EXTENSIVE FACTORY AUDIT REPORT GENERAL INFORMATION

Transcription

 Asia Quality Focus Limited. All rights reserved.
EXTENSIVE FACTORY AUDIT REPORT
GENERAL INFORMATION
CQF Report#
Client Name
10349
Challenge Electronics
Your Ref#
Microsoft
Audit Date
Mar. 10 & 11, 2010
Vendor Name
Universal (Changzhou) Electronics Co., Ltd.
Factory Name
Universal (Changzhou) Electronics Co., Ltd.
Factory Address
Changzhou, China
Factory Tel/Fax #
0519-88864155
Item Description
Speakers, buzzers transducers
REMARKS AND OBSERVATIONS
1. The factory’s management is cooperative with this audit.
2. Overall quality and environment management system is good; however there are some problems
with social accountability.
3. The factory has 3 production buildings: 1 building for Speakers and buzzers transducers, 1 building
for Piezo Transducer, and 1 building was vacant (not on production). The auditor performed the audit
on Speakers, buzzers transducers only; there are totally 4 workshops and 10 production lines.
4. The factory mainly manufactured Speakers, buzzers transducers and has much experience on client
desired product. As declared by factory, the production lead time will be 15-45 days.
5. The factory process capability is about 4,000,000 - 5,000,000pcs per month.
AUDIT CONCLUSION
Unsatisfactory
(<50%)
Needs Improvement
(50%-70%)
Satisfactory
(70%-90%)
Outstanding
(>90%)
This report is issued by Asia Quality Focus (HK) Limited.
The results reflect our findings at time and place of inspection and this report does not relieve sellers / manufacturers from their contractual liabilities & responsibilities for their
products or prejudice buyers’ right for compensation for any apparent and/or hidden defects not detected during our random inspection or occurring thereafter.
This report does not evidence shipment.
www.AsiaQualityFocus.com
Page 1 of 56
A. FACTORY PROFILE AND INFO (Non-scoring section)
Managing director/GM
Jim Ge/ [email protected]/0519-88812136
Sales/marketing manager
Jane yang/[email protected]/0519-88864155
QA manager
Miss Peng yuanzhen
Technical/design manager
Miss wangxuezhen/ [email protected]
Factory/production manager
Mr. yufengyan
Factory contacts/Position/Email
Jane yang/[email protected]/0519-88864155
Ownership of the factory
Private
Date of establishment
2001-11-26
Total operating space
27,000 ㎡
Product ranges
Speakers, buzzers transducers
Export percentage
90%
Last year turnover
12,000,000 US dollar
Payment Terms (L/C, T/T, etc)
T/T
Total Lead Time
(from getting order to delivery)
15-45days
Nearest seaport / airport
Shanghai seaport/ shanghai airport
Total employees
702
Manufacturing personnel
572
Quality controllers
30
R&D
18
Engineering personnel
22
Others
60
Production capacity per factory
4,0,000,000- 50,000,000pcs per month
Production capacity per auditor
4,0,000,000- 50,000,000pcs per month
ASUS/China/12.5%
Major customers
(name/country/percentage)
DELL/USA/12%
APC/PHILIPPINES/6.5%
CANON/TAILAND/3.8%
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Overview of the factory (factory gate/office building/production plant/dormitory if any)
Gate
Production building
Office building
Dormitory building
Plastic injection building
Office
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Sample room
A small sample room on the factory.
Production lines/workshops
The factory has 3 production buildings: 1 building for Speakers and buzzers transducers, 1 building for
Piezo Transducer, and 1 building was vacant (not on production). The auditor performed the audit on
Speakers, buzzers transducers only; there are totally 4 workshops and 10 production lines.
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Speakers
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Buzzer
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Manufacturing machines
Electric oven:23; Auto transfer printing machines:43; winding machines:189; gluing machines:118;
spot welding machine:37; auto banding machine:1; magnetizer:11; solder pot:6; reflow soldering
machines:2; CCD magnifier:2; ultrasonic riveting machine:3; auto packing machine:1; baking tunnel:14；
laser printing machine:1; ultrasonic cleaner:2; wire stripping machine:1; air pump:4; gas storage
tank:2; exhaust fan:4; accurate air pump:1; grinder:2; CNC:4；sparking machine:2; milling machine:1；
hardening furnace:1; injection machine:11; muller:2; mixer: 1; drying machine:2; punch:2; drilling
machine:1; lathe:3; engraving machines:2; sawing machine:1
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Backup electricity generator
No Backup electricity generator on the factory.
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B. DOCUMENTS VERIFICATION (Non-scoring section)
B1.
Business License
Issued and expired date: 2001-11-26 to
2021-11-25
B2.
Export license
Issued and expired date: 2006-4-30 to 2011-5-30
B3.
Products certificates (RohS, CE, etc)
Only components ROHS report provided.
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ISO 9000 Certificate
ISO 9001: Issued and expired date:2008-7-14 to
2011-7-13;
B6.
Social Accountability Compliance
Certificate
Labor Contracts/Factory Regulations
No social Accountability Compliance
Certificate.
Labor Contracts/Factory Regulations provided
B7.
Payrolls and Attendance Records
Payrolls and Attendance Records provided
B4.
B5.
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B8.
Fire Certificate
Fire Certificate provided
B9.
Environmental Certificate
ISO 14001: Issued and expired date:2007-4-19 to
2010-4-18
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C. MANAGEMENT SYSTEM
Part 1: Design Control
C1.
Does the factory review design input & outputs relating to product requirements?
Yes
No
For design input, according client requirement: object suggestion letter, inspect and verify.
For design outputs: products specification, chart make, material inspect, router, product test, etc
Design inputs
Design outputs
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C2.
Does the design output provide information for purchasing, production (including
packaging) use, and determine product specifications, special inspection & test
requirement where necessary?
Yes
No
The design output provide information for purchasing, production (including packaging) use, and
determine product specifications, special inspection & test.
requirement
Schedule
Specification for approval
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Design doc
Design doc
BOM
Packing information
Reliability test
Specification
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C3.
Does the factory conduct design testing and record customer review prior to
production, i.e. first article, pilot run?
Yes
No
For first article and pilot run, the factory conduct design testing and record customer review prior to
production.
First article and pilot run plan
New product test report (pass)
Test report (failed)
Work instruction and scheduled plan
Customer review
Customer review
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C4.
When there is change to product design, does the factory conduct verification and
validation to the changed product?
Yes
No
Yes
No
Yes
No
The factory claimed that there has been no design change so far.
C5.
Does the factory have a method of controlling product changes, e.g. ECN?
The factory had a method of controlling product changes (ECN, application, action).
Part 2: Purchasing Control
C6.
Does the factory have a method for selecting, assessing, measuring and monitoring
the capabilities of suppliers, i.e. supplier audits, supplier rating etc?
Process: investigation, sample assessment, restriction material guarantee letter and quality assurance
agreement, grading system, supplier approval list, on-site auditing, monthly assessment report, yearly
assessment report.
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Investigation
Sample assessing
Sample assessment
Sample test
Restriction material guarantee letter
Quality assurance agreement
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Evaluation rule
Supplier grading criteria
Supplier approval list
On-Site assessment form
Monthly evaluation
Monthly statistics
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C7.
Does the factory have an approved list of suppliers?
Yes
No
Yes
No
The factory had an approved list of suppliers (3 grade: A, B, C).
C8.
Does the factory purchase materials based on inventory count and lead time?
Auditor selected 5pcs Purchase order from ERP system, found the factory purchases material according
to PO, not based on inventory count; the factory explained that the stock material is not too many. And the
lead time of some materials is not shown on ERP system, the factory claimed that they purchase materials
according to production plan (for example: 12K/day).
P/O from client
Material purchase order
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Inventory count
C9.
Inventory count
Are product specification and requirements (including delivery, quality) defined in
the factory’s purchase orders?
Yes
No
Yes
No
Product specification and requirements defined in the factory’s purchase orders.
C10.
Does the factory have priority contracts with critical suppliers, and does the factory
provide forecasts?
The factory had priority contracts with few critical suppliers for normal products.
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Part 3: Storage Management
C11.
Does the factory record incoming material inventory?
Yes
No
Incoming material inventory kept on computer (with ERP system), auditor selected 5pcs incoming
material, and they were recorded.
Showing on stock card
Showing on computer
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C12.
Showing on computer
Does the factory store inventory in an appropriate environment and safe condition?
Yes
No
The factory store inventory in an appropriate environment and safe condition, humidity and
temperature are normal, some material stored on constant temperature bin.
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C13.
Does the factory record outgoing finished goods?
Yes
No
The factory records outgoing finished goods, auditor selected 5pcs finished products, and they were
recorded.
C14.
Showing on inventory
Does the factory clearly identify materials and products in warehouses?
Yes
No
The packing material, e.g. inner/master cartons were not clearly identified in the warehouse. And in
finished products warehouse, found one lot is not identified too.
Material identification
Material identification
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Material identified
Material identified
Packing Material was not clearly identified
Finished products identified
Finished products identified
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Finished product was not clearly identified (one item)
C15.
Is there a First In First Out, FIFO or other method to control and rotate inventory?
Yes
No
According the records, the factory with First In First Out method to control and rotate inventory.
Part 4: Incoming Inspection
C16.
Does the factory define the inspection requirements, sampling plan and acceptance
criteria for incoming inspection of materials & components?
Yes
No
The inspection requirements, sampling plan and acceptance criteria for incoming inspection of materials
& components were defined.
Inspection requirements
Instruction
Page 34 of 56
Sampling plan
C17.
Acceptance criteria
Does the factory conduct incoming inspection as planned? Are the results of
incoming inspection recorded?
Yes
No
Yes, the factory conduct incoming inspection as planned, classify “A+”, “A”, “B”, “C” grade for
inspection(for example, A+: the material should inspected immediately, B: the material should inspected
in one day).
Selected 5 items for incoming inspection recorded checking, the result was OK.
Inspection as planned
Inspection as planned
Incoming inspection recorded
Incoming inspection recorded
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C18.
Is the status of raw materials clearly identified, i.e. Approved, Rejected, Pending
etc.? Is rejected material recorded and segregated?
Yes
No
Raw materials were clearly identified.
Pending products
Pending products
Passed products
Passed products
Inspection area
Inspection area
Page 36 of 56
C19.
Does the factory review, determine and record the disposition of rejected material,
i.e. RTV, Deviate to Use, Rework, Sort to use?
Yes
No
Yes
No
Yes
No
As claimed by factory, for rejected material, it RTV or Deviate to Use.
Inspection report
C20.
Deviate to Use
Does the factory notify suppliers of rejected materials? Is it recorded?
The factory notified suppliers of rejected materials and recorded.
Part 5: Production Control/Inspection/Testing
C21.
Does the factory define material for manufacture, i.e. a production BOM, router or
tag?
The factory defined material for manufacture, production BOM, and also router is used.
Page 37 of 56
C22.
Production BOM
Production BOM
Production BOM
Production BOM
Production BOM
Router
Does the factory plan production based on capacity, orders, stock, product type,
etc.?
Yes
No
The factory plans production based on capacity, orders, stock, and product type.
Page 38 of 56
C23
Does the factory control and monitor lead times? i.e. monitor material lead time,
safety stock, production planning, etc.?
Yes
No
The factory control and monitor lead times according to material lead time, safety stock, production
planning.
Page 39 of 56
C24
Does the factory monitor, control and record all applicable process parameters?
Yes
No
Yes
No
The factory monitors, controls and records all applicable process parameters
C25
Does the factory calibrate all applicable process control points, including inspection
and test equipment, e.g. temperature/ pressure gauges, timers, hi-pot tester,
multi-meter, caliper, etc?
All measuring and testing equipment are calibrated with valid date, and certificates can be traced to
international / national standards.
Page 40 of 56
C26.
Does the factory plan and conduct equipment/ tooling maintenance?
Yes
No
Yes
No
The factory plan and conduct equipment/ tooling maintenance, and recorded.
C27.
Are products identified at all stages of manufacture?
The products were identified at all main stages of manufacture.
Page 41 of 56
C28.
Does the factory define method of manufacture, i.e. work instructions,
workmanship standards, defect classification, etc?
Yes
No
The factory defines method of manufacture, i.e. work instructions, workmanship standards, defect
classification.
One production line was found with wrong work instructions or no work instructions attached.
Wrong work instructions or no work instructions
Page 42 of 56
C29.
Does the factory conduct in-process inspection as planned? Are the results of
in-process inspection recorded?
Yes
No
The factory conducts in-process inspection as planned.
Found the actual defects quantity does not match the quantity on router.
On router (266pcs)
C30.
Actual defects quantity 254pcs
Does the factory summarize and analyze in-process inspection results, i.e. by using
control chart, run chart, etc., in various process/workshops?
Yes
No
Yes, the factory summarizes and analyzes in-process inspection results, i.e. by using XbarR.
Page 43 of 56
C31.
Are rejected material identified and segregated? Are reworked products
re-inspected?
Yes
No
Rejected material identified and segregated. Reworked products re-inspected.
Rejected material identified and segregated
Rejected material identified and segregated
Reworked products re-inspected
Reworked products re-inspected
C32.
Does the factory clearly define package requirements, i.e. pack list, packaging
method, etc.?
Yes
No
The factory clearly defines package requirements.
Page 44 of 56
C33.
Does the factory define the inspection and test requirements, especially for critical
features like dielectric resistance, hi pot testing, metal detection, or ground
continuity, sampling plan and acceptance criteria for final product inspection?
Yes
No
Yes
No
The factory defines the inspection and test requirements for critical features.
C34.
Does the factory conduct final product inspection and test as planned? Are the
results of inspection and test recorded?
The factory conducts final product inspection and test as planned, and inspection and test recorded.
Inspection area
Inspection plan
Page 45 of 56
Inspection plan
C35.
Inspection plan
Are operators /QC personnel trained and are records available?
Yes
No
The operators /QC personnel trained and are recorded, it conformed by the workers.
Page 46 of 56
Part 6: Continual Improvement
C36.
Does the factory have continuous improvement program, i.e. management review,
CAPA, 5S, Six Sigma, collect and review statistical data points etc?
Yes
No
The factory have continuous improvement program.
Management review report
Internal audit report
CAPA
Page 47 of 56
5S
Review statistical data points
C37.
Does the factory initiate actions or projects to improve quality performance and
processes base on above analysis results?
Yes
No
The factory improve quality performance and processes base on analysis results.
Action
Action validation
Page 48 of 56
Revised working instruction
C38.
Does the factory have a method of reviewing customer complaints? Is complaint
data entered into the continuous improvement program, i.e. CAPA, Trend Analysis,
etc.?
Yes
No
According customer complaints, Investigation, Analysis, improvement, complaint data entered into the
continuous improvement program.
Investigation
Analysis
Complaint data entered into the continuous
improvement program
CAPA
Page 49 of 56
C39.
Does the factory have an Internal Audit program?
Yes
No
Yes
No
The factory had an Internal Audit program (once per year).
C40.
Does the factory management conduct management review based on data analysis,
to determine strategies, align recourse to drive continuous improvement?
The factory management conduct management review based on data analysis, to determine strategies,
align recourse to drive continuous improvement.
Page 50 of 56
Part 7: Social Environment Responsibility
C41.
Is overall air quality and lighting condition generally acceptable?
Yes
No
No
Yes
The overall air quality is good and lighting condition is adequate.
C42.
Is there any worker less than 16 ages on site or less than 16 ages at join date?
No worker less than 16 ages on site or less than 16 ages at join date.
Page 51 of 56
C43.
Do workers’ regular working time and overtime meet local labor laws?
Yes
No
Interviewed with the workers and auditor observed that Only half an hour were allowed for lunch. The
working time: 8:00 to 11:30, and 12:00 to 17:00. The workers claimed that the overtime is less than 2
hours each day.
C44.
Do workers have at least one day off in seven?
Yes
No
Found the worker has two days off in one month. Normally, the workers have at least one day off in
seven.
C45.
Are workers voluntarily employed? (No ID card, diploma, or money detained)
Yes
No
For new workers, the ID card kept on the office about 19 days, but has not return to the workers. The
factory claimed that they used their ID card to make bank card for salary payment, they will normally
return the worker after one month.
The salary wound be detained 1 month, for example: on Mar 1, the workers received the salary for Jan.
C46.
Is worker’s monthly/hourly salary equal to or higher than the government
standard?
Yes
No
Found worker’s monthly/hourly salary equal to or higher than the government standard.
Page 52 of 56
C47.
Are first aid supplies available on each floor?
Yes
No
Yes
No
First Aid supplies were only kept on the office, and found one medicine was invalid.
C48.
Is there any PPE (personal protection equipment) in place when necessary?
There are PPE in place. But found one transmission belt was not safeguarded (covered).
Page 53 of 56
The belt was not safeguarded
C49.
Are fire extinguishers, fire alarms and emergency lights properly equipped?
Yes
No
Fire extinguishers, fire alarms and emergency lights equipped, however, found 2 emergency lights were
not properly workable.
Page 54 of 56
C50.
Are fire drills and evacuation drills conducted periodically?
Yes
No
The factory conducted fire drills and evacuation drills periodically (once per year).
Page 55 of 56
SUMMARY OF POINTS ACHIEVED
Maximum
Points Possible
Total Points
Achieved
Design Control
5
5
Part 2 (C6-C10)
Purchasing Control
5
4
Part 3 (C11-C15)
Storage Management
5
4
Part 4 (C16-C20)
Incoming Inspection
5
5
Part 5 (C21-C35)
Production Control/Inspection/Testing
15
13
Part 6 (C36-C40)
Continual Improvement
5
5
Part 7 (C41-C50)
Social Environment Responsibility
10
4
50
40
Section No.
Section Description
Part 1 (C1-C5)
Total:
80%
Overall Rating:
CQF Audit/Inspection Conditions:
CQF Audit findings:
SIGNATURE OF FACTORY REPRESENTATIVE
Signature: Miss Jane (sales)
Date: Mar 11, 2010
Page 56 of 56

EXTENSIVE FACTORY AUDIT REPORT GENERAL INFORMATION

Transcription

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