Factory Audit Report - s3.qima.com · ISO 9001:2008 AQSIQ Licence 7. Factory had established...

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ISO 9001:2008 AQSIQ Licence

Factory Audit Report

General Overview of the Audit’s Findings

Fields Amount

Score

Theoritical

max Score / 5 Weight / 5

Weighted

Score

Work Flow and Organizational Charts 20 /20 5.00 1 5.00

Production Lines - Capacity 20 /35 2.86 1 2.86

Factory Facilities - Machinery Condition 25 /40 3.12 1 3.12

Quality Assurance System 12 /35 1.71 1 1.71

Social Accountability 0 /140 0 1 0

Supply Chain Management 10 /10 5.00 1 5.00

R&D – Sampling Capacity 20 /20 5.00 1 5.00

Environment 16 /25 3.20 1 3.20

Total 8 25.89

Overall Score 6.5/10

Important remarks

Based on onsite observation and interview with factory management, it is noted that the operation plant was

rent in the 4th and 5th floors out of 1 building with 5 floors from XXX Manufacture Co., Ltd which is used as

workshop, warehouse and office. No dormitory and canteen were provided for employees. The lease

agreement expire date is 9/Jan/2018. The main market of its business is domestic of PRC and Europe by trade

agent, factory didn’t have own import/export license and custom register

Negative Findings :

1. Based on the interview with factory management, the procurement time was 15 days, but records were unavailable

for review.

2. No anti-explosive lightings were installed in material or goods stored area.

3. No work instructions for all the machines in the workshop. No Training records of machinery operation for this audit

review.

4. No independent warehouse or separated area and limited space for raw material and finished goods storage.

5. No clear instruction except approved sample visible at all work stations.

6. Factory performed regular control at major production steps and the IQC, IPQC & OQC reports available for review

during audit. The containers in the inspection line for acceptable and defective goods stored were without clear

marked and separate label.

Client Bxxx Pxx AI Service No R-us3-1426951

Supplier XxAx Apparel Co.Ltd Auditor Snow Ma

Factory XxAx Apparel Co. Ltd Audit Date 04-Sep-2014




7. Factory had established documented calibration system but no relevant calibration records for steel rule and

electrical balance which was used in workshop and warehouse are available.

8. QC staff is qualified, but no training records available for this audit review.

9. The QC staff is not easily identified without visual badge or armband etc

10. 22 out of total 63 (factory stated 15 among of them just joined within 1 month) were provided with social insurance.

11. Working hour and wage could not be verified, as no attendance records and wage record were available for

auditor's review.

12. Only cleanser and machine oil were used and not properly separated in workshop.

13. No secondary container and MSDS available for chemical storage and usage.

Content :

General Overview of the Audit’s Findings ............................................................................................................... 1

Important remarks ................................................................................................................................................. 1

Content : ............................................................................................................................................................... 2

PART 1 ....................................................................................................................................................................... 4

FACTORY PROFILE ....................................................................................................................................................... 4

General Information ............................................................................................................................................... 4

Communication infrastructure ................................................................................................................................ 4

Products / Markets ................................................................................................................................................. 4

Recommendations / credentials ............................................................................................................................. 5

Building: ................................................................................................................................................................ 5

PART 2 ....................................................................................................................................................................... 9

FACTORY ORGANIZATION AND PRODUCTION PROCESS ..................................................................................................... 9

Factory Organization chart ..................................................................................................................................... 9

Production workflow chart .................................................................................................................................... 10

PART 3 ..................................................................................................................................................................... 11

PRODUCTION LINES / CAPACITY................................................................................................................................... 11

Production area condition .................................................................................................................................... 12

PART 4 ..................................................................................................................................................................... 14

FACTORY FACILITIES / MACHINERY CONDITIONS ............................................................................................................ 14

Machines for production....................................................................................................................................... 14

Machine Documentation ...................................................................................................................................... 14

Warehouse/Factory condition............................................................................................................................... 15

Sample room condition ........................................................................................................................................ 15

Public power supply ............................................................................................................................................. 17

Shipment capabilities ........................................................................................................................................... 17

PART 5 ..................................................................................................................................................................... 18

QUALITY ASSURANCE SYSTEM & RELATED CERTIFICATES (OPTIONAL)............................................................................. 18

Export license ...................................................................................................................................................... 18

Quality system management................................................................................................................................ 18

Quality system management................................................................................................................................ 19




PART 6 ..................................................................................................................................................................... 22

SOCIAL ACCOUNTABILITY (OPTIONAL)........................................................................................................................... 22

Preliminary / Document ....................................................................................................................................... 22

1. Child Labour, Forced and Compulsory Labour: ............................................................................................. 23

2. Working time: ............................................................................................................................................... 24

3. Wages:......................................................................................................................................................... 24

4. Discrimination .............................................................................................................................................. 25

5. Disciplinary practices.................................................................................................................................... 26

PART 7 ..................................................................................................................................................................... 29

SUPPLY CHAIN MANAGEMENT (OPTIONAL) .................................................................................................................... 29

PART 8 ..................................................................................................................................................................... 30

R & D / SAMPLING CAPACITY (OPTIONAL) ..................................................................................................................... 30

R & D facilities ..................................................................................................................................................... 30

PART 9 ..................................................................................................................................................................... 31

ENVIRONMENT (OPTIONAL) ......................................................................................................................................... 31

PART 10 ................................................................................................................................................................... 33

SYNOPSIS OF MAJOR FACTS AND PROBLEMS FOUND ...................................................................................................... 33

Capacity to manufacture client’s product: (Part 2 and 3) ....................................................................................... 33

Social accountability conditions: (Part 7) .............................................................................................................. 33

Factory behavior during Audit: ............................................................................................................................. 33

Auditor : Snow Ma Supervisor : Sunny Sun




Part 1

Factory profile

General Information

1 Date of foundation 27/Feb/2012

2 Legal status Private

3 Location 114#XX Road, JXX Distric, Xx City

4 GPS Location XX° N 11X° E

5 Area 1500 square meter

6 Number of employees Total Male Female

63 14 49

7 Breakdown of employees Managers Engineering Admin QA/QC Workers

2 2 2 4 53

8 Number of shifts 1 shift (from 8 :00 AM~11 :45, 13 :15 PM ~17 :15 PM)

9 Factory owner Mr CXX HX

10 Factory manager Mr XXX WX

11 Main products Knitting Sport wear

12 Main market Domestic

13 Business license Certificate No: Issued Date: Expiration Date:

35XX11XX0XX594 21/Aprail/2014 26/Feb/2032

14 Annual turnover

for the past 3 years

2013 :RMB 22 Million

2012 :RMB18 Million

2011 :RMB 15 Million

Communication infrastructure

15 Telephone 0XX2-6XX7XX5

Fax 0XX2-6XX7XX5

Homepage N/A

Products / Markets

Product type Major customer name Market location Monthly order qty

Comments : factory denied to provide these information for reference due to their commercial confidence

2011 2012 2013

Turnover




Building:

Gate of Factory Factory exterior view

Office Office

Recommendations / credentials

Company name Country Contract Products Details (date)

N/A N/A N/A N/A N/A




Business licence

Lease Agreement With Landlord Business License Of Landlord




Production Lines:

Raw Material Cutting Line

Sewing Line Inspection Line

Iron Pressing Line Packing Line




Managing staff:

Factory manager : Mr Cxx Sales : Lx Cxx

Workers In Sewing Line Workers In Packing Line




Part 2

Factory Organization and Production process

Factory Organization chart

Questions Findings/Comments Score

Does the factory have a clear

Organization chart?

Yes, based on the documents review, the factory had a clear

organization chart. 5 /5

Is it available for the entire employee?

Do they all know the responsibilities of

each other?

Yes, based on interview with employees, all the employee knows

the responsibilities of each other. 5 /5

Organization Chart




Production workflow chart


Does the factory have a written production

Process?

Yes, based on the documents review, factory has a written

production process. 5 /5

Is the production process followed? Yes, the production process is followed based on on-site visit. 5 /5

Production workflow chart

Actual Score Theoretical Max

20 /20




Part3

Production lines / Capacity

Daily output check :

Questions Findings/Comments

Is there a running production in the factory during the Audit? Yes

START FINISH Total time

(14 :00)

(15 :00)

1

Raw material Raw material Consumption

Fabric

200 meters

Finished products Finished products Output

140 Pcs

60 Pcs

What is the overall capacity?

Daily Weekly

1500 pcs/8 hours 7500 pcs/8 hours*5

days

What is the theoretical maximum capacity?

Daily Weekly

2000 pcs/10 hours 1200 pcs/10

hours*6days

Questions Findings / Comments Score

Is the Production capacity sufficient to

cover the potential client order?

Auditor didn’t know the detailed order quantity from factory

management and no way to verify this capacity. N/A

Lead times for client’s production:


What is the raw material procurement

time? Are records available?

Based on interview with factory management, the procurement

time was 15 days, but records were unavailable for review. 0 /5




Production area condition


Does the assembly line is tidy and

organized?

Based on the onsite observation, it is noted that the assembly

line was in average tidy and organized condition.

3 /5

Is the production area well enlightened? No anti-explosive lightings installed in material or goods stored

area.

1 /5

Is the production area suitable; ventilated;

cooled & heated?

Based on onsite observation, it is noted that the production

area was in average suitable, ventilated, cooled & heated level.

3 /5

Are production lines laid out in an efficient

manner?

Based on the on-site observation and review of production

workflow chart, the production lines laid out in an average

manner.

3 /5

Does the production area have floor

markings?

Based on the on-site observation, the production area have a

clear floor markings.

5 /5

Are corridors free from obstruction? Based on onsite observation, it is noted that the corridors are

free from obstruction.

5 /5

Pictures

Sewing Line In Average Tidy & Organized Condition Packing Line In Average Tidy & Organized Condition




Workshop In Average Enlightened & Ventilated

Condition

Clear Mark For Working Area

Corridors Free From Obstruction No Anti-explosive Lightings For Material & Goods

Stored Area

Special Remarks on this section

1. Based on interview with factory management, the procurement time was 15 days, but records were unavailable for

review.

2. No anti-explosive lightings installed in material or goods stored area.


20 /35




Part 4

Factory Facilities / Machinery Conditions

Machines for production

No. Type of Machinery No. of

machines

Condition/

Service

time

Maintenance

/ Calibration

record Score

Name Brand Country Yes No

1 Computerized Sewing

Machine

QXX China 48 10 Years Yes

2 Edge Seaming Machine QXX China 28 10 Years Yes

3 Cutting AXX China 2 10 Years Yes

4 Iron Pressing Machine SXX China 4 10 Years Yes

5 Stud Machine ZXX China 2 10 Years Yes

Score (overall) 5 /5

Machine Documentation


Does the factory have an equipment and

machinery list?

Based on documents review, it is noted that the factory had

an equipment and machinery list. 5 /5

Do the machines have instructions?

Procedure Manual? Available for workers?

No work instruction for all the machine in the workshop.No

Training records of machinery operation for this audit review. 0 /5

Pictures

Equipment & Machinery List Maintenance Records Of Machinery




Appropriate PPE Available For Involved Operators Safeguard Available For Machinery

Warehouse/Factory condition


Are the storerooms/warehouse tidy? Can it

stock all the potential order?

No independent warehouse or separated area and limited

space for raw material and finished goods storage. 2 /5

Estimated warehouse capacity: 2*40c

Sample room condition


Does the factory have a sample room tidy? Based on the onsite observation, it is noted that factory had

a tidy showroom. 5 /5

Related pictures:

Warehouse / Sample room




Finsihed Goods Stored Area Raw Material Stored Area

Different Color Fabric Stored Together Without

properly Separated

Accessory Warehouse And Around 30% Material

Without Clear Batch Label

Sample room view Sample room view




Public power supply


Connected? Yes. 5 /5

Does the factory employ an electrician

with certificate? No full-time certified electrician available on site. 0 /5

Frequent power outage in the area?

Does the factory have backup electric

power generator?

(Ask several people: workers &

management)

Based on the interview with factory management, power

outage in the area is unusual / No Backup Generator. 3 /5

Electric power generator count: No electric power generator.

Shipment capabilities

Questions Findings/Comments

What are the Delivery /

loading conditions?

Based on the on-site observation, the delivery/ loading conditions is in average level.

How far is the nearest port /

airport?

60 minutes to XXX Port

60 minutes to XXX Airport


1. No work instruction for all the machine in the workshop. No training records of machinery operation for this audit

review.

2. No independent warehouse or separated area and limited space for raw material and finished goods storage.


25 /40




Part 5

Quality Assurance System & Related Certificates (optional)

Export license

Date of the license: N/A

Comments: Based on the on-site observation and interview with factory management, it is

noted that the main market of its business is domestic of PRC and Europe by trade

agent. Factory didn’t have own import/export license and custom registration.

Quality system management


Does the management have an understanding of

ISO 9001 or similar quality system?

Certificate available?

Based on the interview with factory

management, it is noted that they had an

average understanding of quality system, the

quality manual available for this audit review.

3 /5

Picture(s)

Quality Manual Quality Guidance & Objective




Quality system management


Are clear instructions visible at all work stations? No clear instruction except approved sample

visible at all work stations. 1 /5

Is QC staff fully independent of production staff?

Does the QC manager have sufficient authority to stop

production?

The QC staff is completely independent from

production staff and the QC manager had

sufficient authority to stop production.

5 /5

Does the factory perform regular quality control at

major production steps?

Factory performed regular control at major

production steps and the IQC, IPQC & OQC

reports available for review during audit. The

containers in the inspection line for acceptable

and defective goods stored were without clear

marks and separate label.

1 /5

Is there a documented calibration system for

equipment?

Factory had established documented

calibration system but no relevant calibration

records for steel rule and electrical balance

which was used in workshop and warehouse

area available.

1 /5

Is the QC staff qualified? QC staff is qualified, but no training records

available for this audit review. 1 /5

Are QC supervisors easily identified The QC staff is not easily identified without

visual badge or armband, etc. 0 /5

Did the factory have had QC inspection by another

company? Which one? When? The factory has no QC inspection by another company.

Record / reports available? No

Picture(s)

Approved Sample Available At Work Station IQC On Site




IQC Report IPQC Report

Documented Calibration System No Clear Instruction Available At Work Station

No Clear Mark & properly Separated Available For

The Containers Stored Acceptable And Defective

Goods Of Inspection Line

No Calibration Records For Electrical Balance




No Calibration Records For Steel Rule QC Staff Not Easily Identified


1. No clear instruction except approved sample visible at all work stations.

2. Factory performed regular control at major production steps and the IQC, IPQC & OQC reports available for review

during audit. The containers in the inspection line for acceptable and defective goods stored were without clear marks

and separate labels.

3. Factory had established documented calibration system but no relevant calibration records for steel rule and

electrical balance which was used in workshop and warehouse.

4. QC staff is qualified, but no training records available for this audit review.

5. The QC staff is not easily identified without visual badge or armband, etc.


12 /35




Part 6

Social Accountability (optional)

Preliminary / Document


Do all the workers have a labor

contract?

Yes, based on the interview with employees, they had signed labor

contract and got the copy. 5 /5

Do all the workers have a social

insurance included in their labor

contract?

22 out of total 63 (factory stated 15 among of them just joined within

1 month) were provided social insurance and no waiver from local

agent available for this audit review.

1 /5

Result Total found 6

Theoretical Max /10

Picture(s)

Labor Contract Labor Contract

Participant List Of Social Insurance Payment Evidence Of Social Insurance




NB: If one item of this section is 0, the overall result of SA part will be 0

1. Child Labour, Forced and Compulsory Labour:

Item Findings / Comments Score

Ch

ild

lab

ou

r Minimum legal age Above 16 years old.

Workers under legal age Based on onsite observation and workers’ interview, no violation

found, but no relevant policy or procedure established by factory.

3 /5

Fo

rced

and

co

mpu

lso

ry

lab

ou

r

Prisoners at work: Forbidden

according to SA 8000

Based on onsite observation and workers’ interview, no violation


3 /5

ID Papers Deposit: Forbidden

according to SA 8000

Based on onsite observation and workers’ interview, no violation


3 /5


Theoretical Max /15

Picture(s)

Employees Roster Employees’ ID Copy Kept In Factory





2. Working time:


Wo

rkin

g tim

e

Local Standard 1, Employees shall work for 8 hours one day and 40 hours one week;

2, Overtime shall not exceed 3 hours one day and 36 hours one month;

3, The factory shall make sure that employees can take at least one rest day

per seven days.

Factory working hours Could not be verified, as no attendance records for this auditor review. 0 /5

Day off / Holiday Could not be verified, as no attendance records for this auditor review. 0 /5

Work at night Could not be verified, as no attendance records for this auditor review. 0 /5


Theoretical Max /15


3. Wages:


Wa

ges

Local Standard (See below for

Local laws)*

The local minimum wage was RMB 1320 per month since 1 May. 2013

(before this time is RMB 1200 per month); 150%, 200% and 300% of normal

wage for the overtime hours in week days, rest days and statutory holidays.

Wages Could not be verified, as no wage records for this auditor review. 0 /5

Night work Could not be verified, as no wage records for this auditor review. 0 /5

Overtime Could not be verified, as no wage records for this auditor review. 0 /5

Disciplinary deductions Could not be verified, as no wage records for this auditor review. 0 /5

Sufficiency to meet basic need of

workers and their families

Could not be verified, as no wage records for this auditor review. 0 /5


Theoretical Max /25





4. Discrimination


Dis

crim

ina

tion

Gender Based on onsite observation and workers’ interview, no violation

found, but no relevant policy or procedure was established by factory.

3 /5

Race Based on onsite observation and workers’ interview, no violation


3 /5

Age Based on onsite observation and workers’ interview, no violation


3 /5

National or social origin Based on onsite observation and workers’ interview, no violation


3 /5

Religion Based on onsite observation and workers’ interview, no violation


3 /5

Disability Based on onsite observation and workers’ interview, no violation


3 /5

Sexual orientation Based on onsite observation and workers’ interview, no violation


3 /5

Family responsibilities Based on onsite observation and workers’ interview, no violation


3 /5

Union membership Based on onsite observation and workers’ interview, no violation


3 /5

Political opinions Based on onsite observation and workers’ interview, no violation


3 /5


Theoretical Max /50




NB : If one item of this section is 0, the overall result of SA part will be 0

5. Disciplinary practices


Dis

cip

lina

ry p

ract

ice

s

Sexual harassment Based on onsite observation and workers’ interview, no violation


3 /5

Corporal punishment Based on onsite observation and workers’ interview, no violation


3 /5

Mental coercion Based on onsite observation and workers’ interview, no violation


3 /5

Physical coercion Based on onsite observation and workers’ interview, no violation


3 /5

Verbal abuses Based on onsite observation and workers’ interview, no violation


3 /5


Theoretical Max /25

Picture(s)

Suggestion Box Training Course List





First worker

Questions Results Comments

General

1 Name of the employee : Ms ZXX XX N/A

2 Documented age and sex (according to ID / Photo ) 3XXX1X84X10X28XX Female

3 Name of the Company/Factory you work for? XIX XX Apparel Co., Ltd N/A

4 How long have you worked here? Are you satisfied

with your job? 3 Month N/A

5 What specific manufacture process/component are

you working on? What is your job?

Sewing and she was

satisfied with her job N/A

SAFETY

6 Have you had first aid training? Yes Frequency: when hiring

7 Does the factory provide Personal Protective

Equipment to all employees? Yes

What kind of? Operation

safety of sewing machine

8 Have all employees been trained in case of fire

emergency? Yes

Frequency: twice per year

CHILD LABOUR

9 Have you seen children at work in the factory? No

FORCED LABOUR

10 Have you seen prisoners at work in the factory? No

11 Have you seen people asked to deposit their ID

paper to work? No

12 Are employees allowed to assemble in order to

bargain with management? Yes

DISCIPLINARY PRACTICES

13 Are some employees sexually threatened by people

from the factory? No

14 Are there employees that are physically punished in

case of mistakes? No

ASSOCIATION




15 Are the employees able to create or join any union as

they want? Yes

16 Does the factory let you play games or practise

sport? Yes

17 Does a Suggestion Box exist for employees to give

anonymous messages to the manager? Yes

DISCRIMINATION

18 Does the factory use pregnancy test as a condition of

hiring? No

19 Does a difference of wages exist between men and

women? Yes

WAGES

20 Are employees able to meet their basic needs with

their wages? Yes

HOURS OF WORK

21 Have you ever worked during 7 days without

interruption? Yes

Result Violation was found


1. 22 out of total 63 (factory stated 15 among of them just joined within 1 month) were provided with social insurance.

2. Working hour and wage could not be verified because no attendance records and wage record were available for

auditor review.


0 /140




Part 7

Supply Chain Management (optional)

Raw materials


Is the factory able to provide data about

supplier? Does the factory control them?

Yes, based on documents review, it is noted that the data

about suppliers available for this audit review. 5 /5

Who are the suppliers of raw materials and components?

Material Supplier name Country of origin / location

Zipper

Hardware

Label & Tag

Fabric

SX XX

FUX

JTX

WXX

FXX WX

YXX

XXDXX

TXLX

China/JXX

China/JXX

China/SXX

China/SXX

China/XXX

China/XXX

China/XXX

China/SXX

Sub-contracting


Is the factory able to provide data

about sub-contractors? Does the

factory control them?

Based on documents review and interview with factory management,

it is noted that the process of printing and embroider are

sub-contracted which are under factory controls.

5 /5

Which part of the production process is outsourced? Printing and embroider

Production step (ex: packaging) Supplier name Country of origin / location

Printing

Embroider

JXBX

HXCX

DXX

XXYX

LCAX

NWX

China/XX

China/XXX

China/XX

China/XXX

China/XX

China/XXX


10 /10




Part 8

R & D / Sampling capacity (optional)

R & D facilities


Does the factory have a R&D

Department?

Based on the on-site observation, it is noted that factory had a R&D

department.

5 /5

What is the sample production

process?

Based on the on-site observation, it is noted that the sample

production process is same as the assive production.

5 /5

Does the factory have special

facilities?

(sample production line or

equipment)

Based on the on-site observation, it is noted that factory had the

special facilities of drawing machines.

5 /5

What is the approval sample lead

time?

Based on the interview with factory management, it is noted that

the approval sample lead time is 7 days.

5 /5

Picture(s)

Clear Mark Of Sample Room View Of Sample Room


20 /20




Part 9

Environment (optional)

Item Findings Comments / Justifications

Score

En

viron

men

t

Is waste management arranged

in a way that does not lead to

pollution of the environment?

No finding Based on the on-site observation,

it is noted that separated

containers are available for

recycled and non-recycle waste

storage.

5 /5

Are chemicals properly and

separately disposed off?

Only cleanser and machine oil

were used and not properly

separated in workshop.

The different chemicals should

be separately stored and

disposed off.

1 /5

Is it ensured that chemicals do

not leak into the ground?

No secondary container and

MSDS available for chemical

storage and usage.

The secondary container and

MSDS should be available for the

chemical storage and usage.

0 /5

Is effluent treated to prevent

environmental pollution?


it is noted that no hazardous stuff

was produced on site.

5 /5

Are emissions in legal

conformity?


it is noted that no hazardous stuff

was produced on site.

5 /5


Theoretical Max 25

Picture(s)

Specific Container Available For Recycle Waste No Properly Separately Stored, Secondary Container

& MSDS For Different Chemicals





1. Only cleanser and machine oil were used and not properly separated in workshop.

2. No secondary container and MSDS available for chemical storage and usage


16 /25




Part 10

Synopsis of major facts and problems found

Capacity to manufacture client’s product: (Part 2 and 3)

Very bad Bad Average Good Very good

Comments:Nil

Production conditions: (Part 4 and 5)


Comments:Nil

Social accountability conditions: (Part 7)


Comments:Nil

Factory behavior during Audit:


Comments:Nil

IMPORTANT NOTES

THE ABOVE RESULT(S) REFLECT(S) ASIAINSPECTION LIMITED’S FINDINGS AT THE TIME AND

PLACE OF AUDIT.

WITH REGARD TO THE RANDOM SAMPLE CHARACTER OF THE AUDIT, IT SHOULD BE NOTED THAT

ADDITIONAL NONCONFORMITIES MAY EXIST, WHICH WERE NOT FOUND DURING THE AUDIT.

THE AUDITOR'S FINDINGS DO NOT RELIEVE THE AUDITEE OF ITS RESPONSIBILITY TO ENSURE

THAT THE REQUIREMENTS OF THE STANDARD ARE FULFILLED AND CONSTANTLY ADHERED TO.




Corrective Action Plan With Factory Signature & Chop Confirmation Of COC With Factory Signature & Chop

Original signature from Factory Manager accepting AsiaInspection conditions on Shipment

authorization and bribery issues

END

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