Technical/ QMS/ Quality Audit Checklist of The Footwear Industry
Footwear is what we wear on our feet. Then all the shoes and boots together fall into this category. Technical is very important for the footwear industry. The audit define quality standard of a footwear factory. In this article, we will discuss on Technical/ QMS/ Quality Audit Checklist of Footwear Industry.
Technical/ QMS/ Quality Audit Checklist of The Footwear Industry
| Section | Technical/ QMS/ Quality Audit Checklist of The Footwear Industry |
| 01 Warehouse | 1. Do they have clear SOP on trim inspection & testing procedures, Is there light box to validate the color based on PP sample approval? |
| 01 Warehouse | All trims are checked 100% to ensure correct quality, color, contents in label and packed qty with record. Clear SOP. Workers are checking on site. There are basic testing like pulling zipper, buttons, colorfastness to rubbing conducted. For K&B trims, check via metal detector. |
| 01 Warehouse | 10% inspected and found workers are inspecting both quality and quantity of all trims. There is no testing equipments, workers use manual test method. |
| 01 Warehouse | Any needed checking / testing are missing or incomplete SOP, reports. Did not found workers checking on site. |
| 01 Warehouse | There is no inspection. |
| 01 Warehouse | 2.Does the factory test outsourced components & materials to ensure their durability, color and safety as per the standard ? For example, slip resistance test, sole and welt bonding strength, outsole aging test, EVA, TPR, TPU, RUBBER hardness checked and abrasion test done in the laboratory before production? Does the supervisor or designate person sign the report? |
| 01 Warehouse | All tests listed are done properly, test equipments are calibrated, reports are clear and tested specimens show regular testing done. |
| 01 Warehouse | less than 20% missing while bulk quality could still pass Final |
| 01 Warehouse | more than 20% missing and bulk quality is at risk to fail |
| 01 Warehouse | There is no material testing. |
| 01 Warehouse | 3.Is the warehouse with correct temperature, humidity controlled to ensure the material will not deteriorate, is there a dehumidifier? |
| 01 Warehouse | The temperature has the proper control and there is dehumidifier for all warehouses. |
| 01 Warehouse | There is only temperature and humidity control at finishing product location. |
| 01 Warehouse | Insufficient temperature or humidity control. |
| 01 Warehouse | no control, open area with humidity and temperature depends on weather |
| 01 Warehouse | 4.Are all materials stored indoors ? |
| 01 Warehouse | All material is stored indoor and not exposed to sunlight and rain |
| 01 Warehouse | All production material is stored indoors, just leftover material is put outdoors with covers. |
| 01 Warehouse | There are less than 20% of material are store outdoors or covers without walls. |
| 01 Warehouse | More than 20% of materials are storage outdoors. |
| 01 Warehouse | 5.Are rejected bulk lots being separated and put under quarantine? |
| 01 Warehouse | – Rejected lots of raw materials / trims / parts are clearly marked and put into designated area / boxes. – Separated rooms or locked containers from the remainder of bulk with clear record; – assigned person were responsible for allocation and separate these from good product, limited access to all workers. |
| 01 Warehouse | – Rejected lots of raw materials / trims / part are clearly marked but stored were not locked. – There is no designated person to handle these rejected lots. |
| 01 Warehouse | – Rejected raw materials were put in designated area with open cover boxes. – There is high possibility of mix those rejected from the good products in packing. |
| 01 Warehouse | – Found rejected lots are mixed with the rest of the bulk in packing and not clearly marked. |
| 02 Cutting | 1.Are all material before cutting procedure with approval report signed by the warehouse supervisor or designated person as per the approved standard in visual and measurement? |
| 02 Cutting | The cutting supervisor only start cutting after receiving the material report approved by supervisor or person designated. |
| 02 Cutting | The material has approved report but not signed by anyone. |
| 02 Cutting | There are checked process but insufficient report. |
| 02 Cutting | No checking. |
| 02 Cutting | 2.Is there a clear SOP instruction on how to organize the textile/PU/leather material, before starting cutting? Is there a cutting direction? Do they relax the textile/PU material in a proper station? Is there a instruction on how many layers should be cut for each material ? |
| 02 Cutting | All styles has clear SOP for cutting direction. proper relaxation done with labelled time and lay flat at racks, pile height controlled so the upper layer has no deviation with the bottom layer in shape. |
| 02 Cutting | less than 20% deviation from the Good practice while bulk quality could still pass Final |
| 02 Cutting | more than 20% deviation from the Good practice and bulk quality is at risk to fail |
| 02 Cutting | no SOP found. |
| 02 Cutting | 3.Operator of the cutting machinery is following the basic safety protocol, such as using the two buttons’ activation switch and ensuring the machine is turned off when they are placing the material under the iron plate. |
| 02 Cutting | Operator is following the safety protocol |
| 02 Cutting | Operator is not follow the two buttons activation only turning off the machine to place the material under the iron plate. |
| 02 Cutting | any missing process from the list |
| 02 Cutting | There is no safety protocol. |
| 02 Cutting | 4.Operators are trained to cut the material and visible checking the components to ensure the quality, and no any damaged piece and clean cutting edges it will be performance against the PP sample? |
| 02 Cutting | Operator are trained and follow the correct procedure and comparing with PP sample. |
| 02 Cutting | Only operators who works for high value brands or Gap Inc products are following SOP. |
| 02 Cutting | Less than 20% operators are not follow the procedures. |
| 02 Cutting | Most operators are working without checking. |
| 02 Cutting | 5.Is the cutting board flat under the iron plate? Is there any instruction to rotate the cutting board to avoid waviness of the cutting board? Does the cutting board have the minimum 15mm thickness? |
| 02 Cutting | The cutting plastic board is flat. There are complete rotation instruction and has the acceptable thickness. |
| 02 Cutting | The cutting board is flat and qualified as Good rating, some operators are not cutting accurately. |
| 02 Cutting | Some cutting board is not qualified as Good rating. |
| 02 Cutting | All cutting boards are not flat, there is no rotation instruction and wrong thickness with less than 15mm. |
| 02 Cutting | 6.Does the cut and die stored and transported in a correct way to cutting station and the way back to stored? Is there any cutting die in contact to each other or with a metal part that might damaged the sharpness? |
| 02 Cutting | The cutting die is well organized and no contact on any sharp parts with each other. There is a proper trolleys for transportation cutting die without damage. |
| 02 Cutting | the cutting die is well stored but the trolleys are insufficient to protect the cutting die, workers need to handle with care. |
| 02 Cutting | Inappropriate storage method or inappropriate transportation trolleys. Some die cuts found damaged. |
| 02 Cutting | No proper storage nor proper transportation trolleys. |
| 02 Cutting | 7.Does the operator has a proper gauge and uses them to spot the cutting parts to avoid cutting die distortion? |
| 02 Cutting | There is a gauge with regular calibration and the operator uses them. |
| 02 Cutting | Same as Good rating while the gauge do not have calibration record. |
| 02 Cutting | Insufficient gauge or some operators did not use. |
| 02 Cutting | No gauge. |
| 02 Cutting | 8.Is the cutting room well organized with the maintenance of the machine with records and safety protocol to the operators? |
| 02 Cutting | Meets all listed requirements. |
| 02 Cutting | Same as Good rating while the maintenance record is insufficient. |
| 02 Cutting | Fairly organized cutting room, insufficient safety protocol listed. |
| 02 Cutting | Not organized, no safety protocol and no maintenance with records. |
| 03 Stitching & grouping | 1.Is there any SOP, Technical specification, PP sample signed or any instruction on the stitching production line, for the actual shoe upper production? |
| 03 Stitching & grouping | All the instruction is available, SOP, Technical specification, PP sample signed for the actual production. |
| 03 Stitching & grouping | Technical specification and PP sample signed for the actual production. Other SOP cannot identified. |
| 03 Stitching & grouping | Insufficient technical information/ instructions and some PP sample missing. |
| 03 Stitching & grouping | no technical info nor approved PP sample |
| 03 Stitching & grouping | 2.Are the operators trained for the stitching upper operation/ assembling the upper components/Skiving, and general required process for the daily upper production? Does the stitching operator being trained to perform standard base maintained on the machineries? |
| 03 Stitching & grouping | The operator has a technical training for the daily upper production and performance basic maintenance on the machines. |
| 03 Stitching & grouping | The operator is trained for the daily production but doesn’t performance basic maintenance on the machineries |
| 03 Stitching & grouping | The operator has insufficient training on how to use the machines |
| 03 Stitching & grouping | There is no training for new operators. |
| 03 Stitching & grouping | 3.Is the Upper components in the correct position avoiding stacking? Is there any gauge/jigs to support correct marking/ alignment of the upper parts? Are the components clean and trimmed during the processing? |
| 03 Stitching & grouping | The uppers is well organized, gauges/jigs it’s in place to the operators and the components are well managed. |
| 03 Stitching & grouping | Same as Good rating except there is no gauges/jigs to the operators. |
| 03 Stitching & grouping | Less than 10% of Upper components are in wrong positions and dirty. |
| 03 Stitching & grouping | More than 10% of the uppers are staked all over the place, no gauges/jigs and upper are not well managed. |
| 03 Stitching & grouping | 4.Does the technical department provide a technical meeting to the Stitching department team before any new style going to production? Is there any record for the technical meetings signed by both departments? |
| 03 Stitching & grouping | Full transition from Technical department to the Stitching room with records signed by both departments. |
| 03 Stitching & grouping | The technical meetings is done but missing some signed reports. |
| 03 Stitching & grouping | Factory only conduct meetings for new products. There is no meeting for carryover products. |
| 03 Stitching & grouping | No meeting is done and no reports signed. |
| 03 Stitching & grouping | 5.In case of broken needles, does the operator stop the stitching machine and call the supervisor? Is the broken needle collected and placed in the file paper with both parts broken together and numbered and located in a place for authorized staff only? Does the factory follow the Needle Policy? |
| 03 Stitching & grouping | Every broken needle is placed in designated place and the factory is following the needle policy. There is a Product Safety Officer ( PSO) audit monthly on broken needle process in all depts. |
| 03 Stitching & grouping | Factory follows Gap Inc broken needle policy, there is record and correct needle replacement procedures. The supervisor controls the new needle and broken needle record. |
| 03 Stitching & grouping | Found some missing broken needle record or new needle storage is not locked. |
| 03 Stitching & grouping | Missing parts of the broken needles found in production or needles found in worker’s own storage area. |
| 03 Stitching & grouping | 6.Is there maintenance department to support the stitching/skiving/tools and equipment in daily tasks to keep the machineries in good and safe condition to the workers? Is the machinery maintenance schedule available with documented? |
| 03 Stitching & grouping | Yes, the factory has maintenance department and each machine has a maintenance card to indicate the checking record. |
| 03 Stitching & grouping | There is a maintenance department and maintenance record is kept by maintenance dept. |
| 03 Stitching & grouping | Found some machines are in worn condition or insufficient maintenance record. |
| 03 Stitching & grouping | There is no maintenance department. |
| 03 Stitching & grouping | 7.Does the factory has a proper machineries and process for different types of shoes construction matching to the accepted orders to delivery? Example boots with crimping upper machine/blocking shape and technical system? Espadrille construction with a moccasin stitching machine…. |
| 03 Stitching & grouping | The factory has the corrected machineries and process per product type. Factory could self-design new machine parts to control production consistency. |
| 03 Stitching & grouping | Same as Good rating except that factory will buy all machine parts needed. There is on IE to design new machine parts. |
| 03 Stitching & grouping | Insufficient machines or process found. |
| 03 Stitching & grouping | wrong machines used or no control production process. |
| 03 Stitching & grouping | 8.As a part of stitching process, is there any other process in place like Punching hole for eyelets, Pre back part mold, Elastic process, Buckles placement, Lining printing? Are those process properly done following the stitching process based on SOP’s instruction? |
| 03 Stitching & grouping | There is a clear production instruction posted and semi-product sample display at production line. Every process is following the SOP instruction. |
| 03 Stitching & grouping | The production line process is identical for same product with a finished approval sample while there is no production instruction nor semi-product sample. |
| 03 Stitching & grouping | Found variations between lines producing same product. Insufficient approval sample/ production instructions given. |
| 03 Stitching & grouping | The process is not done correctly and no SOP instruction available. |
| 03 Stitching & grouping | 9.Does the QC check overall workmanship at different operations, Does the QC knows where is the critical operations? Are the QC’s able to work with the operator and support them with a proper technical instruction? |
| 03 Stitching & grouping | The QC’s team is roving to cover all stations in hourly basis and they are able to give a technical instruction to the operator. |
| 03 Stitching & grouping | The QC teams roving to cover all stations once per shift. i.e. 2 times per day. |
| 03 Stitching & grouping | There are insufficient QC team checking or the QC team has insufficient knowledge to teach operator. |
| 03 Stitching & grouping | No roving QC. |
| 03 Stitching & grouping | 10.Does the in charge supervisor/QA know how to make the upper production following the PP sample? Is there a clear instruction on how to make the upper measurement against the PP sample? |
| 03 Stitching & grouping | The supervisor/QA have full understand of the PP sample, there are clear measurement guide for QA to follow. The QC measures accurately as buyer QA. |
| 03 Stitching & grouping | There is no clear measurement guideline while all QC can measure accurately as buyer QA. |
| 03 Stitching & grouping | There are more than 1/8″ deviation in measurement of factory QC vs buyer QA. |
| 03 Stitching & grouping | The supervisor/QC can’t follow the instruction and PP sample with measurement. |
| 03 Stitching & grouping | 11.Is there any rejected upper? Does these rejected uppers has a clear label and is placing a sign to avoid mixing with the corrected uppers? Is there any station with a corrected trained Technician to fix these rejected uppers? |
| 03 Stitching & grouping | The uppers rejected is separated from the approved uppers with a clear label and there is a station with a trained technician can fix the rejected upper. |
| 03 Stitching & grouping | Same as Good rating except that the rejected upper is separately stored in a box without individual label per piece. |
| 03 Stitching & grouping | There is not clear storage of rejected upper nor insufficient fix of the rejected upper. |
| 03 Stitching & grouping | The rejected upper has no label and found some rejected upper do not fix properly. . |
| 03 Stitching & grouping | 12.Is the approved uppers done with a proper packing in pair wise, placed in a box/shelves/ trolleys keeping the good shape to transport to the Lasting room department? |
| 03 Stitching & grouping | The approved uppers are well packed by pair and placed in a box/Shelves/Trolleys in good shape to transport to lasting room department. |
| 03 Stitching & grouping | There are little crowded in packing while it does not lead to shape distorted. |
| 03 Stitching & grouping | The approved uppers are not packed by pair and no proper placed in a box/Shelves/Trolleys to transport to lasting room department. |
| 03 Stitching & grouping | The approved uppers are not packed by pair and send to lasting room by bags with a bad upper shape. |
| 03 Stitching & grouping | 13.Does the production has every components to start the assembling montage? Is the SOP instruction available? Is the lasting in place? Is the Insole in place? Is the Upper in place? Is the outsole in place? Is the internal sock lining in place? Is the packing information, labels in place? |
| 03 Stitching & grouping | The production has every components in place to start production, including all trims and packing materials. |
| 03 Stitching & grouping | Major components for product assembly are in place to start production. Factory has process to chase missing components in time or using stocks from other styles as a back up plan. |
| 03 Stitching & grouping | There are less than 10% of piling up of semi-finished product pending for missing components for assembly. |
| 03 Stitching & grouping | More than 10% of the semi-finished products piling up. |
| 06 Finishing – Packing | 1.Is there a fitting instruction clear to production team? Is the production team performing daily fitting? How many times per day? Is the fitting done with the fitting model? Is it same as PP sample? Is there any action to re fitting in case tight/looseness? |
| 06 Finishing – Packing | The production team is performing daily fitting during production 2 time per day, and records is done, the fitting model is comparing with PP sample, there is a records done and action re fitting is following up by in charge supervisor. |
| 06 Finishing – Packing | Same as Good rating except factory use last mold to fit instead of a fitting model. and perform one time per day. |
| 06 Finishing – Packing | The fitting is done one time per day but there is no records and action taken in case of variances from PP sample |
| 06 Finishing – Packing | No any fitting done. |
| 06 Finishing – Packing | 2.Is the operator trained to check the shoe quality, pair wise/cleanness/height back, side in and out/ vamp? Does the operator has the knowledge to put the hand inside the shoes to double check if any metal or unfriendly material like glue or sharp material is inside the shoes before packing? |
| 06 Finishing – Packing | The operator is trained to check the shoe quality,1- pair wise2-cleaness3-height back, side in and out4-vamp. The operator has the knowledge to put the hand in side the shoes to double check if any metal or unfriendly material like glue or sharp material is in side the shoes before packing. |
| 06 Finishing – Packing | Same as Good rating except there are 80% or above operators are doing correctly. |
| 06 Finishing – Packing | There is an operator but is not performing all the check points on the shoes. |
| 06 Finishing – Packing | There is no process checking points. |
| 06 Finishing – Packing | 3.Is there any rejected shoes separated and added a clear label of rejection to avoid mixing with the approval shoes? |
| 06 Finishing – Packing | The rejected shoes is separated and added a clear label of rejection in each pc and it is easy to identify. |
| 06 Finishing – Packing | The rejected shoes is separated in labelled boxes but there is no label for individual pcs. |
| 06 Finishing – Packing | The rejected shoes is separated but missing a clear label of rejection. |
| 06 Finishing – Packing | The rejected shoes is not being separated, very easy to get mixed. |
| 06 Finishing – Packing | 4.Is there a well- implemented rework/repair procedure? Are rejected shoes assessed and evaluated prior rework, repair or disposal? Is it the repair done by a proper technician? |
| 06 Finishing – Packing | There is a well- implemented repair procedure, the rejected shoes is assessed and evaluated prior rework, the repair is done and the bad shoes is totally rejected, handle by a proper technician. |
| 06 Finishing – Packing | Same as Good rating, found 0 or 1 pc of minor defectives out from 5 pcs after repair. |
| 06 Finishing – Packing | The report procedures are insufficient, found 2+ out of 5 pcs of defective shoes after repair. |
| 06 Finishing – Packing | There is no repair procedure, the rejected shoes is keeping waiting to be fix it and no action in most of the time. |
| 06 Finishing – Packing | 5.Is there a packing instruction with packed sample in place? Is the correct label in the packing line available as per the shipment? Does the supervisor check the packing by drop test to ensure it can protect the shoes? Is there regular monitoring by supervisor to ensure it is followed? |
| 06 Finishing – Packing | There is a packing instruction with packed sample in place. There is correct label in the packing line available as per the shipment. The supervisor check the packing by drop test to ensure it can protect the shoes. There is regular monitoring by supervisor to ensure it is followed. |
| 06 Finishing – Packing | 80+% Good Practices are done. little risk in wrong packing. |
| 06 Finishing – Packing | Insufficient checking or control in packing. |
| 06 Finishing – Packing | no checking or control in packing. high risk in wrong packing. |
| 04 Lasting | 1.Is the assembling line well organized considering cleanness, safety, no obstacles at aisles with a good ventilation? |
| 04 Lasting | Lasting production floor is well organized, clean, aisles clear, no obstacles and with good ventilation. |
| 04 Lasting | Same as point 1 Lasting line is organize but some obstacles is on the way, not good light illumination, but has good ventilation. |
| 04 Lasting | The assembling line has a obstacles, not good light illumination and poor ventilation. |
| 04 Lasting | no checking no light box. New factory said cannot agree to buy. |
| 04 Lasting | 2.Does the production line holds the approval sample with signed tag and Lasting instruction for every process for easy visibility to the workers? |
| 04 Lasting | The production line holds the approval sample with signed tag and Lasting instruction for every process for easy visibility to the workers |
| 04 Lasting | Have clear lasting instructions but not approval sample |
| 04 Lasting | Only have approval sample but no lasting instruction |
| 04 Lasting | No approval sample and not lasting instruction |
| 04 Lasting | 3.Does the technical department provide a technical meeting to the Lasting department team before any new style going to production? Is there any record for the technical meetings signed by both departments? |
| 04 Lasting | Full transition from Technical department to the Lasting room department with records signed by both departments. |
| 04 Lasting | Full transition from Technical department to the Lasting room department with records signed by all departments. |
| 04 Lasting | The technical meetings is done with some info missing in the signed reports or missing some departments’ signature . |
| 04 Lasting | No meeting is done and no reports signed. |
| 04 Lasting | 4.Is there a define process to set up the machineries required to the shoe construction? like; back part mold, blocking vamp shape for boots, toe last, back counter close allowance, Heater and cooler machines, pressing outsole, heel nail machine, Rough paper sand machine? |
| 04 Lasting | The production line has process to set up the machineries required to the shoe construction.1-back part mould,2- blocking vamp shape for boots,3- toe last,4- back counter close allowence,5- Heater and cooler machines,6- pressing outsole, 7-heel nail machine8- Rough sand paper machine….. |
| 04 Lasting | There are standard production lines for same shoes styling running all over the year. |
| 04 Lasting | No any define process to set up the machineries they work as the styles coming into the line, major important machines is available. |
| 04 Lasting | Missing process or major machines have mechanical problems. |
| 04 Lasting | 5.Is the insole fixed on the last with correct process? No nail/screw or any metal is allowed. |
| 04 Lasting | The insole is fixed on the last with correct process. No nail/screw or any metal is used. |
| 04 Lasting | The insole is not properly fixed on the last some are twisted , but no nail/screw or any metal found in the process. |
| 04 Lasting | 6.Does the insole have the correct shape on the last? Does the upper fit into the last with no wrinkles? |
| 04 Lasting | The insole has the correct shape on the last and the upper is fitting in the last with no wrinkles. |
| 04 Lasting | The insole has the correct shape on the last but the upper is not fit into the last, there are little acceptable winkles found in the production. |
| 04 Lasting | The insole has the correct shape on the last but the upper is not fit into the last, many winkles found in the production. |
| 04 Lasting | The insole and upper is not fitting into the last. |
| 04 Lasting | 7.Is the Back part mold done as per the instruction? Time? Heating? Is the mold following the same shape as the last? |
| 04 Lasting | The back part mold is done as per the instruction,1- Time, 2- Heating, 3- the mold following the same shape as the last. |
| 04 Lasting | The back part mold is not done as per the instruction, the setting are not been followed by the worker. However, the shape of the mold is the same as the last. |
| 04 Lasting | There are more than 5% of distorted shape found in some pieces due to operator did not follow per instruction. |
| 04 Lasting | The back part mold is not done as per the instruction, the setting are not been followed by the worker, the shape of the mold is totally different. |
| 04 Lasting | 8.Is there a QC station in the lasting room? Have the QC correct skills to follow the quality and inform the supervisor in case problem start to show out? |
| 04 Lasting | There is enough QC station in the lasting room 1- the QC has the correct skills to follow the quality and inform the supervisor the problems in hourly basis. The light intensity is 600-800 lux. |
| 04 Lasting | There is a QC station in the lasting room1- the QC could only listed out issues to supervisor per shift. i.e. 2 times per day. |
| 04 Lasting | Products checked and passed by the QC are found with defects. QC has incomplete or delay report to supervisors. Light intensity is out of 600-800 lux. |
| 04 Lasting | No of insufficient QC station in the lasting room part. |
| 04 Lasting | 9.Does the heater conveyor machine on the lasting room station with a proper heat temperature and speed as per the instruction? |
| 04 Lasting | The heater conveyor machine on the lasting room station is with the proper heat temperature and speed as per the instruction. There is checking and record one time per shift. |
| 04 Lasting | The heater conveyor machine on the lasting room station is with the proper heat temperature upon checked but there is no regular checking records. |
| 04 Lasting | Some of the heater conveyor machines are checked and found in wrong temp/speed setting. |
| 04 Lasting | There is no control on temp and speed setting of heater conveyor machine. |
| 04 Lasting | 10.Is the last with correct mark on the front/side in/side out and on the back part, is this mark done by designated technician with gauge provided by technical department? The workers have instruction not to use damaged last, the damaged last must take away and inform the supervisor for replacement. |
| 04 Lasting | 1.The last is with correct mark on the front/side in/side out and on the back part, the mark is done by designated technician with gauge provided by technical department. 2-The workers is following the instruction for not use the damaged last. 3 the workers is giving information to the supervisor, 4 supervisor is replacing the damaged last. |
| 04 Lasting | No damaged last but the mark on last unclear or too many mark line on the last not easy exactly know which line is correct line |
| 04 Lasting | Any of the listed process are missing or insufficient. |
| 04 Lasting | Most of last is missing the correct mark and the damaged last still using. |
| 04 Lasting | 11.Does the Toe last machine has the right set to last the shoes? Does the operator has a proper skills to complete the correct toe last operation? Is there a instruction of lasting to follow the PP sample? Does the machine has a mark by laser light to guide the operator to avoid any upper to be crocked? |
| 04 Lasting | The toe last machine has the right set to last the shoes, 1-The operator has a proper skills to complete the correct toe last operation, 2-The instruction of lasting to follow the PP sample is in place, 3- The machine has a mark by laser light to guide the operator to avoid any upper to be crocked. |
| 04 Lasting | The toe is in correct shape after lasting even though there is missing instruction posted at site or no laser light guide marking. |
| 04 Lasting | There are > 5% distorted toe after lasting. Insufficient process is found. |
| 04 Lasting | The toe last machine has no right set to last the shoes 1-The operator has no proper skills to complete the correct toe last operation, 2-No instruction on the lasting machine and no laser light. |
| 04 Lasting | 12.Are the workers on the lasting room with skills to last different types of shoes? Boots/pumps/espadrilles/sandals/ by hand and machines? Are the workers in charge lasting being trained before the production starts? |
| 04 Lasting | The workers on the lasting room has skills to last different types of shoes 1- Boots/pumps/espadrilles/sandals/ by hand and machines 2-The workers in charge lasting has being trained before the production starts. |
| 04 Lasting | Some of the workers on the lasting room has skills to last different types of shoes 1- Boots/pumps/espadrilles/sandals/ by hand and machines 2-There is no training record for the workers |
| 04 Lasting | More than 5% defectives are found in some workers. There is no proper training process set up for new unskillful workers. |
| 04 Lasting | The workers on the lasting room has no skills to last different types of shoes, and no training. |
| 05 Bonding | 1.Is there a instruction for bonding shoes in the technical instruction provide by glue supplier? |
| 05 Bonding | The instruction for bonding shoes is provided by glue supplier after factory send the bulk material for them to test. |
| 05 Bonding | Same as Good rating except that the factory just provide the bulk material construction and chemical content info instead of actual sample to glue supplier. |
| 05 Bonding | Factory technician based on own experience to decide the glue and bonding instructions. |
| 05 Bonding | No any instruction available. |
| 05 Bonding | 2.Is the roughing done evenly on the upper with no skipped spot in the last allowance? |
| 05 Bonding | The roughing is done evenly on the upper and there is no skipped spot in the last allowance upper. |
| 05 Bonding | The roughing is evenly done on the upper on 80% of areas while less than 20% are uneven without affecting the bonding strength. |
| 05 Bonding | The roughing is done on the upper but is not evenly done. |
| 05 Bonding | The roughing is badly done, there is no control from the supervisor. |
| 05 Bonding | 3.Are appropriate solvents being used to clean PU/TPU/TPR/TR outsole? Is the primer’s container and brush free of metal parts? Is the brushes and container clean all the time? |
| 05 Bonding | The solvents being used to clean PU/TPU/TPR/TR outsole, the primer’s container and brush is free of metal parts, the brushes and container is clean all the time. |
| 05 Bonding | Around 80% of containers are clean as mentioned in Good rating. |
| 05 Bonding | The solvents being used to clean PU/TPU/TPR/TR outsole, the primer’s container and brushes are not clean. |
| 05 Bonding | The primer is not properly applied and there is a lot of dirtiness in the container and brushes with no supervision. |
| 05 Bonding | 4.Are adhesives being applied with adequate and even coverage on the upper? Is the adhesive drying properly? Is the application of adhesive done twice before pressing the outsole? |
| 05 Bonding | The adhesives being applied to coverage on the upper evenly , 1- the adhesive drying properly, 2- the application of adhesive done twice before pressing the outsole. |
| 05 Bonding | Same as Good rating except that around 80% of adhesives are applied evenly. |
| 05 Bonding | Insufficient process in applying adhesives, drying time or pressing. |
| 05 Bonding | The adhesives process has no supervision as per instruction. |
| 05 Bonding | 5.Is the outsole and last being pressed with correct time?( 8 to 10 sec) as per the instruction? Is there a corrected tool mold to support the outsole press to be flat? |
| 05 Bonding | The outsole and last being is been pressed with correct time( 8 to 10 sec) they have correct tool mold to support the outsole press to be flat. |
| 05 Bonding | The outsole and last being is been pressed with correct time( 8 to 10 sec) missing proper mold to press. |
| 05 Bonding | Insufficient time used in pressing. |
| 05 Bonding | There is no instruction and the operator is not respecting the proper time to press the outsole. |
| 05 Bonding | 6.Is there a pressure testing carbon paper done by shift? How many times per day? Is there a responsible supervisor ‘s signature and date? |
| 05 Bonding | The pressure testing carbon paper is done 2 times per day, the responsible supervisor is signing and the reports are available to reach out right away. |
| 05 Bonding | The pressure testing carbon paper is done by 2 times per day but no signature in reports. |
| 05 Bonding | Test done one time per day or less or incomplete report to show test has been done. |
| 05 Bonding | The carbon test is not done. |
| 05 Bonding | 7.Is there a QC station after pressing the outsole ? Does the QC has the skills to approve/ reject the open outsole and over cement issue? Is there a station to fix the open outsole and over cement? |
| 05 Bonding | There is a QC station after pressing the outsole 1-The QC has the skills to approve/ reject the open outsole and over cement issue 2-there is a station to fix the open outsole and over cement. |
| 05 Bonding | The QC station is far from pressing while there is process to fix and check all outsole open. |
| 05 Bonding | Insufficient QC, or QC with insufficient skill, found some outsole open in bulk lot. |
| 05 Bonding | There is no QC station and no repair station as well. |
| 05 Bonding | 8.Is the cooling machine with a proper cooling set up with temperature/speed as per the instruction? Does the operator follow the instruction? |
| 05 Bonding | The cooling machine is with a proper cooling set up with temperature/speed as per the instruction, the operator is following the instruction. |
| 05 Bonding | 90% of machines are compliance to the requirement |
| 05 Bonding | The cooling machine is with a proper cooling set up but the operator is not following the instruction, the speed is too fast. |
| 05 Bonding | The cooling machine is not functioning correctly. Nobody is take care of cooling machine properly. |
| 05 Bonding | 9.Is there a bonding test done daily up front 8 hours after attaching the outsole on the upper? Does the supervisor follow up the daily test by report with signed document? |
| 05 Bonding | The bonding test is done daily up front 8 hours after attaching the outsole on the upper1- The supervisor is following up the daily test by report with signed document. |
| 05 Bonding | The bonding test is done daily up front 8 hours1- The supervisor is following up the daily test, but there is no signed report. |
| 05 Bonding | Insufficient boding test or incomplete report. |
| 05 Bonding | The bonding test is not done in daily bases and there is no report signed. |
| 05 Bonding | 10.Does operator knows how to unlast the shoes and keep the proper shape? Is there an instruction in place for the operator not to unlast the shoes if the temperature is not correct? |
| 05 Bonding | The operator knows how to unlast the shoes and keep the proper shape ,1-the instruction to the operator is in place to not unlast the shoes if the temperature is not correct. |
| 05 Bonding | There are 80% or above operators follows correct unlash process as Good rating. |
| 05 Bonding | The unlash shoes is done too quick and the shoes remain hot. |
| 05 Bonding | 11.Does the factory have proper machine to attach the nail/table nail into the heel base in necessary shoe construction? Is the machine located right after the cooling machine? |
| 05 Bonding | The factory have the proper machine to attach the nail/table nail into the heel base in necessary shoe construction right after the cooling machine. |
| 05 Bonding | There are 80% or above machines are setting as Good rating. |
| 05 Bonding | The factory have a machine to attach the nail into the heel base but has some setting problems. |
| 05 Bonding | The machine can’t make proper process due to he maintenance, the nails is not totally in the heel causing uncomfortable fitting. |
| 07 Inspection | 1.Does factory has a complete set of their buyer’s technical manual hard copy/ approved samples provided to each QA and knows how to obtain updated information? |
| 07 Inspection | -Factory has a complete set of their buyer’s technical manual hard copy. -Approved samples are provided to each QA. -QAs have access to obtain updated information with translations when needed. |
| 07 Inspection | -Factory has a complete set of their buyer’s technical manual hard copy. -Approved samples are shared between production and QA. |
| 07 Inspection | -Their buyer’s technical manual hard copy is incomplete or outdated . – Only some approved samples are provided to QA. -QAs do not know how to obtain updated information. |
| 07 Inspection | -Factory does not have their buyer’s technical manual hard copy. -Most of approved samples cannot be access by QA. |
| 07 Inspection | 2.Has the factory an independent QA/QC team? Check the organization chart. |
| 07 Inspection | -All roving/inline/end line QA/QC team in all sections is independent. They are not reported to the production. Factory has a clear organization chart. |
| 07 Inspection | Only the finishing section end line inspection QC and AQL shipment QA/DA are independent from the production team. |
| 07 Inspection | Only AQL shipment QA/DA teams is independent from the production. |
| 07 Inspection | -Factory does not have clear inline/end line QA/QC team; trimming and QC is same person; or all QA team are reporting to the production head. |
| 07 Inspection | 3.Is there a line inspection in the critical work stations? For example, ensure the attachment strength by control the gluing process, non marking control, shoes not crocked, in side the shoes no any uncomfortable point? |
| 07 Inspection | There is critical work station QC checking 100% bulk. |
| 07 Inspection | There are sufficient critical work station QC to randomly check 10% in hourly basis and mark defectives for sorting/rectified, notify supervisor to correct the production line. |
| 07 Inspection | Insufficient critical work station QC, defectives were found in boxes without clear label. |
| 07 Inspection | No inline QC |
| 07 Inspection | 4.Are defective shoes clearly identified and separated with a defected label to easy visualization? |
| 07 Inspection | The rejected shoes is separated and added a clear label of rejection in each pc and it is easy to identify. |
| 07 Inspection | The rejected shoes is separated in labelled boxes but there is no label for individual pcs. |
| 07 Inspection | The rejected shoes is separated but missing a clear label of rejection. |
| 07 Inspection | The rejected shoes is not being separated, very easy to get mixed. |
| 07 Inspection | 5.Is lighting adequate and enough space with completed information and acceptable temperature & humidity in QC room/QC stations ? |
| 07 Inspection | -Lighting is adequate (800-1000 for apparel and 600-800 for non-apparel) lux and space is enough in all inspection station from warehouse to finishing. -There is a complete information, quality standard, approval sample, at shading / QC stations. air con available in QC room to control temp and humidity. |
| 07 Inspection | -Lighting is adequate and space is barely enough for table and inspection. cartons needs to put outside the room. -There is complete information but not for their own, they need to share information with other production departments. |
| 07 Inspection | -Lighting is out of desire range or space is not enough to have 2-3 QC working in same room. -Information is incomplete at QC stations. |
| 07 Inspection | There is no QC room, QC station is at open space area next to production stations. |
| 07 Inspection | 6. Regarding the inspection combined with this TE/PA, is the inspection result Pass or Fail? |
| 07 Inspection | pass brand AQL |
| 07 Inspection | failed brand AQL |
| 08 Product Safety | 1.Is metal control efficiently done in sample room, the whole production floor and QC room ? |
| 08 Product Safety | – No metal staples, pins and wires used in any part of the production process for bundling, tacking, sewing, packaging or securing components; it is verified that the Metal Tool Control Log (incl. scissors, razors, clippers, hand-sewing / embroidery needle, replacement needles for Kimball tag guns) is being monitored. – If pins must be used in specific garment manufacturing process, such as fabric laying and cutting, the factory is requested to maintain the documented record for the control of pins. – Records must be kept minimum one year on site. – Any suspicious broken needle missing, all products should undergo scanning to identify or disposal if cannot find. |
| 08 Product Safety | found non-conformance part as per the listed policy. |
| 08 Product Safety | 2.Are metal tools and hard tags in the Metal Free Zone in packing area under proper control and Metal Free Zone is free from unauthorized entry ? |
| 08 Product Safety | – Metal free zone is properly controlled with limited authorizes person to enter. Entry always keep close and arranged security check for the in & out person with record. – All the authorizes persons are with a permit to enter the metal free zone. ‘- all hard tag are proper control with record. |
| 08 Product Safety | There is no metal-free zone or found non-conformance part as per the listed policy. |
| 08 Product Safety | 3.Does Needle Detector function consistently and 9-point calibration and relevant record keeping are completed 3 times per shift? (1.2 mm sensitivity) |
| 08 Product Safety | – Needle Detector functions correctly (1.2 mm sensitivity) and 9 point calibration is performed correctly with complete record. – Calibration is done for more than 3 times per shift. – Well maintenance by needle detector supplier with valid record. – Recalibration is not expired. – Needle Detector in GSS listed brand. |
| 08 Product Safety | There is no needle detector or fails in calibration. |
| 08 Product Safety | 4.Are all needle control and detection logs done, verified and retained properly ? |
| 08 Product Safety | – No broken needle parts are found in production areas. Record every needle breakage and be completed at the time of the occurrence, allocate all parts of the needle and securely mounted to the log for each entry, maintain clear records for 1 year. – If part of needle fragment cannot be found after the intensive search, the operator must clearly report the follow-up action and date/time of needle detection for broken needle in the broken needle log. |
| 08 Product Safety | There is no needle control process or found non-conformance part as per the listed policy. |
| 08 Product Safety | 5.For Machine-Attached Hardware (MAH) applied on Kids/Baby products, is Garment Check & Recommendation (GCR) Datasheet issued by MAH Supplier per style and reviewed in the PP meeting ? |
| 08 Product Safety | – GCR Datasheet is issued by Gap Inc. Qualified Kids/Baby Trim Supplier. – GCR Datasheet is issued before production. – GCR Datasheet is issued for every Kids/Baby style (unless the style is carry-over) – GCR Datasheet is concluded as “APPROVE” – GCR Datasheet is downloaded from Vendor headquarter to Factory and Factory reviews during PP meeting. – GCR Datasheet is ready in production floor for operator’s usage to check machine pinch setting. – A person or team is assigned to follow up the GCR Datasheet from receipt from MAH Supplier, booking supplier’s technician for machine setting, a copy filed in MRP to retaining e-copy for 12 years. |
| 08 Product Safety | There is no GCR Datasheet or found non-conformance part as per the listed policy. |
| 08 Product Safety | 6.Is there regular checking and maintenance of the die molds and attaching machines used for MAH trims ? |
| 08 Product Safety | – Ensure regular machine maintenance from MAH Supplier. Actively call out if not happening. – Do not use damaged die molds. Do not keep or re-use damaged die molds. – Must use same attaching machine, die mold, MAH trim from the same MAH Supplier for Baby products. – Attaching machines must be semi-automatic or fully automatic pneumatic / electric presses. – Keep records of the die molds and attaching machines for monitoring. |
| 08 Product Safety | found non-conformance part as per the listed policy. |
| 08 Product Safety | 7.Are MAH control logs at PP, inline daily shift, 100% inspection done, verified and retained properly ? |
| 08 Product Safety | – 50 sets or pcs of mock-up in correct quality are checked for attachment strength, 5 sets or pcs checked for pinch setting at PP stage. – 5 sets or pcs of mock-up in correct quality are checked for attachment strength, 1 set or pc checked for pinch setting at inline daily shift. – For Baby style with snaps attached: Factory uses Saf-Q to test bulk garments for Attachment Strength and Unsnapping per style at each stage of production (beginning, middle, end). – 100% physical and visual inspection done immediately after attachment. – Correct templates (Form 1, 2, 3, 4 as specified at PSR SOP 010) are used. Provide with local languages for translation is acceptable. – Retain hard copies of the Control Logs (Form 1, 2, 3, 4) for 1 year. – More often inline checking than required. |
| 08 Product Safety | found non-conformance part as per the listed policy. |
| 08 Product Safety | 8.For Baby production, does new MAH attachment operator receive training from MAH Supplier ? |
| 08 Product Safety | – Notify MAH Supplier to arrange on-site training to new hired attachment operators. – Hold regular training to factory operators, QC inspectors. – Keep training records of each attachment operator, QC inspector. |
| 08 Product Safety | found non-conformance part as per the listed policy. |
| 08 Product Safety | 9.For MAH applied on Kids/Baby products, does factory own Saf-Q attachment strength tester and operator is able to perform testing per Gap Inc. Test Method S-2001 ? |
| 08 Product Safety | – Factory own Saf-Q tester. – Operator understands and performs MAH Attachment Strength and Unsnapping testing correctly. – Factory use correct clamping devices for Attachment Strength and Unsnapping tests (specified at TM S-2001). – Factory know to pull bulk products (with ring prong snaps or any styles identified as high risk and Expedited Attachment Strength test is needed) from different attaching machines and submit to Lab for Expedited Attachment Strength test once production starts. |
| 08 Product Safety | There is no SafQ tester or found non-conformance part as per the listed policy. |
| 08 Product Safety | 10.Is there Lock Stitch button attachment machines? |
| 08 Product Safety | Yes. There is Gap required machines. |
| 08 Product Safety | No. For new factories, put in remark to mention if factory is willing to buy or not upon order. |
| 08 Product Safety | 11.Is Button Control Procedure checked, verified and maintained the records properly? |
| 08 Product Safety | – Stitch pattern is complete and in tidy, clear-cut thread-ends and cross-stitch shape, which is also adjusted to fit in the button line size and design – No discrepancy is found in attached buttons and observes the button check procedure in place – Operator always checks the evenness of thread tension and record the details in daily records ‘- All important information is properly recorded and filed, such as date, time, output, failure nature and correction made, etc. |
| 08 Product Safety | found non-conformance part as per the listed policy. |
| 08 Product Safety | 12.For Kids/Baby production, does factory have Approved Safety Line Review Reports downloaded from Safety Line Review Focals (SLRF) and gone through in PP meeting ? (N/A for new factory) |
| 08 Product Safety | – the vendor has empowered Safety Line Review Focal (SLRF) recognized by Gap Inc. – the Safety Line Review Report is signed off by SLRF, filed at MRP. – additional control set by factory on top of Gap Inc. SOP. |
| 08 Product Safety | found non-conformance part as per the listed policy. |
| 09 Sample Making Room | 1.Are there design technician support prompt sample making with buyer specification? |
| 09 Sample Making Room | – There are qualified pattern makers / production designer technician / sample maker assigned per brand on site. – Pattern making / adjustment / corrections range is 1/2 of the tolerance for bulk pattern. – All patterns are verified and signed. |
| 09 Sample Making Room | – There are qualified pattern makers while there is no assigned per brand. – Pattern making is 1-2 days per style. – Pattern making / adjustment / corrections range is the total tolerance for bulk pattern. – All patterns are verified and signed. |
| 09 Sample Making Room | The current pattern maker is not knowledgeable of similar GAP styles. Or there is insufficient pattern maker. ‘- Pattern making / adjustment / corrections range is more than total tolerance for bulk pattern. |
| 09 Sample Making Room | There is no pattern maker on site. All patterns are made in vendor sample room. No technical support for pattern adjustment. |
| 09 Sample Making Room | 2.Is there a sample development process to evaluate production capability against customer requirements prior to order commitment? |
| 09 Sample Making Room | There is a process to involve sample technician and production supervisor during sample development to sign off the sample construction that can be consistence in bulk production. Actual bulk production template and machine setting are designed during sample development. Factory use the highest quality level among their buyers for all brands and give options to buyer. |
| 09 Sample Making Room | Same as Good rating while factory starts involvement upon order confirmation. |
| 09 Sample Making Room | There is insufficient communicate between sample technician and production or insufficient understanding of the sample room technician on their buyer’s requirement. |
| 09 Sample Making Room | There is no indication or document or process to show |
| 09 Sample Making Room | 3.Are there last device or technician to measure and confirm if the copy of the last is in acceptable measurement against the original last? Is there a record? |
| 09 Sample Making Room | There is a correct size last device and technician always use to measure the last and record in sample comments. |
| 09 Sample Making Room | Same as Good rating while technician has insufficient clear sample comment record. |
| 09 Sample Making Room | Technician did not measure correctly or no record |
| 09 Sample Making Room | No last device or technician available. |
| 09 Sample Making Room | 4.Is there a process to ensure that design and development changes are verified, approved, communicated and executed? |
| 09 Sample Making Room | For each changes, there is involved of process in Q2 and Q3 to ensure product qualified to end use. |
| 09 Sample Making Room | Factory only checks in the initial stages and before sample adoption. There is no checking as per each changes. |
| 09 Sample Making Room | There is insufficient checking before sample adoption. |
| 09 Sample Making Room | Factory follows buyer’s request without any verification. |
| 09 Sample Making Room | 5.Is the sample room fully equipped with proper machines in good condition to produce approved samples that are representative of factory’s specific product types? |
| 09 Sample Making Room | – Sample room is well organized. – Sample room is fully equipped including cutting equipment and table, fusing machine, sewing machines of all types, including finishing machines (button, buttonhole, snap), pressing equipment, working aids, needle gauge, attachments, forms, computerized grading system; computer art work (sweater); dimension design system; all kinds of machineries for hardware product as needed for Gap Inc styles. All machines are in good condition and plotter calibrated. |
| 09 Sample Making Room | – sample room has same setting as Good rating. Just missing some sub-con machines like embroidery, printing. |
| 09 Sample Making Room | – sample room did not equip with same set of machinery as in production. |
| 09 Sample Making Room | – No sample room |
| 09 Sample Making Room | 6.Does the sample room have complete sample technical packages records ? Is the Technical specification/PP sample and full size report signed by buyer authorized person? |
| 09 Sample Making Room | There are completed info as listed |
| 09 Sample Making Room | Insufficient record. |
| 09 Sample Making Room | 7.Is there a Fitting model with a proper fitting standard to make fitting in the samples before sending to buyer technician? |
| 09 Sample Making Room | There is a fitting model with proper foot measurement and the samples shoes are done fitting before sending to GSS technician. |
| 09 Sample Making Room | There is a fitting model but the foot measurement is not ideal, however have experience to give a proper comment before sending the shoes to buyer |
| 09 Sample Making Room | Factory use the last to check before sending sample. |
| 09 Sample Making Room | Factory did not check by any last or fitting model before sending sample. |
| 10 Lab | 1.Are there in-house lab tests performed in order to control bulk material consistency? |
| 10 Lab | Full scope of test per category + technician was trained and certified by third party + inhouse lab was accredited by third party or GSS for basic test+ can perform FGs test (not only materials) + clear testing plan and procedure |
| 10 Lab | Consisted equipment of those “must have” tests listed + technician was trained by third party + inhouse lab was approved by GSS PI OR lab meet requirement of correlation program + clear testing plan and SOP |
| 10 Lab | Insufficient test or testing personnel / equipment setting. |
| 10 Lab | no testing conducted. |
| 10 Lab | 2.What is the sampling size for raw material/ trims test conducted per style in-house lab? |
| 10 Lab | Factory had clear testing plan with sample size and acceptance, requirement for all materials/trims – daily or weekly bulk batch testing. |
| 10 Lab | Factory had testing plan with sample size and acceptance, requirement for main materials and few trim only. Testing per style per season. |
| 10 Lab | Insufficient test or sample size. |
| 10 Lab | no testing conducted. |
| 10 Lab | 3.Is there an organized testing report keeping? |
| 10 Lab | Records are well kept for each material for 1 year period. |
| 10 Lab | Records are well kept for each material for minimum 6 month period. |
| 10 Lab | There was insufficient reports or report keeping less than 6 months. |
| 10 Lab | No report, no indication of material bulk testing control. |
| 11 PP meeting | 1.Is there a completed MRP / QC file for each style? |
| 11 PP meeting | The info below is found in MRP: 1. Purchase Order/DPO 2. Tech Pack or technical specification for accessories 3. Fabric/Garment Test Report for apparel, Product Test Report for accessories) 4. Buyer final comment 5. GAP approved sample/ mock up 6. Approved Trim card <5-6 needs GSS VM/ Vendor merchant / VKR/FKR stamp/ signature> |
| 11 PP meeting | Same as Good Rating while items 5-6 have email only, no signature. |
| 11 PP meeting | Any 1-2 items missing from Good rating. |
| 11 PP meeting | No QC file. |
| 11 PP meeting | 2.Does Quality manager follow PPM Guideline effectively and record in PPM report? (such as who attend PPM, critical operation, safety….etc.) |
| 11 PP meeting | Quality manager follows for key style/ high risk style extensively and setting critical operations and assign QC. All PPM report done by FKR. Quality manager. |
| 11 PP meeting | Quality manager follow all styles as per PPM Guideline, clear PPM report and all dept. supervisor follow with report on site. |
| 11 PP meeting | Quality manager role in PPM is insufficient. |
| 11 PP meeting | Quality manager did not aware PPM guideline. |
| 11 PP meeting | 3.Is size set sample per color way prepared and reviewed according to measurement, visual, fitting, testing and related performance test with report for bulk adjustment? |
| 11 PP meeting | – Full/Jump size set sample in combine color <include all colors> is prepared and reviewed according to measurement, visual, fitting, testing and related performance test with report for bulk adjustment. |
| 11 PP meeting | – Jump size set in selected colors <not all colors> is prepared and reviewed according to measure, visual, fitting, testing and related performance test with report for bulk adjustment. |
| 11 PP meeting | – S/M/L set in one color way is prepared and reviewed according to measure, visual, fitting, testing and related performance test with report for bulk adjustment. |
| 11 PP meeting | – Only 1 size is prepared and reviewed according to measure, visual, fitting, testing and related performance test with report for bulk adjustment. |
| 12 Management | 1.Is there a computerized system to access reports highlighting production output and efficiencies, quality control performance, order status and other essential and helpful data to properly manage factory operations? |
| 12 Management | -Review the system which can show style level daily output and quality performance is clear enough for root cause analysis. |
| 12 Management | – The system can only be reviewed on a weekly basis so the reaction to a problem is slow but still can react to avoid delivery delay. – daily manual report are inputted into computer for analysis. |
| 12 Management | – All the systems are hand written, which does not allow managers to make decision and follow up on time. |
| 12 Management | – There is limited manual system which does not allow managers to make correction to prevent delivery delay when quality issues/output issues. |
| 12 Management | 2.Is there an internal system to work with their suppliers on evaluation the material quality performance and pro-actively work out to prevent raw material/trim/ semi-product quality issues? |
| 12 Management | – There is system to show the trim/fabric supplier performance and ranking and regular score card/ meetings conducted to request for improvement |
| 12 Management | – There is raw data in electronic database available to draw the data when factory wants to have a performance improvement from supplier. 80% of supplier are covered. |
| 12 Management | Insufficient data or less than 80% supplier has record. |
| 12 Management | -There is limited paper inspection reports which needs a lot of time to generate supplier scorecard. |
| 12 Management | 3.Is the quality mind set of the factory management staff and their reaction when there is a CAP / suggestions during the visit appropriate? |
| 12 Management | – Found all staffs are very proactive/ motivated/ take quick action when reacting to CAP/suggestions during visit. They can fully demonstrate commitment with resources and concrete timeline. Clear SOP of CAP provided. FKR uses QC 7 tools or IE approaches to solve issues. |
| 12 Management | – Found only middle/ top management are proactive/ motivated/ quick when react to CAP/suggestions during visit. |
| 12 Management | Only the FKR is proactive while found FKR is incapable to execute the changes. |
| 12 Management | Found all staff are very passive/slow/negative to react to CAP/suggestions during visit. |
| 12 Management | 4.Are there procedures in place to measure and analyze process, product quality data including analysis of long-term trends? |
| 12 Management | There is clear SOP with report of last 3 months shown. Factory should implement this for min 1 year. There should be improvement shown in the performance trend chart. |
| 12 Management | Same as Good rating while this is implemented start in last 3 months. |
| 12 Management | There is either no improvement in the performance trend chart or the SOP is incomplete implemented so the supervisor is not using the data to improve. |
| 12 Management | No procedure. No record. |
| 12 Management | 5.Are the results of preventive or corrective actions reviewed by top management and used to improve the Quality and Product Safety management System? |
| 12 Management | There is clear SOP that there is appointed IE/QA person consistently review the performance report and keep upgrade their QM system to improve. There should be improvement shown in the performance trend chart. |
| 12 Management | Same as Good rating while the CAP demonstrated are within 1 year period. None is done in current 3 months. |
| 12 Management | Factory only perform CAP as per customer request. |
| 12 Management | no CAP record found. |
| 13 Hiring & Training | 1.Is there a proper hiring program so relative product experience and English proficiency are included? |
| 13 Hiring & Training | Clear record, factory can demonstrate how they do it. |
| 13 Hiring & Training | with some record and factory can demonstrate how they do it. |
| 13 Hiring & Training | Clear record but factory cannot demonstrate how they do it. |
| 13 Hiring & Training | no record and factory cannot demonstrate how they do it. |
| 13 Hiring & Training | 2.Is there a proper training program for new hires before they can work independently? |
| 13 Hiring & Training | Clear record, factory can demonstrate how they do it. |
| 13 Hiring & Training | with some record and factory can demonstrate how they do it. |
| 13 Hiring & Training | Clear record but factory cannot demonstrate how they do it. |
| 13 Hiring & Training | no record and factory cannot demonstrate how they do it. |
| 13 Hiring & Training | 3.Are there goals and incentives for all operators to improve quality, product safety, efficiency? |
| 13 Hiring & Training | There is operators output/defect % record in real time with display per operator for the incentive plan. The reaction of operators toward the supervisor correction action are all very positive. |
| 13 Hiring & Training | same as Good rating while the output/defect % capture is in a white board in front of the sewing section. There is no individual person data, only data per sewing line. |
| 13 Hiring & Training | Factory show some proof for the incentive plan while there is no output/defect % capture on site. Or the operator is not very positive on changes/corrections. |
| 13 Hiring & Training | Operators are negative or ignore all the corrections / changes. |
| 13 Hiring & Training | 4.Is there any policy and incentives to reduce the undesired turnover rate? |
| 13 Hiring & Training | There is attractive policy and incentives so that undesired turnover rate is less than 5% |
| 13 Hiring & Training | Same as Good rating while the turnover rate is 5-10%. |
| 13 Hiring & Training | not enough incentive so the turnover rate is 10-20%. |
| 13 Hiring & Training | no incentives at all. Turnover rate over 20%. |
| 13 Hiring & Training | 5.Is there a regular performance review with improvement plans for staff so they can keep upgrading in their skills? |
| 13 Hiring & Training | There is a regular performance review ( every 3 months or less than 3 months) with improvement plan |
| 13 Hiring & Training | There is a regular performance review ( longer than per quarter while at least per year with improvement plan |
| 13 Hiring & Training | There is no regular performance review, only supervisor identify any staff who needs improvement. |
| 13 Hiring & Training | no performance review. |
| 15 Printing | 1.Are in-process and finished EVA pieces inspected in hourly basis to ensure consistency in Print Quality ? |
| 15 Printing | There are 100% checking in hourly basis. The light intensity of QC station is 600-800 lux. |
| 15 Printing | There are random checking in hourly basis |
| 15 Printing | There are insufficient checking in daily basis. The light intensity in QC station is out of 600-800 lux. |
| 15 Printing | Not often inspection done in the EVA logo printing. |
| 15 Printing | 2.Is the primer used as per the supplier instruction? Is the brushes and container clean all the time? Is the printing chemical ink mixed by supplier? Is the full processed following the instruction? Is the table/environment clean? |
| 15 Printing | The primer used is correct, the brushes and container is clear all the time and the ink for logo printing is mixed by supplier, the environment/table is well clean avoiding contamination. |
| 15 Printing | Same as “Good rating” while the environment is a little dirty without affect the product |
| 15 Printing | Insufficient / monitoring of the process. Some process are not follow as instruction. |
| 15 Printing | Very dirty environment, poor process setting. |
| 15 Printing | 3.Is there any recipe with records for each printing lot with date of fabrication, quantity and numbered each recipe? |
| 15 Printing | Printing with recipes is well organized with a clear information. |
| 15 Printing | 80% or above styles are compliance to “Good rating” |
| 15 Printing | less than 80% or above styles are compliance to “Good rating” |
| 15 Printing | 50% or above styles are not compliance to “Good rating” |
| 15 Printing | 4.Is the temperature set monitored at each process of drying to ensure the temperature is always correct? |
| 15 Printing | The control of the temperature is checked per hour with record as per the instruction. |
| 15 Printing | The temperature is monitored by shift before production starts with record. |
| 15 Printing | Insufficient check or incomplete record |
| 15 Printing | no checking of temperature regularly after the m/c setting. |
| 16 Embroidery | 1.Are buyer’s approved samples/Tech Pack/trim cards provided as guides for operators? |
| 16 Embroidery | Buyer’s approved samples/Tech Pack/trim cards are provided in the production floor/line. Technical Audit checklist of Footwear |
| 16 Embroidery | Buyer’s approved samples/Tech Pack/trim cards are provided in the production supervisor’s desk. |
| 16 Embroidery | Some of the supporting documents are incomplete. |
| 16 Embroidery | >50 styles have incomplete approval sample / tech pack / trim cards |
| 16 Embroidery | 2.Are embroidery machines properly maintained, regularly cleaned and serviced, and in good condition? |
| 16 Embroidery | All machines are in good condition and clear maintenance record displayed per machine. |
| 16 Embroidery | All machines are in good condition but the maintenance record are in the mechanic’s log book. |
| 16 Embroidery | No clear/ incomplete maintenance record. Found some machines in poor conditions. |
| 16 Embroidery | No maintenance record, most machines found in poor condition. |
| 16 Embroidery | 3.Does the embroidery facility have a broken needle control process and are all outgoing panels checked? |
| 16 Embroidery | 1/Product Safety Officer (PSO) executes Gap product safety procedure in factory. 2/Needle keeper executes Gap control broken needle procedure in factory. 3/Factory checks all embroidery semi-pieces by Gap certified needle detector before delivers to garment factory. |
| 16 Embroidery | Point 1 & 2 as “Good Rating”, but bulk is checked and scanned at garment factory |
| 16 Embroidery | Same as “Good Rating” while there are some stations with Partial compliance to GAP requirement |
| 16 Embroidery | No PSO or insufficient PSO checking. No record to show needle detection on all panels. |
| 16 Embroidery | 4.Is thread SPI/tension well monitored and controlled, and thread ends properly trimmed? |
| 16 Embroidery | – There is daily SPI/tension checking per machine according to design/fabric/thread. – All thread ends are trimmed by auto trimmer at machine or manual QC station with <1/8 left. |
| 16 Embroidery | 80% or above machines are well monitored and controlled. And thread ends defect is <20%. |
| 16 Embroidery | 20% or above machine not set up properly and 20% or above thread ends defects. |
| 16 Embroidery | 50% or above machine not set up properly and50% or above thread ends defects. |
| 16 Embroidery | 5.Is there a complete visual checking and separate packing per shade in enough lighting when needed? |
| 16 Embroidery | There is 100% visual checking and clearly labelled per panel – Desire lighting intensity is 800-1000 lux for apparel and 600-800 for non-apparel. |
| 16 Embroidery | There is 100% visual checking and only labelled per bundle. |
| 16 Embroidery | Random visual checking and labelled per bag. – lighting intensity is out of the desire range mentioned in “Good rating”. |
| 16 Embroidery | No visual checking or no label used to separate shading. |
| 16 Embroidery | 6.Are there in-process and finished pieces inspected and seconds replaced before releasing back to production workflow? Are there proper control of deviations per load? |
| 16 Embroidery | – Buyer approved detail information available for QC. – Check by AQL sampling with clear QC report per load. – There is a clear separation of seconds and return back to rectify by batch/load. – Bulk rectified before sending back to production. |
| 16 Embroidery | Same as “Good Rating” while checking and rectifying in daily basis. |
| 16 Embroidery | Same as “Good Rating” while some pieces/ stylings are not follow properly. |
| 16 Embroidery | no QC report. Only rectify till next section or finishing QC rejected. |
| 14 Chemical Control | 1.Is the stock of chemical( glue, primer, other chemicals) always stored properly and kept updated with current quantities? |
| 14 Chemical Control | The stock of chemical( glue, primer, other chemicals) always kept updated with current quantities in daily basis, in a organized room with ventilation. |
| 14 Chemical Control | The stock of chemical( glue, primer, other chemicals)is in a organized room with ventilation but the quantify updated in weekly basis. |
| 14 Chemical Control | The stock of chemical are store in separate room while there is no secondary container and poor ventilation, |
| 14 Chemical Control | The stock of chemical are store beside the production area which proper secondary container, poor organized. |
| 14 Chemical Control | 2.Are all chemicals identified with original sub- supplier labels? If packaging is re-used/re-filled, is the identification label clearly indicating it? |
| 14 Chemical Control | All chemicals is identified with original sub- supplier labels, The packaging is re-used/re-filled with identification label. |
| 14 Chemical Control | Most of the chemicals is not identified with labels, The packaging is re-used/re-filled with identification label. |
| 14 Chemical Control | Some chemicals have unclear labels. |
| 14 Chemical Control | No proper control of the chemicals. |
| 14 Chemical Control | 3.Are solid and liquid chemicals stored separately to avoid contamination? |
| 14 Chemical Control | The solid and liquid chemicals is stored in separated way to avoid contamination. |
| 14 Chemical Control | The solid and liquid chemicals is stored is storage together, it is easy to get contamination. No proper control of the chemicals. |
| 14 Chemical Control | 4.Is there any appropriate place for finishing, gluing and chemical material storage with controlled temperature/humidity? Is it well organized? |
| 14 Chemical Control | There is a appropriate place for finishing, gluing and chemical material storage with controlled temperature/humidity, is very well organized and easy to identify. |
| 14 Chemical Control | There is air conditional rooms for storage. |
| 14 Chemical Control | There is separate room for storage without air conditioning. . |
| 14 Chemical Control | The storage room is poorly build with same humidity and temperature as outdoors. |
| 14 Chemical Control | 5.Does the factory have a chemical management process or system to ensure no contaminated material/products are being used at each step of the production? |
| 14 Chemical Control | The factory has the management process for every step of the process and implemented fully in production. |
| 14 Chemical Control | There is clear process while only around 80% of operators uses it. |
| 14 Chemical Control | There is insufficient process or less than 80% operators follow the process. |
| 14 Chemical Control | No any process available. |
| 14 Chemical Control | 6.Is the traceability throughout the process ensured through recording at each step of the process and not leaving any concern? |
| 14 Chemical Control | The traceability and process is applied with records. |
| 14 Chemical Control | There is clear process while only around 80% of operators uses it. |
| 14 Chemical Control | There is insufficient process or less than 80% operators follow the process. |
| 14 Chemical Control | No traceability available. |
Conclusion
Finally, Technical/ QMS/ Quality Audit Checklist of the Footwear Industry have requirements from warehouse, cutting, bonding and finishing.
- You may love to read: Technical Audit Checklist of the Garments Industry
Technical/ QMS/ Quality Audit Checklist of Footwear Industry