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Home >> Factory Audit >> Quality And Productivity >> FCCA >> FCCA Quality System Audit

FCCA Quality System Audit

2008-12-18 Author: From:BigTimes(China)Products Testing and Technical Services Ltd  Font:16 14 12

                                                                     2008/04/01

FCCA Quality System Audit Outline

(Quality System part for Home Textile category)           

 

1.0

Factory Facilities and Environment

 

 

1. There is sufficient lighting on: Production, revising, finishing, inspection, packing and loading areas?

 

 

2. The facility maintains clean and organized production, finishing and packing areas.

 

 

3. Facility has separate inspection area with inspection table and proper ventilation.

 

 

4. No broken windows or leaking roofs that may result to product contamination was observed during Audit.

 

Critical

5. Factory has metal detecting unit and located at the right finishing area. (Scoring will not apply (N/A) if factory does not need this machine.)

 

Critical

6. Factory implements strict sharp tools control procedure to prevent scissors, knives, blades, broken glasses and needles to be mixed with product.

 

 

7. Factory has back-up power supply available. ^Generator ̄

 

1.1 Machine Calibration and Maintenance

 

 

1. Factory machines and equipments are appropriate to produce Wal-Mart products.

 

 

2. Factory has documented system and procedure for scheduled equipment cleaning and repairs.

 

 

3. Factory machines and equipments appear to be clean and in good running condition.

 

 

4. Machines, equipments and tools are properly labeled with date of last maintenance, calibration and schedules.

 

 

5. Machines, equipments and tools that need to be repaired are properly labeled or marked to avoid accidental use.

 

 

6. Factory has proper, clean and organized storage area for critical defects that can be used for segregation.

 

 

7. Factory has proper documentation and updated inventory of machines, tools, spare parts and equipments.

 

 

8. Factory has maintenance team with suitable skill level and equipments to perform necessary repair and calibration on machines.

2.0

Quality Management System

 

 

1. Factory has established Quality Management System that is appropriate to their products and procedures.

 

 

2. Workers & Supervisors are familiar to these quality policies and objectives.

 

 

3. Factory has documented customer complaint system and documented recall program.

 

 

4. Factory QC team is independent from Production division.

 

 

5. Production management and QC team discuss and work together in solving Quality issues and concerns. (Documented) 

 

 

6. Factory has systems and procedures in place to control the risk of physical, chemical and biological contamination that may damage the product and personnel as well.

 

 

7. Factory conducts risk Audits to identify safety of products, in process equipments and tools.

 

 

8. Is factory accredited with any international, national or customer quality standards association (e.g. ISO 9001, etc.)?

3.0

Incoming Materials Control (Warehousing and Storage)

 

 

1. Has factory taken adequate measures to ensure raw materials conform to required specifications before use? Are color relevant materials such as fabrics, threads, yarns and accessories sorted by lot numbers?

 

 

2. Proper first in-first out (FIFO) system on materials are practiced.

 

 

3. Factory has procedures (instructions, guidelines and documented records) for quality inspection on incoming raw materials, accessories and components.

 

 

4. Are needed testing equipments available and maintained in good condition?

 

 

5. Are raw materials properly labeled, stored and traceable?

 

 

6. Factory has documented process and reference samples that ensure incoming raw materials conform to specifications. (e.g. approved fabric swatch for fabric quality and color at Fabric Store)

 

Critical

7. Factory has proper documented system on material segregation to avoid accidental contamination from rejected items.

 

 

8. Factory properly separate good quality items from rejects and identifies non-conforming materials (rejects) for replacement.

 

 

9. Facility¨s storage areas have sufficient lighting, well ventilated and clean surrounding.

 

 

10. Materials, components and accessories are properly stacked and identified with tags or labels and are off the floor.

 

Critical

11. Chemicals and maintenance substances are properly marked and stored to prevent risk of contamination.

 

 

12. Does factory have a documented supplier selection and approval process?

 

 

13. Does factory track, evaluate and document material supplier's reliability and performance?

 

 

14. Does factory have an established, documented quality procedure and does factory evaluate, monitor sub-contractor quality performance and reliability?

4.0

Process and Production Control

 

 

1. Does factory PD study and apply product safety features, evaluates patterns and discussed with Production team for production feasibility?  

 

 

2. Factory has documented Quality procedures (QP) at each stage of operation.

 

 

3. Does factory conduct Pre-production meeting prior to start of production internally? Are production, quality supervisors and merchandiser present during PP meeting and same is documented in style files?

 

Critical

4. Are critical quality and safety checks reviewed, identified, and actions for improvement documented during Pre-production meeting?

 

 

5. Does factory conduct "Pilot Run"? Review product quality against specification sheet and document results with corrective actions prior to production?

 

 

6. Was in house lab-testing performed on current production? (Request for test copies)

 

 

7. Does factory QC compare first piece samples with approval sample and specification sheet?

 

 

8. Are there adequate approved samples, first piece samples, reference samples and work instructions to provide workers with proper guidelines?

 

Critical

9. Does Quality Control have authority to stop production if quality of products did not meet specification?

 

 

10. In-line inspections (IPQC) are performed by QC at every operation process.

 

 

11. Is quality of item acceptable on current production? (Check 32 finished products taken from factory final inspected goods and check for major defects on the item.)

 

 

12. Factory QC inspect per customer standard and documents pre-final report? Is customer advised to conduct inspection only after passed factory final QC report?

 

 

13. Factory performs 100% functionality check on final products?                          

 

 

14. Does factory use corrective actions and root cause analysis methods? (Please provide examples)

 

 

15. Does factory have documented guidelines in place to ensure packaging is correct for product?

 

 

16. Does packing area have enough space to perform packing functions properly? Is it clean and organized? Are approved finished products packed immediately in order to avoid dust and dirt? If not, are they properly stored and protected?                                                                                      

 

 

17. Packed cartons are stored in enclosed area not exposed to sunshine and wet weather.

 

 

18. Does factory track and document on-time ship performance?

5.0

In-House Lab-Testing

 

 

1. All gauges and test equipments have valid calibrations displayed. Standard laboratory operating procedures are placed near the equipments.

 

 

2. Testing manuals of various industry standards are available as reference.

 

 

3. In-house Lab Technicians are properly trained to perform testing functions.

 

 

4. Does factory perform in-house lab testing and are facilities appropriately equipped? SOP for key tests?

 

 

 

Tests usually performed are:

 

 

Physical Testing: In-hose Lab test checking points

 

 

1)  Fabric Weight

 

 

2)  Yarn Count

 

 

3)  Thread Count

 

 

4)  Shrinkage (After Wash Test)

 

 

5) Color evaluation

 

 

6)  Colorfastness (After Wash Test)

 

 

7)  Light Fastness (After Wash test)

 

 

8)  Crocking (After Wash Test)

 

 

9) Fiber Content (Composition)

 

 

10) Fabric Construction

 

 

11) Tensile Strength

 

 

12) Tear Strength

 

 

13) Laundering/ Dry Cleaning

 

 

14) Pilling

 

 

15) Loft Retention

 

 

16) Fiber Fill Weight

 

 

17) Seam Slippage

 

 

   Product Testing

 

 

18) Shade Matching

 

 

19) Dyeing

 

 

20) Fabric Quality

 

 

21) Workmanship

 

 

22) Product Construction

 

 

23) Product Dimensions

 

 

24) Product Embellishments

 

 

25) Product Weight (If needed)

 

 

     Packaging/ Labeling

 

 

26) Bag/ Package Material

 

 

27) Care Label Accuracy

 

 

28) UPC Accuracy and Placement

 

 

29) General Appearance

 

 

30) Correct Fold Size

 

 

 

6.0

Final Inspection

 

 

1. Does factory have procedure and working instruction for final QC?

 

 

2. Factory QC conducts final inspection per standard AQL or as per industry standards.

 

 

3. An approved sample or reference sample with packing list and shipping marks are available as reference for factory QC.

 

 

4. Are there formal written final inspection reports? Are they properly filed and traceable for review on quality of products?

 

 

5. Does factory final QC performs internal mechanical tests to ensure the safety of product?

 

 

6. Where appropriate, are inspection and testing equipment used by the inspector in good condition and calibrated?

 

Critical

7. Failed inspections are properly corrected prior to final inspection by customer.

 

 

8. Factory does not ship goods unless subjected to release procedures from customer.

7.0

People Resources and Training

 

Critical

1. Factory conducts documents and maintains on-job training for all personnel and conducts pre-hire testing of skilled workers prior to hiring.

 

 

2. Factory conducts and documents technical training programs for Electrical/ Mechanical Engineer, Machinist, QA Auditor and Lab Test Technician.

 

 

3. Records of trainees, contracted and all regular personnel with corresponding performance records are kept and maintained.