SUMARY INITIAL SOP AUDIT REPORT

September 14th 2015

I. Business Overview
Not check
II. Product Development & Sampling
Not check
III. Pre-Production Controls
Follow to check point No. 19, 20, 21, 23,1 the other point No. 22, 24, 252 will not check
because belong in team belong office.
-

n the general, almost factory follow procedure in section 12 from Chicos RFT manual.
But not yet build the procedure as the actual practice like PP-meeting plan, Plan for
pilot run. It should have procedure (ex timeline) and record.
Almost factory have done well the point No. 20 with translate buyers specs.
PP meeting done and have minutes
In Pilot run we have section 12A from Chicos RFT manual. But in actual practice we not
really follow the recommend from recommend in Pilot run size as a minimum of one
unit per size and color

Recommend for CAP

19

23

PI #5
Done well with post
and translate, need
include the time line
in PP meeting and
Pilot run procedure.
Need to record the
pilot run follow
recommend in
section 12A

PI #3
Need to post in
working area
Need include the
time line in PP
meeting and Pilot
run procedure
Need to record the
pilot run follow
recommend in
section 12A

PI #2
Need to post in
working area
Need include the
time line in PP
meeting and Pilot
run procedure
Need to record the
pilot run follow
recommend in
section 12A

PI #1
Need to post in
working area
Need include the
time line in PP
meeting and Pilot
run procedure
Need to record the
pilot run follow
recommend in
section 12A

IV. QA Systems & Support

-

We have clear organization structure for QA report for managing Director

In general SOPs factory activity have
Inline inspection have follow procedure and have record

19. Written procedure for pre-production process available and used by relevant associates.[MANUAL]20. Internal spec package- done by translating buyers
specs to local language for easy communication. [RECORDS]
21. Pre-Production meeting- for all styles attended by senior representatives of all involved departments. Minutes & documentation are distributed to all relevant
areas. [RECORDS]
23. Pre-Production Pilot Lot (Size Set) - evaluated, approved prior to cutting bulk production. [RECORDS]

22. Approved Sample- issued to production with a colored tag for Pilot Run Reference.[PROCEDURE]24. Sample evaluation- evaluated by trained technician.
[RECORDS]
25. Mannequins- CHS approved mannequins used for fit evaluation during pre-production and production stages. [PROCEDURE]

Certificate auditor: almost the factory told that dont have, some factory have for
other buyer.
Audit procedure have follow but only factory #5 have post with translation, other
factory dont have post or post place difficult to found.
All factory we have audit room for difference customer. Some we combine but have
separate room for inspection
The information full set receive from Merchandise
We dont practice with Final sealed bag sample
Barcode scanner done by self audit team. Not done by factory team

Recommend for CAP

PI #5

PI #3
PI #2
PI #1
- Should prepare
- Should prepare
- Should prepare
SOPs for all
SOPs for all
SOPs for all
production activity
production activity
production activity
and post in working
and post in working
and post in working
area with translate
area with translate
area with translate
in area missing
in area missing
in area missing
28
Post SOP in line
Post SOP in line
Post SOP in line
inspection with
inspection with
inspection with
translate and active
translate and active
translate and active
follow procedure
follow procedure
follow procedure
29 Please re-confirm is it correct current we dont have person was trained & responsible to
brand for Quality & SOP implementation
30
Post audit procedure Post audit procedure Post audit procedure
with translate in
with translate in
with translate in
inspection room with inspection room with inspection room with
active follow
active follow
active follow
procedure
procedure
procedure
37 Better using the same format for internal using (self audit) and report form send for
Buyer
38 Should post the result of performance quality for all follow up
With point No. 393, I still not clear instruction, I will check and update later.
27

V. Training program
-

The actual in all Poongin Factory we dont have training separate with production.
Training program we just have for QC only. Dont have sewer
Cross training dont have
Career advancement program dont have

This area need will feedback later

VI. Raw material management Primary (fabric warehouse management)
-

In general all Poongin factory done proper way with procedure and follow the require
from section 3B from Chios RFT manual
For shade variation we have done better than requirement from CHICOS for side
center side checking, we apply rule 2413 (only PI #5 apply with 6 piece cut), but for
end to end roll checking we not follow according the request from CHICOS RFT Manual,
some factory just check with 5 yard, and PI #3 not follow all fabric test, just check end
to end when found shading when check 4213 only.

39. Reporting System- Used to update management & initiate corrective action

Shade group4 have factory #1 is the best one done in proper way, the follow is Factory
#1 and #5 but missing the group report, and Factory #3 is not follow according
proper.
Lab room, only in PI #1&2 we have separate lab room. In factory only have light box
and darkroom but for fabric inspection only.
For point No. 565 and No. 576 current all PI factory have difference practice and not yet
build as SOP, in PI #3 have material handling procedure we can reference.

Recommend for CAP

50
55

52

56
57

PI #5
PI #3
PI #2
PI #1
- Practice with the standard form for fabric shade test (PI/LAB1-2015-08), fabric weight
test report (PI/LAB2-2015-08)
- Using standard form for fabric in rack (PI/WH1-2015-08), relax fabric in rack (PI/WH12015-08)
- all should practice with traffic light system for indentify fabric already pass inspection or
relax meet time require can be use (green sticker)
Coordinate with
Practice the shade
Coordinate with
Share your practice
factory #1, practice
group.
factory #1, practice
to other factory
with shade group
Coordinate with
with shade group
practice as good as
record and group
factory #1, practice
record and group
your done
info.
with shade group
info.
record and group
info.
Build SOP for fabric storage and material handling as your current practice and we
will benchmark

VII. Raw material management Trim, sundries & Packing (accessories warehouse)
-

Factory #3 and #5 have procedure built by own format, I will collect and provide later
for all have same manual.
Trim information, we not yet have procedure for trim information. Still have case
warehouse inspection accessories without approve sample.
Trim inspection in actual practice in Poongin factory we have apply better than the
requirement. We apply AQL 1.0 for accessories inspection, the requirement is AQL 2.5
Only in factory 1&2 have barcode scanner checking. Factory #3 and #5 dont have
this process
Pre-shrinking elastic and tape only factory #1 practice, the rest none.
We are not apply color fastness test for accessories
Trim card, in each factory have difference number trim card provide for relative
department. Need to make SOP and benchmark

Recommend for CAP

63
64

PI #5
PI #3
Make SOP for trim information
Follow checking

PI #2

PI #1

48. Shade variation- checked per dye lot at side, center, side and end to end. [RECORDS]

56. Raw Material Storage- Raw materials are stored in an appropriate manner, indoors, packaged, and by lot [PROCEDURE]

6 57. Raw Material Handling- Raw materials are handled in a manner that ensures purchased quality is maintained. [PROCEDURE]

65
69
70

procedure for
accessories in
inspection report.
Make SOP for trim card with lead time, number copies, provide relative department

VIII. Patterns, maker making & molding

-

Factory has separate pattern room for patterns and maker making.
In Poongin factory software using is Gerber Accumark, only PI #5 using Lectra
Calibration & preventive maintenance of plotters, only factory #5 have period
maintenance, and the rest is none. In this issue I suggest all Poongin factory
sign the maintenance plotter contract with 01 company and ask them
maintenance for all in period time, so we can save money than one by one. In
the requirement do monthly7. In addition, the current when I check the plotter in
factory #3 have problem, cannot work.
No. 76 and 77, for maker signoff and maker shrinkage signoff in actual practice have,
but not yet have standard procedure

Recommend for CAP

75

76
77

PI #5
PI #3
PI #2
Continues with
calibration with
record and keep file
the maintenance
report
Make SOP for maker signoff and make shrinkage signoff

PI #1

IX. Cutting production

-

In factory #5 is the good practice with post CHICOS SOP with translate and detail
process in cutting. Factory #3 with limited only post a book, but not in visual place
(everybody can read), in factory #1&2 have very good banner but put not in proper
(behind the shell or SOP over SOP)
For point No. 858 the actual we have practice but not yet build SOP
For cutting inspection only factory #5 follow proper inspection procedure as require in
cutting procedure in section 13 from CHICOS RFT manual, the rest still missing some
step from No. 86 to No. 939
Do not have preventive maintenance in cutting equipment. Only breakdown
maintenance
No. 94, Bulk part only factory #2 have, the rest done in subcontract.

Recommend for CAP

PI #5
78
7

PI #3
Visualize the SOP

PI #2
Arrange the current

PI #1
Arrange the current

75. Calibration & preventive maintenance of plotters- on a routine basis at least monthly. [RECORDS]

885. Equipment- correct equipment & appropriate for use [PROCEDURE]

9 Reference cutting inspection in page 3 section 13

86
89

90
92
93

procedure banner in procedure banner in

cutting and proper
cutting and proper
way
way
Preventive maintenance for cutting equipment.
QC should record
immediately after
spreading, dont
wait after cut finish.
Share your practice
Should have bundle/cut report
with other factory
Built procedure for numbering of part. Maximize using color sticker
for identify purpose
Follow practice as section 13 in Chicos Manual 10

X. Fusing
-

We have fusing procedure. But in the actual practice we have something need
highlight: in factory #1, fusing test the bond strength only do 01 piece, and no
preventive or cleaning belt for fussing machine. Factory #2, the record in the test not
update according in machine to report, it look ok but if check where in machine setting
is not look as the record. In Factory #3, done for 02 times/day, when change the new
fabric they did not check fusing.
All factory do not have AQL checking for fusing. As the factory explain that they have
at least 02 worker/machine already check 100%, no do AQL checking.

Recommend for CAP

PI #5
Post fusing
procedure from PI
#1 or #2 in fusing
area.

96

98
101

PI #3

PI #2

PI #1

Build Preventive maintenance & routine cleaning and record

Bonding strength 02
times/day

XI. Assembly area (sewing line)

-

Only factory #2 have show first step the progress TPM, factory #1 have follow up with
machine check list, the rest machine maintenance is poor
Needle control in the general look well. But we dont have hand needle detector only
using magnet. In factory #2 have this equipment but not charge to use.
Operator contract (example), Factory #5 practice with small piece in machine but cut
from finish garment from pilot run. Factory #3, have small piece for normal operation
and for critical have sign and approve from FQA. Factory #1, the mockup full piece for
critical operation and the rest dont have. Factory #1, mockup with small piece and
some line dont have.

10 No. 4 Bundling & piece control from page 2 and 3 section 13

We have using template for some operation, but the setting in machine not look in
maximize utilize machine, for example the worker still using hand to press re-back
stitch while we can set up automatic re-back stitch in single needle.
Skill inventory we just stop in grade A,B,C and not really using as a tool for line
balancing. And no post in the line.
In factory #5 have good practice with show the picture and technical skill staff in the
line
We dont have progress control WIP in the line
In line control we have done and do 100% for end line inspection

Recommend for CAP

PI #5
Practice TPM
Got procedure for
bundle/piece control
from factory #3 or
#1

105
110

117

PI #3
Practice TPM

PI #2

PI #1
Practice TPM

Post line staff and technical in each line same as factory #5 have
done

XII. Finishing, pressing & packing

-

We have procedure but in factory #3 not post in work place, factory #1&2 have post
but not in proper place.
No preventive for suction table and iron
Only factory #5 have approve pressing standard post in pressing area, other factory
dont have pressing standard or old style
For security tape apply for some buyer only, not all.

Recommend for CAP

PI #5
184
185

PI #3

PI #2

PI #1

Should have pressing standard, can understand that is operator

contract for pressing
Build SOP for trim distribution & usage