工厂质量评估分析报告.doc

General Mills

NON-DOMESTIC AUDIT (e.g. Asia, Middle East, India)
QUALITY ASSESSMENT REPORT工厂质量评定汇报

Date日期: August 20 to 21, Auditor审核员: Mr Lee Fai
Date of Visit审核日期:

Reason for Visit: X Initial/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供给商: Blanco

Manufacturer生产商: 昆山统福美耐磁制品
Location地址: 中国江苏省昆山市同丰东路９６８号
Telephone:[phone]
Fax: [phone]
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审核方参与者
Supplier/Factory Attendees; Titles工厂参与者/职位

ＭR,GU/厂长

MRS,ZHOU／人事经理

Requirement 要求
Result 结果
Critical Items 严重项目
MEET / DNM
Section Minimum Acceptable Percentage 章节最低接收百分比
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

SCORING OF ASSESSMENT评定得分

章节

Minimum accepted (%)最低接收(%)
% yes
Section weighting章节比重
Minimum
最少
% x weight比重
Section 1
Facility & Maintenance
厂房设备和维修保养
85
44
0.10
8.5
4.4
Section 2
Control of Incoming Raw Materials
来料控制
85
45
0.10
8.5
4.5
Section 3
Sanitation (Molding, Production, Assembly, Packout)
卫生 (啤塑, 生產, 装配, 包装)

85
32

0.20

17
6.4
Section 4
Quality Systems: 质量系统
· Organization and Management
· 组织和管理

85
67

0.10

8.5
6.7

· Quality Programs质量程序
90
71
0.20
18.0
14.2

· In-Process Control and Testing制程控制和测试
90
76
0.20
18.0
15.2
Section 5
Pre-Shipment Inspections
出货前检验
85
100
0.05
4.25
5
Section 6
Product Testing產品测试
85
0
0.05
4.25
0

Overall Section Score (1-6)
整体部份得分
Limit overall section score (1-6)
限制整体部份得分
87
56.4
Section 7
Wages & Labor Practices
工资和劳工
85
100
0.25
21.25
25
Section 8
Child Labor 童工
100
33
0.25
25

8.25
Section 9
Health & Safety健康和安全
85
92
0.25
21.25
23
Section 10
Dormitories宿舍
85
90
0.25
21.25
22.5

Overall Section Score (7-10)
整体部份得分
Limit overall section score (7-10)
限制整体部份得分
88.75
78.75

NOTE: Items marked with "*" are considered as critical non-compliance areas.
Any 'No' rated in the (*) will lead to immediate failure of the Factory Audit.
注意: 有"*"部份為关键不符合地方。
任何在(*) 位置上有'No'将立即造成工厂审查不合格。

The percentage of yes' within each section must meet or exceed the minimum acceptable percentage requirement for that section. Non-compliance with this requirement will result in an overall failure of the audit.
在每一部份”yes”百分比必需达成或超出该部份最低可接收百分比要求。如不能符合这项要求，审查结果将会视為整体不合格。

Final approval of factory is determined by General Mills/CPW.
最终工厂审批由General Mills/CPW负责。

Assessment Scope and Summary: 审查范围及总结:

Signature of Auditor审查员签署：

Print Name全名:

Factory Profile - Self Questionnaire工厂介绍-自我调查表
A. Certificate of Quality License for Export Commodities? 出口许口证?发证日期
[ √] Yes
Date of Issue? J an 20 1994__________
[ ] No
B. Is the factory ISO 9002 certified?
是否经过ISO 9002认证?若无,估计日期?
[ √] Yes
[ ] No
If not, date anticipated? _________
C. Is factory ISO 14001 certified?
是否经过ISO 14001认证?若无,估计日期?
[ ] Yes
[ √ ] No
If not, date anticipated? ____未定_____
D. Factory Organizational Structure 工厂组织架构
Managing Director 董事长
√
General Manager 总经理
√
Marketing Manager 市场部经理
√
Technical Manager 技术部经理
√
Engineering Manager工程部经理
√
Q.C./Q.A. Manager 品质经理
√
Production Manager 生产经理
√
Factory Manager 工厂经理
√
E. Year of establishment/operation 建厂年限
１３年
F. Factory Size
blocks:
stories covering:
Production Area
sq. m:
G. Capability of Factory (indicate all that apply): 生产能力
Injection molded toys注塑玩具
Ｎ／Ａ
Roto-cast molded toys 搪胶玩具
Ｎ／Ａ
Blow molded toys 吹塑玩具
Ｎ／Ａ
Electrical/Battery operated toys 电动/电子玩具
Ｎ／Ａ
Stuffed/Plush toys 填充/毛绒玩具
Ｎ／Ａ
Die-cast toys 合金玩具
Ｎ／Ａ
Others (List) 其它
密胺餐具　２５０万／月

H. Major Business 关键业务
[ ] Premiums 赠品 [ √] Retail 零售
I. Does factory subcontract any work?
If yes, specify what is subcontracted.
本厂是否给其它工厂加工?若有,需尤其注明
[] Yes
[√] No

Factory Profile - Self Questionnaire工厂介绍-自我调查表
J. Number of employees in factory: 工厂人数
Workers 工人
５１９
Q.A./Q.C (exclude production QC)品质人员
３０
Engineering 工程人员
１２
Maintenance 维修人员
７
Tooling 夹具部人员
１０
Mgmt. staff 管理人员
９２
Total 总计
６７０
K. Q.A. Manager/Q.C. Manager report(s) to:
品质经理汇报给:
总经理
L. Does Q.A. Manager/Q.C. Manager have responsibilities other than quality? If yes, please specify.
品质经理除质量外是否对负责其它?若有,请指明
[] Yes
[ √ ] No
M. Major Machines and Equipment (include number of each): 关键机器和设备(包含数量)
集尘器
１３
立式沙带机
１９
打孔机
６
抛光机
３０
高周波机
１１８
油压成型机
１２０
Sewing Machines: 衣车
无
Die Cutting Press: 冲压机
无
Hair Rooting: 车发机
无
Assembly Lines: 生产线
无
Rotocast Machines: 搪胶机
无
Injection Molding: 啤塑机
无
Blow Molding: 吹气机
无
Plating: 电镀
无
Tooling Equipment 工具装备
Lathes: 车床
4
EDM: 火花机

Other 其它
Drying Ovens: 焗炉
１４
Metal Detectors (type) - include aperture size and detection capabilities: 金属探测器
无
Power Generator: 发电机
无
UV Tunnels (type): 紫外光管道
无
Additional Equipment: 其它设备
无

1.0 Facility & Maintenance设备/维修保养
Yes
No
NA
Comments
1.1 Are the factory grounds and surrounding environment within factory boundaries clean and free of undesirable contamination?
企业周围环境及地面全部保持洁净,不受污染吗?
√

1.2 Does factory have a master sanitation/maintenance program?
有没有卫生保养制度?

√

没有具体清洁方法和程序及清洁人员培训统计
No appropriate procedure on cleaning method and training record
1.3 Do records indicate cleaning/sanitation for equipment/machines/production schedule lines? Define schedule in Comments.
是否有设备/机器及生产线清洁/卫生统计?
√

1.4 Are factory's maintenance policy and procedures for major equipment adequate (i.e., generator, injection, molding machines, etc.), frequent enough and being followed? Are maintenance records of machines and equipment documented?
工厂有没有对关键设备(发电机,啤机及模具等)制订维修保养政策及程序,并保持充足及符合?
有没有机器及设备维修保养统计?
√

1.5 Does factory have a well-organized / established maintenance/engineering team to give appropriate response to machinery breakdown or emergency that affects production?
在机器故障或紧急情况以致影响生产情况下,工厂有没有合适维修及工程人员作出立即行动?
√

1.6 Are regularly scheduled pest elimination services provided by a professional service inside and outside factory, or does the factory have documented regular internal procedure? Define schedule in Comments.
(Review documentation.)
Advise name of pest service in Comments.
有没有厂内或厂外专业服务提供定时害虫控制, 或有定时内部程序文件?提供PCO服务者名称.

√

工厂没有进行定时害虫控制及无杀虫剂使用清单
No regular pest control service and do not have the list of pesticide used in the fty.
1.6.1 Does Factory have a pesticide usage log?
工厂有没有杀虫剂使用日志?

√

工厂无杀虫剂使用日志。No pesticide usage record.
已提议工厂去完成日志，在每次灭害后。Suggest fty to add record.
1.6.2 Does Factory have MSDS sheets for all pesticides and dangerous chemicals used at this facility?
全部杀虫剂及危险化学品设备,工厂是否保留MSDS证实?

√

工厂无杀虫剂及危险化学品MSDS证实。No MSDS cert available.
已要求工厂保留MSDS证实。Suggest fty to obtain a copy of MSDS cert for all chemical used in the facilities.
1.6.3 Are checks of bait stations and insect electrocuters documented?
是否有诱饵区及电子脉冲装置检验统计?

√

工厂外墙内侧未诱饵区及蒱获器
No bait station around the exterior of the facility.
1.6.4 Does Factory have a report of pest control activity including corrective action?
工厂是否有害虫活动迹象控制汇报(CAP)
√

1.7 Are roofs inaccessible to pests and free of excess debris and attractants?
厂内无显著害虫及远离死昆虫和碎片?
√

1.8 Are factory grounds (factory compound areas) paved to prevent dust?
工厂地面铺面可预防灰尘吗?

√

工厂地面（生产区域）是一般水泥地面。Production area with cement floor.
1.9 Are buildings adequate for the processes and well maintained?
建筑物有合适监控及及很好维护？
√

1.10 To have orderly storage inside the factory, are adequate (clean, well maintained) plastic storage containers available for in-process storage and finished product?
厂内有没有提供足够洁净好容器来贮存半品及成品, 且存货整齐有序?

√

很多用来贮存半品及成品存在灰尘
Heavy dust found on the semi and final product.
1.11 Are toilets provided within facility boundaries?
生产区有没有厕所?
√

1.12 Are toilets and urinals clean and functioning?
How often are toilets cleaned? Define frequency in Comments.
Sanitizing agent used for cleaning? Define in Comments.
厕所及便槽是否洁净可用? 清洁周期:____________ 消毒剂:_____________
√

工厂使用外购消毒剂清洁消毒（无固定牌号），清洁周期：天天一次。No specific brand name of sanitizer used to clean the toilet. They clean the toilet once a week.
提议清洁工人常常性巡检，保持厕所卫生。Suggest fty to clean the toilet more often and apply sanitizer.
1.13 Are there adequate hand sanitizing facilities available in/near toilets? (liquid soap, water and hand dryers or hand sanitizer)
厕所内有没有洗手设施?(洗手液/水/干手机/杀毒剂)

√

工厂使用外购滴露除菌洗手液和使用纸巾擦手，外购消毒剂清洁消毒无固定牌号）。不过，有多个水龙头损坏
Fty use “ Dettol” as hand sanitizer and use tissue paper to dry hands instead of air dryer. Several wash stations are not working
1.14 Are there maps of fire exits on each floor?
每层楼有没有安全走火通道图?
√

1.15 Are all emergency passages and exits clear?
走火通道及出口是否通畅?

√

部分车间走火通道被货物堵塞，和有走火门被关闭。Emergency passage blocked with products and the fire exit is locked.
已提议全部指定走火路径须保持通畅，和不用锁走火门。
1.16 Are fire extinguishers, sand and/or other fire protection equipment on hand properly maintained within expiration date?
灭火器、消防沙及其它灭火设施是否在使用期内合适保养及随时可取?
√

Total
44%

2.0 Control of Incoming Raw Materials
来 料 控 制
Yes
No
NA
Comments
2.1 Are raw materials kept in controlled (sealed), locked storerooms to avoid theft, loss and quality deterioration?
原材料使用是否受控, 是否锁在仓库以避免被盗、损失及变质？

√

全部来料处理依据来料控制程序，但部分原料未放置在指定区域，及没有温湿度控制。All incoming materials are controlled according to the incoming material control procedure, however not sign or poster to specify the product location area and no temp/humidity control.
2.2 Is an 18” perimeter maintained for inspection and cleaning?
储存区保持最小周长为18英寸(45cm)检验区域及清洁区

√

在原料仓摆放原料之间未有预留18英寸检验及清洁通道。Raw material are placed with less than 18” perimeter.
工厂须重摆放，以预留该通道。Explained to the fty on this requirement.
2.3 Are incoming materials clearly identified, properly packaged for storage and traceable to sources of manufacture as required?
来料有没有清楚标识、合适包装方便储存, 并依据生产需要作追踪？

√

部分材料标识未有立即更新，和外包装破损。Some incoming material label are not up to date and packaging are broken.
提议工厂立即更新标识，和采取方法，封好已破损包装，预防污染。Explain to the fty that this will cause contamination of the product.
2.4 Are toxic and potentially hazardous materials adequately and effectively contained, identified, stored and documented?
有毒及危险材料是否有效标识,储存并有文件统计?

√
无指定有毒或危险材料使用在工厂。No toxic material being used in the fty.
2.5 Are MSDS sheets maintained for toxic and potentially hazardous materials?
可提供有毒物质及潜在危险材料MSDS？

√

两种材料，密胺粉及尿素粉是制造产品关键材料，但工厂只能提供密胺粉MSDS。Two main type of raw material – melamine molding compound and urea-formaldehyde compound. The fty only able to provide MSDS for melamine compound.
已要求工厂提供相关尿素粉MSDS。Explain to the fty and suggest them to obtain the MSDS of urea compound.
2.6 Are receiving procedures and records adequate to keep track of the date of receipt, lot number and vendor?
是否有来料控制程序,并统计收据日期,批次及供给商名称方便追踪？
√

2.7 Are quality requirements and acceptance criteria clearly defined with signed samples available for reference?
用户对质量要求及接收标准是否明确, 和签办是否可供参考？
√

2.8 Is non-conforming material properly segregated from other production materials to prevent use in production?
不合格材料有没有合理地和其它生产材料隔离以避免在生产中不小心使用？

√

部分不合格原料和合格原料存放在同一区域，且没有显著标识。Non conforming and conforming material are both place in the area and no sign or poster to segregate these material.
要求工厂立即隔离不合格原料，并正确标识。
2.9 Is non-conforming material properly labeled as to the status and disposition instruction?
不合格材料是否正确标识其情况及处理方法?
(不合格品处理程序)

√

部分不合格原料未被正确标识。Non conforming material not properly labeled.
已要求工厂立即去正确标识不合格原料。
2.10 Are inspection records available and complete, which identify accepted and non-conforming materials?
可否提供完整确实定合格或不合格材料检验汇报？
√

IQC收货或退货汇报。Yes, with IQC report.
2.11 Does Factory have a list of approved raw material suppliers?
工厂有没有合格供货商名单？
√

2.12 Is there a written supplier certification procedure used for selection and approval of suppliers?
在选择及确定合格供货商时有没有用到书面供货商证书程序作依据？
√

Total
45%

3.0 Sanitation (Molding, Production, Assembly, Packout)
衛生-啤塑/生产/装配/包装
Yes
No
NA
Comments
WORKERS工人

3.1 Is liquid hand sanitizer or other hand cleaners available? Please specify in Comments. 有没有洗手液或其它?
√

外购滴露洗手液。Yes, use Dettol sanitizer.
3.1.1 Are signs posted instructing workers to use sanitizer before entering the production area?
有没有张贴标识说明工人在进入生产区域前要洗手及干手?

√

提议工厂张贴GMP指导在生产区域入口。Suggest fty to have poster on GMP instruction in the production area
3.2 Do workers wear hairnets? Are they worn properly? Please specify in Comments.
工人有没有戴工作帽,且是否佩戴正确?

√

各部门全部有部分工人没有戴帽，及佩戴不正确。No hairnet for some workers and not properly worn.
提议工厂给工人明确佩戴方法和管理人员须常常去检验和纠正不正确佩戴。Demonstrate how wear the hairnet properly and supervisor need to continuously check and remind the workers.
3.3 Are all workers free of dangling jewelry?
全部工人不准戴摇摆饰物?

√

生产车间仍有工人佩戴手链等饰物。
提议工厂加强GMP教育。Dangling jewelry found in the production area. Suggested the fty to train up workers on GMP management.
3.4 Do all workers have clean, fully protective clothes (smocks)?
全部工人是否穿着洁净且有保护作用工作服?

√

部分工人没有穿着工作服工作。Some workers without protective clothing.
提议加强GMP教育。Suggested the fty to train up workers on GMP management.
3.5 Are employee personal items such as eating utensils, cups, etc., restricted from the production areas?
生产区域不可放置有个人物品, 比如饭兜、水杯等?

√

工人饮用水杯随意摆放在工作位。Drinking cups found in the production area.
提议加强GMP教育。Suggested the fty to train up workers on GMP management.
3.6 *Are workers who are visibly sick, have open wounds or sores excluded from direct contact with raw materials or products?
对于显著生病或有伤口工人有没有被严禁直接接触原材料或产品?
√

FACILITY设备

3.7 Are door entrances, windows, vents, and fans (in all areas of factory- molding, spray painting, assembly, pack out, etc) adequately sealed or screened with fine mesh to exclude insects, birds and animals?
工厂内(啤塑/喷油/装配/包装等区域)出入口、窗户、排气扇、风扇有没有合适纱网围住或屏蔽以防害虫,鸟及动物入内?

√

全部生产部门关键出入口没有安装塑料屏蔽帘及风机，且大门是被打开。另外，货仓没有装上合适纱网。No plastic curtains at all entrance, no fine mesh for vents and fans. Door wide open at the production area.
3.8 Is rubbish stored and disposed to minimize odors and prevent the attraction of insects, birds and animals? How often is it disposed? Define Schedule in Comments.
垃圾贮存及有效清理减至最低气味并