Title Page

  • A. Factory/Organization Information

  • Date of Information

  • Location
  • Total Production area (sqm)

  • Total Staff in factory

  • Total Worker

  • Main Customer

  • Product Type

  • Factory Contact (name)

  • Job Title

  • E-mail

  • Telephone

Machine/Equipment List

  • 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

Quality Management System

1.Quality Manual

  • 1.1 Update Quality Manual Available

  • 1.2 Regularly Revised

2. Mission, Vision, Goal, Policy & Objectives

  • 2.1 Organizational Mission & Vision

  • 2.2 Organizational Goals

  • 2.3 Quality Policy & Procedure

  • 2.4 Quality Objectives

3.Documents Control

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

  • 3.2 Customer's document are controlled

  • 3.3 External Documents are available

  • 3 .4 Document change is applied & effective

  • 3.5 Document change system controlled using IT system

Planning & Management Review

1.Production Planning & Control

  • 1.1 Production Planning System[any software]

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

2. P.P. Meeting

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

  • 2.2 Size set sample report

  • 2.3 Product conformance record

  • 2.4 Record of PPM copy with sign and seal.

3. Management Review Meeting

  • 3.1 MRM Policy, Procedure & Report

  • 3.2 Corrective & Preventive Actions

Resources

1. Human Resource (Men)

  • 1.1 Organizational Organogram & Job Description.

  • 1.2 Training Record & Communication

  • 1.3 Interview Record (Policy & Process)

  • 1.4 Skill Matrix

2. Machine

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

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

  • 2.3 Machine Maintenance Policy & Procedure

  • 2.4 Machine Maintenance Plan, Schedule & Record

  • 2.5 Working Instruction available for machine

3. Materials

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

  • 3.2 Material Receiving, Storing & Issuing system

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

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

  • 3.2.3 Special materials storage condition

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

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

  • 3.5 Dedicated Qualified Lab Technician are available

  • 3.6 Qualified Inspector available

  • 3.7 Proper light source are available

  • 3.8 Inspection area are separated from workstation

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

4.Mother of Nature (Environment)

  • 4.1 Overall environment for worker

  • 4.2 Housekeeping system (5S)

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

Manufacturing

1. Cutting

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

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

  • 1.3 Pattern & Marker Check

  • - CAD & Pattern

  • - Pattern adjustment system (grain line)

  • - Area and CAD software with quailed person.

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

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

  • 1.6 Cutting replacement work instruction are available.

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

2. Print & Embroidery

  • 2.1 Print & Embroider SOP

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

  • 2.3 Checking procedure & Record

3. Fusing

  • 3.1 Fusing Data Sheet is available

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

4.Sewing

  • 4.1 Sewing layout & Machine adjustment record.

  • 4.2 Traffic Light System update or not

  • 4.3 In process Checking System

  • 4.4 BIN Card & Mock Up for critical operations.

  • 4.5 Process Risk & Opportunity assessment

  • 4.6 How many tools are using for

  • 4.7 Defect Control Procedure

  • 4.8 Traceability of Production

  • 4.9 Oil Control Report is available

  • 4.10 Bingo Card is every MC

  • 4.11 Trim Card is available in sewing line

  • 4.12 Approved sample is in Sewing line

  • 4.13 Output QI report is available

5. Finishing

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

  • 5.2 Visible work instruction about packing method.

  • 5.3 Pre-final & Final Report with measurement

  • 5.4 Defect Control List

  • 5.5 Corrective & Preventive action plan

  • 5.6 Independent Qualified QA team

  • 5.7 Visual Product and measurement Check like 32 pcs

  • 5.8 Product Re-call Procedure & Record

  • 5.9 Customer complaint Procedure & Record

  • 5.10 Final Product storing area use palate and maintain procedure

  • 5.11 Leftover procedure & record

  • 5.12 Final Product Disposal policy & Procedure

  • 5.13 Product disposal Record

  • 5.14 Output QI report is available

  • 5.15 Dry room report is available

  • 5.16 CTPAT area free for Sharp Tool

  • 5.17 Metal free zone is available

  • 5.18 Is iron SOP is available

  • 5.19 Is the Iron approved sample with a comment available

  • 5.20 Is the folding approved sample with a comment available

0. Raw Material Inspection/ Warehouse

0.1 Warehouse Layout & Inventory Control(6)

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

  • 0.1.2 All fabric rolls in plastic bag or covered

  • 0.1.3 All fabric rolls on palette or rack

  • 0.1.4 Plastic palettes used

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

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

0.2 Fabric And Visual Inspection

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

  • 0.2.2 Written procedure available for inspection

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

  • 0.2.4 Measure fabric skew and fabric width with records

  • 0.2.5 Handle of fabric assessed against Epyllion approved handle standard

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

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

  • 0.2.8 Fabric inspector demonstrates correct inspection with records

  • 0.2.9 Each roll identified and quarantined when rejected

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

0.3 Colour Assessment

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

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

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

  • 0.3.4 Check selvedge to selvedge shading

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

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

Product Safety & Integrity

1. Button & Label Control

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

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

2. Machine Attachment Control

  • 2.1 Machine Attachment regularly check and maintain data sheet

  • 2.2 Machine Attachment control regularly and recorded.

  • 2.3 Machine oil level is ok.

3. Needle & Sharp metal Control

3.1 Basic Requirements

  • 3.1.1 Needle & Sharp metal control policy & procedure.

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

  • 3.1.3 Broken Needle Procedure are followed properly.

  • 3.1.3.1 Needle balance is updated

  • 3.1.3.2 Sewing M/C knife balance is updated

  • 3.1.4 Qualified Needle man are available

  • 3.1.5 List of Sharp metal

  • 3.1.6 Sharp metal procedure must be maintained.

  • 3.1.7 Metal Detector procedure must be followed.

  • 3.1.8 Dedicated qualified Metal Detector Operator are available

  • 3.1.9 Metal Detection Calibration report are availble.

  • 3.1.10 Metal Operator are Trained.

  • 3.1.11 Metal free zone is free for Matel

  • 3.1.12 1 Hour keeping area is available

  • 3.1.13 Are Sharp tools updated or not?

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

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

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

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

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

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

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

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).

  • 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…).

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

  • Finished goods metal detection records kept

  • 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

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

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

  • 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

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

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

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

  • 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

  • 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

  • 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

3.4 Needle Control Procedure

  • 3.4.1 Broken needle records kept

  • 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

  • 3.4.3 A documented needle procedure in factory

  • 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

  • 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

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

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

  • 3.4.8 Needles have been removed from the idle machines

  • 3.4.9 No syringe needle used in footwear factory

3.5 Sharp Tool Control Procedure

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

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

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

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

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

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

4. Mold Control

  • 4.1 Mold Control policy & procedure

  • 4.2 Record of Humidity & temperature

  • 4.3 Communicate all about mold control procedure.

  • 4.4 Are any SOP for dehumidifier?

5. Pest Control

  • 5.1 Pest control policy & Procedure

  • 5.2 Record of pest control system.

6. Chemical Control

  • 6.1 Hazardous chemical list

  • 6.2 Chemical control policy and procedure must be followed.

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…)

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

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

Internal Audit

1. Audit

  • 1.1 Internal Audit Policy & Procedure

  • 1.2 Internal Audit plan, notice, checklist & Report

  • 1.3 Internal Auditor Qualification & Job Description.

  • 1.4 Corrective & Preventive Action plan

Improvement

1. Evaluation & Monitoring, Performance & Feedback

  • 1.1 Supplier Evaluation, Selection, Monitoring Procedure.

  • 1.2 Supplier Performance data

  • 1.3 Customer Feed back data

2. Traceability

  • 2.1 Record of entire Product traceability system

  • 2.2 Verification of Product traceability

Pictorial Evidence

  • A. Factory/Organization Information

  • B. Quality Management System

  • C. Planning and Management Review

  • D. Resources

  • E. Sample Requirements

  • F. Manufacturing

  • G. Product Safety & Integrity

  • H. Internal Audit

  • I. Improvement

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