out records?□□□□3.2.8 Does the factory have stock take on a regular base? Did thefactory have any stock take records?□□3.2.9 Are there procedures for the verification, storage, andmaintenance of customer- supplied materials?□□3.2.10 Is there a system for recording and reporting customer-suppliedor self purchased products lost ,damaged or unsuitable for use?Remark:3.3 PRODUCTION PLANNING Yes No 3.3.1 Does the factory maintain a master production plan? □□□□3.3.2 Does the factory maintain a production plan which definedthe quantity and lastest completion date of each process for allthe purchase orders?3.3.3 Does the factory have any regular weekly review cycle? Does □□the factory maintain meeting records?□□3.3.4 Does the factory organize pre-production meeting? Who areat the meeting? Please list.3.3.5 Does the factory maintain a daily production report? □□3.3.6 Does the factory maintain a weekly production report? □□□□3.3.7 Does the factory have any verification between the productionplan and production reports?3.3.8 Does the factory operate in a JIT(just-in-time) environment? □□Remark:3.4 SHIPPINGYes No ★3.4.1 How many staff are responsible for shipping in the factory?★3.4.2 How many years have they worked in handling the shipping?3.4.3 Does the factory have any container loading facilities? □□□□3.4.4 Does the factory keep adequate records and documents such asinvoice, packaging list, country of origin, foam A or B/L aftershipping the products?3.4.5 Were these shipping documents accurate? □□□□3.4.6 How many days does the factory require to arrange the trailer(s)or container(s) prior to the ship day(s) date in the purchaseorder?Remark:4. DESIGN / ENGINEERING Yes No ★4.1.1 Do the factory have Design / Engineering / R & D department(s)? □□★4.1.2 What are they?Product Design □Graphic Design □Packaging Design □Model Shop □Mechanical Eng □Electronic Eng □Industrial Eng □Packaging Eng □Quality Eng □Remark:4.1 DESIGN CONTROL Yes No□□4.2.1 Does the factory have the ability / capacity for Design?(If No, skip to section 4.3)□□4.2.2 Does the company have documented procedures for thecontrol and verification of design activities?□□4.2.3 Is there objective evidence that design personnel possessadequate resources and equipment?□□4.2.4 Are the methods used to communicate design activities betweenfunctional groups defined and documented?□□4.2.5 Are the applicable and regulatory requirements for design inputidentified and documented?□□4.2.6 Are incomplete, ambiguous, and/or conflicting requirementsresolved with those responsible for imposing the requirements?□□4.2.7 Are there formal documented reviews of design planned andconducted?4.2.8 Are records of design reviews maintained? □□□□4.2.9 Has design validation been performed to insure that productconforms to defined user needs and/or requirements?□□4.2.10 Are design changes and modifications identified, documented,reviewed and approved by authorized personnel prior to theirapplication.Remark:4.2 INDUSTRIAL ENGINEERING Yes No N/A□□□4.3.1 Is there a manufacturing flow chart/line layout for eachprocess or product, with inspection points?□□□4.3.2 Are critical processes/materials identified in themanufacturing flow chart/line layout?4.3.3 Are there work instructions for each process or product? □□□□□□4.3.4 Do the factory maintain a pilot run report for each of thenew product prior to bulk production ?□□□4.3.5 Do the factory have any production engineers? Do theymaintain any performance data for each process of eachproduct?Remark:5.IN-HOUSE QUALITY ASSURANCE5.1 GENERAL COMMENT FOR INSPECTION AND TESTINGGood Fair Poor Incoming □□□In-process □□□Final □□□5.2 INSPECTION AND TESTING5.2.1 Are there document instructions for inspection and test activitiesIncoming Yes□No□In-process Yes□No□Final Yes□No□5.2.2 Is the quality plan (or documented procedure) provided for required inspection, testing, and records?Incoming Yes□No□In-process Yes□No□Final Yes□No□5.2.3Are products inspected, indentified, and tested according to quality plans /procedures?Incoming Yes□No□In-process Yes□No□Final Yes□No□5.2.4If product is released for urgent production purposes prior to verification, is itpositively identified and recorded?Incoming Yes□No□In-process Yes□No□Final Yes□No□5.2.5Are all inspections, tests, and records completed before release?Incoming Yes□No□In-process Yes□No□Final Yes□No□5.2.6Do procedures and practices prevent the release of product that has not passedinspections and test?Incoming Yes□No□In-process Yes□No□Final Yes□No□5.2.7Are Quality Control Inspectors responsible for production work in addition to theirregular duties?Incoming Yes□No□In-process Yes□No□Final Yes□No□5.2.8Is there a statistically valid sample plan for all inspection activities, and are AQLlevels for inspections appropriate for the product produced?(see AQL Guide) Incoming Yes□No□In-process Yes□No□Final Yes□No□5.2.9Are records of inspections establisted and maintained?Incoming Yes□No□In-process Yes□No□Final Yes□No□5.2.10Is a product/dock audit completed on a regular frequency to insure all specificrequire ments were met?Yes □ No □Yes No□□5.2.11 Are there documented procedures for the identification,collection, indexing, access, filing, storage, maintenance, anddisposition of quality records?5.2.12 Are quality records legible and retrievable? □□5.2.13 Is the retention time for all records specified and adhered to? □□5.2.14 Does the factory management review the quality records? □□5.3CONTROL OF NONCONFORMING SEMI-FINISHED/FINISHEDPRODUCT Yes No□□5.3.1Are nonconforming semi-finished/finished products documented,identified and segregated?□□5.3.2Are nonconforming semi-finished/finished products traceable toa quality record?□□5.3.3 Do Quality Assurance have the authority to stop productionand shipment of nonconforming lots?□□5.3.4 Has the authority for the evaluation and dispositionof nonconforming semi-finished/finished products beenidentified?Remark:5.4 CORRECTIVE AND PREVENTIVE ACTION Yes No□□5.4.1 Are records of nonconforming materials published and actedupon for corrective action?□□5.4.2 Are records of nonconforming materials reviewed and analyzedfor repetitive discrepancies?5.4.3 Are corrective actions effective? □□□□5.4.4 Are appropriate sources of information utilized to detect, analyzeand eliminate potential causes?5.4.5 Are corrective/preventive action investigation results reviewed □□by upper management?□□5.4.6 Are corrective/preventive actions taken and confirmed byconcerned parties?Remark:5.5 CONTROL OF INSPECTION MEASURING AND TEST EQUIPMENTYes No N/A□□□5.5.1 Are there documented procedures for the control ofinspection, measuring, and test equipment?□□□5.5.2 Are all inspection, measuring and test equipmentused to verify product quality verified and calibratedbefore release for use?□□□5.5.3 Are all inspection, measuring and test equipmentcapable of measuring the required attribute?□□□5.5.4 Are all inspection, measuring and test equipmentsuitably identified as to their calibrated status?□□□5.5.5 Are all inspection, measuring and test equipment ona suitable recall system, i.e. traceable when therearise a problem?5.5.6 Are calibration records maintained? □□□□□□5.5.7 Are the environmental conditions suitable for thecalibrations, inspections, measurements and testbeing carried out?Remark:5.6 PRODUCT SAFETY Yes No N/A6. QUALITY SYSTEM6.1 QUALITY SYSTEMYes No N/A□□6.1.1 Is there a Quality Manual, and has it been reviewd byupper management?□□□6.1.2 Are there Quality Procedure Sections in the QualityManual for control of activities affecting quality?□□6.1.3 Is there any working instruction at each of the workstation?6.1.4 When was the Quality Manual last reviewed? □□□□□6.1.5 Does Quality Assurance have the support of UpperManagement? How is this demonstrated?□□□6.1.6 Are the Quality Policy and supporting proceduresknown and undertood at all levels?□□□6.1.7 Is the quality system evaluated to be efficient and effectivein the manufacturing facilities?□□□6.1.8 Is the Quality manual found to be comprehensive andfulfilled the ISO 9001 quality management systemstandard?6.1.9 To whom does the head of Quality Department report to? □□□Remark:7. CONCLUSIONS AND RECOMMENDATIONShas been assessed to be in the Hardline technical evaluation.The results of the assessing areas were summarized as follows:A-Excellent, B-Good, C-Acceptable, M-Marginal, F-Fail1. Management / Housekeeping………………………………………………( )2.Material Control / Production Planning / Shipping ………………………( )3.Design / Engineering…………………………………………………………( )4.Capacity and Facilities………………………………………………………( )5.In-house Quality Assurance…………………………………………………( )6.Quality System………………………………………………………………( )Overall Rating ( ) Other comments:Inspector:_____________________________ Date:________________________________Please insert pictures on the following table:。