2019 2020 2021

NO. EVIDENCE REQUIREMENT LOOK FOR… COMMENTS

Aug May Aug

1 Management Review
.1.1 Is there an annual quality plan of improvement?
1.1 YES
.1.2 Does the management team review the quality analysis report at least monthly?
Show Minutes, and copies of the
reports that are discussed in the Managers are aware of their numbers, their actions plans and show
1.2
meetings. Copies of that they are following up on these actions to improve final numbers
presentations that are reviewed.

.1.3 Have countermeasures been generated after the management review ?

1.3

.1.4 Are the countermeasures assigned to a person of authority and held accountalbe for follow up?
1.4

.1.5 Are the results of countermeasures reviewed by the management team on a monthly basis?
Validate some of these actions on
1.5
the floor

.1.6 Does the maker have a visual dashboard in the local language to communicate results to their people?
1.6

2 Roles and Responsibilities

.2.1 Is there a Quality Manual ?
2.1

.2.2 Does the quality manual include defined responsibilities and authorities?
2.2

.2.3 Are production leads responsible for quality?

2.3

.2.4 Are SOP's updated and renewed at least annually?

2.4

.2.5 Are SOP documents written in local language and English? Are they accessible and easy to understand ?
 2.5

.2.6 Does maker create a standard format of inspection report ?

2.6

.2.7 Is there an organization chart for QA Department ?

2.7

.2.8 Is QA Manager available ?

2.8

.2.9 Does QA Manager report to the General Manager (not to the Production Manager) ?
2.9

.2.10 Does QA have the authority to request corrective actions?

2.10

.2.11 Is there a formal escalation process ?

2.11

.2.12 Does QA have the authority to stop production?

2.12

.2.13 Is the production manager held accountable for quality?

2.13

.2.14 Are production supervisors held accountable for quality and review quality metrics during production at same level
2.14

3 Pre-production Capabilities/New Production Introduction

A. New Program Style Set Up
.3.1 Does sample room create operation list ?
Show list of operations of Draws Detail draws and instructions so the floor knows what is important in
3.1
of each operation the new cosntruction. Measurements are being taken

.3.2 Does maker inspect new raw material as it comes in?

1) Heat transfer adherence
2) Heat transfer print quality
3.2
3) Ticketing print quality
 4) validates labels withstands the wash

.3.3 Is there any sample inspection report ?

3.3

.3.4 Has sample room recorded the reasons and qty of rejected samples within a fixed period of time ?
3.4

.3.5 Does the maker validate the bill of materials needed before the sample is processed?
3.5

.3.6 Is there a kick off meeting with production reviewing the new construction , validate machine needs and a sign off b
Minutes of meeting with evidence
3.6 of Draws reviewed, machine
requirements, special folders?

.3.7 Does maker monitor the new production to validate bulk is to Spec?
3.7

.3.8 Has maker set sampling plan for raw material inspection ?
3.8
B. Raw Material Inspection and Verification
.3.9 Is the fabric inspection method aligned with customer's requirements ?
3.9

.3.10 Does maker do the fabric shrinkage test & record the findings ?
3.10

.3.11 Does the fabric shrinkage test follow customer's requirement (on sample size and washing method) ?
3.11

.3.12 Does maker taper and follow it thru to the spreading process ?
3.12

.3.13 Does maker have an escalation mechanism when the raw materials fail ?
3.13

.3.14 Does the factory have an SOP to control and handle Non-conformance Raw Material
3.14
.3.15 Are Non-conforming raw materials Isolated and Identified properly?
3.15

.3.16 Is production pattern adjusted properly according to the shrinkage test results ?
3.16
C. Patter Review/Confirmation
.3.17 Does pattern room created enough set of patterns to accommodate the shrinkage range ?
3.17

.3.18 Are all pattern adjustment done by the authorized/certified personnel only ?
3.18

.3.19 Does maker do pilot run / test cut ?

3.19
D. Pilot Run/ Test Cut
.3.20 Prior to running pilot run, has a process flow been established to include CTQs by job?
3.20 Get list of test cuts generated

.3.21 Were process parameters documented during the pilot run?

3.21

.3.22 Is there evidence that the Department QC checks the Pilot/test cut before it leaves their area of responsibility?
3.22

.3.23 Is there evidence that Local QC reviews garments before submitting ?

Validate list of test cuts generated
3.23 to reports of audits done to the
cuts
.3.24 Has maker created follow-up actions after the inspection by local QC and Corporate QA ?
Loof for percent test cuts passing and records of fallout rate (work
3.24
and fit)
.3.25 Has maker calculated the pilot run / test cut rejection rate ?
3.25

.3.26 Is there a threshold defect rate defined which must be achieved prior to releasing submission for approval?
3.26
.3.27 Is measurement evaluated on basis of capability? (cpk or probability)
3.27

.3.28 Is there a threshold for measurement capability to be achieved prior to release of approval submission?
3.28

4 Cutting Capability
.4.1 Has maker relaxed the fabric before spreading ?
4.1

.4.2 Does maker follow SOP to check the cut panels & make records ?
4.2

.4.3 Are machine calibration done (e.g. on fusing machine ,GERBER offset) ?
4.3

.4.4 Does maker validate the cutting of bands outside of the marker to validate the correct dimension as a daily audit?
4.4

.4.5 Housekeeping: Are machines well kept, aisles clear, WIP organized?
4.5

.4.6 Is there visual controls to clearly identify status of material (In process, rejected, QA Hold, acceptable for next opera
4.6

.4.7 Do jobs utilize visual management?

4.7

.4.8 Is there a process in place to validate proper marker and fabric used for work order?
4.8
.4.9 Does the department visually post cutting waste?
4.9

.4.10 Does the department post re-cuts or quality metrics?

4.10

.4.11 Does the department have in place problem solving teams utilizing a process such as Trend, Pareto , Action?
4.11

.4.12 Does maker use controlled tension on fabric when Fabric is spread?
4.12

.4.13 Cut, bundle & shade integrity mantained through process?

4.13

.4.14 Fabric inspection process in place?

4.14

.4.15 Is the cutting and spreading personnel trained and certified to run automated equipment?
4.15

5 Sewing Capability
.5.1 Are sewing standards accessible in the line ?
5.1

.5.2 Are QC trained, evaluated & qualified ?

Proof of training records and
5.2
training material.
.5.3 Does maker create an SOP for audit process ?
5.3

.5.4 Does QC follow SOP to check the products ?

5.4

.5.5 Does QC record the data (from workmanship & measurement checks)?
5.5

.5.6 Are rejected bundles status clear at all times (fail / waiting-to-inspect/ time waiting) ?
5.6

.5.7 Production that fails is revised and repaired before cleared to continue?
5.7

.5.8 Does line supervisor analyze the data and take corrective actions within two working days ?
i.e. MDI boards, rejected bundles
have time written on them, no
5.8
bundles rejected not being
followed up
.5.9 Does Supervisor have weekly quality meeting to review quality issues and lead the action plans?
5.9
.5.10 Housekeeping: Are machines well kept, aisles clear, WIP organized?
5.10

.5.11 Does the QC follow critical POM for measurement?

5.11

.5.12 Does maker follow bundle integrity (bands, loops, risers, facings sewn to correct bundle)
5.12

.5.13 Does the maker have a needle control SOP?

5.13

.5.14 Is there visual controls to clearly identify status of material (In process, rejected, QA Hold, acceptable for next opera
5.14

.5.15 Do jobs utilize visual management?

5.15

.5.16 Does the department have in place problem solving teams utilizing a process such as Trend, Pareto , Action?
5.16

.5.17 Cut, bundle & shade integrity mantained through process?

5.17

6 Laundry Capability
.6.1 Does maker follow customer's washing recipe to wash the garments and report any deviation to client?
6.1

.6.2 Are the washing standards protected and stored in a light free environment?
6.2

.6.3 Are washing standards (dry and wet process) accessible in the line ?
6.3

.6.4 Does maker create SOP for audit process ?

6.4

.6.5 Does QC follow SOP to check the measurement & visual effects of the garment to standard?
6.5

.6.6 Does maker use correct light source (CWF) and intensity to check the color / shade ?
 6.6

.6.7 Does QC record the data (from measurement and dry/wet process checks) accurately and on-time ?
6.7

.6.8 Are all inspection status (pass / fail / waiting-to-inspect) clear ?

6.8

.6.9 Does line supervisor analyze the data and take corrective actions within two working days ?
6.9

.6.10 Housekeeping: are machines well kept, aisles clear, WIP organized
6.10

.6.11 Are chemicals stored in a safe environment (safe containment)?

6.11

.6.12 Are the washer baskets and drier baskets audited for damage on a regular basis?
6.12

.6.13 Is there a regular audit and calibration on the dryers to validate temperature is within tolerance (i.e. 180 on denim, 16
6.13

.6.14 Does the laundry adhere to the local laws of water treatment?
6.14

.6.15 Is there visual controls to clearly identify status of material (In process, rejected, QA Hold, acceptable for next opera
6.15

.6.16 Do jobs utilize visual management?

6.16

.6.17 Does the department have in place problem solving teams utilizing a process such as Trend, Pareto , Action?
6.17

.6.18 Cut, bundle & shade integrity mantained through process?

6.18

7 Finishing Capabilities
.7.1 Are packing standard (e.g. folding method / sticker position, etc.…) accessible in the line ?
7.1
.7.2 Are the QC inspection tables brightly lit (min 1000 lux) and spacious enough?
7.2

.7.3 Does maker create SOP for audit process ?

7.3

.7.4 Does QC follow SOP to check and measure the garments ?

7.4

.7.5 Does QC record the data accurately and on-time ?

7.5

.7.6 Are all inspection status (pass / fail / waiting-to-inspect) clear ?

7.6

.7.7 Does line supervisor follow up on production that fails and make sure the failed garments are identified and repaire
7.7

.7.8 Does line supervisor analyze the data and take immediate corrective actions ?
7.8

.7.9 Housekeeping: are machines well kept, aisles clear, WIP organized
7.9

.7.10 Does the maker have a needle control SOP?

7.10

.7.11 Is there visual controls to clearly identify status of material (In process, rejected, QA Hold, acceptable for next opera
7.11

.7.12 Do jobs utilize visual management?

7.12

.7.13 Does the department have in place problem solving teams utilizing a process such as Trend, Pareto , Action?
7.13

.7.14 Cut, bundle & shade integrity mantained through process?

7.14

8 Continuous and Permanent Correction Action

.8.1 Does maker use the correct method (Pareto, Fishbone, Root Cause, etc.) to analyze the quality data ?
 8.1

.8.2 Have corrective actions been generated after the analysis ?

8.2

.8.3 Have corrective actions been monitored and executed on a monthly basis to evaluate the progress?
8.3

.8.4 Does maker have Internal Auditor team to do process audit ?

8.4

.8.5 Are process flows in place showing process controls to prevent passing bad product to next job?
8.5

.8.6 Visual management in place which highlights process performance and makes none adherence to process easily id
8.6
.8.7 Does maker have a process to review customer feedback and provide Corrective Actions?
8.7
.8.8 Does maker audit their raw material suppliers?
8.8

9 Preventive Maintenance
.9.1 Does maker have machine maintenance policy ?
9.1
.9.2 Do mechanics keep all maintenance records ?
9.2
.9.3 Are machines well maintained on the floor & laundry ?
9.3

10 Training and Organizational Development

.10.1 Does maker have QC training program ?
10.1
.10.2 Are all training materials readily available (i.e.. Manuals, presentations)?
10.2
.10.3 Are there any training records ?
10.3
.10.4 Is there any quality concept training done for all staff?
10.4
.10.5 Are QC trained, evaluated & qualified ?
10.5

11 Warehousing and Material Handling

.11.1 Is warehouse well maintained with good housekeeping ?
11.1
.11.2 Are all raw materials stored properly and a correct FIFO (First In First Out) inventory system applied?
11.2
.11.3 Have all packed cartons been stored per SOP ? (to prevent molding)
11.3
.11.4 Trailers being loaded appropriately (pre-inspected for damage?)
11.4
.11.5 Finished goods stored off the floor/appropriately to prevent mold, pest and rodent control
11.5
.11.6 Are there controls and procedures to follow up on non conforming/rejected products on the production floor?
11.6
.11.7 Trims or findings inspection process in place?
11.7
.11.8 Is there a disposition process for non conforming materials?
11.8
.11.9 Are there process in place to ensure damage such as soil, holes, tears are not created within processes and during
11.9

12 Final Quality Audit

.12.1 Does the factory have a final audit process that insures product meets customer requirements?
12.1
.12.2 Does the factory correlate well within 20% of customer quality data
12.2
.12.3 Do they have a process in place to insure audit integrity (shadow audits) ?
12.3