Interstoff Apparels Ltd. DC-1219872-Costco RE-FE Report

Soft-lines/Textile Factory Capability Audit
Report No.: 1219872 Date of Report: 29-11-2012 Page 1 of 23
Supplier Certification Program

Initial Certification
Costco Supplier Certification
 100% - 85% no critical Audit Valid for facility for 1 year from the date of audit – No further
action required.
 99% - 85% with critical Audit Valid for facility for 1 year from the date of audit. Corrective
Action Plan (CAP) is required to be provided with 14 days of audit. No Re-Audit
necessary.
 Less than 85% - 70% Audit Valid for 6 months from date of audit. Corrective Action Plan
(CAP) is required to be provided within 14 days of audit. CAP must be completed
prior to re audit within 6 months and will be verified at next audit.
 Less than 70% - 60% Audit Valid for 3 months from date of audit. Corrective Action Plan
(CAP) is required to be provided within 14 days of audit. CAP must be completed
prior to the re audit within 3 months.
 Less than 60% No Certification, Corrective Action Plan (CAP) is required to be provided
within 14 days of audit. Re Audit must take place within 60 days.
Questions marked CRITICAL (with**) denote Costco’s most essential areas of concern
regarding Quality and Safety. On FAILED audits (total score less than 85%), a re-audit is
required within a certain period for, at minimum, the critical failures OR prior to any new
production of Costco goods.
Re-Audits will not be scheduled unless a CAP has been submitted to Costco and approved for
all noted violations OR your company has communicated with Costco the reasons for non-
compliance and that reasoning was deemed acceptable by Costco.
Question Rating Guideline:
All questions answered as N/A must be supported by an explanation in the remarks section
Score 3 points for each asterisk (**) marked yes and 1 point each for all others marked yes
Subtract the N/A points from the “Maximum possible points available” to get the “Adjustable
Maximum points” under each section if any question marked N/A, and update the “Summary of
The Points That The factory Achieved” table accordingly
Rev: June 27, 2012

Factory Information
Factory Name: Interstoff Apparels Ltd.

Address: Chandora, Kaliakoir, Gazipur, Bangladesh
Telephone: (+ 880 06822) 521 19
Fax: (+ 880 06822) 51958
E-Mail: rafiq@icl.bdrmg.com
Agent/Vendor: KHQ Investment
Factory producing Kirkland Signature
YES NO
items
Type of Audit: Initial Audit If Re-Audit: Original Audit Date: NOVEMBER 23, 2011
Re-Audit Report #: DC1114154
Other (please specify): Original Score: 94.08%
Audit Result
Audit Valid for facility for 1 year from the date

of audit. No further action required
Score: 100%-85% with no critical
Audit Valid for facility for 1 year from the date
of audit. Corrective Action Plan required. No Score: 99%-85% with critical
Re-audit necessary.
Audit Valid for facility 6 months from the date
of audit. Corrective Action Plan required. CAP
must be completed prior to re-audit within 6
Score: Less than 85% - 70%
months and will be verified at next audit.
Audit Valid for 3 months from date of audit.
Corrective Action Plan required. CAP must be Score: Less than 70% - 60%
completed prior to the re-audit within 3 months
No Certification
Re-audit within 60 days. Shipment may be held
depending on audit results regardless if Critical
Score: Less than 60%
defect is present or not
Total Score 88.39 %
Date of Audit: November 28, 2012 Auditor: Md. Abdullah Al Mamun Talukder
Rev: June 27, 2012

Company Organization Met during Audit? (name of the person)

Managing Director No Md. Shahinur Rahman
Marketing Manager No S. M. Shafiqur Rahman
Plant Manager No Mr. Amzad Hossain
QC/ QA Supervisor / Manager Yes Mr. Anwar Hossain
Factory Manager Yes Mr. Amzad Hossain
Factory has been in operation since 2002
Staff Information
# of Manufacturing Personnel: 3000
# of Quality Controllers: 387
# of Engineers: 15
Production Information
Types of Product Produced: Knit Garments Costco Dept. No (2 digits) 31
Monthly Production Capacity: 150,000 pieces
Required Lead Time: (time between placing 90 days
an order to starting production)
On average how many units of each type of item can be produced daily?
Items Daily Production Quantity
Kids 33000 pieces
Mans 20000 pieces
Ladies 12000 pieces
Manufacture
Major Machinery: Quantity: Remarks:
Date:
Dyeing machine Not provided 09
Stenter macnine Not provided 02
Dryer Not provided 02
Compactor Not provided 02
Sue ding machine Not provided 02
Fabric inspection Not provided 03
Plain machine Not provided 517
Over lock machine Not provided 416
Flat lock machine Not provided 201
Button stitch machine Not provided 28
Hole stitch machine Not provided 28
Bar tack machine Not provided 02
PMD Not provided 10
Snap button machine Not provided 08
Belco attach machine Not provided 02
Back Tape Machine Not provided 19
Fusing machine Not provided 02
Cutting machine Not provided 14
Spreading machine Not provided 2
Band knife machine Not provided 02
Rev: June 27, 2012

Metal detector machine Not provided 03 Conveyor belt type

Steam iron Not provided 73
Heat transfer machine Not provided 14
A. METAL DETECTION PROCEDURES (All Critical Questions)

Please note: Costco requires some form of metal detection for all garments produced.
1.) Are metal detectors used? ** Yes No N/A

Type of metal detector: Conveyer belt type
Quantity available for use: 01
Frequency of calibration: 6 times per day
Who is responsible for calibration: Mr. Aminur Rahman (Quality officer)
2.) Are needle guards used? ** Yes No N/A
3.) If needle guards are used, are they used consistently on Yes No N/A
all machines? **
4.) Is there a needle replacement policy in effect? ** Yes No N/A

If so, explain this policy below in remarks:
NOTE: All factories producing wearing apparel are required to have an operable metal detector along with an
efficient policy/procedure in place for metal detection. Costco may approve the factory in-lieu of metal
detectors. Example:
a.) Use of needle guards
b.) Needle replacement policy or
c.) Other means of ensuring no metal is inadvertently left in garments.
Rating: Metal Detection (3) out of 4 Critical items rated as "YES" = ( 09 ) Points
Total Score for Section A: ( 09 ) /12
*N/A answers will not be factored into the Maximum Points Available
Item #: Remarks:
It was noted that approximately 90% of the needle guard of the sewing machines are not in
A-3
appropriate height.
Factory has a broken needle policy which covered needle replacement procedure. According to
the policy needle must be replaced on a one for one basis. New needle is issued only when all
A-4 the parts of the broken needle found and registered, if not then the garments of that particular
(Remarks) machine passed through metal detector to find out the broken parts of the needle as well as the
area of that machine took under special consideration to find out all the broken parts by using
magnet. If all needle fragments cannot be found the garment (s) must be destroyed.
Rev: June 27, 2012

B. FACILITIES
1. Does the plant layout appear acceptable for the type of Yes No N/A
Product being manufactured? **
2. There is no evidence of damage due to flooding or inadequate drainage? Yes No N/A
3. Does overall maintenance of the premises appear acceptable? Yes No N/A

working toilets
hand washing stations
first aid kits / stations
fire extinguishers
floor free from debris
4. Does the general housekeeping appear tidy and is it Yes No N/A
overseen by appointed management?
5. Are housekeeping schedules established and maintained? Yes No N/A
6. Did you see a complete company quality manual? Yes No N/A
7. Did you see documentation that all production machines are on a Yes No N/A
maintenance schedule and a maintenance team was in place?
8. Were all machines and equipment calibrated and checked to run Yes No N/A
efficiently and are maintenance records readily available? **
9. Did you see that all machines/equipment/fixtures Yes No N/A

were suitable to produce the intended product?
10. Did you see evidence that the factory has a well Yes No N/A
organized maintenance team that could immediately
respond to a machinery breakdown or emergency?
11. Did you confirm that telephones were available Yes No N/A
for employees in case of emergency?
12. Did you confirm electronic communication systems were in place? Yes No N/A
(PC’s with word processing, spreadsheet and e-mail capabilities).
13. Are isles kept clean and free of debris? Yes No N/A
14. Does factory provide a separate area for workers Yes No N/A
break time and eating, away from the production area?
15. There is no evidence of smoking, eating or drinking in the Yes No N/A

production area?
16. Are the lighting and ventilation conditions adequate? Yes No N/A
Rev: June 27, 2012

Rating: Facilities -
(2) out of 2 Critical items rated as "YES" = (6) Points
(14) out of 14 Non-critical items rated as "YES" = ( 14 )Points
Total Score for Section B: (20) / 20
Item #: Remarks:
Factory has updated calibration certificates for the measuring devices e.g,
B-8
measuring tapes, Pull test machine, weighing balance Light boxes, physical
(remarks)
testing equipments (crocking meter, washing machine).
C. QUALITY CONTROL SYSTEM
1. Is factory operating a formal & written internal quality Yes No N/A

control procedure? **
2. Are there adequate internal training programs provided Yes No N/A

for all quality control personnel involved?
3. Are there adequate traceable training records for factory Yes No N/A
personnel?
4. Are the factory’s Q.C. personnel certified or assessed Yes No N/A

before they perform their job as outlined in the Q.C. procedures?
5. Has management defined its quality control objectives? Yes No N/A

If so, are those objectives clearly understood
by personnel?
6. Does the factory use international, national, client’s, Yes No N/A

or its own approved standards to perform in-house
quality control? Explain in remarks.
7. Does the factory have a detailed written plan Yes No N/A

demonstrating how safety requirements on products are
checked in-house?
8. Do detailed Factory Records reflect that products are properly Yes No N/A
checked in accordance with customer requirements &
specifications prior to proceeding to the next production process?
9. Is there Q.C. supervision on all shifts? Yes No N/A
10. Does quality controller fully understand factory’s Yes No N/A

quality policy, quality consciousness and the
importance of the quality assurance concept?
Rev: June 27, 2012

11. Does Q.C. personnel have knowledge and expertise on Yes No N/A
products to be made?
12. Are all QA staff a separate team and different personnel from Yes No N/A
the trimming and inspection teams?
13. Is there an adequate number of QA staff to deal with the quality Yes No N/A
and quantity of spot-checking?
Rating: Quality Control Systems –
(1) out of 1 Critical items rated as "YES" = (3) Points

(9) out of 12 Non-critical items rated as "YES" = (9 ) Points
Total Score for Section C: ( 12 ) / 15
Item #: Remarks:
C-3 Factory does not have any traceable training records for factory personnel.
C-4 QC personals are not certified before they perform their job as outlined in the QC procedures.
It was noted that factory checking some safety requirement on products like pull test and snap
C-7
button test without any detailed written plan.
Factory use international standard like 4 point system for fabric inspection, roll to roll shade
C-6 check, AQL- 0.65 for accessories inspection, traffic light system followed in sewing inline and
(remarks) 100% end line visual inspection for sewing confirmation, AQL- 1.5 for pre final and AQL-2.5 for
final inspection or according to their buyer standard.
D. INCOMING INSPECTIONS
1. Does the factory verify that raw materials meet required Yes No N/A
specifications before use? **
2. Are raw materials properly labeled, stored and traceable? Yes No N/A
3. Are raw materials kept in controlled storerooms/areas to Yes No N/A

avoid theft, loss and any deterioration of quality?
4. If raw materials need inspection before use in production, Yes No N/A

are they properly inspected and are records maintained
and traceable?
5. Is the inspection sampling schedule adequate and can the Yes No N/A
quality of the product be guaranteed with confidence?
6. Are inspection records maintained to prove products Yes No N/A

meet all requirements?
Rev: June 27, 2012

7. Are there written inspection instructions available Yes No N/A

rd
as guidelines to 3 party inspectors?
8. If testing equipment is needed during inspection, is there a Yes No N/A

sufficient quantity of equipment in order to do so in timely
manner?
9. Does the factory have a system for lot control of Yes No N/A
raw materials that requires oldest date to be pulled first for
use, “First in/ First out”?
10. Does the factory have a policy and procedure for inspecting Yes No N/A
incoming fabric?
11. Are incoming and outgoing raw materials registered to prevent Yes No N/A
intermingling?
12. Are raw materials kept in controlled storerooms to avoid theft, Yes No N/A
loss and deterioration of quality?
13. Does the factory possess a fabric inspection machine? If so, Yes No N/A
is there a policy/procedure for it’s usage on all material?
14. Does the factory have its own light box? Yes No N/A
15. Are faulty fabrics / raw materials well separated in order to avoid Yes No N/A
mixing?
16. Are different shade lots of fabric well separated in order to avoid Yes No N/A
mixing?
Rating: Incoming Inspections –

( 1) out of 1 Critical items rated as "YES" = ( 3 ) Points
(15 ) out of 15 Non-critical items rated as "YES" = (15) Points
Total Score for Section D: ( 18 ) / 18
Item #: Remarks:
D-1 Factory use international standard like 4 point system for fabric inspection, roll
(remarks) to roll shade check, AQL- 0.65 for accessories inspection
Rev: June 27, 2012

D-7 Factory preserves approved samples, Pre Production meeting minutes, Fabric
(Remarks) construction details, Measurements as a reference for the auditors.
E. IN PROCESS QUALITY CONTROL

1. Are all toolings fully tested and evaluated with all Yes No N/A
measurements and safety issues?
2. Are samples of pilot run, or approved client samples Yes No N/A

carefully reviewed by engineers and/or quality staff to see that
all safety aspects are being met?
3. Is the factory able to perform pre-development testing? Yes No N/A
4. Is there an In Process QC system to prepare for mass Yes No N/A

production? **
5. Is there any documentation from either engineering, Yes No N/A

Q.C. department or top management to authorize
mass production?
6. Are there line patrols by quality controllers or other Yes No N/A

means to monitor the compliance of the product to
meet safety requirements? **
7. Does factory use international or other approved Yes No N/A

standards to carry out in-process inspection? Are
there records?
8. Do records reflect the action taken on the rejected Yes No N/A

lots?
9. Do records show rejected lots are well identified and Yes No N/A
segregated from accepted lots?
10. Is there a system or policy in place for permanently removing Yes No N/A
non-conforming manufactured items?
11. Are there clearly written criteria/instructions Yes No N/A

available for employees to follow?
12. Are there approved samples attached to all areas Yes No N/A
to give inspectors or workers a guideline?
13. Is the inspection and test equipment reliable to Yes No N/A

verify the conformance of the semi-finished final product?
Rev: June 27, 2012

14. Are the inspection defects charted, analyzed, and Yes No N/A
monitored to improve the problems encountered?
15. Are QC supervisors and management easily identifiable? Yes No N/A

(e. g. QC supervisors and management wear certain colored vest/shirt
uniforms, other than badges)
16. Are rejected lots well-identified and segregated from accepted? Yes No N/A
17. Are shade batches separated in a lay while cutting? Yes No N/A
18. Are cutting panels checked before they are put into the sewing floor? Yes No N/A
19. Is there a tearing test for fused parts? Yes No N/A
20. Are cutting panels properly placed into containers / boxes? Yes No N/A
21. Are workers wearing protective gloves while operating cutting machines? Yes No N/A
Rating: In-Process Quality Control -

(2) out of 2 Critical items rated as "YES" = ( 6) Points
(13 ) out of 19 Non-critical items rated as "YES" = ( 13) Points
Total Score for Section E: ( 19 ) / 25
Item #: Remarks:
Factory does not preserve any defect rework reports. However, factory preserves inspection
E-8, E-9
reports along with defect quantities.
E-11 Working instructions are not given in pressing area.
E-12 No reference sample found at ironing area.
QC supervisors or personnel were not provided with identification uniform to be worn for easy
E-15
identification.
Factory has no physical segregation between accepted cut panels and rejected cut panels.
E-16 Factory provided a reject box, but workers are observed to keep damage cut panel bundles in
same table where cut panel inspection take place.
F. FINAL INSPECTION
1. Do factory’s quality controllers perform any internal Yes No N/A
final inspection on merchandise? **
2. Are international, client’s or other approved standards Yes No N/A
Rev: June 27, 2012

used? For example: USA federal and state regulations.
3. Are there written internal inspection reports/logs and are Yes No N/A
they properly filed and traceable to review quality of products?
4. Are customer drawings/specifications readily available Yes No N/A

from quality control or posted on each line? **
5. Does factory perform internal mechanical tests on finished Yes No N/A

goods to safeguard the product’s quality? If so, note below
how often.
6. Are there records to show factory has regularly performed Yes No N/A
such mechanical safety tests?
7. Are inspection and testing records maintained and readily available? Yes No N/A
8. Does the factory have a process for quantity of sample size Yes No N/A
pulled for internal review and inspection?
9. Are there normal procedures that require acceptable Yes No N/A

inspection reports in order to authorize and shipment of products?
10. Does factory perform check on functionality of final production? Yes No N/A
11. Does the factory have a process by which to review and Yes No N/A
compare finished product at different stages of production run
for customers order? – beginning, middle or at the end of
production run?
12. Are measurement audit conducted during final inspection? Yes No N/A
13. Are dummies (fit models) used to check the fit and hang aspects Yes No N/A
of the finished garments?
14. If some operations are sub-contracted out, will the factory send its Yes No N/A
QC to the sub-contractor’s site for monitoring the quality and are
the out-inspection records readily available?
Rating: Final Inspection -

(2) out of 2 Critical items rated as "YES" = ( 6 ) Points
(11) out of 11 Non-critical items rated as "YES" = ( 11 ) Points
Total Score for Section F: ( 17 ) / 17
Rev: June 27, 2012

Factory performs internal mechanical tests on finished goods. Besides this, factory has an
F-5 (Note)
internal lab where factory is doing physical and chemical tests.
F-14 Factory has no operations which are subcontracted out, however they do embroidery which is
(Remarks) outsourced from their sister concern named Southeast textile limited and Anam clothing limited.
G. FINISHING AND PACKAGING

1. Is the packaging area clean and free of contaminants? Yes No N/A
2. Are there any safeguards to prevent another company’s Yes No N/A

products from being packaged into master cartons for another order?
3. Is there any control to prevent any defective or rejected Yes No N/A

products from being packed into master cartons? **
4. Are semi-finished products well segregated from final Yes No N/A

finished products in the packing area?
5. Are finished approved products packed promptly for best Yes No N/A
manufacturing process in order to avoid dust and dirt?
If not, are they properly stored and protected until packing?
6. Do workers wear gloves, hats/caps, shoe covers when Yes No N/A

necessary?
7. Is there an established and posted packing procedure for product Yes No N/A
according to the customers specific requirements?
8. Is the weight of packed master cartons randomly checked to Yes No N/A

avoid product shortages? If not, is there a procedure to avoid
the possibility of shortages?
9. Are packed master cartons well stored in a covered area or a Yes No N/A
good shelter to keep from exposure to climate conditions which
could compromise final appearance or structural integrity?
10. Is there equipment to use for stamping the date code, lot code, Yes No N/A
and case number?
11. Does the facility have a working barcode scanner to verify Yes No N/A
that the barcode on packaging is correct?
12. Does the facility have a policy for storing and stacking Yes No N/A
finished cartons prior to shipment? **
13. Is a filter connected to the water pipe used for steam boiler in pressing? Yes No N/A
Rev: June 27, 2012

14. Have the steam boilers been examined periodically by outside Yes No N/A
Certified engineers and are those maintenance records readily
available?
15. Are cleaning liquids and agents properly stored to avoid catching fire Yes No N/A
or being inhaled by workers?
16. Are scales used to accurately obtain the carton weight? If so, how Yes No N/A
often are those scales calibrated? Answer in remarks below.
17. If laundry or washing machines are used, are there any written Yes No N/A
procedures for wastage water treatment?
Rating: Finishing and Packaging -

(2) out of 2 Critical items rated as "YES" = (6 ) Points
( 13 ) out of 15 Non-critical items rated as "YES" = ( 13 ) Points
Total Score for Section G: ( 19 ) / 21
Item #: Remarks:
Factory has randomly checked weight of packed master cartons to avoid
G-8 product shortages but no records maintained to track or cross check product
shortage.
There is no equipment to use for stamping the date code, lot code, and case
G-10
number.
G-16 (Note) Calibrated weight measuring scales used for obtaining carton weight.
Factory does not have any washing plant. But factory have an effluent
G-17 (Note)
treatment plant for treatment of the waste water of dyeing and printing section.
H. NON-CONFORMING MATERIALS
1. Is there a documented procedure for non-confirming materials? Yes No N/A
If so, are those procedures clearly understood and implemented
by factory personnel and are records readily available?? **
2. Are non-conforming materials properly segregated at all stages? Yes No N/A
3. Are non-conforming materials easily identifiable? Yes No N/A
4. Is scrap or non-conforming material easily distinguished from Yes No N/A

good product?
5. Is there a corrective action procedure for non-conforming Yes No N/A

materials? **
Rev: June 27, 2012

6. Can the factory demonstrate how they handle non-conforming Yes No N/A
materials such as product that fails the mechanical tests? If so,
does this demonstration coincide with its written procedure?
7. Can the factory supply solid proof to guarantee non-conforming Yes No N/A
materials/products are unquestionably segregated from conformed
production and will not intermingle?
8. Does the factory have a process for notification to client when Yes No N/A
non-compliant product is identified as being introduced into the
production run?
9. Is it found that there are no workers wearing garments identical to Yes No N/A
garments being produced?
Rating: Non-Conforming Materials -

(1) out of 2 Critical items rated as "YES" = ( 3 ) points
(3) out of 7 Non-critical items rated as "YES" = (3) points
Total Score for Section H: (6) / 13
Item #: Remarks:
Alter/reject/ Ok garments are not segregated at all the production process. Factory has
H-2 provided alter/reject box in sewing, finishing section but it is not functional. Worker are not
aware about alter/reject box.
Non conforming materials are segregated at all stage but no proper marking system found to
H-3, H-4 identify the non-conforming product. In sewing section factory has provided separate
alter/reject box but no identification found at those box.
Factory does not track the re-work activity and non conformance products to ensure re work
H-5
quality.
Factory does not have a process for notification to client when non-compliant product is
H-7
identified as being introduced into the production run.
I. COMMUNICATION, DOCUMENTATION CONTROL AND WORK MOVEMENT
1. Does factory management and key staff understand English Yes No N/A
sufficiently to ensure communication with vendor/US Rep/Retailer?
2. Is there an adequate and formal system for receiving and Yes No N/A
applying line drawing, procedures, design change?
3. Are approved line drawings and specifications used properly, Yes No N/A
filed in chronological sequence and traceable?
4. Are line drawings, records and specifications that reflect an Yes No N/A
Rev: June 27, 2012

adequate history of changes readily available?
5. In the case of authorized subcontracting, does factory Yes No N/A

provide adequate supervision and specifications to ensure
compliance to the requirements of client’s standards? **
6. Does the factory conduct a 100% inspection on all subcontracted Yes No N/A
work? **
7. Does factory have clear written instructions to its departments, Yes No N/A
delegating authority to stop production if the products do not
meet the safety requirements of client’s standards?
8. Is technical information clearly identified to QA personnel with Yes No N/A

adequate controls to insure process is replicated throughout
the production run?
9. Does factory have a policy for keeping all client’s technical Yes No N/A
project information confidential?
10. Does the factory have an efficient policy to notify the client and Yes No N/A
advise/discuss any failure on processing problems?
11. Does the factory retain copies of internal test reports? Yes No N/A
If yes, note type of test reports in remarks section.
12. Does the factory retain copies of external test reports? If yes, Yes No N/A
note type of test reports in remarks section.
13. Do records show the daily production output of each section? Yes No N/A
14. Are pre-production samples or pilot lots evaluated in writing with Yes No N/A
comments attached?
15. Do records show that regular pre-production meetings are held Yes No N/A
before a new style is put into production?
Rating: Communication, Documentation Control and Work Movement

(0 ) out of 0 Critical items rated as "YES" = ( 0 ) Points
(13) out of 13 Non-critical items rated as "YES" = (13 ) points
Total Score for Section I: (13 ) / 13
Item #: Remarks:
Factory has no operations which are subcontracted out, however they do embroidery from their
I-5, I-6 (Note)
sister concern Southeast textile ltd and Anam clothing limited.
Rev: June 27, 2012

rd
Factory perform external test through 3 party testing company (Bureau Veritas / SGS etc) for
I-12(remarks) color fastness to wash, color fastness to light, color fastness to crocking ,Dimensional stability
,tensile strength, pilling resistance and others garments test as per their buyer requirement.
J. HANDLING OF COMPLAINTS
1. Is there a procedure for the handling, investigating and Yes No N/A
resolving customer/product complaints? **
2. Are customer complaint handled by factory management? Yes No N/A
3. Are the complaints analyzed and root causes investigate? Yes No N/A
4. Are corrective and preventive actions taken to eliminate the Yes No N/A
non-conformity?
5. Is the corrective and preventive plan communicated with the Yes No N/A
customer?
6. Are there traceable records for the handling of complaints? Yes No N/A
7. Do records show that the corrective and preventive actions Yes No N/A
are properly conducted and monitored to client satisfaction?
Rating: Handling of Complaints:

(1) out of 1 Critical items rated as "YES" = (3 ) points
Total Score for Section J: (3) / 3
Item #: Remarks:
J-1
It was noted that, factory does not face any complain from their client yet.
(Remarks)
K. TRANS-SHIPMENT INFORMATION – (All Critical Points) **
1. Is the factory free from any evidence of trans-shipping? ** Yes No N/A
Rev: June 27, 2012

2. Does all WIP (Work in Progress) present at the time of audit Yes No N/A
have appropriate paperwork? **
3. Is the correct Country of Origin on all paperwork? ** Yes No N/A
4. Is the factory free from any evidence of diverted shipments from Yes No N/A
Other countries? **
5. There is no evidence of contraband production. ** Yes No N/A
6. There is no evidence of fraudulent labels. ** Yes No N/A
7. Can WIP (Work in Progress) be completed within this factory? ** Yes No N/A
8. There is no evidence that the factory is subcontracting our garment Yes No N/A
Production. **
Rating: Trans-shipment Information

( 8 ) out of 8 Critical items rated as "YES" = ( 24 ) points
Total Score for Section K: (24 ) / 24
Item #: Remarks:
Its confirmed by last shipment documents Verification of Costco Canada, PO

#45009992,Style No# Harg 1003/1004/1005/1007,Total cartons : 2000 ; that
K-1
the factory free form trans-shipping. Factory direct shipped from Chittagong
port (Port of loading) to buyer destination Canada. (Port of Discharge).
Additional Questions - Information Only (No Points Achievable)
1. Is the facility monitored by security cameras, gated or guards? Yes No N/A
2. Does the factory have an in-house testing facility? Yes No N/A
3. List any Factory Accreditations. Yes No N/A
4. Does the factory possess any other accreditations? Yes No N/A
Remarks:
1. Factory has installed CCTV to monitor the key entrance and exits and security
Rev: June 27, 2012

guards are posted to ensure security of the premises.

Factory has in house testing facility to conduct test for product’s safety and
2.
quality assurance.
3. Factory has ISO 9001:2008 and WRAP certification.
Factory Name: Interstoff Apparels Ltd

Address: Chandora, Kaliakoir, Gazipur, Bangladesh
Initial Audit Re Audit
Rev: June 27, 2012

SUMMARY OF THE POINTS THAT THE FACTORY ACHIEVED

Maximum Points Total Points
SECTIONS
Available Achieved
A. Metal Detection – Critical Points 12 09
B. Facilities 20 20
C. Quality Control System 15 12
D. Incoming Inspections 18 18
E. In-Process Quality Control 25 19
F. Final Inspection 17 17
G. Finishing and Packaging 21 19
H. Non-Conforming Materials 13 06
I. Communication, Document
13 13
Control, Work Movement
J. Handling of Complaints 03 03
K. Trans-Shipment Information - 24
24
Critical Points
Total Points Available 181 (B)
Total Points Achieved 160 (A)
Audit Result: Total Score in %=88.39

(A/B X100%)
28 Critical questions (with **) worth 3 points each (84 possible points). Total Score less than 85%
constitutes an automatic failed audit and re-auditing is required within 60 days for, at minimum, the
critical failures OR prior to any new production of Costco goods.
Rev: June 27, 2012

Digital Photo Records
Factory Outlook Factory Name Dyeing section
Dyeing finishing Chain mail gloves used in Cutting Sewing section

section
Ironing section Packing and folding section Fabric store
Rev: June 27, 2012

Accessories store Finished carton store Sample section
Pattern making section with CAD Fabric relaxation area Cut panel numbering
facility
Rev: June 27, 2012

Cut panel stored in separate boxes Printing section. Fusing section

color wise.
Cutting section Snap button attachment section Calibrated pull test machine
Reference sample in sewing line End line inspection Final inspection
Metal detector Reject box for metal contaminated Test card for calibration Metal
garments detector
Rev: June 27, 2012

Weighing balance for Cartons Bar code scanner Broken needle register
Button pull test machine Dummy used for fitting Light box
confirmation
Traffic light introduced in the sewing

section.
Fabric inspection machine Shade band Band knife cutting machine
Separate
Rev: boxes
June 27, 2012found for alter / reject Workers are keeping damage cut Needle guard are not in appropriate
/ okay in sewing section. panel bundles in same table where cut height.
panel inspection taking place.

Interstoff Apparels Ltd. DC-1219872-Costco RE-FE Report

Загружено:

Сведения о документе

Исходное описание:

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Interstoff Apparels Ltd. DC-1219872-Costco RE-FE Report

Загружено:

Авторское право:

Доступные форматы

Soft-lines/Textile Factory Capability Audit

Report No.: 1219872 Date of Report: 29-11-2012 Page 1 of 23

Supplier Certification Program

Costco Supplier Certification

Rev: June 27, 2012

Factory Name: Interstoff Apparels Ltd.

Audit Valid for facility for 1 year from the date

Total Score 88.39 %

Rev: June 27, 2012

Company Organization Met during Audit? (name of the person)

Factory has been in operation since 2002

Rev: June 27, 2012

Metal detector machine Not provided 03 Conveyor belt type

A. METAL DETECTION PROCEDURES (All Critical Questions)

1.) Are metal detectors used? ** Yes No N/A

2.) Are needle guards used? ** Yes No N/A

4.) Is there a needle replacement policy in effect? ** Yes No N/A

Total Score for Section A: ( 09 ) /12

Rev: June 27, 2012

2. There is no evidence of damage due to flooding or inadequate drainage? Yes No N/A

3. Does overall maintenance of the premises appear acceptable? Yes No N/A

5. Are housekeeping schedules established and maintained? Yes No N/A

6. Did you see a complete company quality manual? Yes No N/A

9. Did you see that all machines/equipment/fixtures Yes No N/A

15. There is no evidence of smoking, eating or drinking in the Yes No N/A

Rev: June 27, 2012

Total Score for Section B: (20) / 20

C. QUALITY CONTROL SYSTEM

1. Is factory operating a formal & written internal quality Yes No N/A

2. Are there adequate internal training programs provided Yes No N/A

4. Are the factory’s Q.C. personnel certified or assessed Yes No N/A

5. Has management defined its quality control objectives? Yes No N/A

6. Does the factory use international, national, client’s, Yes No N/A

7. Does the factory have a detailed written plan Yes No N/A

9. Is there Q.C. supervision on all shifts? Yes No N/A

10. Does quality controller fully understand factory’s Yes No N/A

Rev: June 27, 2012

Rating: Quality Control Systems –

(1) out of 1 Critical items rated as "YES" = (3) Points

Total Score for Section C: ( 12 ) / 15

3. Are raw materials kept in controlled storerooms/areas to Yes No N/A

4. If raw materials need inspection before use in production, Yes No N/A

6. Are inspection records maintained to prove products Yes No N/A

Rev: June 27, 2012

7. Are there written inspection instructions available Yes No N/A

8. If testing equipment is needed during inspection, is there a Yes No N/A

Rating: Incoming Inspections –

Total Score for Section D: ( 18 ) / 18

Rev: June 27, 2012

E. IN PROCESS QUALITY CONTROL

2. Are samples of pilot run, or approved client samples Yes No N/A

3. Is the factory able to perform pre-development testing? Yes No N/A

4. Is there an In Process QC system to prepare for mass Yes No N/A

5. Is there any documentation from either engineering, Yes No N/A

6. Are there line patrols by quality controllers or other Yes No N/A

7. Does factory use international or other approved Yes No N/A

8. Do records reflect the action taken on the rejected Yes No N/A

11. Are there clearly written criteria/instructions Yes No N/A

13. Is the inspection and test equipment reliable to Yes No N/A

Rev: June 27, 2012

15. Are QC supervisors and management easily identifiable? Yes No N/A

19. Is there a tearing test for fused parts? Yes No N/A