泉州某服装厂_沃尔玛FCCA质量验厂报告

initial Factory Capability & Capacity Audit (FCCA)QUALITY SYSTEM:Particulars Audit 3210N/A1.0Factory Facilities and Environment1. There is sufficient lighting on:Production, revising, finishing,inspection, packing and loading areas?X 2. The facility maintains clean andorganized production, finishing andpacking areas.X 3. Facility has separate inspection areawith inspection table and properventilation.X 4. Facility has documented pests/mildewand moisture control program whichincludes frequent inspections. (in-houseor 3rd party)X 5. No broken windows or leaking roofsthat may result to product contaminationwas observed during audit.X Critical 6. Factory implements strict sharp toolscontrol procedure to prevent scissors, knives, blades, broken glasses andneedles to be mixed with product.X 1.1 Machine Calibration and Maintenance3210N/A 1. Factory has documented system andprocedure for scheduled equipmentcleaning and repairs.X 2. Factory machines and equipmentsappear to be clean and in good runningcondition.X3. Machines, equipments and tools areXproperly labeled with date of lastmaintenance/calibration and schedule.4. Machines, equipments and tools thatneeds to be repaired are properlyXlabeled to avoid accidental use.5. Factory has proper, clean andorganized storage area of critical toolingX(i.e. injection moulds) with labeledshelves.6. Factory has proper documentationXand updated inventory of machines,tools, spare parts and equipments.7. Factory has maintenance team withsuitable skill level and equipments toXperform necessary repair and calibrationon machines.1.0 Total Possible Points Total Actual Points Total N/A Total Adjus10880010 REMARKS:The lighting was not sufficient on inspection area. Examples: inspection of final pro products:283lux. IQC workstation:200lux.1.0.4The factory did not establish humidity control and mildew control procedure and no1.0.5The roof for the finished goods packing and storage area was unclosed, and thereBlades using in Cutting workshop, Scissors using in sewing workshop were not cod1.1.3Factory did not have scheduled maintenance and calibration. Some of machines,labeled with date of last maintenance and calibration.2.0Quality Management System3210N/A1. Factory has established QualityXManagement System that is appropriateto their products and procedures.2. Workers & Supervisors are familiar toXthese quality policies and objectives.3. Factory has documented customer complaint system and documented recall program.XCritical 4. Factory QC team is independent from Production division.X5. Production management and QCteam discuss and work together insolving Quality issues/ concerns. (Documented)X6.Factory has systems and proceduresin place to control the risk of physical,chemical and biological contaminationthat may damage the product andpersonnel as well.X7.Factory conducts risk audits to identifyhazards from chemicals, raw materials,process equipments and tools.X8. Is factory accredited with anyinternational, national or customerquality standards association (e.g. ISO9001,etc.)?X2.0 Total Possible Points Total Actual Points Total N/A Total Adjus10881010 REMARKS:2.0.6Procedures and record of actions taken to control risks were available such as broken needprocedures to control these risks of other physical, chemical and biological contaminationFactory did not conduct risk audit and documents were not available to identify hazards from equipments and tools.The factory didn't accredit with any international, national or customer quality standards asso3.0Incoming Materials Control (Warehousing andStorage)3210N/A1. Has the factory taken adequatemeasures to assure raw materials conformance to required specificationsbefore use?X2. Proper first in-first out (FIFO) systemon materials are practiced.X3. Factory has procedures (instructions, guidelines and documented records) forquality inspection on incoming rawmaterials, accessories and components.X4. Is needed testing equipmentavailable, and maintained in goodcondition?X5. Are raw materials properly labeled,stored and traceable?X6. Factory has documented process and reference samples that ensure incomingraw materials conform to specifications.XCritical 7. Factory has proper system onmaterial segregation to avoid accidental contamination from rejected items.X8. Factory properly separate goodquality items from rejects and identifiesnon-conforming (rejects) materials for replacement.X9. Facility’s storage areas have sufficientlighting, well ventilated and cleansurrounding.X10. Materials, components andaccessories are properly stacked andidentified with tags / labels and off thefloor.XCritical 11. Chemicals and maintenancesubstances are properly marked andstored to prevent risk of contamination.X12. Does factory have a documentedsupplier selection and approval process?X13. Does factory track, evaluate anddocument material’s supplier reliability(performance)?X14. Does factory have an established,documented quality procedure and doesfactory evaluate, monitor sub-contractorquality performance and reliability?X3.0 Total Possible Points Total Actual Points Total N/A Total Adjus141106014 REMARKS:3.0.8In the Injection workshop, the factory didn't separate good quality items from rejects.3.0.11Chemicals such as alcohol, paint, and gas were not properly marked and about one thirdThe factory evaluated its material suppliers and kept evaluation records, but the evaluation per the procedure. For example, the evaluation score of one fabric supplier (Xingchangli)requirements of the procedure, it couldn't be used unless under urgent situation, and the fac Xingchangli was still the main suppliers of the factory.4.0Process and Production Control3210N/A1. Does factory PD study and applyproduct safety features, evaluatespatterns, moulds and samples duringproduct design and development?X2. Factory has documented Qualityprocedures (QP) at each stage ofoperation.X3. Does factory conduct Pre-productionmeeting prior to start of production?XCritical 4. Are critical quality and safety checksreviewed, identified, and actions forimprovement documented during Pre-production meeting?X5. Does factory conduct “pilot-run”,review product quality againstspecification sheet and documentresults with corrective actions prior toproduction?X6. Was in house lab-testing performedon current production? (Request for test copies)X7. Does factory QC compare first piece samples with approval sample and specification sheet?X8. Are there adequate approvedsamples, first piece samples, reference samples and work instructions to provide workers with proper guidelines?XCritical 9. Does Quality Control have authority tostop production if quality of products didnot meet specification?X10. In-line inspections (IPQC) areperformed by QC at every operationprocess.X11. Is quality of item acceptable oncurrent production? (Check 8 finishedproducts taken from factory finalinspected goods and check for majordefects on the item.)X12. Factory QC inspects per standardAQL or as per industry standards.X13. Factory performs 100% functionalitycheck on final products?X14. Does factory use corrective actionsand root cause analysis methods?(Please provide examples)x15. Does factory have guidelines inplace to ensure packaging is correct forproduct?X16. Does packing area have enoughspace to perform packing functionsproperly? Is it clean and organized?X17. Packed cartons are stored inenclosed area not exposed to sunshineand wet weather.X18. Does factory track and document on-time ship performance?X4.0 Total Possible Points Total Actual Points Total N/A Total Adjus180132018 REMARKS:4.0.4Parts of the pre-production meeting records were simple, and didn't state the improve meas 4.0.17The roof for the finished goods packing and storage area was unclosed and the packed cartweather.5.0In-House Lab-Testing 3210N/A1. Does factory perform in-house labtesting and are facilities appropriatelyXequipped? (Pls.refer to the FCCAattachment for in-house lab testingrequirements.)2. All gauges and test equipments haveXvalid calibrations.3. Testing manuals of various industryXstandards are available as reference.4. In-house Lab Technicians areXproperly trained to perform testingfunctions.5.0 Total Possible Points Total Actual Points Total N/A Total Adjus72510REMARKS:All gauges and test equipments were calibrated by unqualified person since 2008.The factory didn't have testing manual of any industry standard as reference.5.0.4The inspectors acted as In-house Lab Technicians, but they were not properly trained to per6.0Final Inspection 3210N/A1. Does factory have procedure andworking instruction for final QC?X2. Factory QC conducts final inspectionper standard AQL or as per industrystandards.X3. An approved sample or referencesample with packing list and shippingmarks are available as reference forfactory QC.X4. Are there formal written finalinspection reports? Are they properlyfiled and traceable to review quality ofproducts?X5. Does factory final QC perform internalmechanical tests to ensure the safety ofproduct?X6. Where appropriate, are inspectionand testing equipment used by theinspector in good condition andcalibrated?XCritical 7. Failed inspections are properly corrected prior to final inspection by customer.X8. Factory does not ship goods unless subjected to release procedures from customer.X6.0 Total Possible Points Total Actual Points Total N/A Total Adjus69576REMARKS:6.0.6No inspection and testing equipments were used during the final inspection process.7.0People Resources and Training3210N/ACritical 1. Factory conducts, documents andmaintains on-job training for allpersonnel or conducts pre-hire testing ofskilled workers prior to hiring.X2. Factory conducts and documentstechnical training programs for Electrical/ Mechanical Engineer, Machinist, QC andLab Test Technician.X3. Records of trainees and all regularpersonnel with correspondingXperformance records are kept andmaintained.7.0 Total Possible Points Total Actual Points Total N/A Total Adjus36200REMARKS:7.0.2Factory didn't conduct and maintain technical and quality training for machinist, lab test tech 7.0.3The records of trainees were incompletely.SummaryBasic Information:Capability:Capacity:Quality System:The quality management system was established according to principle of ISO9001:2000. ISO9001:2000 certificate. The latest internal audit date was on Feb. 11-14, 2009. The lates Feb. 16, 2009. The relevant records were reviewed during the audit. There were about 30 They were clearly divided to IQC, IPQC and QA. Incoming materials, semi-manufactured inspected by competent inspectors according to recognized standards GB/T2828.1-2003. Internal Lab was set up in the factory. Some tests were conducted by inspectors, and there reference.The operation procedure and related work instructions were established and all the docum During the factory audit, the operation was smooth and most of the operators were trained should make improvement in those areas that listed in the supplier CAP.Calculation of points:1.1 Per Categorya. Each question has a corresponding Audit Point and Weight. Multiply the marked “WTG” to get the score for that particular question.b. If the question is not relevant. Mark Not Applicable “N/A”. To get the score, multip points) to get the score.c. Once the category questions are completed and marked, total all scores by:- Relevant questions with corresponding points (Total Actual Points)- Not relevant questions marked N/A (Total N/A Points)d. Subtract the N/A points from the “Total Possible Points” to get the “Total Adjustede. Divide the "Total Actual Points" by the "Total Adjusted Points" to get the scoringf. A corresponding space is provided for all these scores in the report.g. If there are no N/A points, simply divide “Total Possible Points” by the “Total Actuh. Percentage score = Total Actual Points/ Total Adjusted Points(Total Adjusted Points = Total Possible Point – Total N/A Points)1.2 Report Total Scorea. Total all scores per category level:Total Possible PointsTotal Actual PointsTotal N/ATotal Adjusted Pointsb. Repeat the calculation steps on point 1.11.3 QA Point System GuideEvery question involving factory systems or process must be rated by QA baseda. 3 - Strongly Agreeb. 2 - Agreec. 1 - Needs Improvementd. 0 - Disagreee. N/A – Not Applicable. Question is not relevant to factory process.。