factory audit service - ChinaDirect Sourcing (Importing ... · Quality assurance system Acceptable...

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China Made EasyChina Made EasyChina Made EasyChina Made Easy

C h i n a D i r e c t S o u r c i n g S e r v i c e s P t y L t d www.chinadirectsourcing.com.au A.B.N.:19 115 914 906

FACTORY AUDIT REPORT

�� FIRST AUDIT DATE OF AUDIT: MAY 11, 2006

�� RE-AUDIT, PREVIOUS REPORT #: CLIENT/APPLICANT: VENDOR/SUPPLIER:

AUDIT ITEMS:

�� Factory profile

�� Factory organization

�� Production equipment and capacity

�� Quality assurance system

�� Technical standard

�� R&D

�� Supplier management

�� Hygiene, Environment and Security

�� Social accountability COMMENTS AND/OR RECOMMENDATIONS:

AUDIT ITEMS GRADE GRADING OPTION

Factory management Good Excellent/ Good/ Acceptable/ Borderline/ Poor

Production equipment and capacity Excellent Excellent/ Good/ Acceptable/ Borderline/ Poor

Quality assurance system Acceptable Excellent/ Good/ Acceptable/ Borderline/ Poor *** The factory and its production lines seem to be suitable for denim production, all of main machines are made

by famous manufacturers and the name-branded weaving machines are suitable for high-quality fabric

weaving.

*** Suggested that the factory establish a set of clear quality control instructions and quality control standards for

the whole QA system, and set up files for the recordation of inspection reports as well as testing reports.

*** Suggested that the weaving workshop should keep as clean as possible to reduce the unexpected fiber be

woven in the fabric.

PREPARED BY: APPROVED BY:

CHOCO XIAO (INSPECTION ENGINEER) LINDY CHEN

FOR AND ON BEHALF OF

CHINADIRECT SOURCING SERVICES PTY LTD.

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PART A. FACTORY PROFILE

A-1. GENERAL INFORMATION:

Factory Name Jiangyin Tianda Textiles Co., Ltd.

Date of foundation 2001

Legal status Private

Location Zhouzhuang Town, Jiangyin, Jiangsu, China

Number of office staff 18

Total number of workers 205

Factory manager Mr. Zhou Guanxiang

Main products 100% Cotton Denim fabric, T/C Denim fabric

Main market North America, West Europe

Business license Certificate No.: 3205023321790

Date issued: 27/09/2001

Expiration: 26/09/2016

A-2. COMMUNICATION INFORMATION:

Telephone number +86-510-84122032

Fax number +86-510-84122036

Email address [email protected]

Website / Homepage www.hytianda.com.cn

A-3. OTHER SURVEY RESULT FOR THE FACTORY PROFILE:

1. Does the factory confirm its mill with local/national environmental laws Y \ N Y

2. Does the factory confirm its mill with Occupational Safety Laws Y \ N Y

3. Does the factory have clear aisles? Y \ N Y

4. Is the workshop capacious? Y \ N Y

5. Is the workshop bright some? Y \ N Y

6. Does the factory have clear emergency, fire exits on each floor? Y \ N Y

7. Is the building steel or masonry? Both

8. What is the factory’s square meters? 30,000

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A-4. PICTURES FOR FACTORY PROFILE:

Factory gate

Workshop

Office building

Office area

Show room

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PART B. FACTORY ORGANIZATION:

B-1. ORGANIZATION CHART:

B-2. FACTORY EMPLOYEE HEADCOUNT:

Total 258

Admin Dept. 25

Production Dept. 215

QA Dept. 11

Sales Dept. 4

Financial Dept. 3

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PART C. PRODUCTION PROCESS:

C-1. PRODUCTION EQUIPMENT AND CAPACITY:

1. Production Lines:

2 production lines for Sizing yarn

5 production lines for Weaving

2 production lines for Finishing

2. Main Products Materials

�� Cotton

�� Polyester

�� T/C blended

�� Others

3. Major Dyestuff Sorts

�� Direct

�� Reactive

�� Vatting

�� Disperse

�� Others

4. Main Sizing Machines:

2 sets of Hong Kong made continuous size machine for sizing cotton yarn

5. Main Weaving Machines:

90 PICANOL branded machines suitable for plain and dobby woven fabrics

6 PICANOL branded jacquard machines suitable for jacquard fabrics

48 SULZER branded machines suitable for plain and dobby woven fabrics

46 local branded machines suitable for plain woven fabrics

6. Main Finishing Machines:

2 sets of Germany made Heating machines

1 set of Singe machine

1 set of Singe & Pre-shrinkage machine

1 set of machine for Desizing & Mercerizing & Pre-shrinkage

7. Weaving Machines Type:

Shuttle loom 144

Rapier loom 46

8. What is the factory’s average age of machinery? 2

9. How many mechanics in the workshops? Y \ N Y

10. The mechanics work on call? at part time? or at full time? Full time

11. What is the production area’s square meter? 8,000

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C-2. PRODUCTION PROCESS WITH PICTURES:

1. Yarn in warehouse

2. Winding machine

3-1. Warping machine (front view)

3-2. Warping machine (end view)

4. Sizing & dyeing machine (entering view)

5.Sizing & dyeing machine (ending view)

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6-1. 96 sets of Picanol branded weaving machine

6-2. Picanol - branded imported weaving machine

6-3. 48 sets of Sultzer branded weaving machine

6-4. Sultzer - branded imported weaving machine

7-1. Inspection and mending

7-2. Inspection and packing

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8. Finishing workshop

9. 2 production lines in the finishing workshop

10-1. Singe machine of finishing

10-2. Machine for singe & pre-shinkage & dryer

11. Machine for desizing, mercerizing & liquid

ammonia finishing & pre-shinkage

12-1. Germany branded heat setting machine (side

view)

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12-2. Germany branded heat stetting machine (end

view)

13. Inspection and packing for finished fabric

14. Packed fabric in warehouse

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PART D. QUALITY ASSURANCE SYSTEM: D-1. QUALITY ASSURANCE SYSTEM SURVEY:

1. Does the factory have an independent quality control department? Y \ N Y

2. Does the factory have a standard working procedure for quality controls? Y \ N N

3. Does the factory have a clear quality control instruction for yarn/filament using? Y \ N Y

4. Does the factory have a clear quality control instruction for fabric weaving? Y \ N Y

5. Does the factory have a clear quality control instruction for finishing? Y \ N Y

6. Does the factory have a clear quality control instruction for fabric inspection Y \ N N

7. Does the factory have yarn inspection prior to pre-treatment for dyeing? Y \ N Y

8. What percent is inspected? 1~2 package per lot

9. Does the factory have fabric inspection prior to finishing? Y \ N Y

10. What percent is inspected? 100%

11. Does the factory have fabric inspection prior to packing? Y \ N Y

12. Is there a 100% final inspection? Y \ N Y

13. Is there an in-process quality control person? Y \ N N

14. Does the ticket on yarn contain the lot #? Y \ N Y

15. Are the woven fabrics stacked by lot? Any ticket or instruction indicating the lot? Y \ N Y

16. Does inspector check the fabric length and width? Y \ N Y

17. Does operator or the QA dept. keep records of defectives? Y \ N N

18. Does the factory have a light box? If yes, please indicate the light source： Y \ N Y

�� D65

�� TL84

�� CWF

�� U30

�� UV

�� Others

19. Do they perform in factory wash test? If yes, test by Y \ N Y

�� U.S.Washer

�� Tumbler

20. Do they perform in factory colorfastness test? If yes, please indicate Y \ N N

�� To washing

�� To crocking

�� To water

�� To dryclean

�� Others

21. Are records kept for product testing Y \ N N

22. Does the corrective action implement appropriately Y \ N N/A

23. Is there any final statistical audit? Y \ N N

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24. What is the percent of seconds? Y \ N N/A

25. Is there any formal operator-training program? Y \ N N

26. Does the factory have testing machines for yarn/filament quality testing? Y \ N Y

If yes, please describe: Strength testing

27. Does the factory have testing machines for grey fabric quality testing? Y \ N Y

If yes, please describe: Washing testing for Shrinkage and Visual effective

D-2. QUALITY CONTROL PICTURES:

Yarn winding instruction

Yarn testing report

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Fabric testing report

Fabric inspection report

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Technical instruction on each weaving machine

Analyzing & testing room

Yarn strength tester

Electronic wrap reel

Color assessment light

Washing machine for shrinkage pre-testing

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Dryer machine for shrinkage pre-testing

Inspection for woven fabric

Inspection for finished fabric

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factory audit service - ChinaDirect Sourcing (Importing ... · Quality assurance system Acceptable...

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