Đánh giá khả năng năng lực nhà máy wal mart APPAREL FCCA outline

FCCA Quality System Audit Outline
1.0

On-Site Laboratory
1. Is there an on-site, fully equipped laboratory with trained technician on site?
2. Is your Laboratory certified by other major US companies? If yes by whom?
3. Are critical laboratory tests performed (either in house or use 3rd party lab) and
result used by production for problem prevention?
4. Are there consistent fabric/garment shrinkage/wash tests conducted in-house/ at
outsourced washing plant and properly evaluated?

2.0

Sample Room, Pattern & Marker Making
1. Is the sample room fully equipped to produce samples that are representative of
factory's specific product type?
Critical

2. Is there a skilled sample room technician available and capable of modification of
patterns when required and responsible for pattern handover to production floor
with record available?
3. Are CAD system and plotter used for grading, consumption and marker?
4. Are bulk patterns and markers checked for accuracy?
5. Are shrinkage tests conducted for each bulk lot received?
6. Are sample room fabric, trims & accessories well organized in sample room? Is
housekeeping acceptable?
7.

3.0

Is lighting adequate (100 FC and above)?

Warehousing of Fabrics, Yarn, Trims & Accessories
Critical

1. Are all fabrics / yarns / trims / accessories organized and stored indoors, off of
floors, and remain covered / protected until ready for use and has required space?

2. Are the inspections processes appropriate for bulk fabrics / yarns and quality /
weight / color shade/ fiber content are verified and are fabric inspectors trained?
3. Are the inspection processes appropriate for bulk trims / accessories and finishing
trims, carton and quality / weight / color are verified and inspectors trained?

© 2014 Wal-Mart Stores, Inc. All rights reserved. Walmart and Wal-Mart are registered trademarks of Walmart. All other trademarks and company
names or logos cited herein are the property of their respective owners. This is an electronically Controlled Document. Once printed, this copy is considered
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4. Is light box and approved shade band available for bulk color verification?

5. Is lighting adequate for all the inspection areas (100 FC and above)?

4.0

Spreading, Cutting & Fusing (Go to SECTION #5 for Sweater)
1. Is there work-in-process balance between cutting and production output to
adequately fulfil daily production requirement?
2. Are acceptable processes in place for adequate fabric relaxation?
3. Are shade variances controlled within spreading process?
4. Is spreading methodology acceptable?

5. Is there proper control for matching / cutting of patterned fabrics such as plaids &
stripes?
6. Does factory have adequate storage for bulk cut inventory?
7. Are cut pieces properly inspected and numbered?
8. Is fusing & heat seal quality acceptable, machines regularly calibrated and
records maintained?
9. Are bulk cut goods and accessories, which are designated for either internal or
off-premise handling (such as sewing, laundry, embroidery, printing), transported
in a well-organized and protected manner & records kept?
10. Is lighting adequate (100 FC and above)?
11. Does cutting have its own approved sample for reference?

5.0

Sweater
1. Are yarns checked for color continuity within dye lots and deliveries, by
comparison to knitted swatches from randomly selected cones of yarn?

© 2014 Wal-Mart Stores, Inc. All rights reserved. Walmart and Wal-Mart are registered trademarks of Walmart. All other trademarks and company
names or logos cited herein are the property of their respective owners. This is an electronically Controlled Document. Once printed, this copy is considered
an “Uncontrolled Document”.
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2. Are yarns randomly checked for essential key properties, including yarn size, yarn
weight, absence of knots and foreign contamination?
3. Is winding room tidy / clean and winding machines freed of excessive dust, dirt
and contamination?
4. Is there procedure in place to segregate light color yarns?
5. Are knitting lines efficiently organized?

6. Are Knitting lines well lit (60FC or above)?
7. Do all operators have the approved written procedures explaining the knitting
sequence and the amount of weights required for each style, coarse/inch,
Wales/inch, panel width and weight (for hand frame machines)? Are the
automatic knitting machines properly set (for auto machines)?
8. Is in-line inspection conducted on panels, for basic measurements and general
quality, such as holes, etc.?
9. Are there controls in place to ensure that shade consistence of the returned yarns
are properly managed?
10. Are linking sections well organized?
11. Are linking sections well lit (60 FC or above)?
12. Is inline inspection conducted over lamp form, following linking process and
including basic measurement?
13. Is the ratio of the Mending/Stitching Operators to Linking Operators appropriate
based on the production and the complexity of the styles? ( Line balancing )
14. Are Mending / Stitching Operators skilful?

6.0

Production Processes
1. Is on site industrial engineering department adequate and effective?

2. Is there production planning department?

3. Is there a proper training program for new operators?

© 2014 Wal-Mart Stores, Inc. All rights reserved. Walmart and Wal-Mart are registered trademarks of Walmart. All other trademarks and company
names or logos cited herein are the property of their respective owners. This is an electronically Controlled Document. Once printed, this copy is considered
an “Uncontrolled Document”.
Page 3 of 8

4. Are in-house pre-production meetings and Pilot runs conducted for each style,
prior to bulk production, and meetings attended by relevant factory personnel?
5. Are approved samples available on every line for review, and sample comments
translated into local language?
6. Are production lines well balanced and set up in systematic process, without
bottlenecks?
Critical

7. Is there a proper system to record broken/damaged needles, scissors, thread
cutters, tag gun needles & hand stitching needles etc. at both sample room and
production floor?
8. Is production floor well organized and clean, and isles clear, free of clutter?

Critical

9. Are adequate systems used to isolate defective and / or repaired products?
10. Are there on site mechanics who regularly maintain all machines and
maintenance records well kept?
11. Is there proper maintenance department equipped with adequate tools and
necessary equipment?

Critical

12. Are sharp objects such as trimmers and scissors effectively tracked e.g. that they
are permanently attached to the machines and there is regular monitoring so
missing of 'attached' sharp objects will not go unnoticed?

13. Is lighting adequate (100FC and above)?

7.0

Inspection Processes
Critical

1. Does factory have inspection system at inline and end line? Does factory measure
complete garment?
2. If garments, or garment parts, are constructed at subcontracted facilities, or if
embroidery, printing, or laundry functions are handled at off-premises facilities, are
returned garments and/or panels properly inspected before they are released
back to bulk production work flow again?

© 2014 Wal-Mart Stores, Inc. All rights reserved. Walmart and Wal-Mart are registered trademarks of Walmart. All other trademarks and company
names or logos cited herein are the property of their respective owners. This is an electronically Controlled Document. Once printed, this copy is considered
an “Uncontrolled Document”.
Page 4 of 8


Critical

3. Does QA/QC department have an independent reporting structure? Are all QA/
QCs trained regularly?
4. Factory has a complete set of their buyer's technical manual hard copy and knows
how to obtain updated information.
5. Does factory conduct Inspection on daily completed garments after sewing line
using buyer AQL or tighter and does factory take measure on audit failures?
6. Is lighting adequate (100 FC and above)?
7. How is alteration/defective garments handled in all section?
8. Does factory has sufficient well equipped inspection room ?

8.0 Pressing
1. Is there a pressing supervisor available and pressing standards and method of
pressing displayed within the area? Is there sufficient space for keeping
garments?
2. Does factory use appropriate pressing equipment, template and guides for
ironing? How is the condition of the equipment & quality of steam? Calibration of
the boiler and iron machine maintenance card attached and updated?
Housekeeping of pressing area?
3. Is there measurement audit after pressing? If yes, is audit result properly
documented?
4. Is ventilation and lighting (60-80 FC) adequate?
5. Are pressed garment handled properly prior to packing? How is WIP handled in
the section?

9.0 Finishing/Repairing /Packing
1. Are packaging standard and samples readily available for reference?

Critical

2. Is there a 100% final checking after finishing and is there a random audit done
after finishing? Is there a 100% measurement for key points and audit done after
finishing?

3. Is there an effective stain management and repair operation on site?

© 2014 Wal-Mart Stores, Inc. All rights reserved. Walmart and Wal-Mart are registered trademarks of Walmart. All other trademarks and company
names or logos cited herein are the property of their respective owners. This is an electronically Controlled Document. Once printed, this copy is considered
an “Uncontrolled Document”.
Page 5 of 8

4. Is there an organized and efficient work flow in the finishing area? How are the
WIP levels?
5. Is lighting adequate (100 FC for Inspection and 60-80 FC for other areas)?
Critical

6. Does factory conduct final audit based on same (or tighter) AQL of buyer?
7. How are alteration/ defective garments handled in the section?
8. How is the infrastructure and housekeeping in the section?
9. Is the storage space for packed goods enough as per the factory capacity?
10. Is there a procedure in place to remove uncut thread and loose threads and
foreign materials?

10

Printing
1. Is printing automatic or manual (including drying)? Do they maintain record of
recipes and samples available for operator? Are operators trained and do they
hire based on skill level and how do they measure?
2. Are screens made in-house or contracted to outside source?

3. Are machines regularly maintained and serviced, and in good condition?
4. Are in-process and finished pieces inspected and seconds replaced before
releasing back to production workflow? Lighting level at inspection area (100 FC
and above)?
5. Is there organized and controlled storage area for chemicals?
6. How is the housekeeping & organization in the section?

11

Embroidery

1. Does the embroidery facility have a broken needle control process?

© 2014 Wal-Mart Stores, Inc. All rights reserved. Walmart and Wal-Mart are registered trademarks of Walmart. All other trademarks and company
names or logos cited herein are the property of their respective owners. This is an electronically Controlled Document. Once printed, this copy is considered
an “Uncontrolled Document”.
Page 6 of 8


2. How is the quality assurance process within the embroidery facility? Are proper
approvals/samples available? Are thread ends and embroidery backings properly
trimmed-off before re-entering to bulk production?
3. Are embroidery machines properly maintained, regularly cleaned and serviced,
and in good working condition?
4. Is lighting levels (100FC and above) sufficient in the embroidery section?
5. How is the housekeeping in the section? How are the embroidery threads stored?

12

On-Site Garment Laundry
1. Are machines adequately maintained?
2. Are laundry washing methods, reference samples and approved shade band
readily available for operators' and inspector's easy reference?
3. Is in-process and finished goods inspected prior to re-entering bulk production
flow, to eliminate shade variances and defective units?
4. Are the laundry facility clean, chemicals properly stored and free of unnecessary
standing water pools?
5. Is laundry managed by qualified technician & chemist?

6. Is lighting levels (100FC and above) sufficient in the Laundry section?
7. Does laundry has effluent treatment facility?

13

Product Safety & Satisfaction
1. Does factory has a sufficient & proper metal detection process for all the
products? (Metal detection is Mandatory for all product areas. However, it is
critical for the following areas:
All children’s clothing
Critical

All nightwear (sleepwear)
All underwear and lingerie
Asda / George and Seiyu market hence scoring would be 10-0 for critical and 10-5-0
for rest and Asda new factory.

© 2014 Wal-Mart Stores, Inc. All rights reserved. Walmart and Wal-Mart are registered trademarks of Walmart. All other trademarks and company
names or logos cited herein are the property of their respective owners. This is an electronically Controlled Document. Once printed, this copy is considered
an “Uncontrolled Document”.
Page 7 of 8


2. Does factory has pull strength equipment‘s for buttons/snaps/rivets or any other
fastener? (Mandatory For children’s wear dept. 26, 24, 33 score 10-0 and adult
10-5-0.)
Critical

Note: Number of mocks need to be mentioned
(For ASDA /George UK product, 21lbs/90 N should be applied for tension

test, while for U.S. product, 15 lbs. /64 N should be applied for tension test)

3. Does factory use lockstitch for button attach?
Critical

(Mandatory for children wear dept. 26, 24, 33, score 10-0 and adult 10-5-0 hence
scoring dept. 26, 24, 33, score 10-0 and adult 10-5-0)

Critical

4. How is Snap/Rivet (or any metal fastener) attaching process & machinery in the
factory?

Critical

5. Is there arrangement for disposal of non-conforming goods & materials?

Critical

6. Does factory maintain chemical test for printed items? (For children wear for US
dept. 26, 24, 33)

Critical

7. Does factory have documented REACH control system? (For GEORGE/ASDA
UK only)

© 2014 Wal-Mart Stores, Inc. All rights reserved. Walmart and Wal-Mart are registered trademarks of Walmart. All other trademarks and company
names or logos cited herein are the property of their respective owners. This is an electronically Controlled Document. Once printed, this copy is considered
an “Uncontrolled Document”.

Page 8 of 8