Fundamental Technical Audit Form - V1.0

• Audit No.

• Auditor Name

• Factory Name

• Conducted on

  Date
• Location
  Address

Factory Profile

• Date Of Foundation

• Number Of Employees

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

  Yes

  No

  N/A

• Please select grade:

  Red

  Amber

  Green

• Please state audit result here:

• Is the factory vertical?

  Yes

  No

  N/A

• Does the factory have its own laundry?

  Yes

  No

  N/A

• Does the factory have its own embroidery site?

  Yes

  No

  N/A

• 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

  Media

• Factory Exterior

  Media

• Factory Exterior

  Media

• Offices

  Media

• Showroom

  Media

• Do you have in house design facilities?

  Yes

  No

  N/A

• Are first patterns hand cut?

  Yes

  No

  N/A

• Is grading computerised?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Do you have a sample room?

  Yes

  No

  N/A

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

• Do you hold pre-production meetings?

  Yes

  No

  N/A

• Please state who attends:

• Are pilot runs produced?

  Yes

  No

  N/A

• Please state number of pieces:

Fabric Details

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

  Yes

  No

  N/A

• Please state where these are stored:

Fabric Storage Area

• Is the fabric stored on pallets?

  Yes

  No

  N/A

• Is the fabric covered?

  Yes

  No

  N/A

• Is the fabric stored in batches?

  Yes

  No

  N/A

• Are the fabric rolls ticketed and identified?

  Yes

  No

  N/A

• Are fabrics identified by customer?

  Yes

  No

  N/A

• Do you have a light box?

  Yes

  No

  N/A

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

• Is there a fabric rejection area?

  Yes

  No

  N/A

• Do you control fabric rejections?

  Yes

  No

  N/A

• Please state how you control fabric rejections:

Housekeeping In Fabric Storage Area

• Is the cleanliness in the fabric storage area acceptable?

  Yes

  No

  N/A

• Is the tidiness of the fabric storage area acceptable?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

Fabric Inspection System

• Is the fabric inspected at the factory?

  Yes

  No

  N/A

• Do you inspect to the 4 point system?

  Yes

  No

  N/A

• Please state period of time records are maintained for:

• Please state number of inspection machines available:

• Is the colour standard available?

  Yes

  No

  N/A

• Are colour continuity cards maintained?

  Yes

  No

  N/A

• Do you conduct fabric shrinkage tests prior to production?

  Yes

  No

  N/A

• Do you produce stitch blankets prior to production?

  Yes

  No

  N/A

Trims & Components Storage

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

  Yes

  No

  N/A

• Are trims & components ticketed and identified?

  Yes

  No

  N/A

• Are trims & components identified by customer?

  Yes

  No

  N/A

Trims & Components Inspection

• Are the trims inspected on delivery?

  Yes

  No

  N/A

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

• Are records maintained?

  Yes

  No

  N/A

• Please state how long records are maintained for:

• Do you control trims & components rejections?

  Yes

  No

  N/A

• Please state how you control trims & components rejections:

• Is there a trims & components rejected area?

  Yes

  No

  N/A

Housekeeping in Trims & Components Area

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

Cutting Room

• Please state number of cutting tables:

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

• Are these correctly guarded?

  Yes

  No

  N/A

• Are the operators wearing chain mail gloves?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Please state what & where this is:

• Is the cutting equipment labelled?

  Yes

  No

  N/A

• Does the safe place have an inventory?

  Yes

  No

  N/A

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?

  Yes

  No

  N/A

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

Cut Piece Storage

• Are there controls in place for shaded panels?

  Yes

  No

  N/A

• Please state controls:

• Is there batch awareness of fabric dye lot numbers?

  Yes

  No

  N/A

• Are the panels numbered?

  Yes

  No

  N/A

• Are bundles / panels inspected?

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

• Is the tidiness of the cutting room acceptable?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

• Is the fusing machine calibrated?

  Yes

  No

  N/A

• Please state how often the machine is calibrated:

• Is the fusing machine clean?

  Yes

  No

  N/A

• Is the fusing temperature checked?

  Yes

  No

  N/A

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

• Are records maintained?

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

• Is the tidiness of the fusing area acceptable?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

Sewing Machinery

• Please state machinery types:

• Please state any specialist machinery:

• Is the sewing room well ventilated?

  Yes

  No

  N/A

• Are needle guards in place?

  Yes

  No

  N/A

• Are belt guards in place?

  Yes

  No

  N/A

• Does each machine have a machine maintenance card?

  Yes

  No

  N/A

• Do the sewing machines have draws in place?

  Yes

  No

  N/A

• Are scissors / snips attached to the workstations?

  Yes

  No

  N/A

Quality Systems

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

  Yes

  No

  N/A

• Please take a photo of standard:

  Media

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

  Yes

  No

  N/A

• Please state process in place:

• Are records maintained?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Do you control labels / trims?

  Yes

  No

  N/A

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

• Does the factory carry out in line inspections?

  Yes

  No

  N/A

• Please state percentage checked:

• Are records maintained?

  Yes

  No

  N/A

Sewing Room Processes

• Is in line trimming taking place?

  Yes

  No

  N/A

• Do you have in line pressing?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

• Is the tidiness of the sewing room acceptable?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

Needle Procedure & Policy

• Are needles stored in a secure location?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Is there a needle policy in place?

  Yes

  No

  N/A

• Is this displayed in both English & local language?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Is there a needle record sheet for needle changes?

  Yes

  No

  N/A

• Is this correctly completed?

  Yes

  No

  N/A

• Please state how long records are maintained for:

• Is there a needle record sheet for broken needles?

  Yes

  No

  N/A

• Are records maintained for this policy?

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

• Are hand sewing needles available?

  Yes

  No

  N/A

• Please state procedures in place:

• Are there records maintained?

  Yes

  No

  N/A

• Please state how long records are maintained for:

Housekeeping In Needle Room

• is the cleanliness of the needle room acceptable?

  Yes

  No

  N/A

• Is the tidiness of the needle room acceptable?

  Yes

  No

  N/A

Metal Control Policy

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

  Yes

  No

  N/A

• Are there any cutting blades being used as knives?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

Stud & Rivets Processes

• Please state where studs & rivets are purchased from:

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

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?

  Yes

  No

  N/A

• Please state stud & rivet machines & dyes sources:

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

  Yes

  No

  N/A

• Does each machine have a machine maintenance card?

  Yes

  No

  N/A

• Are defective studs and rivets stored in correct manner?

  Yes

  No

  N/A

• Please take a photo of practice in place:

  Media

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

  Yes

  No

  N/A

• Please take a photo of controls in place:

  Media

Stud & Rivet Procedures

Pinch Settings

• Are pinch settings taken?

  Yes

  No

  N/A

• Please state how often readings are taken:

• Are records maintained?

  Yes

  No

  N/A

• Please state how long records are maintained for:

Pull Tests

• Does an in line pull test take place?

  Yes

  No

  N/A

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

• Are records maintained?

  Yes

  No

  N/A

• Please state how long records are maintained for:

Housekeeping in Stud & Rivet Attachment Area

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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?

  Yes

  No

  N/A

• Please state the system in place:

• Does the factory identify seconds?

  Yes

  No

  N/A

• Does the factory separate inspected / faulty garments?

  Yes

  No

  N/A

• Please state system in place:

• Please take a photo of the system:

  Media

• Are rejected garments disposed of?

  Yes

  No

  N/A

• Please state how rejected garments are disposed of:

Spot Cleaning

• Does the factory use a spot cleaning process?

  Yes

  No

  N/A

• Please state what substances are used:

• Are there labels for information regarding hazards?

  Yes

  No

  N/A

• Is this area clearly identified?

  Yes

  No

  N/A

• Is the area well ventilated?

  Yes

  No

  N/A

• Is PPE provided?

  Yes

  No

  N/A

• Please state number of pressing tables:

• Please state type of pressing equipment used:

• Is pressing equipment suitable for production in progress?

  Yes

  No

  N/A

• Does it operate with controls?

  Yes

  No

  N/A

• Are pressing tables suitable for garment type?

  Yes

  No

  N/A

• Are pressing covers clean?

  Yes

  No

  N/A

• Please state how garments are stored once pressed:

Housekeeping of Pressing Area

• Is the cleanliness of the pressing room acceptable?

  Yes

  No

  N/A

• Is the tidiness of the pressing room acceptable?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

Metal Detection

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

• Please state model type:

• Does the metal detector have a calibration certificate?

  Yes

  No

  N/A

• Please take a photo of the calibration certificate card:

  Media

• Please state how often metal detection machine is calibrated:

• Is the metal detector positioned in an airport system?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Are records being maintained?

  Yes

  No

  N/A

• Please state how long the records are maintained for:

• How many times a day is it calibrated?

  Yes

  No

  N/A

• Does the factory use the 9 point system?

  Yes

  No

  N/A

• During evaluation was the card detected?

  Yes

  No

  N/A

• Are there photos of trained employees at metal detector?

  Yes

  No

  N/A

• Is the machine operator trained to use the machine?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Please state who has the key

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

  Yes

  No

  N/A

Metal Free Zone

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Is final packing taking place in metal free zone?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Are records maintained?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Does the factory have facilities for hanging garments?

  Yes

  No

  N/A

• Does the factory have facilities for boxed garments?

  Yes

  No

  N/A

• Please state volume of storage area:

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

  Yes

  No

  N/A

• Do you carry out a 100% final inspection?

  Yes

  No

  N/A

• Are records kept?

  Yes

  No

  N/A

• Please state how long records are maintained for:

• Do you carry out a final AQL inspection?

  Yes

  No

  N/A

• Please state what level this is carried out at:

• Are records maintained?

  Yes

  No

  N/A

• Please state where the AQL inspection is conducted?

Pull Test Machinery

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

• Please state machine model:

• Is the machine calibrated?

  Yes

  No

  N/A

• Please state how often the machine is calibrated:

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Are records being maintained?

  Yes

  No

  N/A

• 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?

  Yes

  No

  N/A

• Please state how pull tests are being recorded:

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