Factory

Factory organisation

  • Available

  • Organisation Chart Images

  • Production Workflow Chart

  • Export licence issue date

  • Observations and Risk

  • Images

Images environment and ethics

  • Images for - Punch card area, Drinking water areas, Fire exits, Safety guards on machines, PPE used, Electric wiring / box, First aid, Hazardous chemical storage, Accommodation overview

  • Images

Production lines

Goods In

  • All incoming goods assigned with the bath number and any identifying codes assigned by the factory

  • Sample and specification available

  • Frequency of checks by trained staff

  • There must be a record (and test reports where applicable)

  • What are the delivery / loading conditions?

  • Observation and Risk

  • Images

Storage and segregation

  • Components should be stored in racking, well labelled and a system in place for identifying location.

  • Components have an identifying code that relates back to the incoming goods records

  • NC goods and components should be quarantined in clearly labelled areas away from acceptable stock

  • What is done with the non conforming materials?

  • Observation and Risk

  • Images

Production lines

  • Production planning notice board

  • Are the lines in production during visit

  • Product line overview and instructions

  • Is the assembly line tidy and organised?

  • Floor markings around the production area?

  • Walking areas free from obstruction?

  • Tools kept clean, well maintained and replaced where necessary?

  • Observation and Risk

  • Images

Quality Assurance System and Related Certificates

  • Does the management have an understanding of ISO 9001 or similar?

  • Are QC staff fully independent of production staff?

  • Are QC supervisors easily identified?

  • Are the QC staff trained?

  • Does the QC manager have authority to stop production?

  • Does the factory perform regular QC checks at major production stages?

  • Are records available

  • Frequency

  • Online QC and testing stations

  • Are clear instructions visible at all work stations?

  • Observations and Risk

  • Images

Production Documentation

  • Must maintain and be able to demonstrate traceability from final product back to a specific batch of raw materials and associated test reports

  • Correlation of records to labels, batch numbers or marks attached to the furniture

  • Does the factory have equipment and machinery list?

  • Documents for calibrated machines?

  • Records available

  • Frequency

  • All tools must be signed in and out

  • Missing tool procedure?

  • Has the factory had a technical audit

  • Audit company

  • Date

  • Available

  • Observation and Risk

  • Images

Approved samples

  • Approved samples on display at each area with a signature and date from a technical representative

  • Observation and Risk

  • Images

Finished product inspection

  • The checks are made against the specification to ensure product, its components, packaging and labelling is correct

  • Observation and Risk

  • Images

Handling and Packing

  • Packaging stored on pallets in dry indoor location

  • Handling process protects finished or semi finished product from damage

  • No risk of foreign bodies being packed

  • Only safety tools are used during packaging process

  • No staples are used during packing

  • Board showing all approved components

  • Controls in place to ensure correct numbers of components are added to each hardware pack

  • No risk of foreign bodies being packed

  • No staples are used during packing

  • Observation and Risk

  • Images

Metal CCP

Goods In

  • Dimensions - Cross sectional profile including wall thickness

  • Physical properties i.e. Tensile strength, elongation %, yield strength and hardness (being the minimum)

  • Observation and Risk

  • Images

Welding

  • Pre welding - Use of jigs and approved samples to ensure correct components and assembly

  • Correct welding techniques and weld quality

  • Observations and Risk

  • Images

Grinding

  • Prevention of over grinding and weld deteriation

  • Ensure all weld spatter and other sharp edges are removed

  • Observations and Risk

  • Images

Assembly

  • Bent rivets, malformed rivets or joints

  • Observations and Risk

  • Images

Finishing

  • Dustraction to ensure a consistently good quality finish

  • Observation and Risk

  • Images

Checks

  • Specification check to ensure product, its components, packaging and labelling are correct

  • Observations and Risk

  • Images

Metal detection

Sewing Controls

Sewing Needle Controls - New

  • A designated supervisor must be responsible for issuing new needles

  • New needles must be stored in a clearly marked container and in a locked cupboard, one person responsible with key

  • New needles must only be obtained when broken or damaged needles are returned or when there is a change of fabric type

  • Used needles must only be replaced with new needles

  • The exchanged needles must be held in a clearly marked secure container, ready for disposal, in separate location to the secured "new needles" container

  • All used needles must be accounted for

  • Sewing operatives must never have spare needles in their possession

  • Any spare or unused machines in the factory must have all needles removed from them

  • The mechanic must perform daily checks of all machines and any problems relating to needles must be recorded and the needle changed

  • All machines must be equipped with the correct type and functionally required quantity of needles

  • Observations and Risk

  • Images

Sewing Needle Controls - Broken Needles

  • If a needle is broken, all parts must be accounted for before a new needle is issued

  • Isolate all products involved or in the vicinity within a sealed container or bag and remove to be fully detected by the supervisor

  • If all parts of the needle are found and the product detected successfully the product may be returned to stock

  • All parts of a broken needle must be securely attached to a "broken needle record form" by the nominated supervisor along with details of date, machine and operator. The needle parts should be "built" together to clearly highlight any missing fragments

  • If all parts of a needle can't be found then the whole area within the vicinity must be checked with a magnet or a hand held detector

  • If all parts of the broken needle are still not found, then all "at risk" products concerned must be destroyed

  • Following the above, if all parts have still not been located then the issuing of a new needles must be approved by a senior member of staff

  • Replenishment of the authorised needle controllers stock must be on a strict 'new for old' exchange

  • A broken needle control record must be kept for 12 months to facilitate traceability in case of complaint

  • Observations and Risk

  • Images

Hand Sewing Controls

  • Hand sewing can only be used where an automated solution is not feasible

  • For children's products it is only permitted by exception and agreed with Ventura QC

  • Any hand sewing operation on a product must be agreed with Ventura QC manager at the product development stage. Hand sewing on repairs is not permitted

  • An established quantity of hand sewing kits (needle/scissors/clippers etc) must be held by an authorised person

  • Hand sewing equipment must be counted out and in at the end of the shift by a line supervisor along with a maintained record

  • A designated and quarantined area must be established to carry out hand sewing

  • All products hand sewn must be metal detected before release onto the next stage of production

  • Replacement of broken and blunt hand sewing needles must follow the New and Broken Needle Control procedures above

  • Observations and Risk

  • Images

Other Sharp Controls

Pins, Drawing Pins or Staples

  • Pins, drawing pins, metal staples and tacks must not be used in any part of the manufacturing unit, including raw materials warehouse, sample room, cutting, production, knitting and warehousing

  • Where pins are used in packaging for another customer, this must be done in a separate area quarantined from any other production and the issue of pins to be controlled

  • Observations and Risk

  • Images

Scissors and Clippers

  • Scissors, shears or clippers must be secured to workstations to avoid contamination

  • An established quantity of scissors and clippers must be held by an authorised person

  • For "mobile" workers such as QC inspectors, scissors and clippers must be permanently attached/clipped to the worker with an extendable chain. These must be counted in at the end of every shift

  • Observations and Risk

  • Images

Kimball Needles, Tweezers and Cutting Tool Blades

  • Drill holes, spikes, kimball gun needles, notch punchers, tweezers, knives/blades etc must be counted out and in at the end of each shift by a supervisor

  • Observations and Risk

  • Images

Knife Blades

  • Safety knives must be used where blades are required - define tool source

  • No snap blade knives or old straight knives from cutting machines may be used

  • Observations and Risk

  • Images

Carding Machine Hooks, Overlock Machine Blades and Thread Wires

  • Carding hooks, overlock blades and threading wires must be held by the mechanic only and securely stored away from the production area

  • Overlock machine blade must be checked by the operator at the beginning of each shift and any damage reported to the mechanic for immediate repair

  • Spare machine blades must be checked by the operator at the beginning of

  • New blades must be issued as a 'new for old' basis. Where the old blade was broken, all parts must be accounted for before a new blade is issued

  • Old blades must be retained in a secure location

  • Observations and Risk

  • Images

Metal Popper, Studs, Rivets

  • Loose poppers, studs, rivets, zips and other small components must be stored in segregated containers at each work station

  • Observations and Risk

  • Images

Machinery, Equipment and Spare Parts

  • Upon delivery and before release into the production area, all machinery and equipment must be held in a quarantine area to be

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