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Walmart FCCA 沃尔玛质量验厂审核纲要

Walmart FCCA Quality System Audit Outline
沃尔玛FCCA质量体系审核纲要 (家纺 类-纺织)
1.0Factory Facilities and Environment 工厂设施与环境


1. Are lighting sufficient in the following key areas? 下面关键区域的照明足够吗?


1.1.   Inspection Areas 检验区


1.2.   Production Areas [Spinning, Weaving, Processing (Pre-treatment, Dyeing/Printing, Finishing), Cutting, Stitching] 生产区 [纺纱,织布, 加工(前处理,染
/印,后处理),裁剪,缝纫]


1.3.   Packaging 包装区


1.4.  Warehouse/Storage and Loading Areas 仓库/堆放处和装货区


2. The facility maintains clean and organized production, finishing and packing areas.
工厂的生产, and 修整和包装区域应保持干净整洁.


3. Facility has separate inspection area for each department with inspection tables and proper ventilation.
每个部门有独立的检验区, 配有检验桌,并且通风条件良好.


4. Facility has documented and adequate pest control program which includes frequent inspections ( in-house or 3rd party)
工厂有文件化充分的虫害控制程序, 该程序包括定期的检查(工厂内部或第三方)


5. Are storage conditions appropriate and adequate for raw materials, WIP, finished products to avoid deterioration of quality or safety? 材料, 半成品和成品的储存条件充分适当避免品质和安全受损.
Especially for sensitive materials/components, example, IC Storage. Does Factory have good environmental control on temperature, humidity, etc.?
特别针对那些敏感的材料/部件, 例如, IC 存, 工厂在温湿度等方面, 有适当的环境控.


6.  No broken windows or leaking roofs that may result to product contamination was observed during Audit.
审核过程中, 没有观测到可能导致产品污染的破损窗户或漏水屋顶.

Critical
关键点
7. Factory implements strict sharp tools control procedure to prevent scissors, knives, blades, broken glasses and needles to be mixed with product.
工厂有执行严格的利器控制程序去预防剪刀, 刀片, 破玻璃和针混到产品中

Critical
关键点
8. Factory implements a broken needle control process
工厂执行断针控制程序

Critical
关键点
9. Factory has metal detecting unit (Airport System) and located at the right finishing area and is enclosed and secured and have regular calibration records  [Scoring will not apply (N/A) if factory does not need this machine for products like Rugs or Bathmat (Rubber) for which handheld detector can be used]
工厂是否有验针机(空港式)并且布置在适当的后整理区域,验针区域必须是封闭安全的,验针机必须定期校准和记录[如果工厂产品不需要验针,如地毯、浴垫等,可用手持验针机,此项 N/A]


10.  Does the plant have a back up power supply available that will allow production to continue in case of power failure?
工厂有后备的电源供应设备, 就算停电生产也能继续


11.  Does the factory have established procedure and effective industrial waste management system in place
工厂有没有建立有效的工业废品管理体系和程序?

1.1 Machine Calibration and Maintenance 机器校准和维护


1. Factory has documented system and procedure for scheduled production machines & equipment cleaning and repairs and calibration (Preventive Maintenance Program).工厂对预定的生产机器设备清洁,维修和校验(预防性的保养程序)建立文件化的系统和程.


2. Factory has documented system and procedure for scheduled calibration of Inspection and Testing tools and equipment.
工厂对检验和测试用的设备和工具校验建立文件化的系统和程序.


3.  Is calibration accuracy traceable to specific International and National Standards?
校验能追溯到相关的国家和国际的标准.?


4. Factory machines and equipment appear to be clean and in good running condition.
工厂的机器和设备干净清洁, 运行良好.


5. Machines, equipment and tools that needs to be repaired are properly labelled or marked to avoid accidental use.
需要维修的生产机器, 设备和工具有适当标识防止误用


6. Factory has proper, clean and organized storage area of critical tooling (i.e. injection moulds) with labelled shelves.
对于关键的工具模具(例如注塑模具), 工厂有没有指定一个适当的, 干净整洁的区域来储存并配置带有标识的存储架


7. Factory has proper documentation and updated inventory of machines, tools, spare parts and equipment.
机器设备, 工具和备件的库存清单, 工厂进行文件管控并保持更新


8. Factory has maintenance team with suitable skill level and equipment's to perform necessary repair and calibration on machines.
工厂具有一定技术水平的机修团队和基础设施, 来进行必要的设备维护和校.
2.0Quality Management System 质量管理系统


1.  Does the factory have accredited Quality Management System in place with any international, national or customer quality standards association (e.g. ISO 9001, etc.)?工厂是否获得国际,国家,或客户的质量标准协会的质量管理体系(如 ISO 9001,等认证)。


2. Does the factory have established Quality Management System (QMS) that is clearly documented in their Quality Manual which follows ISO9001 or other International Quality Standard that is appropriate to the products they manufacture?
工厂是否建立文件化的符合 ISO9001 或其他适合工厂生产的国际质量标准的质量管理体系?


3. Workers & Supervisors are familiar to these quality policies and objectives.
员工和主管熟悉这些品质方针和目标.


4. Factory has documented customer complaint system and documented recall
program.工厂有建立客户投诉处理体系和产品召回流程

Critical
关键点
5. Factory QC team is independent from Production division.
QC 部门独立于生产部门


6. Does the factory have some type of listing to identify specific defects [similar to Defect Classification List (DCL) or Critical-Major-Minor Defect List (CMM)] and is it being used in their inspections?
工厂有定义不同缺陷, 有列出缺陷类型并在检验中使用.(类似缺陷分类表 DCL 或关键不良项-主要缺陷-次要缺陷分类表.)


7. Production management and QC team discuss and work together in solving Quality issues/ concerns. (Documented)
生产管理层和品质部门一起工作讨论解决品质问题(文件化)


8. Factory maintains effective traceability system that can determine immediate source from raw material to finished product.
工厂拥有有效的追溯机制,从原材料到成品能立即追根溯源.


9.  Factory has systems and procedures in place to control the risk (Risk Assessment) of physical or chemical contamination that may damage/affect raw materials, process, equipment & tools, products and personnel as well.
工厂有建立风险控制的程序和系统, 来控制物理和化学污染的风险, 避免影响到原材料,流程设备,工具和人员.


10.  Has the factory registered the Law Labels in GRS (Global Registration Services)? [Mandatory WMUS requirement for all Upholstered and Stuffed Articles]
工厂有没有在 GRS(全球注册服务)上注册法律标? [出往 Wal-Mart US 的带有软垫或填充物玩具的强制要求]
NOTE: Applicable only for existing factories.  New factory is exempted (N/A) for this requirement during the Initial Pre-Qualification Audit.
注意:只适用于 WM 旧工厂。新工厂初次预审不适用。
3.0. In-coming Materials Control 进料材料控制


1. Factory has documented process & procedures (instructions, guidelines and records) for quality inspection and verification on all in-coming raw materials, accessories, components and/or sub-assemblies to ensure that it conforms to specifications, quality standards, safety & regulatory requirements.
工厂有建立原材料, 料, 部件和外发件进料检验和确认的流程和程序 (范, 指导和文件化的记录), 保证他们符合规格, 品质标准, 安全和法规的要求.


2.   Proper first in-first out (FIFO) system on materials are practiced.
工厂有执行材料先进先出管理系统.


3. Is the system can trace back to the raw material source or know where they are
from? 有一套系统保证原材料可追溯到其来源?


4. Incoming and outgoing material quantities are monitored and documented.
材料的进出数量有监控和文件化.

Critical
关键点
5. Does the factory maintain records showing proof that all paints, coatings and non- paint components (hardware, labels, etc.) are tested for Lead and Heavy Metals content and complied with the safety & regulatory requirements where the products are sold, as applicable?
工厂有保存相关的证据记录证明所有的油漆, 涂料和非涂层部件(五金, 标签等)有通过有害金属的测试, 符合出口国的法律法规要求.


6. Does the factory maintain records showing proof that all raw materials are tested for EU REACH Substance of Very High Concern (SVHC) and complied with the safety & regulatory requirements where the products are sold, as applicable? ASDA requirement
严重项-工厂有无记录证明所有原材料进行了欧盟 REACH 有关高度关注物质(SVHC)的测试,并符合产品销售地的安全法规的要求?ASDA 的要求)


7. Is needed testing equipment available and maintained in good condition?
有必要的测试设备, 并且维护在完好的条件.

Critical
关键点
8. Critical- Is the checking equipment, e.g. Color Lighting Cabinet (Light Box) being put under a proper environment and well maintained and approved shade band available for bulk color verification?
严重项- 检验设备, 如灯箱是否放置在适当的环境并保护良好,有确认的色差样供大货颜
色的验证
ASDA:  as per ASDA colour Manual  (colour evaluation)
ASDA: 根据 ASDA 颜色手册(颜色评估)
All other Retail Markets:  as per WMUS Color Evaluation Manual
所有其他销售市场:根据沃尔玛美国市场的颜色评估手册。

Critical
关键点
9. Factory has proper system on material segregation to avoid accidental contamination from rejected items. These are stored in the designated Quarantine area
关键项 – 工厂有适当的系统来隔离拒收材料避免污染.这些拒收材料将存储在指定的隔离区.


10.   Does the factory review, determine and record the disposition of rejected raw material, i.e. Return to raw material supplier, Deviate to Use, Rework, Scrap?
工厂有无审查,决定和记录被拒收的原材料,如退回材料供应商,降级/特采使用,返工,废弃?


11. Materials, components and accessories are properly stacked and identified with tags / labels and off the floor.
.材料,配件和辅料是否合理存储,标识清楚,并离地堆放。

Critical
关键点
12. Chemicals and maintenance substances are properly marked  and stored to prevent risk of contamination
化学品和维护保养的化学物质有适当的标识和储存预防污染风险.


13.  Does factory have documented REACH document control system?
[ASDA Requirement]
工厂有文件化的 REACH 文件控制系统. [ASDA 求]


14. If applicable, Fire Resistant (FR) foam/filling (fibers)  material shall have independent test certificates, and factory properly segregate Fire Resistant Foam/Filling (fibers) Material from non-Fire Resistant Foam/Filling (fibers) Material FOR ASDA:  (Only applies  for Filled Bedding manufacturer except Mattress Protector & Duvet)
如果适用情况下,阻燃(FR)海绵/填充材料要有单独的测试证书,并且工厂应适当地隔离阻燃材料和非阻燃材料。
ASDA:只适合生产有填充材料的寝具制造商, 床垫套和羽绒被除外。

3.1 Suppliers & Sub-contractors 供应商和分包商


1. Does factory have a documented supplier selection and approval process?
工厂是否有文件化的供应商选择和审批流程?


2. Does factory have an established, documented quality procedure and does factory evaluate, monitor or track material supplier's quality performance and reliability? Is there an assessment report of the material supplier factory?
工厂是否有已制定的文件化的质量程序,是否评价,监控和追踪原料供应商的质量绩效
和可靠性?是否有材料供应商评估报告?


3. Does factory have an established, documented quality procedure and does factory evaluate, monitor or track Sub-Contractor quality performance and reliability? Is there an assessment report of the sub-contractor's factory?
工厂是否有已制定的文件化的质量程序,是否评价,监控或追踪分包商质量绩效和可靠
性。是否有分包商评估报告?


4. Are the records for supplier & subcontractor approval properly maintained and kept according to the defined retention period? (Minimum 1 year)
是否按照保持期限保存供应商和分包商的批准记录?(至少一年)


5.  Are the personnel with adequate product knowledge and skill sets conducting material supplier & sub-contractor qualification?
人员是否有足够的产品知识和技能组合进行材料供应商和分包商资格审查?

4.0Process and Production Control 生产和过程控制


1. Does factory PD study and apply product safety features, evaluates patterns, moulds and samples during product design and development?
在产品开发设计阶段,是否有对样品和模具等进行了有效地评估来确保产品安全性?


2. Factory has documented Quality Process & Procedures with Work Instructions
at each stage of operation.
在质量控制的每个阶段是否有相应的书面的程序文件以及作业指导书?


3. Factory has documented Production Process & Procedures with Work Instructions at each stage of operation.
在生产过程的每个阶段,是否有相应的书面程序文件以及作业指导书?


4. Are required production control parameters stipulated/defined and maintained during the production processes?
生产过程中的控制参数是否被有效定义以及监控?


5. Does factory conduct Pre-production meeting prior to start of production?
在开始生产前,工厂是否召开了产前会议?


6. Are production and quality supervisors present during Pre-production meeting?
生产和质量主管是否出席了产前会议?

Critical
关键点
7. Are critical quality and safety checks reviewed, identified, and actions for improvement documented during Pre-production meeting?
在产前会议中,是否评估和识别了质量和安全的关键控制点以及是否有相应的改善措
施?


8. Does factory conduct “Pilot-run” on new products, high value, high volume and high risk items and review product quality against specification sheet and document results with corrective actions prior to mass production?
工厂是否针对新产品, 高价值产品,高风险产品, 数量多的产品做试生产并大货生产前对于试生产时存在的问题是否进行了有效地整改并有相关记录?


9. Was in house testing performed on current production? (Request for test copies)
在制程中,是否进行了内部测试?(需要测试的复印件)


10. Does factory QC compare first piece samples with approval sample and specification sheet?
QC 是否按照相应的首件检检验规范和样板进行首件确认?


11. Are there adequate approved samples, first piece samples, reference samples and work instructions to provide workers with proper guidelines?
是否有足够的确认样,首件,参考样和作业指导书提供给生产线员工作为作业参考

Critical
关键点
12.  Do Quality Control Department personnel (Inspectors/Supervisors/Managers/Directors) have authority to stop production if quality of products did not meet specification?
在产品不合格的情况下,工厂品管部门人员(检查员/主管/经理/总监)是否有权停线?


13. Does the factory have systems in place for the handling of product specification/communication documents?
工厂是否有系统来管理有关产品规格和沟通文件?


14. Does factory use defective/ reject samples to demonstrate examples of common defects?
工厂是否使用缺陷或拒收样板来展示常见缺陷类型以供参考?


15. Does factory has proper in-process inspection procedure and standard? Does QC strictly follow the procedure and all inspection records are properly retained.
工厂是否有适用的检验流程和标准?QC 是否严格的按照相关检验流程或标准开展工
作?所有检验记录是否被有效地保留?


16. In-line inspections (IPQC) are performed by QC (both by Production Line QC & Quality Dept's QC) at every operation process.
每个生产环节都有由 QC(生产现场 QC 和品质管理部门 QC)进行的在线检查.
Please refer to latest WM AQL Std
参考 WM 最新
AQL 标准
17. Factory QC inspects per standard AQL or as per industry standards.
工厂 QC 根据标准的 AQL 还是行业标准执行检查?


18.  Where applicable, factory performs 100% functionality check on final products?
如果适用 - 工厂是否对最终产品进行 100%的功能检查?


19.  Does factory use corrective actions and root cause analysis methods? (Please provide examples)
对于不符合项目或存在的问题,工厂是否开展了根本原因分析和纠正预防行动?(请举
例)


20. Does factory have guidelines in place to ensure packaging is correct for product?
工厂是否有指导方法来确保产品的包装正确?


21. Does packing area have enough space to perform packing functions properly? Is it clean and organized?  Storage is separate
包装区域是否有足够的空间来完包装工作?包装区域是否干净和有序?存储是分开独立
?


22. Packed cartons are stored on pallets in enclosed area not exposed to sunshine and wet weather.  Space is available and cartons are not stored too high or against walls or windows
包装好的卡通箱用栈板储存在封闭的区域, 防止日晒雨淋. 储存区足够, 并且卡通箱不能堆得太高, 或离墙和窗户太近.


23. Does factory track and document on-time ship performance and take necessary actions (CAP) for delayed shipments [Check rolling 12 months shipment record]工厂有跟踪并记录准时出货率吗?对于延迟发货采取必要的行动(纠正措施计划)检查连续 12 个月出货记录.


24. Does factory have the Chemical name and information of safe use of each EU REACH Substance of very high concern (SVHC) on the candidate list?  [ASDA Requirement]
工厂是否有欧盟 REACH 法规要求高关注物质的化学品名称以及如何安全使用的信息?


25. Does factory keep all the REACH document for more than 10 years after the related substance was imported to Europe?  [ASDA Requirement][Auditor need to verify and see if any REACH document can be retrieved from the system]
当有关物质出口到欧洲以后,工厂是否保留其相关的 REACH 文件 10 年以上?
[ASDA 要求] [审核员需要确认是否所有 REACH 文件能在其控制系统中检索到]


26.   Does factory use statistical process control (SPC) for quality? Are SPC controls maintained at the manufacturing operation as required?
工厂是否使用了统计技术工具(SPC)来改进和保证品质的?SPC 是否对生产过程中
各个阶段进行了控制?

5.0In-House Testing  内部测试


1. Does factory perform any kind of in-house testing? Are test equipment/tools well maintained, organized and technicians are well trained. Test Standards used are traceable to any international or local standards?
工厂是否执行了各种内部测试?测试设备/工具是否保养良好并存放有序,测试技术人员是否有良好培训?采用的测试标准是否可追溯到相关的国际或地方标准?


2. All gauges and test equipment have valid calibrations and are properly labelled
所有的测量测试设备需要有有效的校验以及需要贴上校验标贴.


3. Testing manuals of various industry standards and WM Test Protocols are available as reference & are up to date
测试作业指导书所遵循的的行业标准和 WM 测试方案保存良好, 随时有据可查并保持更新?


4. Technicians conducting in-house testing are properly trained to perform testing functions and Certificates of training are available.
内部测试技术人员有适当培训以执行测试工作, 有培训证书.
NOTE: Factory that trains their own technicians must show evidence that their Chief/Master Technician has been trained & certified by qualified professional trainers.
意: 必须有证据显示,工厂对技术人员进行培训的首席技术员(技术主管),必须经过权威的有资质机构的培训和认证.


5.  Does factory have appropriate testing equipment/facility for screening / checking the presence of SVHC on the candidate list?   [ASDA Requirement]
工厂是否有适当的测试设备/设施来甄别和检查 SVHC 候选清单的物质.(仅对 ASDA 的要求)
6.0Final Inspection 最终检验


1. Does factory have procedure and working instruction for Final QC Inspection?
工厂是否有相关成品检验程序或检验指导书提供给检验员作为检验依据?


2. Factory QC conducts final inspection based on client-specific AQL sampling plan.
成品检验是否基于客户专门规定的 AQL 和抽样计划?


3. An approved sample or reference sample with packing list and shipping marks are available as reference for factory QC.
是否签板或附带包装明细和箱唛信息的封样件提供给成品检验员作为检验参考?


4.  Approved sample or Reference samples shall be stored in good conditions to maintain product integrity.
产品参考样或签板是否储存在适宜的环境来保持其完整性.


5. Are there formal written final inspection reports? Are they properly filed and traceable for review on quality of products?
是否有正式的书面成品检验报告?成品检验报告是否有效地存档以及能有效地追溯来评
估产品质量?


6. Where applicable, does factory final QC performs internal mechanical/functional tests to ensure the safety of product?
如果适用,工厂的成品检验员是否实施内部机械或是功能 的测试来确保产品的安全?


7. Where appropriate, are inspection and testing equipment used by the inspector in good condition and calibrated?
检验员使用的检验和测试设备是否校正, 并处于良好状态?

Critical
关键点
8.  Failed inspections are properly corrected prior to final inspection by customer.
在内部检验结果不通过的情况下, 工厂是否在客人验货之前整改完毕?


9. Factory does not ship goods unless subjected to release procedures from customer.
没有获得客户批准授 权,工厂不能安排出货.

7.0People Resources and Training 人力资源和培训

Critical
关键点
1. Factory conducts documents and maintains on-job training for all personnel or conducts pre-hire testing of skilled workers prior to hiring.
工厂对所有的员工提供在职培训, 并且对技术工人在雇佣前进行考试..


2.  Is there a formal, documented Technical training/cross-training or certification program for PRODUCTION WORKERS on process, work station, equipment that they perform/use?
针对生产线员工, 工厂是否在制程阶段, 工作区, 设备使用方面, 建立了正式的文件化的技能培训/交叉培训或资格认证程序.


3.  Is there a formal, documented Technical training or certification program for QC INSPECTORS on QC processes?
针对品质检验人员, 工厂是否在品质控制方面,建立和执行正式的,文件化的技能培训或资格认证程序.


4.  Is there a formal, documented Technical training or certification program for ENGINEERS, MAINTENANCE OR EQUIPMENT TECHNICIANS?
针对工程师, 设备维护或设备技能人员, 工厂是否建立了正式的,文件化的技能培训或资格认证程序.


5. Records of trainees and all regular personnel with corresponding performance records are kept and maintained.
所有员工的培训记录和绩效考核, 都有保存和维护.


6.  Are training courses / materials suitable for trainees with different job scope?
工厂是否基于岗位的需求提供针对性的培训? 课程和教材是否得当?


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