工厂质量评估报告.doc

NON-DOMESTIC AUDIT (e.g. Asia, Middle East, India) QUALITY ASSESSMENT REPORT 工厂质量评估报告工厂质量评估报告 Date 日期: August 20 to 21, 2007Auditor 审核员:Mr Lee Fai Date of Visit 审核日期: Reason for Visit: XInitial/New Facility Audit新厂审核 审核原因Re-Audit/Follow-up Visit復审/跟踪访问 Production/In-line Surveillance生產/线上监督 Other _ Type of Manufacturing:Printing 印刷 生产类型Injection Molding 啤塑 Overwrapping 自动包装 Plush (Soft Toy) 毛绒玩具 Die Cast 合金 X Other 其它_密胺餐具_ Supplier 供应商: Blanco Manufacturer 生产商: 昆山统福美耐磁制品有限公司 Location 地址: 中国江苏省昆山市同丰东路号 Telephone:， Fax: ， E-mail: Premium(s) being considered for manufacture if applicable: 若适用,赠品亦在考虑生产之内: GMI/CPW/Laboratory Attendees审核方参加者Supplier/Factory Attendees; Titles 工厂参加者/职位 R,GU/厂长 MRS,ZHOU人事经理 Requirement 要求要求Result 结果结果 Critical Items 严重项目MEET / DNM Section Minimum Acceptable Percentage 章节最低接受百分比MEET / DNM Overall Section Score (1-6), 87% minimum 整体章节分数(1-6),87%最低MEET / DNM Overall Section Score (7-10), 88.75% minimum 整体章节分数(7-10),88.75%最低MEET / DNM General Mills SCORING OF ASSESSMENT 评估得分评估得分 章节章节 Minimum accepted (%) 最最低接受低接受(%) % yes Section weighting 章节章节比重比重 Minimum 最少最少 % x weight 比重 Section 1Facility disposition established; and segregated from production materials? 在加工过程中, 不合格品是否被清楚地标识与处 理并与生产材料区分开？ 4.14Are in-process inspection records available, complete, traceable to production lots, with disposition of acceptance or rejection? 有没有半成品检验记录, 是否完整及可追踪, 并 设有合格与不合格品？ 文件程序没有详细如何从原材料追踪到 成品，也未有确定追踪代码系统。 4.15* Recall Capabilities/Procedures: Is production identifiable throughout the production process? (e.g. traceability system - inspector should trace at least one final packed box of product through entire production system - all materials should be able to be verified with corresponding batch numbers of raw materials.) 产品召回能力产品召回能力/程序程序:整个生产过程中是否定义生整个生产过程中是否定义生 产工序产工序?(例:追踪系统-检查员在整个生产过程中 可至少追踪成品包装箱 1-所有物料应能够追溯 到原料批次) 文件程序没有详细如何从原材料追踪到 成品，也未有确定追踪代码系统。No detail procedure on how to trace the finished product and define the traceability code system. 工厂未能从成品追踪到每一批次原料， 仅可追踪整个订单的原料批次，也无进 行摸拟追踪召回测试。Fty was not able work out the detail information from finished product to raw material. Total71% Quality Systems 质量系统质量系统YesNoN/AComments IN-PROCESS CONTROL AND TESTING 制程控制与测试制程控制与测试 PAINTING PROCESS喷油工序喷油工序 4.16 Is the paint used for touch up from the same lot as production? 油漆是否使用同一批型号? 无此类工序 N/A 4.17 Are all painted parts painting process properly stored to avoid damage? 所有油漆部件是否恰当存放以防损坏? 无此类工序 N/A Quality Systems 质量系统质量系统YesNoN/AComments 4.18 Are all paints, solvents, spray mask cleaning agents clearly/ properly labeled? 所有油漆/溶剂/喷油模/清洗剂是否清晰标识? 无此类工序 N/A 4.19 Is the painting process controlled by means such as reference samples and Standard Operating Procedures? 喷油过程是否用参考办及标准操作程序方法来 控制? 无此类工序 N/A GLUING/SOLVENT BONDING PROCESS 胶水胶水/溶剂粘合工序溶剂粘合工序 4.20 Is the application process well controlled to ensure consistent coverage and application of glue/solvent to pieces being joined? (e.g. automated vs. syringe, stick, etc.) 胶水/溶剂粘合过程较好控制确保一致覆盖及胶 件接合?例:自动与注射,粘合等 无此类工序 N/A 4.21 Are the surfaces to be joined smooth, clean and dry? 表面是否接合得光滑,干净和干燥? 无此类工序 N/A 4.22 If applicable, after the application of the glue, is constant pressure applied until the joint has become dry and hard? 若使用胶水后,是否使用固定压力直到接合处变 干和坚硬? 无此类工序 N/A 4.23 Is additional processing on the joined parts started only after the joint has had ample time to set? 在接合部位有没有其它工序延迟直到接合外有 足够时间来设置? 无此类工序 N/A 4.24 Is the gluing quality process controlled by means such as reference samples and Standard Operating Procedures? 胶水质量过程序是否用参考办及标准操作程序 方法来控制? 无此类工序 N/A 4.25 Is there a break open procedure to verify amount of glue or solvent is adequate? 是否有拆开程序检查胶水或溶剂量足够? 无此类工序 N/A 4.26 Are glue and solvents properly labeled? 胶水及溶剂是否适当标识? 无此类工序 N/A INJECTION MOLDING 啤塑啤塑 Quality Systems 质量系统质量系统YesNoN/AComments 4.27If re-grind material is used, is the ratio correct as per plastic manufacturer specification? 水口料比例是否正确?跟胶料供应商的规格 N/A 无水口料应用。 4.28Are all molding parameters recorded (cycle time, temperature, pressure)? 记录所有啤塑参数?(周期/温度/压力) 全部参数记录在产品成型卡上。All parameter are record on the product card. 4.29Is the injection molding process quality controlled by means of reference samples and Standard Operating Procedures? 啤塑过程是否用参考办及标准操作程序来控制? 采用首件签办放产程序。Sign samples are available. SONIC WELDING PROCESS 超声工序超声工序 4.30Is there documentation for the welding parameters? (e.g. frequency, hold time, weld time, pressure) 是否记录超声参数?(例:频率/暂放及超声时间/压 力) 无此工序。N/A 4.31Is there any break open inspection after the sonic welding process? 超声焊接工序之后是否有检查裂口的情况? 无此工序。N/A 4.32Is the sonic welding process quality controlled by means of reference samples and Standard Operating Procedures? 是否超声过程用到参考办及标准操作程序来控 制? 无此工序。N/A SCREWING PROCESS 螺丝工序螺丝工序 4.33Are the automatic screwdrivers calibrated (torque)? 自动螺丝批有校准(力矩)吗? 无此工序。N/A 4.34Is there documentation of the calibration? How often is calibration? (note in comments) 有无文件化校准记录?多久校验一次? 无此工序。N/A 4.35Is the screwing assembly process quality controlled by means of reference samples and Standard Operating Procedures? 螺丝装配过程是否有参考办及标准操作程序来 控制? 无此工序。N/A MANUAL ASSEMBLY (Eye to Washer, Wheel to Axle) 手工装配（打眼，打轴）手工装配（打眼，打轴） Quality Systems 质量系统质量系统YesNoN/AComments 4.36Are the components aligned properly? 设备有没有适当地调校？ 无此工序。N/A 4.37Is the displacement calibrated? 有移位校准吗? 无此工序。N/A 4.38Is there a quality control check of components before and after assembly for proper assembly, no knurling, short mold shots, etc.? 在装配前/后是否有质量控制来检查部件(正确装 配/无搓花/少胶等？ 无此工序。N/A 4.39Is the manual assembly process quality controlled by means of reference samples and Standard Operating Procedures? 手工装配过程是否用到参考办及标准操作程序 来控制质量? 无此工序 N/A SHARP TOOL/NEEDLE CONTROL 利器利器/针器控制针器控制 4.40 *Does factory have a documented sharps control policy? 工厂是否有文件化的利器控制方针? 4.41Are sharp tools (razor blades, drills, scissors) tied on working benches? 利器(刀片/鑽/剪刀)有没有绑在工作台/凳上？ 花纸车间的剪刀没有绑在工作台或凳上。 所有利器均未篇号，从而影响追踪效果。 Scissor without tied on the working benches and no assigned number. No way to trace the 要求车间立刻改善并加强 GMP 培训。 Suggested to strengthen the GMP training. 4.42Are sharp tools absolutely restricted or satisfactorily controlled in the packaging area? 在包装区, 利器有否绝对控制, 如不可避免, 控制 是否令人满意？ 无利器(刀片/鑽/剪刀) 在包装区使用 No sharp tools were used in the packing area 4.43Is the distribution of sharp tools to workers controlled by assigned staff? 是否由专人负责或适当处理利器的分发？ 4.44Is there a record (log) book to register the daily issuance and return of the total number of sharp tools/needles? 有没有对每日利器的发放与归还总数作登记？ 4.45Is there a record (log) book to track broken sharp tools/needles? 有没有记录跟踪损坏的利器/针器？ Quality Systems 质量系统质量系统YesNoN/AComments 4.46Is there a written procedure and policy to investigate missing sharp tools/needles? 是否有书面程序和制度来调查失踪的利器/针器？ METAL DETECTION 金属探测器 4.47 Are there metal detectors in the pack out area? Tunal Type_ Quantity_ Others_ Quantity_ 在生产或包装区有没有任何金属探测器？ 隧道型：_ 数量：_ 其 它： _ 数量：_ 无此设备。 4.48Are the metal detectors well maintained and calibrated? 对金属探测器有没有进行校准与良好保养？ 无此设备。 4.49Are there calibration and maintenance logs for the metal detectors? How often calibrated? Define in Comments. Size of test piece? Define in Comments. 对金属探测器有没有校准与保养记录 如何校准?_金属尺寸?_ 无此设备。 PACKAGING/SHIPPING包装及运输包装及运输 4.50Are packaging materials stored properly to prevent contamination and deterioration? 适当正确贮存包装材料以免污染或变质? 4.51Are packaging materials inspected prior to use? 包装材料被使用之前是否经过检查? 4.52Are shipping cartons properly marked to identify the contents? 走货卡通箱是否标识清楚内容? 4.53Are finished goods transported under conditions that will prevent contamination and protect against product deterioration? 最终成品在运输过程中是否在防止污染及产品 恶化的条件下运送？ Total76% 5.0 Pre-Shipment Inspections 出货前检验出货前检验YesNoNAComments 5.1 Does Factory routinely conduct pre- shipment inspections? 工厂有无执行出货前检验? 5.2 Are quality requirements and acceptance criteria clearly defined with signed samples available for use? 质量要求和接受的标准是否清楚定义, 签办可否 提供使用？ 5.3 Are sampling plans used for pre-shipment inspection capable of providing reasonable confidence that clients requirements are satisfied? What sampling plans are used? (Note in Comments.) 按产品及客户的要求, 关于出货前的成品检验, 有没有一个抽样计划？并指明抽样计划标准 AQL GENERAL LEVEL II 1.5 2.5 5.4 Are rejected finished goods clearly identified; disposition established; and segregated from accepted finished goods? 不合格品与合格品有无明显隔离,并清楚标识不 合品？ 5.5 Are pre-shipment inspection records available, complete, traceable to production lots, with disposition of acceptance or rejection? 有没有完整的、可追踪的生产数量和合格品或 不合格品的装船前检验记录？ 5.6 Is there a written procedure for sorting, reworking, or scrapping the rejected lots of finished products? 是否有产品分类, 返工及报废不合格产品的书面 程序？ Total 100 % 6.0Product Testing 产品测试产品测试YesNoNAComments 6.1 Are laboratory facilities available for product testing in the factory? 工厂是否有进行产品测试的实验室？ 无实验室。 6.0Product Testing 产品测试产品测试YesNoNAComments 6.2 Is the laboratory environment specified and controlled? (e.g. humidity & temp) 实验室的环境是否适宜和受控?(例:湿度/温度) 6.2 Are the latest revisions of product standards available? e.g. ASTM, EN71, 16CFR1500 有没有最新版本的产品标准？ 6.4 Does the laboratory possess the following common toy testing equipment applicable to the product being manufactured for GMI or CPW? (Circle testing equipment below available at factory) 实验室是否配备有以下一般玩具测试所需设置？ 适用于 GMI 或 CPW 产品的生产. a)Push and pull gauge 拉力磅 b)Torque gauge 扭力磅 c)Compression head 压力头 d)Two-pronged clamp 双爪钳 e)Three-pronged clamp 三爪钳 f)Washer clamp (seam clamp) 线钳 g)Vice clamp 虎钳 h)Torque clamp 扭力钳 i)Bite jaw 咬齿夹具 j)Small part cylinder 细零件 k)Sharp point tester 利边 l)Sharp edge tester 利角 m)Rattle gauge (oval gauge) 圆形尺 n)Supplemental rattle gauge 椭圆形尺 o)Drop platform 掷台 p)Accessibility probes (testing finger) 触摸性测试 q)Oven 焗炉 r)Freezer 冰箱 6.5 Are quality control personnel trained to adequately conduct critical testing? 是否为培训合格的品质人员执行关键测试? 仅由品质检查进行外观的检查。 6.0Product Testing 产品测试产品测试YesNoNAComments 6.6 Are tests conducted to control product quality according to the product specification? 产品质量测试是否根据产品规格进行? 客户没有提供明确的产品测试规格。 6.7 Are procedures available which provide instructions and methods for performing required testing, i.e., force diagrams? 可否提供执行测试所需指引与方法的程序?如拉 力图 6.8 If materials fail to meet acceptable limits, is there follow up and corrective action to prevent the same problem from recurring? (e.g. adjustment to injection molding machine) 若物料未能符合接收界限,是否有跟进及纠正行 动 CAP 防止再发现此类问题?例:调整啤塑机 6.9 When applicable, does test equipment have the precision required to meet test standards? (e.g. test to failure or modified mechanical hazards testing) 在使用时, 测试仪器有没有符合测试标准和要求 的精密度？例:TTF 或机械测试 6.10Is there a documented program for calibration of test and inspection equipment? 有没有用于测试和检验仪器的文件化指引？ 6.11Are test equipment and gauges identified with the calibration status and uniquely traceable to calibration record? 所有测试设备及基子设施是否与校准状态及可 跟踪的测试记录一致？ 6.12Are calibration records maintained and traceable to national or international standards? 校准记录是否按国家或国际标准来保存与追踪? 6.13Are samples for testing appropriately identified and controlled? 用于测试样办有适当标识及控制? 6.14Are testing reports available which are traceable to specific production period or production lot? 可否提供有追踪具体生产期或产品批次的测试报 告？ 6.0Product Testing 产品测试产品测试YesNoNAComments 6.15Are third party laboratories used to perform testing beyond the scope and resources of the factory? (List laboratories used under Comments.) 超出本厂实验室(如资源、设备)能力以上的测试, 是否有用到外面的实验室？指明 LAB 名称 Total 7.0 Wages & Labor Practices 工资及劳工行为工资及劳工行为 YesNoNAComments 7.1 *Is the minimum wage paid at this facility equal to, or higher than, the local or government standard? 工工厂厂给给予予工工人人的的最最低低工工资资是是否否等等于于或或高高于于本本地地 或或政政府府标标准准？ 昆劳社薪【2006】20#文件，发布时间： 2006 年 9 月 28 日。According to the local regulations document issued on Sept 28, 2006. 7.2 *Is this facility in compliance with all local government labor and wage laws? *工工厂厂是是否否完完全全符符合合政政府府的的劳劳工工及及工工资资法法例例？ 7.3 Are regular working hours set? 有否订立正常工作时间？ 7.4 Is a regular pay period established? 有否订立正常工资发放时间？ 7.5 Are wages paid on time based on payroll records? 工资是否根据工资单上的发放日期按时发放？ 7.6 Are workers provided with an understandable wage statement each pay period? 每次发工资时，工人是否得到一份简易明白的 工资单？ 7.7 Is work time documented by timecard? If no, please explain system in Comments section. 工时是否用工咭记录？ 如如不不是是，请请在在意意见见栏栏内内解解释释其其系系统统. 工厂使用电子工卡。Electronics timecard used in the fty. 7.8 Do the employees punch their own timecard? 员工是否自行打咭？ 7.9 Do timecards indicate the pay week ending? 工卡上有显示周末工资吗? 未有此项功能。N/A 7.10 Are corrections on the employees timecard initialed in ink by the employee? 工咭上的修正是否有员工自行签字确认？ 工卡的修正由工人、门卫及主管三方确认。 Corrections are done by worker, security and supervisor. 7.11 Are timecards accurate regarding actual time worked by the employees? 工咭是否准确记录员工的工作时间？ 7.12 Do employees complete their own piecework records? 员工的件工记录是否由员工自行填写？ 工厂采用计时工作制。Fty used working hrs to count on the wages. 7.0 Wages & Labor Practices 工资及劳工行为工资及劳工行为 YesNoNAComments 7.13 Are employees free to leave once their shift ends? 下班后,员工是否可自由离开? 7.14 Do workers have the right to refuse overtime? 工人有否权利拒绝加班工作？ 7.15Are all workers given equal opportunity to work overtime? 所有工人是否有同等的加班机会？ 7.16Do workers have at least one day off in seven? 工人是否每七天有一天休息？ 五天工作制，一周六天工作时间，每天 7.5 小时。周六按法律规定计算加班。5 days work. Sat as OT. Each day work 7.5hrs. 7.17Do workers have time each day for lunch? 工人每天是否有午餐时间？ 午餐时间：0.5 小时。0.5 hr for lunch. 7.18Does this facility provide annual leave and holidays as required by law or which meet local industry standards? 工厂是否按法规或本地工业标准要求，提供有 薪年假及假期予工人？ 7.19Are the benefits above given/paid on time? 以上的福利是否按时提供/给予工人？ 7.20 *Are all workers in this facility voluntarily present? How verified? (Note in Comments) *是是否否工工厂厂内内所所有有工工人人都都是是自自愿愿上上班班的的？怎怎样样确确 认认?（在在意意见见栏栏内内注注明明） 与工人进行面谈。Discussed with workers directly. 7.21 *Are there guards posted only for normal security reasons? *聘聘请请保保安安员员是是否否只只限限于于正正常常安安全全理理由由？ 所有保安由工厂自请。All security are employed by the fty. 7.22 *Is the facility free of any evidence of guard towers, guard dogs, prisoners, chained workers, or weapons? *工工厂厂是是否否不不存存在在有有监监视视塔塔、守守卫卫犬犬、囚囚犯犯、被被 锁锁链链锁锁上上的的工工人人或或武武器器？ 7.23When disciplinary action is taken, is a witness present? 当有惩戒的行动时,有否目击者在场？ 无扣薪及罚款惩戒行动。No wages deduction or any punishment found. 7.24Is the facility free of any citations, penalties, license revocations, etc., that are in violation of local labor laws and regulations? 工厂过往是否没有就违反本地劳动法及相关规 定而得到传票、惩罚、牌照失效等？ 7.0 Wages & Labor Practices 工资及劳工行为工资及劳工行为 YesNoNAComments 7.25If this facility subcontracts any production, does it require and enforce its subcontractors to adhere to social compliance requirements? 如工厂外发生产,工厂有没有要求及强迫加工厂 符合社会责任要求？ 无外发生产。No sub contractor. 7.26Are employee records maintained on the work site in a safe and secure location? 员工资料是否妥善保存在安全可靠的工作地点? 所有人事档案保存在人事部。All employee records are stored in the personnel department. 7.27Are payroll records (12 months) maintained on the work site in a safe and secure location? 薪资资料（12 个月）是否妥善保存在安全可靠 的工作地点？ 保存在人事部 Payroll are kept in the personnel department. 7.28Has the auditor been given full access to all personnel and payroll records? 审查员可否查核所有人事及薪资数据？ 7.29Do the personnel records appear to be complete, accurate and updated? 人事档案是否完整、正确及最新？ 7.30Are workers rights clearly documented and placed in an area where all employees have access? 工人权益是否清楚文件写明并张贴在所有员工 通行处？ 工人权益清楚列出并张贴在员工饭堂。 Worker right are clearly posed in the dinning room. Total 100 % 8.0Child Labor 童工童工YesNoNAComments 8.0Child Labor 童工童工YesNoNAComments 8.1 *Does this facility comply with all applicable child labor laws including those relating to hiring, wages, hours worked, and working conditions? How verified? Note in Comments. *工厂是否符合所有有关童工的法规，包括招聘、 工资、工作时间及工作环境？如何确认？在意 见栏内注明。 查看人事档案及现场察看，并通过与员 工面谈确认。Review the employee record and on site review as well as directly discuss with workers 8.2 *Are all workers in this facility at least the legal age or 16 years of age, whichever is greater? How verified? Note in Comments. *工厂内所有工人是否达到法定年龄或超过 16 周岁,取较大者?如何确认?在意见栏内注明. 所有面谈的员工都未能提供身份证原件， 所以不能通过确认身份证明的真伪确定 工人的年龄并且只有复印件供参考。 No ID cards were provided by the worker during interview. Thus, not able to identity the actual age of the workers. 8.3 *Does an audit of records verifying workers date of birth appear acceptable? *审查工人出生日期的方法可否接受？ 工厂未能证明其招收的员工都可以出示 其身份证或户口本原件，且没有能力去 鉴别这些证件的真伪，部分员工是由中 介公司提供。Fty cannot prove that they reviewed the ID when employ the workers and cannot verify whether the ID is fake or not. 建议工厂去购买可识别身份证真伪的仪 器，以及联系公安部门进行核实。 Suggest the fty to purchase ID reader to vertify the ID card and thoroughly review all the empolyees record. Total 33% 9.0Health & Safety 健康与安全健康与安全 YesNoNAComments 9.1 Is facility free of any work related accidents or injuries in the past year? 过往一年工厂是否没有任何因工意外或受伤？ 无工伤记录。No accident or injuries record. 9.1.1 If not, were preventive measures taken? 如没有，有否预防措施执行？ 9.1.2 Are records kept of accident or injuries? 意外或受伤记录有否保存？ 无工伤记录。No accident or injuries record. 9.2 Is there a medical facility within 20 km? 20 公里内有否医疗设施？ 9.3 Are safety education/training programs offered (e.g. First Aid, etc.)? 安全教育/培训课程有否提供(如急救等)? 9.0Health & Safety 健康与安全健康与安全 YesNoNAComments 9.4 Are assigned individuals trained in basic on- site first aid? 是否有已培训工场急救的专人？ 9.5 Are first aid supplies available in the factory? 工厂是否有急救用品？ 9.6 Is personal protective equipment available? (e.g. safety glasses, hearing protection, safety shoes, gloves, etc.) 有否个人防护用品?(如保护眼镜、听觉保护、安 全鞋、手套等） 口罩、耳塞。Ear plug and mask available. 9.7 Are there sufficient fire extinguishers in factory? (comp