SQP factory inspection
一、SQP Audit Evaluation Standards
Part 1- Management Support and Continuous Improvement
Assess the level of support and investment provided by the company's management in terms of resources, communication, and review systems.
Part 2- Risk Management System
The company should establish and implement a management system related to product safety, legality, and quality. (Using basic risk assessment principles)
-Legal and safety requirements require a company to be aware of current legislation, product standards, operating practices, and the latest developments in science or technology, as these may have an impact on the risks faced by products and packaging when sold in the target country.
-Risk assessment - The company should develop a management plan for products and production processes based on a systematic, comprehensive, thorough, and comprehensive risk assessment system that is implemented and maintained.
-Risk Assessment Verification - The company should entrust qualified personnel to verify the risk assessment.
Part 3- Quality Management System
The company should develop and implement an effective quality management system, covering the following contents:
-Policy statement
-Document control - properly preserve and manage all documents, records and Congee related to product safety, legality and quality management
-Records Management
-Specifications
-Responsibilities and responsible persons - Clearly define the organizational structure and assist in developing relevant documents
-Internal Market Audit
-Approval and performance supervision of procurement, suppliers, and subcontractors
-Customer property rights - should control property rights (including intellectual property) that belong to the customer
-Rectification and Prevention Measures - A procedure for recording, calling, analyzing, and correcting the occurrence of product nonconformities or violations of standards, specifications, and procedures
-A system for querying and tracing product information and batches, including raw materials, components, and packaging materials at all stages of the production process (from receiving materials to shipping)
-Plan and system for effective product withdrawal and recall procedures for accidents, product withdrawals, and recalls
-Business Continuity Strategy - Develop effective continuity strategies and procedures to ensure that business and operations are not disrupted in the event of major events/crises
-Customer centric
-Complaint handling
Part 4- Site and Equipment Management
It is necessary to properly maintain and manage the production site and facilities to prevent or minimize pollution and ensure the production of safe and legal finished products. The scope of management includes:
-Production site and surrounding areas
-Factory layout, production, drilling process, and isolation
-Employee facilities - for example, the design and operation of the facilities must fully reduce all risks of product contamination
-Cleaning and Hygiene Operations
-Waste and Waste Disposal - Collection, Handling, and Disposal of Waste Materials
-Prevention and control of pests and diseases - Maximizing control and reduction of pest pollution
Part 5- Product Control
Enterprises should demonstrate effective control over their products to ensure their safety, legality, and quality. The control content includes:
-Reference samples (pre production and during production) - Develop and implement procedures for selecting, handling, storing, approving, and using reference samples
-Chemical Control - The identification, supervision, and recording of the chemical composition of products and chemicals used in the production or processing of products should be carried out in accordance with the regulations of the selling/producing country
-Product packaging materials
-Unqualified materials should be thoroughly identified, labeled, counted, investigated, and recorded for substandard materials, components, and products? Special treatment should be formulated;}‘ Implementation of requirements and specifications for handling special materials
-Product transportation, storage, and distribution
-Inventory management and product delivery - Develop and implement strict procedures, and only when all established procedures are met can finished products be shipped
Part 6- Product Side Trial and Product Efficacy Scale
-Product testing: Enterprises should develop and implement appropriate, complete, and validated testing plans to ensure the production of safe and legal products that meet relevant quality standards
-Product Declaration - Enterprises should verify the claimed product information and, if necessary, monitor the product's compliance with this declaration
Part 7- Process Control
Enterprises should demonstrate effective control over all operations to ensure product safety, legality, and quality - while ensuring that the processes and equipment used can stably produce safe, legal, and quality products that meet expectations. The control content should include:
Ordinary groceries
-Operational Control - Ensure that the processes and equipment used can stably produce safe, legal, and quality products that meet expectations
-Control of input components and raw materials
-Inspection of production and final products to ensure safe, legal, and high-quality delivery of products
-Foreign object search and control
-The calibration and control of measurement and monitoring equipment (delivery, quality, and legality of cold supervised products) should comply with recognized national or international standards and be calibrated according to these standards
-Equipment and tool maintenance
-Finished product packaging and control
clothing
-Sample preparation, style, and labeling
-Pre production work
-Control of input components and raw materials
-Spreading, cutting, and bundling
-Weaving
-Embroidery/Patching
-Printing and dyeing
-Hot melt edge formation
-Sewing
-Combining
-Washing
-Repair and needle corner finishing
-Attachment
-Trimming and ironing
-Final inspection - ensuring the delivery of products that are safe, legal, and of satisfactory quality
-Metal inspection and control
-Finished product packaging
-Final review
-Calibration and control of measurement and monitoring equipment (aimed at monitoring product safety, quality, and legality) - should comply with recognized national or international standards and be calibrated according to these standards
Toys
-Pre production work
-Control of input components and raw materials
-Forming (injection molding, blow molding, clamp molding, ROTO molding, die-casting parts, vacuum template weighing)
-Punching of fiberboard/rigid plastic/PVC board or sheet products, etc
-Forming and stamping
-Decoration (spray painting, coating, TemPo, hand drawn, printing)
-Ultrasonic welding
-Bonding
-Assembly (manual/automatic)
-Cutting
-Sewing/Fur Root
-Attachment (such as eyes, nose, buttons, clips, or other metal buttons)
-Fill
-Metal inspection and control
-Finished product packaging
-Final review
-Calibration and control of measurement and monitoring equipment (aimed at monitoring product safety, quality, and legality) - should comply with recognized national or international standards and be calibrated according to these standards
Part 8- Personnel Training and Qualifications
Enterprises should ensure that operators who may affect product safety, legality, and quality have received professional training, have relevant experience and/or qualifications, and are capable of engaging in corresponding work.
二、SQP file list
1. Organizational Chart
2. Responsibility or Responsibility Description
3. Quality system procedures (including quality policies, objectives, quality management system manuals and procedures, and other processes)
4. Management review records
5. Internal audit documents (audit plans, reports, etc.)
6. Supplier supervision documents (supplier approval procedures/standards, approved supplier list, supplier evaluation records, continuous performance monitoring, etc.)
7. Document supervision procedures and records (including record keeping)
8. Product specifications/requirements
9. Explanation of inspection requirements, acceptable standards, inspection and test reports (including stage, process, and final inspection of IQC)
10. Job Requirements Description/Process Technical Standards for Each Production Process
11. Production schedule/records
12. Definition and Reporting Procedure of 'Accidents'
13. Product Recall Procedure
14. Customer Complaint Record
15. Rectification Action Report (regarding accidents, internal audits, complaints, etc.)
16. Test reports in the traceability system
17. Equipment maintenance documents (plans, procedures, records, etc.)
18. Supervision and calibration of testing equipment (plans, procedures, records, etc.)
19. Cleaning schedule and procedures
20. List of approved chemicals, accompanied by corresponding brands/manufacturers
21. Hazardous substance control documents (list of trained control personnel, contact information of external hazardous substance control agencies, hazardous substance control inspection records, bait feeding records, etc.)
22. Record/Plan of 'Risk Assessment' for the entire production process
23. Risk assessment records for the final product
24. Product testing steps/procedures
25. Laboratory test reports (including lead and heavy metals in coatings, coated and non coated components, hardware, labels, final products, etc.)
26. Inclusion monitoring records (such as metal detection records, daily sensitive material inspection records of metal detectors, etc.)
27. Needle breakage processing program (if applicable)
28. Pre production meeting minutes
29. Program Control Plan
30. Training (Procedures, Training Needs, and Records)
三、SQP factory inspection
SQP factory inspection is a supplier evaluation project developed by ITS, which mainly involves the requirements of quality management system, risk management, and product safety management.
The final results of the SQP audit are divided into four levels, namely: 85 points and above; 71-84 points; 51-70 points; 50 points or less
四、SQP factory inspection result level
SQP is a qualified supplier evaluation plan developed by ITS that has a score of 85 or above and can obtain a certificate with a validity period of one year. Currently, DG has requirements for this.
The audit is divided into 8 parts, including management commitment and continuous improvement, risk assessment, quality management system, on-site and facility management, product control, product testing, process control, and employee training, all of which meet the requirements of ISO9001.
Risk control is a requirement in QS9000, utilizing basic tools such as FMEA and RPN.
SQP factory inspection rating
Green (85-100 points): Most requirements meet
High performance
meet expectations
facility demonstrates readiness to assume responsibilities for managing and monitoring compliance activities
Yellow (71-84 points): For moderate risk issues that meet the requirements, a Corrective Action Plan (CAP) must be submitted within 15 days and filled out in English, and a follow-up review must be conducted 180 days later.
Further lmprovement Needed.
Moderate concern in facility’s readiness to assume responsibilities fo managing and monitoring compliance activities
Orange (51-70 points): Low standard, usually followed up for review after 90 days
Low Performance
Significant Action Required
Singnificant concern in facility’s readiness to assume responsibilities fo managing and monitoring compliance activities
Red (0-50 points): very low standard
VERY LOW PERFORMANCE
Urgent Action Required
Severe concern in facility’s readiness to assume responsibilities fo managing and monitoring compliance activities
五、SQP factory inspection workflow
Factory inspection workflow diagram |
Preparation of work and materials before factory inspection | Provide basic information of the factory | Basic overview of the factory |
Business license of the factory |
Tax registration records of the factory |
Certificate of Import and Export Rights of the Factory |
The production process flowchart of the factory |
Factory floor plan |
List of Machinery and Equipment in the Factory |
The personnel organization chart of the factory |
Detailed Organizational Chart of QC/QA in the Factory |
Determine factory inspection matters | Date of factory inspection |
Location of factory inspection |
Contact person for factory inspection |
Factory inspection schedule, etc |
Execution of factory inspection process | Opening a First Meeting | Convene relevant personnel to explain the requirements of this factory inspection | Order of factory inspection |
Departments and personnel responsible for factory inspection cooperation |
Precautions during factory inspection, etc |
Access to information | Management Department | Original copy of business license |
Original certificate of import and export rights |
Original certificate of national tax and local tax |
Original ISO certificate |
Employee Social Security Certificate |
Certificate of Minimum Wage Guarantee Provided by the Local Government |
Employee Labor Contract |
Employee's attendance card for the past three months |
Employee's salary list for the past three months |
Environmental report/test report from recent factory inspections by the environmental protection department |
Training plan/training materials/training records/training assessments, etc |
Documents for the management of fire prevention and control measures |
Documents and records for sewage pollution and other treatment |
other regions |
quality | Quality manual/department procedures/workflow and work instructions/forms |
All quality inspection standards/work instructions for IQC, IPQC, FQC, and QA |
Quality Standard Change Order (QCN) |
All quality inspection records of IQC, IPQC, FQC, and QA |
Record of non-conforming product handling report or quality abnormality handling form |
Record of quality improvement and preventive measures report |
Customer Complaint Handling Report |
Quality Weekly and Monthly Statistical Analysis Report |
other regions |
production department | Production plan scheduling (weekly and monthly scheduling) |
Production Work Order (or Production Work Order) |
Material Return and Refueling Order |
Production scheduling station diagram |
Production progress follow-up form |
LABEL paper that is unqualified, qualified, waiting for inspection, waiting for repair, waiting for rework, etc |
Daily and monthly production reports |
Daily repair report |
other regions |
Technology Department | working instruction |
Product design drawings |
Engineering Change Notice (ECN) |
Product Material Usage List (BOM) |
Records of machine and equipment usage instructions, maintenance, etc |
Calibration certificates, records, etc. of instruments and equipment |
other regions |
Purchasing Department | procurement contract |
Supplier Evaluation |
Raw Material Certificate/Raw Material Acknowledgment/Test Report |
Procurement Delivery Schedule |
other regions |
business department | Customer Order (P.O) |
Contract Review |
Customer Complaint Handling Report |
other regions |
AUDIT on-site | Incoming inspection area | Raw material inspection standards or work instructions/material recognition certificates and samples/testing instruments, equipment, fixtures calibration and maintenance, etc./incoming material inspection reports/handling reports of non-conforming incoming materials/statistical analysis reports of supplier incoming materials/supplier performance evaluation/raw material certification or testing reports, etc/ |
Raw material storage area | What is the storage environment/classification/labeling for stacking and placement/fire prevention, waterproof, moisture-proof, and moldy proof/separation between qualified and unqualified, waiting for inspection and waiting for return/ |
Semi finished and finished product processing area/inspection area/semi finished and finished product stacking area | How to place and label materials, whether they are qualified or unqualified, whether they are to be inspected or repaired, whether they are to be returned or replaced, whether they are to be replaced, whether they are to be returned or replaced, whether they are to be returned or replaced, whether they are to be replaced or not, whether they are to be returned or replaced, whether they are to be returned or replaced External box marking information/IPQC inspection guide book or standard/packaging method/kanban management/visual management/5S implementation status/storage environment/classification/stacking and placement labeling/fire prevention, waterproof, moisture-proof, and mold proof, etc/ |
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Finished product sampling inspection area | Finished product inspection standards or work instructions/calibration and maintenance of testing instruments, equipment, fixtures, etc./finished product inspection reports/analysis reports on handling non-conforming products/functional performance test reports or third-party test reports/product life tests/product safety inspections/production work orders/PO materials, etc |
Finished product functional performance testing area | Calibration and maintenance of testing instruments, equipment, fixtures, etc./Analysis report on non-conforming product handling/Functional performance test report or third-party test report/Product life test/Product safety inspection/DROP test, etc/ |
Finished product stacking area | What are the storage conditions/classification/stacking height and labeling/fire prevention, waterproof, moisture-proof, and mold proof measures/safety measures |
sample room | Product quality/5S situation/ |
office building | 5S situation |
Living Area | 5S situation/safety |
Canteen area | 5S situation/hygiene situation/hygiene permit |
Factory environment | 5S situation |
Surrounding environment of the factory | 5S situation |
other regions |
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Taking photos and sampling | In different regions | Capture corresponding scenes |
After inspection, no meetings held | Convene relevant personnel to explain the general situation of this factory inspection | Briefly summarize the situation of this factory inspection |
Propose areas for special improvement and improvement |
REMARK：All sites need to AUDIT their 5S implementation status, air quality, fire equipment, fire exits, emergency measures, such as emergency lights; How about the light, the level of noise, the temperature, etc. |
Work after factory inspection | Edit factory inspection report |
Provide terms for improvement and follow-up. |