TESCO验厂报告3-21.doc

Supplier Name:Audit Date:Site Code:TESCO NON FOOD MANUFACTURING STANDARD AUDIT REPORT TESCO 非食品生产标准审核报告Site Name:工厂名称：Site No.工厂编号ST0223Date of Audit:审核日期：Time on site 审核时间(hours):9:30-5:30, 8:30-4:00Persons Present:参会人员Dear Mr. Huang & Team,Thank you for the hospitality extended to myself during the announced Tesco Non Food Manufacturing Standard Audit on 19-20/3/13. Please pass on my thanks to all those involved in the day.THIS SITE HAS BEEN ASSIGNED AN AMBER ( 3 Mj, 14 Mn, 2 Obs) Signed for and on behalf of Tesco: TESCO代表Goh Chun FoongDate: Job Title: 职位Product Integrity Unit Site Representative:Date: Job Title:LegTESCO Non Food Manufacturing Standard Report Version 2.1 Apr 2011 Page 10 of 10TESCO NON-CONFORMANCE SUMMARY TESCO不符合点总结报告SUMMARY总结Covered production and storage facilities, maintenance area and surrounding area.现场审核范围有生产区域和仓库区域，工程部和周边地区。Remarks: 摘要- The previous 4 storeys production and storage facilities were burnt on April 2012. (4 storeys previously cater for production floor, storage floors for raw material, packaging materials, and waste)- 先前的四栋生产和仓库厂房于2012年4月份火灾烧毁。（生产四层楼先前用于生产，原材料，辅料和废料仓储） 2nd, 3rd and 4th storeys were burnt in this fire incident and currently the re-construction is in progress. 2、3、4楼层在火灾中烧毁，目前重建的厂房正在进行中。 First part of ground floor remain as sanitary napkin and panty liner production area; while second part converted to temporary storage area for waste, some packaging and raw materials. 第一楼层部分保留作为生产卫生巾和护垫的车间。另一部分作为暂时存放一些原料，辅料和废料的存储区域。- Temporary warehouse was also built for packaging and raw materials storage.- 临时仓库作为包装材料和原料的仓储。- In house laboratory was burnt as well; currently physical testing was conducted at production area (QC station) while the microbiological testing was sent to external laboratory.- 实验室也在火灾中烧毁，目前物理实验在生产区域进行（现场质检），微生物实验送至外部实验室进行。No.Critical non-conformances 关键不符合点Who负责人When何时完成Corrective Action整改措施Verification (Tesco)Who, When, HowTESCO核实（负责人，何时，如何）None observed 没发现No.Major non-conformances 重要不符合点Who负责人When何时完成Corrective Action整改措施Verification (Tesco)Who, When, How TESCO核实（负责人，何时，如何）(1)1.6.1H1.1.1H14.6MHACCP; Foreign Body Detection 危害分析和关键环节控制点，外来物检测a) No hazard analysis of the manufacturing process conducted; no HACCP plan established to monitor the controls to minimise the risks identified. 没有生产过程控制的危害分析，没有建立控制可识别风 险最小化的危害分析和关键控制点计划。b) A ferrous 0.8mm test piece and a temporary self-customised copper test piece available onsite for metal detector; however, the proper non ferrous and stainless steel test pieces were not in place. 有用一片0.8mm的铁片测试片和一个自制的铜片测试片现场经过金属探测器测试，但是没有可替代的非铁质和不锈钢测试片。 品管部，制造部2013年6月份A. 形成HACCP计划书，并按照相关内容，做好计划执行。B. 重新增设可替代的非铁质和不锈钢测试片。(2)5.10B5.2B5.1.1M5.13BDesign and Construction of Premises 建筑物设计和构造a) The lightings in the production area were not protected with shatterproof covers. 生产车间的灯管没有防爆和防碎的设施。b) Due to the re-construction of the burnt building, some parts of the ceiling found dropped off at the corner of production machinery area. 由于建筑物烧毁重建，生产车间天花板和墙壁角落会有异物掉落。c) There were few holes in the production machinery area, which may pose risk of pest entry. 生产车间有破损小洞，可能会有害虫进入危害。d) The packaging and raw materials warehouse was crowded, and many of the materials were stored against wall which was not facilitated the inspection. 辅料和原料仓库拥挤，许多材料都放在靠墙位置（要求要放置离墙一定距离）。行政部，工程部，后勤保障部，仓储部和杂工组2013年5月份新车间按此要求施工：A. 生产车间灯管加设防爆灯罩或更换成防爆，防碎标准照明设施。B. 旧厂房一楼将进行重新装修。C. 补齐缺漏区，进行隐患清除。D. 对于原料和辅料进行分类整理，并按“五距”标准进行重新布局陈列。(3)Factory Hygiene; Pest Controls 工厂卫生，害虫控制a) The hygiene level in temporary storage facility was not satisfactory. A lot of the waste products were kept in together with the packaging and raw materials. 临时存储间的卫生条件不好，许多废料和包装材料，原 料放置在一起。b) The chemicals dispensing room was dusty. 化学品存储间较脏。c) No location map for pest control programme. 没有害虫控制计划分布图。d) The flying insect killer observed pose potential risk of contamination. 害虫捕捉器可能产生潜在污染风险。e) No pest infestation level report in place. 没有害虫感染程度报告。f) No records for bulb changing record to ensure its effectiveness. 没有灯泡更换记录确保灯泡是可用的。g) No evidence to show that the light bulbs of electrical insect killer were shatterproof. 没有证据可以证明灭蝇灯的灯管是防碎的。h) No safety data sheets for chemicals used in the pest control programme. 没有控制害虫计划的化学品安全说明书。杂工组，仓储部，行政部，工程部2013年4月份A. 进行彻底的清扫，清洁，排除废料，原料进行集中管理。B. 化学品储存间进行整理，清洁工作，并安排指定人员定期进行环境，卫生，安全管理。C. d,e,h,g，去除有害物质如毒鼠药的使用，加设捕鼠笼，并以示意图形式，标识分布图，形成记录管理。D. 做好灯泡的更换记录，并形成巡查制度，确定安全及时效性。No.Minor non-conformances 一般性不符合点 Who 负责人When 何时Corrective Action 整改措施Verification (Tesco)Who, When, How TESCO核实（负责人，何时，如何）(1)Personal Hygiene 个人卫生a) No jewellery control in place; staffs observed wearing hanging earring and necklaces in the production area. 现场没有控制员工佩戴的首饰。生产车间员工中有戴耳 环和项 链。b) Food and drinking water were found in the production machinery area. 生产车间有发现食物和饮用水。制造部2013年4月份A. 设立首饰控制管理程序。B. 加强生产车间制度执行，把控现场生产环境的清洁和卫生。(2)Medical Screening 健康检查a) No medical screening form for the visitors. 没有访客的健康问卷表。b) No return to work procedure established for the production workers. 没有为病假员工建立返回工作的体检程序。制造部，人力资源部2013年4月份A设立访客健康问卷表，并形成有效记录。B设立病假员工返厂体检程序。(3)Employee Facilities and Personal Protective Equipment 员工安全设施和个人保护装备。a) No hand wash practice and protective clothing provided to the visitor or management staff before entering production area to prevent potential contamination. 没有为访客和管理人员提供进入车间前洗手和防护服等程序，以防潜在污染。b) Open toe and high heel shoes were observed in production area. 生产车间有发现穿露脚趾的拖鞋和高跟鞋。（建议员工穿包着脚趾的工作鞋）c) No segregation for the personal and working clothing in the cabinet in changing room. 更衣室的个人衣物和工作服放在柜子里没有单独存放 。d) The changing procedure was not established to ensure the workers wearing the protective equipment properly and by correct sequence. 没有建立更换工作服等程序以确保员工按正确顺序穿好防护装备。制造部，行政部2013年4月份A. 设立访客与管理人员进入车间步骤程序示意图，加强宣传。B. 重新购置生产车间标准鞋具C. 新厂房储柜分开设置，更衣室内增设存储柜，实行标示并分类管理。D. 建立工作服正确穿着示意图，校正规范，并实行有效的培训管理。(4)Maintenance 维修a) Loose tools and parts were not kept properly in the production machinery area. 生产车间的一些零散部件没有合理存放起来。b) Carton box and transparent OPP tape were used as the parts to fix the machine. 纸箱纸皮和透明胶纸用来修理机台。制造部，工程部2013年4月份A. 加强车间现场的”6S”管理，规范现场生产状况。B. 工程部设置相关垫具， 确保安全，清洁及实效性。(5)Process Controls 程序控制a) Some items were not properly labelled in production areas; including the lubricant oil in machine area, the detergent powder in the changing room. 在生产区域一些物品没有合理标示，包括机台旁边的润滑油和更衣室的洗衣粉。b) The products were used as the maintenance part on the production machinery. 产品被用来临时维修生产机台。c) No clear identification for the tray used for rejected items. 没有对二等品使用框做清楚的标识。制造部2013年4月份生产车间实行彻底”6S”A. 整理，整换工作，加强现场督导，及现场物品的有效分类标识。(6)3.5B3.1B3.4B3.10B3.12BRaw Material, Packaging, Secondary Site Management原料，辅料，以及二等仓库管理。a) Approved supplier list established; however, some suppliers such as Yu He and Jin Ming were not included in the list. 有建立合格供应商清单，但是清单上没有玉和和锦明这两个供应商。b) Supplier evaluation conducted but no scoring system established and used to determine supplier approval and monitoring method. 有做供应商评审表但是没有具体的评分标准手册c) Supplier audit conducted but no report produced to record the supplier performance or if any corrective action needed. 有建立供应商审核，但是没有供应商执行记录或者必要的整改措施报告。d) The vehicle cleanliness check for incoming products was not documented. 供应商运输材料进厂的运输车辆没有文件记录清洁状况。e) Some packaging for materials such as part-used material and product after inspection were not wrapped properly to prevent contamination. 部分剩余的或者检验后的材料包装物没有完全合理包裹好 以避免被污染。 采购部，品管部2013年4月份A. 补齐玉和和锦明供应商的合格标准入我司供应商清单。B. 设立供应商评审表评分标准。C. 设立供应商执行记录及涉及整改的措施报告。D. 形成供应商材料进厂运输车辆的清洁状况记录并附加图片取证。E. 对于原料检验及合格产料入库做好及时，有效的外观检验，确保材料安全，清洁。(7)Foreign Body Controls 异物控制a) Wooden tools storage box, wooden handled hammer were used in the machinery area. 生产车间使用木质工具箱和木质手锤b) The cloth was used on the production line which potential pose the foreign body risk. 生产线上使用的抹布可能会带来潜在的异物掉落风险。c) The sharp tool list is established and their quantities were checked monthly; however, the integrity check was not documented. 每个月有做利器的登记和检查数量清单，但是没有文件记录完整性的核查。d) The register for glass and clear hard plastic items in place but the mirror in the changing room was not included in the register. 现场玻璃和透明塑料硬制品有做登记，但是更衣室的整容镜没有在登记本中。a) The glass breakage procedure was established; however, it was not completed as only covered the method to deal with the broken glass.有建立玻璃破碎手册，但是没有完整的玻璃破碎处理手册。2013年4月份行政部，工程部，制造部A. 替代木制品，如更换成硬塑料垫板，铁质柄手锤。B. 生产线及时整理，确保安全清洁。C. 每月定期的做好利器的登记和检查，形成有效的记录。D. 将整容镜列入硬器，利器，玻璃器具管理程序中。E. 设立玻璃破碎处理手册。(8)Calibration and Verification 仪器校准和验证a) New measuring machines were purchased after the fire incident. The weighing scale in production line and chemical dispensing room were yet been included in the calibration programme. 火灾后购置了新仪器。生产线上的电子秤和化学品室也应包含在校准项目中。a) The verification of the pH meter was conducted daily but not documented.每天有进行PH值实验，但是没有文件记录。b) No documented verification procedure established for the weighing scales and pH meter. 没有建立电子称和PH值测试的程序文档。b) Calibration master list was established but no tolerance range established for the equipments.有仪器校准记录但是没有拟定校准程序的误差范围。品管部2013年4月份A. 将电子秤和化学品室列入标准项目，并做好标识，记录。B. 进行每日的PH值试验记录管理。C. 建立电子秤，PH值程序文档。D. 做好仪器校准程序误差范围文件。(9)Product Inspection and Analysis 产品检验和分析The microbiological test for bacillus pyocyaneus was not conducted as per stated in Tesco product specification.TESCO 产品说明书微生物规定的绿脓杆菌没有做测试报告。品管部，国贸部2013年3月形成有效的绿脓杆菌测试报告书（此检验报告已做好。）(10)Customer Complaints 客户投诉a) No documented customer complaints procedure established. 没有建立客户投诉程序的文档记录。b) Some corrective actions were not verified for their effectiveness. 一些纠正措施没有证实有效性。c) No trend analysis conducted on the customer complaints.没有进行客户投诉趋势分析。国内销售部2013年4月份A. 形成系统的客户投诉程序文件，形成记录及时效性，趋势分析。(11)Traceability 追溯Tesco Value panty liner was selected as the traceability exercise: TESOC Value 护垫追溯演习：a) Its shelf life study was conducted; however, it was not fully completed for 3 years shelf life as per declared. 有保质期，但没有完整测试三年保质期的记录。a) The product coding was pre-printed before the production; however, the coding document without the quantity information, and the printing code was wrongly recorded.生产前把生产日期先喷好，但是喷码记录没有数量信息并且喷码日期有错误的记录品管部，制造部2013年4月份A. 形成完整的保质期记录文件。B. 结合生产订单数，做好喷码记录信息数量登记，确保数量，日期的一致性。(12)2.3BFinished Product Specifications 成品规格书Tesco Value Panty Liner selected for traceability exercise; some information in Tesco product specification was not updated, for example the raw materials supplier and the product width was not specified. 选定追溯演习的Tesco Value护垫（2012年8月6日生产日期那批1310货号）：TESCO产品规格书的一些信息没有更新，比如原材料供应商和产品明确的宽度。 国贸部2013年5月份此项需国贸部与客户确认需更新信息，并由TESCO技术部审核后方可修改TESCO产品规格书。(13)Product Recall 产品召回a) Product recall procedure was not established.没有建立产品召回程序b) No key contact information list available. 没有可行的紧急联络名单。c) Mock recall was not conducted to test the incident management system.没有对测试事件管理系统进行召回模拟。国内销售部，品管部，制造部2013年4月份A. 建立产品召回程序B. 建立紧急联络名单C. 实行测试事件管理系统召回模拟(14)Internal Audit 内审No evidence to show that 2012 internal audit conducted as per planned; the complete record was not traceable due to the person in charge resigned.没有记录表明2012年的内审记录有按计划进行，负责人辞职造成没有完整的记录可追溯。总办，行政部2013年5月份自2013年起，做好每一次的内审会议，并形成记录，保持记录完整，有效。No.Recommendations 建议性不符合点WhoWhenCorrective ActionVerification (Tesco)Who, When, How TESCO核实（负责人，何时，如何）(1)Health and Safety安全与健康a) Cigarette butts were found in the dispose items storage area; suspected the construction workers were smoked near that area.在储存室发现烟头，估计是建筑工地的工人抽烟。b) Earplug was provided to the worker in machinery area; however, the staffs were not wearing the earplug during operation.在生产过程有提供耳塞给工人，但是在生产时发现全体工人都没带耳塞。