Epyllion Style Ltd.

• A. Factory/Organization Information

• Date of Information

  Date
• Location
  Address

• Total Production area (sqm)

• Total Staff in factory

• Total Worker

• Main Customer

• Product Type

• Factory Contact (name)

• Job Title

• E-mail

• Telephone

• Fabric Inspection Machine

• Light Box (pls refer to Epyllion C01 requirement)

• Marker Planning machine and Pattern or Marker Printing Plotter

• Industrial Washer, Spinner, Drying Tumbler for Garment Wash products

• Chemical Spray Cabinet, Color Reduction for Garment Dye/Fading products

• Down Filling machine

• Testing Equipment like Home Laundry machine, Pull Tester, Thermocouple

• list out if any additional items:

• Preshrink Fabric machine

• Spreading machine

• Cutting or Die Cutting Machine

• Fusing Conveyor or Flat Fusing Machine

• Embroidery Machine

• Screen / Foil / Heat Transfer Printing Machine

• Seam-Seal Machine

• Single needle lock stitch

• Twin needle lock stitch

• 3/ 4/ 5 thread over lock

• Single thread chain stitch

• Double thread chain stitch

• Buttonhole

• Popper / Eyelet

• Buttoning (pls specify lockstitch/ chainstitch)

• Bartack

• Felling

• Waistband elastication

• Pocket jetter or pocket opening machine

• Flat lock

• Zig zag

• Blind hem

• Pneumatic Snapping

• Sleeve setting

• AMF

• Pleats sewing machine

• Machine for wrapping button stems

• Machine for attaching shoulder pads

• Automatic sewing machine - e.g. darts, label sew, collar, cuff, front placket, sleeve placket, pocket facing and pocket opening stitching

• Main Body Press, Different body parts Press, Tunnel Press

• Iron and Vacuum Board

• Curing Oven for wrinkle free products

• Metal Detection Conveyor Machine

1.Quality Manual

• 1.1 Update Quality Manual Available

  Yes

  No

  N/A

• 1.2 Regularly Revised

  Yes

  No

  N/A

2. Mission, Vision, Goal, Policy & Objectives

• 2.1 Organizational Mission & Vision

  Yes

  No

  N/A

• 2.2 Organizational Goals

  Yes

  No

  N/A

• 2.3 Quality Policy & Procedure

  Yes

  No

  N/A

• 2.4 Quality Objectives

  Yes

  No

  N/A

3.Documents Control

• 3.1 Master list of Document with establish date & Revisions.

  Yes

  No

  N/A

• 3.2 Customer's document are controlled

  Yes

  No

  N/A

• 3.3 External Documents are available

  Yes

  No

  N/A

• 3 .4 Document change is applied & effective

  Yes

  No

  N/A

• 3.5 Document change system controlled using IT system

  Yes

  No

  N/A

1.Production Planning & Control

• 1.1 Production Planning System[any software]

  Yes

  No

  N/A

• 1. 2 Pro duction Planning data match with T&A and workstation.

  Yes

  No

  N/A

2. P.P. Meeting

• 2.1 Tech. Pack file organized. (All documents are available for specific style of buyers)

  Yes

  No

  N/A

• 2.2 Size set sample report

  Yes

  No

  N/A

• 2.3 Product conformance record

  Yes

  No

  N/A

• 2.4 Record of PPM copy with sign and seal.

  Yes

  No

  N/A

3. Management Review Meeting

• 3.1 MRM Policy, Procedure & Report

  Yes

  No

  N/A

• 3.2 Corrective & Preventive Actions

  Yes

  No

  N/A

1. Human Resource (Men)

• 1.1 Organizational Organogram & Job Description.

  Yes

  No

  N/A

• 1.2 Training Record & Communication

  Yes

  No

  N/A

• 1.3 Interview Record (Policy & Process)

  Yes

  No

  N/A

• 1.4 Skill Matrix

  Yes

  No

  N/A

2. Machine

• 2.1 Total Machine List (Running, Idle and Out dated)

  Yes

  No

  N/A

• 2.2 Machine calibration Record (In-house & 3rd. party both)

  Yes

  No

  N/A

• 2.3 Machine Maintenance Policy & Procedure

  Yes

  No

  N/A

• 2.4 Machine Maintenance Plan, Schedule & Record

  Yes

  No

  N/A

• 2.5 Working Instruction available for machine

  Yes

  No

  N/A

3. Materials

• 3.1 List of materials (raw materials of product & any other materials)

  Yes

  No

  N/A

• 3.2 Material Receiving, Storing & Issuing system

  Yes

  No

  N/A

• 3.2.1 Use kanban/FIFO for receiving and separate receiving area

  Yes

  No

  N/A

• 3.2.2 Storing system (ERP or Manual) and capacity (sufficient) check

  Yes

  No

  N/A

• 3.2.3 Special materials storage condition

  Yes

  No

  N/A

• 3.3 Raw Materials Inspection System with Visible instruction Countable & with Visible instruction.

  Yes

  No

  N/A

• 3.4 Raw Materials testing (in-house or 3rd party) Report

  Yes

  No

  N/A

• 3.5 Dedicated Qualified Lab Technician are available

  Yes

  No

  N/A

• 3.6 Qualified Inspector available

  Yes

  No

  N/A

• 3.7 Proper light source are available

  Yes

  No

  N/A

• 3.8 Inspection area are separated from workstation

  Yes

  No

  N/A

• 3.9 Non-conformity items are separated or not (check with record)

  Yes

  No

  N/A

4.Mother of Nature (Environment)

• 4.1 Overall environment for worker

  Yes

  No

  N/A

• 4.2 Housekeeping system (5S)

  Yes

  No

  N/A

• 4.3 Environment for Stakeholder, Customer & Supplier comment & Feedback (Use any complain box)

  Yes

  No

  N/A

0. Raw Material Inspection/ Warehouse

0.1 Warehouse Layout & Inventory Control(6)

• 0.1.1 Designated areas clearly signed for Incoming/ Accepted/ Rejected Materials

  Yes

  No

  N/A

• 0.1.2 All fabric rolls in plastic bag or covered

  Yes

  No

  N/A

• 0.1.3 All fabric rolls on palette or rack

  Yes

  No

  N/A

• 0.1.4 Plastic palettes used

  Yes

  No

  N/A

• 0.1.5 Inventory record with material ordered and received quantity as well as issue to production quantity

  Yes

  No

  N/A

• 0.1.6 Warehouse is air-conditioned and/or using dehumidifier with reader

  Yes

  No

  N/A

0.2 Fabric And Visual Inspection

• 0.2.1 Fabric inspection machine or table with lighting support used for inspection

  Yes

  No

  N/A

• 0.2.2 Written procedure available for inspection

  Yes

  No

  N/A

• 0.2.3 Inspection sample size is at least 10% with inspection records for every lot and color.

  Yes

  No

  N/A

• 0.2.4 Measure fabric skew and fabric width with records

  Yes

  No

  N/A

• 0.2.5 Handle of fabric assessed against Epyllion approved handle standard

  Yes

  No

  N/A

• 0.2.6 Inspection results communicated with related departments and analyzed for rate suppliers

  Yes

  No

  N/A

• 0.2.7 Fabric inspection speed is acceptable (8- 15 meters/ min) .

  Yes

  No

  N/A

• 0.2.8 Fabric inspector demonstrates correct inspection with records

  Yes

  No

  N/A

• 0.2.9 Each roll identified and quarantined when rejected

  Yes

  No

  N/A

• 0.2.10 Routine maintenance policy in place for inspection machine (weekly/ monthly/ yearly, etc.)

  Yes

  No

  N/A

0.3 Colour Assessment

• 0.3.1 Have a light box meets Epyllion 'C01' light box and tube specification requirements

  Yes

  No

  N/A

• 0.3.2 Approved color standard or swatches are available for colour assessment

  Yes

  No

  N/A

• 0.3.3 Colour continuity cards with cuttings marked in roll and dye lot numbers are available for 6 months

  Yes

  No

  N/A

• 0.3.4 Check selvedge to selvedge shading

  Yes

  No

  N/A

• 0.3.5 Trims, ribs and print color matching is reviewed with record

  Yes

  No

  N/A

• 0.3.6 Epyllion approved shade band is available for garment wash/dye orders

  Yes

  No

  N/A

1. Cutting

• 1.1 Fabric Relaxation (Separate area, Use palate, Work instruction, Qualified person & Record)

  Yes

  No

  N/A

• 1.2 Fabric Lay & Spreading (Area, Use Spreading machine or manpower, Work Instruction & Report)

  Yes

  No

  N/A

• 1.3 Pattern & Marker Check

  Yes

  No

  N/A

• 1.4 Cut pane l Checking SOP (TMB & 100 % check) & Work Instruction are available

  Yes

  No

  N/A

• 1.5 Cutting part replacement SOP with separate area & qualified person

  Yes

  No

  N/A

• 1.6 Cutting replacement work instruction are available.

  Yes

  No

  N/A

• 1.7 Cutting parts replacement fabric storing as per SOP (Roll to roll or Lot to lot)

  Yes

  No

  N/A

2. Print & Embroidery

• 2.1 Print & Embroider SOP

  Yes

  No

  N/A

• 2.2 Work Instruction & checking area with adequate light sources.

  Yes

  No

  N/A

• 2.3 Checking procedure & Record

  Yes

  No

  N/A

3. Fusing

• 3.1 Fusing Data Sheet is available

  Yes

  No

  N/A

• 3.2 Work Instruction, Fusing SOP, Dedicated qualified person & Record are available with verification

  Yes

  No

  N/A

4.Sewing

• 4.1 Sewing layout & Machine adjustment record.

  Yes

  No

  N/A

• 4.2 Traffic Light System update or not

  Select Yes No N/A

  • Yes
  • No
  • N/A

• 4.3 In process Checking System

  Yes

  No

  N/A

• 4.4 BIN Card & Mock Up for critical operations.

  Yes

  No

  N/A

• 4.5 Process Risk & Opportunity assessment

  Yes

  No

  N/A

• 4.7 Defect Control Procedure

  Yes

  No

  N/A

• 4.8 Traceability of Production

  Yes

  No

  N/A

• 4.9 Oil Control Report is available

  Yes

  No

  N/A

• 4.10 Bingo Card is every MC

  Yes

  No

  N/A

• 4.11 Trim Card is available in sewing line

  Yes

  No

  N/A

• 4.12 Approved sample is in Sewing line

  Yes

  No

  N/A

• 4.13 Output QI report is available

  Yes

  No

  N/A

5. Finishing

• 5.1 Marking for Pressing, Visible work instruction and Operator must know how to use equipment & template.

  Yes

  No

  N/A

• 5.2 Visible work instruction about packing method.

  Yes

  No

  N/A

• 5.3 Pre-final & Final Report with measurement

  Yes

  No

  N/A

• 5.4 Defect Control List

  Yes

  No

  N/A

• 5.5 Corrective & Preventive action plan

  Yes

  No

  N/A

• 5.6 Independent Qualified QA team

  Yes

  No

  N/A

• 5.7 Visual Product and measurement Check like 32 pcs

  Yes

  No

  N/A

• 5.8 Product Re-call Procedure & Record

  Yes

  No

  N/A

• 5.9 Customer complaint Procedure & Record

  Yes

  No

  N/A

• 5.10 Final Product storing area use palate and maintain procedure

  Yes

  No

  N/A

• 5.11 Leftover procedure & record

  Yes

  No

  N/A

• 5.12 Final Product Disposal policy & Procedure

  Yes

  No

  N/A

• 5.13 Product disposal Record

  Yes

  No

  N/A

• 5.14 Output QI report is available

  Yes

  No

  N/A

• 5.15 Dry room report is available

  Yes

  No

  N/A

• 5.16 CTPAT area free for Sharp Tool

  Yes

  No

  N/A

• 5.17 Metal free zone is available

  Yes

  No

  N/A

• 5.18 Is iron SOP is available

  Yes

  No

  N/A

• 5.19 Is the Iron approved sample with a comment available

  Yes

  No

  N/A

• 5.20 Is the folding approved sample with a comment available

  Yes

  No

  N/A

1. Button & Label Control

• 1.1 Button Control Procedure properly maintain and record are verified.

  Yes

  No

  N/A

• 1.2 Label Control Procedure properly maintain and record are verified.

  Yes

  No

  N/A

2. Machine Attachment Control

• 2.1 Machine Attachment regularly check and maintain data sheet

  Yes

  No

  N/A

• 2.2 Machine Attachment control regularly and recorded.

  Yes

  No

  N/A

• 2.3 Machine oil level is ok.

  Yes

  No

  N/A

3. Needle & Sharp metal Control

3.1 Basic Requirements

• 3.1.1 Needle & Sharp metal control policy & procedure.

  Yes

  No

  N/A

• 3.1.2 Needle management system (receiving, storing, issuing) properly maintain.

  Yes

  No

  N/A

• 3.1.3 Broken Needle Procedure are followed properly.

  Yes

  No

  N/A

• 3.1.3.1 Needle balance is updated

  Yes

  No

  N/A

• 3.1.3.2 Sewing M/C knife balance is updated

  Yes

  No

  N/A

• 3.1.4 Qualified Needle man are available

  Yes

  No

  N/A

• 3.1.5 List of Sharp metal

  Yes

  No

  N/A

• 3.1.6 Sharp metal procedure must be maintained.

  Yes

  No

  N/A

• 3.1.7 Metal Detector procedure must be followed.

  Yes

  No

  N/A

• 3.1.8 Dedicated qualified Metal Detector Operator are available

  Yes

  No

  N/A

• 3.1.9 Metal Detection Calibration report are availble.

  Yes

  No

  N/A

• 3.1.10 Metal Operator are Trained.

  Yes

  No

  N/A

• 3.1.11 Metal free zone is free for Matel

  Yes

  No

  N/A

• 3.1.12 1 Hour keeping area is available

  Yes

  No

  N/A

• 3.1.13 Are Sharp tools updated or not?

  Yes

  No

  N/A

• 3.1.14 Are Sharp tools SOP posted on the sharp tools box?

  Yes

  No

  N/A

3.2 Metal Sharps Control Procedure

• 3.2.1 No pins, staples, stapler, meta paper clips, perforated blades… used in production floor including the sample room

  Yes

  No

  N/A

• 3.2.2 No pin, safety pins, metal paper clips used to secure the trims in store

  Yes

  No

  N/A

• 3.2.3 Offending materials (pins, staples, meta paper clips…) collected and stored in secure area (in a sharps box/bottle)

  Yes

  No

  N/A

3.3 Metal Detection Procedure @ Requirements (Finishing/Packing sections)

• 3.3.1 A conveyor belt metal detector set up in factory for the products metal detection check

  Yes

  No

  N/A

• 3.3.2 The conveyor belt metal detector alarms the 9 points using 1.2mm ferrous metal standard

  Yes

  No

  N/A

• 3.3.3 A sensitivity of 1.2mm ferrous metal standard calibration card available

  Yes

  No

  N/A

A metal free zone set up in the factory

• ⑴For the finished products can pass through conveyor belt metal detector (such as babywear, children’s wear, adult wear, hosiery, soft accessory, plush toys, nursery, footwear, bag).

  Yes

  No

  N/A

• ⑵For the finished products can’t pass through conveyor belt metal detector (such as footwear with metal eyelets, shanks, metal zipper, bag with D ring…).

  Yes

  No

  N/A

• 9 points calibration records maintained (every 2 hours calibration if production running there)

  Yes

  No

  N/A

• Finished goods metal detection records kept

  Yes

  No

  N/A

• For the finished products can pass through conveyor belt metal detector
  (Such as babywear, children’s wear, adult wear, hosiery, soft accessory, plush toys, nursery, footwear, bag).
  

• The person (who executes the metal detection procedure) interviewed can capable of demonstrating the procedure

  Yes

  No

  N/A

• The conveyor belt metal detector calibrated every 6 months and calibration certificate maintained

  Yes

  No

  N/A

• The conveyor belt metal detector sensitivity dial covered and locked.

  Yes

  No

  N/A

• No trimming operation (such as using scissors to trim the thread ends) and no packing operation (such as using tag guns to attach hang tags) in the metal free zone ⑴

  Yes

  No

  N/A

• No paper work with offending materials (staples, clips…) in metal free zone

  Yes

  No

  N/A

• A hand-held metal detector in factory and alarms 1.2mm ferrous metal standard

  Yes

  No

  N/A

• Hand-held metal detector self-calibration records kept (each use)

  Yes

  No

  N/A

• Where the product with large metal components can’t pass through the conveyor belt detector shall be checked by hand-held metal detector. If it is not effective shall be checked by hand

  Yes

  No

  N/A

• Where the product (leather, PU footwear) with many parts assembled using glue can’t pass through conveyor belt metal detector the uppers shall be went through the conveyor belt metal detector before assembly

  Yes

  No

  N/A

• Where the product (leather, PU footwear) with many parts assembled using glue can’t pass through conveyor belt metal detector the finished shoes shall be checked by hand in the QC station before packing into carton on the assembly line

  Yes

  No

  N/A

3.4 Needle Control Procedure

• 3.4.1 Broken needle records kept

  Yes

  No

  N/A

• ⑴For sewing, hand sewing, Tag gun, linking needles (cut & sew factory) is mandatory.
  ⑵For knitting needles (sweater, hosiery factory…) not re quired to tape the broken needles on records while the smashed /broken knitting needles shall be put together and stored into a secure box/case/cupboard in mechanics /needle control room.
  

• 3.4.2 Needle balance records kept

  Yes

  No

  N/A

• 3.4.3 A documented needle procedure in factory

  Yes

  No

  N/A

• For the needle exchanged on for one basis (sewing, hand sewing, Tag gun, linking needles…)

• 3.4.4 No spare needles in the working floor

  Yes

  No

  N/A

• For knitting needles (sweater, hosiery, fabric knitting factory…):
  In production – Smashed/broken needles stored in lided box on the machine, at end of shift to exchange in mechanic room, no loose needles on the machine/ground.
  In mechanics/needle room – All smashed /broken needles put together stored in a secure box/case/cupboard.
  

• 3.4.5 New needles/ broken needles records /smashed knitting needles stored in a secure location

  Yes

  No

  N/A

• 3.4.6 The person (who executes needle replacement procedure) interviewed can capable of demonstrating the procedure

  Yes

  No

  N/A

• 3.4.7 Needle exchange box, magnets, contaminated goods metal detection box are available in the needles using sections

  Yes

  No

  N/A

• 3.4.8 Needles have been removed from the idle machines

  Yes

  No

  N/A

• 3.4.9 No syringe needle used in footwear factory

  Yes

  No

  N/A

3.5 Sharp Tool Control Procedure

• 3.5.1 Sharp tools (scissors, clippers, tweezers…) tied to the working station (table, machine…)

  Yes

  No

  N/A

• 3.5.2 Sharps tools (scissors, clippers, tweezers…) daily checking records kept

  Yes

  No

  N/A

• 3.5.3 Sharps tools (scissors, clippers, tweezers…) balance records kept

  Yes

  No

  N/A

• 3.5.4 Sharps tools returned to store in a secure area when not in use

  Yes

  No

  N/A

• 3.5.5 No extra / missing sharp tools (scissors, clippers, tweezers…)

  Yes

  No

  N/A

• 3.5.6 Cutting blades for band knives and straight knives replacement controlled

  Yes

  No

  N/A

4. Mold Control

• 4.1 Mold Control policy & procedure

  Yes

  No

  N/A

• 4.2 Record of Humidity & temperature

  Yes

  No

  N/A

• 4.3 Communicate all about mold control procedure.

  Yes

  No

  N/A

• 4.4 Are any SOP for dehumidifier?

  Yes

  No

  N/A

5. Pest Control

• 5.1 Pest control policy & Procedure

  Yes

  No

  N/A

• 5.2 Record of pest control system.

  Yes

  No

  N/A

6. Chemical Control

• 6.1 Hazardous chemical list

  Yes

  No

  N/A

• 6.2 Chemical control policy and procedure must be followed.

  Yes

  No

  N/A

7. Product Safety Training

• The factory organized the product safety training to the workers based on the customer’s product safety requirements/manuals regularly (sharp tools, needles, metal detection, component attaching…)

  Yes

  No

  N/A

• The workers product safety training evidences maintained (etc. signed attendance list, photos…)

  Yes

  No

  N/A

• Metal Contamination Policy maintained in factory (File Title: Metal Contamination Policy)

  Yes

  No

  N/A

1. Audit

• 1.1 Internal Audit Policy & Procedure

  Yes

  No

  N/A

• 1.2 Internal Audit plan, notice, checklist & Report

  Yes

  No

  N/A

• 1.3 Internal Auditor Qualification & Job Description.

  Yes

  No

  N/A

• 1.4 Corrective & Preventive Action plan

  Yes

  No

  N/A

1. Evaluation & Monitoring, Performance & Feedback

• 1.1 Supplier Evaluation, Selection, Monitoring Procedure.

  Yes

  No

  N/A

• 1.2 Supplier Performance data

  Yes

  No

  N/A

• 1.3 Customer Feed back data

  Yes

  No

  N/A

2. Traceability

• 2.1 Record of entire Product traceability system

  Yes

  No

  N/A

• 2.2 Verification of Product traceability

  Yes

  No

  N/A

• A. Factory/Organization Information

  Media

• B. Quality Management System

  Media

• C. Planning and Management Review

  Media

• D. Resources

  Media

• E. Sample Requirements

  Media

• F. Manufacturing

  Media

• G. Product Safety & Integrity

  Media

• H. Internal Audit

  Media

• I. Improvement

  Media