CCP assessment

• Document No. 10001

• Product type

• Factory

• Address
  Address

• Attendants

• Conducted on

  Date

• Prepared by

• Signature

  Sign

• Factory external, Factory entrance images

  Media

Factory organisation

• Available

  Yes

  No

  N/A

• Organisation Chart Images

  Media

• Production Workflow Chart

  Media

• Export licence issue date

  Date

• Observations and Risk

• Images

  Media

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

  Media

Goods In

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

  Yes

  No

  N/A

• Sample and specification available

  Yes

  No

  N/A

• Frequency of checks by trained staff

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

  Yes

  No

  N/A

• What are the delivery / loading conditions?

• Observation and Risk

• Images

  Media

Storage and segregation

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• What is done with the non conforming materials?

• Observation and Risk

• Images

  Media

Production lines

• Production planning notice board

  Media

• Are the lines in production during visit

  Yes

  No

  N/A

• Product line overview and instructions

  Media

• Is the assembly line tidy and organised?

  Yes

  No

  N/A

• Floor markings around the production area?

  Yes

  No

  N/A

• Walking areas free from obstruction?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Observation and Risk

• Images

  Media

Quality Assurance System and Related Certificates

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

  Yes

  No

  N/A

• Are QC staff fully independent of production staff?

  Yes

  No

  N/A

• Are QC supervisors easily identified?

  Yes

  No

  N/A

• Are the QC staff trained?

  Yes

  No

  N/A

• Does the QC manager have authority to stop production?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Are records available

  Yes

  No

  N/A

• Frequency

• Online QC and testing stations

  Media

• Are clear instructions visible at all work stations?

  Yes

  No

  N/A

• Observations and Risk

• Images

  Media

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Does the factory have equipment and machinery list?

  Yes

  No

  N/A

• Documents for calibrated machines?

  Yes

  No

  N/A

• Records available

  Yes

  No

  N/A

• Frequency

• All tools must be signed in and out

  Yes

  No

  N/A

• Missing tool procedure?

  Yes

  No

  N/A

• Has the factory had a technical audit

  Yes

  No

  N/A

• Audit company

• Date

  Date

• Available

  Yes

  No

  N/A

• Observation and Risk

• Images

  Media

Approved samples

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

  Yes

  No

  N/A

• Observation and Risk

• Images

  Media

Finished product inspection

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

  Yes

  No

  N/A

• Observation and Risk

• Images

  Media

Handling and Packing

• Packaging stored on pallets in dry indoor location

  Yes

  No

  N/A

• Handling process protects finished or semi finished product from damage

  Yes

  No

  N/A

• No risk of foreign bodies being packed

  Yes

  No

  N/A

• Only safety tools are used during packaging process

  Yes

  No

  N/A

• No staples are used during packing

  Yes

  No

  N/A

• Board showing all approved components

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• No risk of foreign bodies being packed

  Yes

  No

  N/A

• No staples are used during packing

  Yes

  No

  N/A

• Observation and Risk

• Images

  Media

Goods In

• Dimensions - Cross sectional profile including wall thickness

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Observation and Risk

• Images

  Media

Welding

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

  Yes

  No

  N/A

• Correct welding techniques and weld quality

  Yes

  No

  N/A

• Observations and Risk

• Images

  Media

Grinding

• Prevention of over grinding and weld deteriation

  Yes

  No

  N/A

• Ensure all weld spatter and other sharp edges are removed

  Yes

  No

  N/A

• Observations and Risk

• Images

  Media

Assembly

• Bent rivets, malformed rivets or joints

  Yes

  No

  N/A

• Observations and Risk

• Images

  Media

Finishing

• Dustraction to ensure a consistently good quality finish

  Yes

  No

  N/A

• Observation and Risk

• Images

  Media

Checks

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

  Yes

  No

  N/A

• Observations and Risk

• Images

  Media

Sewing Controls

Sewing Needle Controls - New

• A designated supervisor must be responsible for issuing new needles

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Used needles must only be replaced with new needles

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• All used needles must be accounted for

  Yes

  No

  N/A

• Sewing operatives must never have spare needles in their possession

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Observations and Risk

• Images

  Media

Sewing Needle Controls - Broken Needles

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• 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

  Yes

  No

  N/A

• 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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• 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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Observations and Risk

• Images

  Media

Hand Sewing Controls

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• 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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Observations and Risk

• Images

  Media

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

  Yes

  No

  N/A

• 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

  Yes

  No

  N/A

• Observations and Risk

• Images

  Media

Scissors and Clippers

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• 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

  Yes

  No

  N/A

• Observations and Risk

• Images

  Media

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

  Yes

  No

  N/A

• Observations and Risk

• Images

  Media

Knife Blades

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Observations and Risk

• Images

  Media

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

  Yes

  No

  N/A

• 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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• 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

  Yes

  No

  N/A

• Old blades must be retained in a secure location

  Yes

  No

  N/A

• Observations and Risk

• Images

  Media

Metal Popper, Studs, Rivets

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

  Yes

  No

  N/A

• Observations and Risk

• Images

  Media

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

  Yes

  No

  N/A

• Yes

  No

  N/A