Factory Information

Factory Profile

  • Date Of Foundation

  • Number Of Employees

  • Does this site have an FCCA? (Factory Capacity Capability Assessment)

  • Please select grade:

  • Please state audit result here:

  • Is the factory vertical?

  • Does the factory have its own laundry?

  • Does the factory have its own embroidery site?

  • Please state garment type capability:

  • Main Markets

  • Please state customers currently working with:

  • Please state quality team structure:

  • Please state number of QC's:

  • Photo Of Gate

  • Factory Exterior

  • Factory Exterior

  • Offices

  • Showroom

Design & Grading Facilities

  • Do you have in house design facilities?

  • Are first patterns hand cut?

  • Is grading computerised?

  • Do you grade to customers size specifications / grades / tolerances etc?

  • Do you have a sample room?

  • Please state number of machines available and number of employees:

Pre-Production

  • Do you hold pre-production meetings?

  • Please state who attends:

  • Are pilot runs produced?

  • Please state number of pieces:

Fabric

Fabric Details

  • Are there approved lab dyes and handles standards for each fabric?

  • Please state where these are stored:

Fabric Storage Area

  • Is the fabric stored on pallets?

  • Is the fabric covered?

  • Is the fabric stored in batches?

  • Are the fabric rolls ticketed and identified?

  • Are fabrics identified by customer?

  • Do you have a light box?

  • Please state what light is used for checking? (TL84 or D65, etc?)

  • Is there a fabric rejection area?

  • Do you control fabric rejections?

  • Please state how you control fabric rejections:

Housekeeping In Fabric Storage Area

  • Is the cleanliness in the fabric storage area acceptable?

  • Is the tidiness of the fabric storage area acceptable?

  • Is the work in progress flow in the fabric storage area acceptable?

Fabric Inspection System

  • Is the fabric inspected at the factory?

  • Do you inspect to the 4 point system?

  • Please state period of time records are maintained for:

  • Please state number of inspection machines available:

  • Is the colour standard available?

  • Are colour continuity cards maintained?

  • Do you conduct fabric shrinkage tests prior to production?

  • Do you produce stitch blankets prior to production?

Trims & Components

Trims & Components Storage

  • Are trims & components stored on pallets or in racking?

  • Are trims & components ticketed and identified?

  • Are trims & components identified by customer?

Trims & Components Inspection

  • Are the trims inspected on delivery?

  • Please state what percentage of trims & components are inspected:

  • Are records maintained?

  • Please state how long records are maintained for:

  • Do you control trims & components rejections?

  • Please state how you control trims & components rejections:

  • Is there a trims & components rejected area?

Housekeeping in Trims & Components Area

  • Is the cleanliness of the trims & components area acceptable?

  • Is the tidiness of the trims & components area acceptable?

  • Is the work in progress flow in the trims & components area acceptable?

Cutting

Cutting Room

  • Please state number of cutting tables:

  • Please state types of cutting apparatus used: (straight, round, band, computer, die)

  • Are these correctly guarded?

  • Are the operators wearing chain mail gloves?

  • Are the chain mail gloves of a suitable size and standard?

  • Is there a safe place for cutting equipment to be stored at the end of each day?

  • Please state what & where this is:

  • Is the cutting equipment labelled?

  • Does the safe place have an inventory?

Marker System

  • Please state depth of lay:

  • Please state how the markers are attached to the lay: (auto, manual or both)

  • Are the lays separated?

  • Please state how the lays are being separated: (paper, waste fabric)

Cut Piece Storage

  • Are there controls in place for shaded panels?

  • Please state controls:

  • Is there batch awareness of fabric dye lot numbers?

  • Are the panels numbered?

  • Are bundles / panels inspected?

  • Please state percentage of pieces inspected:

  • Please state how bundles are stored: (racking, pallets, work bins, trolleys)

Housekeeping In Cutting Room

  • Is the cleanliness in the cutting room acceptable?

  • Is the tidiness of the cutting room acceptable?

  • Is the work in progress flow in the cutting room acceptable?

Fusing

  • Please state number of fusing machines in total:

  • Please state type of fusing machine: (flat bed or rollermatic)

  • Are recommendation sheets available from the fusing supplier for conditions?

  • Is the fusing machine calibrated?

  • Please state how often the machine is calibrated:

  • Is the fusing machine clean?

  • Is the fusing temperature checked?

  • Please state method of how temperature is checked: (thermal strips, hand gun)

  • Are records maintained?

  • Please state how long records are maintained for:

  • Please state how fusing bundles are stored: (racking, pallets, work bins, trolleys)

Housekeeping in Fusing Room

  • Is the cleanliness of the fusing area acceptable?

  • Is the tidiness of the fusing area acceptable?

  • Is the work in progress flow in the fusing area acceptable?

Sewing

Sewing Machinery

  • Please state machinery types:

  • Please state any specialist machinery:

  • Is the sewing room well ventilated?

  • Are needle guards in place?

  • Are belt guards in place?

  • Does each machine have a machine maintenance card?

  • Do the sewing machines have draws in place?

  • Are scissors / snips attached to the workstations?

Quality Systems

  • Do the machines have sewing guides in place or in line visual standards?

  • Please take a photo of standard:

  • Are there quality standards for each process at needle point?

  • Please state process in place:

  • Are records maintained?

  • Are there approved samples on view in the sewing rooms?

  • Do you control labels / trims?

  • Please state what controls are in place: (trim cards)

  • Does the factory carry out in line inspections?

  • Please state percentage checked:

  • Are records maintained?

Sewing Room Processes

  • Is in line trimming taking place?

  • Do you have in line pressing?

  • Is the needle type appropriate for the work in progress?

  • Are white / light coloured garments stored in a bag?

  • For white / light coloured garments do the workers wear gloves?

  • Please state brand of threads being used:

  • Please state styles checked in the sewing room:

Housekeeping In The Sewing Room

  • Is the cleanliness of the sewing room acceptable?

  • Is the tidiness of the sewing room acceptable?

  • Is the work in progress flow in the sewing room acceptable?

Needles Procedures & Metal Control Policy

Needle Procedure & Policy

  • Are needles stored in a secure location?

  • Are there photos displayed of each authorised employee trained to work in the needle room?

  • Is there a needle policy in place?

  • Is this displayed in both English & local language?

  • Are the authorised employees fully trained to understand the procedure?

  • Is there a needle record sheet for needle changes?

  • Is this correctly completed?

  • Please state how long records are maintained for:

  • Is there a needle record sheet for broken needles?

  • Are records maintained for this policy?

  • Please state how long records are maintained for:

  • Please state who is responsible for broken needle fragments: (line supervisor, sewing room manager, sewing room engineer)

  • Are all the broken needle fragments taped to the page?

  • Please state how the factory records broken needle fragments:

  • Is there a standard for each needle used in the factory displayed in the needle room?

  • Are hand sewing needles available?

  • Please state procedures in place:

  • Are there records maintained?

  • Please state how long records are maintained for:

Housekeeping In Needle Room

  • is the cleanliness of the needle room acceptable?

  • Is the tidiness of the needle room acceptable?

Metal Control Policy

  • Are scissors & other metal items stored in a secure location?

  • Are there any cutting blades being used as knives?

  • Has training been given to employees on metal controls & procedures?

  • Are there any pins or staples used in this area?

Stud & Rivet Attachment

Stud & Rivets Processes

  • Please state where studs & rivets are purchased from:

  • Have operators been trained on stud & rivet machines by supplier?

  • Are studs & rivets stored in boxes in the correct manner, area and identified?

  • Do the machines have in line visual standards in place?

  • Is there an approved sample available & on display for employees to see?

  • Are there quality checks in place in stud & rivet attachment area? (opening, closing, brush hand feel)

  • Please state what checks are asking place:

  • Are all garments turned through to check for any loose studs or rivets before leaving the stud & rivet attachment area?

Stud & Rivet Machinery

  • Please state number of stud & rivet attachment machines:

  • Please state what type of stud & rivet machinery is in place: (fully automatic, semi automatic, manual)

  • Are the stud & rivet machinery & dyes from the same source?

  • Please state stud & rivet machines & dyes sources:

  • Are data sheets available at the machines for style in progress?

  • Does each machine have a machine maintenance card?

  • Are defective studs and rivets stored in correct manner?

  • Please take a photo of practice in place:

  • Are there controls in place to catch spare / loose studs & rivets? (rubber mats on floor)

  • Please take a photo of controls in place:

Stud & Rivet Procedures

Pinch Settings

  • Are pinch settings taken?

  • Please state how often readings are taken:

  • Are records maintained?

  • Please state how long records are maintained for:

Pull Tests

  • Does an in line pull test take place?

  • Please state how often in line pull tests take place: (3 times a day)

  • Are records maintained?

  • Please state how long records are maintained for:

Housekeeping in Stud & Rivet Attachment Area

  • Is the cleanliness of the stud & rivet attachment area acceptable?

  • Is the tidiness of the stud & rivet attachment area acceptable?

  • Is the work in progress flow in the stud & rivet attachment area acceptable?

Finishing

Thread Removal

  • Please state what tools are used for trimming: (hot gun, snips)

  • Please state what tools are used for removing loose threads: (lint rollers, sellotape, vacuum machine)

Repairs & Rejections

  • Does the factory identify repairs?

  • Please state the system in place:

  • Does the factory identify seconds?

  • Does the factory separate inspected / faulty garments?

  • Please state system in place:

  • Please take a photo of the system:

  • Are rejected garments disposed of?

  • Please state how rejected garments are disposed of:

Spot Cleaning

  • Does the factory use a spot cleaning process?

  • Please state what substances are used:

  • Are there labels for information regarding hazards?

  • Is this area clearly identified?

  • Is the area well ventilated?

  • Is PPE provided?

Pressing

  • Please state number of pressing tables:

  • Please state type of pressing equipment used:

  • Is pressing equipment suitable for production in progress?

  • Does it operate with controls?

  • Are pressing tables suitable for garment type?

  • Are pressing covers clean?

  • Please state how garments are stored once pressed:

Housekeeping of Pressing Area

  • Is the cleanliness of the pressing room acceptable?

  • Is the tidiness of the pressing room acceptable?

  • Is the work in progress flow in the pressing room acceptable?

Metal Detection & Metal Free Zone

Metal Detection

  • Is the metal detector located in a seperate area between final QC and packing?

  • Is the metal detector located so all items must be passed through without exception?

  • Please state type of metal detector: (static, conveyor, hand held)

  • Please state model type:

  • Does the metal detector have a calibration certificate?

  • Please take a photo of the calibration certificate card:

  • Please state how often metal detection machine is calibrated:

  • Is the metal detector positioned in an airport system?

  • Is a 1-2mm ferrous test card being used?

  • Are records being maintained?

  • Please state how long the records are maintained for:

  • How many times a day is it calibrated?

  • Does the factory use the 9 point system?

  • During evaluation was the card detected?

  • Are there photos of trained employees at metal detector?

  • Is the machine operator trained to use the machine?

  • Does the operator have a good knowledge of the working procedures?

  • Has the metal detector been serviced in the last 6 months?

  • If metal is detected, does the conveyor stop and an alarm sound?

  • Is the machine re-started by using a key?

  • Please state who has the key

  • Is there an isolation box for items where the metal contamination cannot be found?

Metal Free Zone

  • Is the metal free zone separate from other production areas?

  • Is there a register to infill upon entry to metal free zone?

  • Are people hand wanded upon entry into metal free zone?

  • Is final packing taking place in metal free zone?

  • Are sellotape dispensers checked in and out on a daily basis?

  • Are records maintained?

Warehouse

  • Are the finished goods warehouse separate from other production areas?

  • Does the factory have facilities for hanging garments?

  • Does the factory have facilities for boxed garments?

  • Please state volume of storage area:

Quality Systems

  • Do you have copies of the customer manuals available on the factory floor?

  • Do you carry out a 100% final inspection?

  • Are records kept?

  • Please state how long records are maintained for:

  • Do you carry out a final AQL inspection?

  • Please state what level this is carried out at:

  • Are records maintained?

  • Please state where the AQL inspection is conducted?

Pull Testing

Pull Test Machinery

  • Please state type of pull test machine: (fully automatic, semi automatic, manual)

  • Please state machine model:

  • Is the machine calibrated?

  • Please state how often the machine is calibrated:

  • Are there photos of trained employees near to pull test machine?

  • Are in line pull tests being carried out on any sewn on buttons, studs, rivets?

  • Are records being maintained?

  • Please state how long records are being maintained for:

  • Please state how often pull tests are being carried out:

  • Are pull tests being recorded at breakage?

  • Please state how pull tests are being recorded:

  • Please state where garments that have been pull tested are stored:

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