Wal-mart(沃尔玛)验厂
  • 发布时间:2016/11/23 18:24:36 被阅览数:次 【字号:
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 Wal-mart(沃尔玛)验厂



FCCA新标准:关键区域照明亮度要求



   FCCA验厂全称为:Factory Capability & Capacity Assessment,即工厂产量及能力评估,沃尔玛(Wal-mart)新推行的工厂审核项目,其目的是审核工厂的产量及生成能力是否符合沃尔玛的产能和质量要求。

2013年,WM-FCCA最新标准对关键区域照明亮度要求如下:

1、检测区域 750-1000 lux或更高

2、生产区域 500-750 lux或更高

3、包装区域 300-500 lux或更高

4、仓库/存储/装卸区域 200-300 lux或更高

备注:至少要选择三个不同点进行亮度测量,取最小值。如果照明亮度明显高于范围最大值,工厂在进行评估时,可能得到更高的分数。由此可见,提高关键区域的亮度,有利于提高WM-FCCA验厂评估得分。

沃尔玛要求其所有供应商都要通过 FCCA 的验厂审核,沃尔玛FCCA验厂以打分的形式进行,60 分以上为合格,WM-FCCA 即为沃尔玛对工厂的质量体系要求,FCCA 厂标准如下:



Factory Quality System 工厂的质量体系



1.0 Factory Facilities and Environment 工厂设施和环境

1.0.1 There is sufficient lighting on: Production, revising, finishing, inspection, packing and loading areas? 足够的照明上:生产,返工,加工,检验,包装 及装载的区域?

1.0.2 The facility maintains clean and organized production, finishing and packing areas. 工厂保持清洁和有组织的生产,加工和包装领域。

1.0.3 Facility has separate inspection area with inspection table and proper ventilation. 工厂有单独的检验区与检验台并且适当的通风设备。

1.0.4 Facility has documented pests/mildew and moisture control program, which includes frequent inspections. In-house or 3rd party 工厂已记录害虫/霉菌和湿 度的控制程序,其中包括经常巡查。(在公司内部或第三方)

1.0.5 No broken windows or leaking roofs that may result to product contamination was observed during audit. 没有打破窗户或屋顶漏水,可能导致产品污染的观察审核期间。

1.0.6 Factory has metal detecting unit. Scoring will not apply N/A if factory does not need this machine. 工厂有金属检测单位。

1.0.7 Critical Factory implements strict sharp tools control procedure to prevent scissors, knives, blades, broken glasses and needles to be mixed with product.(重要)工厂实行严格的尖锐工具控制程序,以防止剪刀、刀、刀片、碎玻璃和针头,以混 合的产品。

1.0.8 Factory has back-up power supply available. “Generator” 工厂有后备电 力供应。发电机

1.1 Machine Calibration and Maintenance 机器校准和维护

1.1.1 Factory machines and equipments are appropriate to produce Wal-Mart products. 工厂的机器和设备是适合的生产沃尔玛的产品。

1.1.2  Factory has documented system and procedure for scheduled equipment cleaning and repairs. 工厂有文件体系和程序,预定设备清洗和维修。

1.1.3  Factory machines and equipments appear to be clean and in good running condition.工厂的机器和设备显示是清洁和良好的运行状态。

1.1.4 Machines, equipments and tools are properly labeled with date of last maintenance/calibration and schedule. 机器、设备和工具有适当的标识最后维修/校准日 期及进度表。

1.1.5 Machines, equipments and tools that needs to be repaired are properly labeled to avoid accidental use. 机器、设备和工具需要维修时有标识以避免意外使用。

1.1.6 Factory has proper, clean and organized storage area of critical toolingi.e. injection moulds with labeled shelves. 工厂有适当的,清洁的和有组织的存 储区域的关键模具(即注射模)与标识的货架上。

1.1.7 Factory has proper documentation and updated inventory of machines, tools, spare parts and equipments. 工厂有适当的文件和更新库存机器、工具、零部件和设备。

1.1.8 Factory has maintenance team with suitable skill level and equipments to perform necessary repair and calibration on machines. 工厂维修团队与合适的技术水 平和设备,以履行必要的维修和校准的机器上。

2.0 Quality Management System 质量管理体系

2.0.1 Factory has established Quality Management System that is appropriate to their products and procedures. 工厂建立适合产品和程序质量管理体系。

2.0.2 Workers & Supervisors are familiar to these quality policies and objectives. 工人与主管所熟悉的这些质量的政策和目标。

2.0.3 Factory has documented customer complaint system and documented recall program. 工厂已记录了顾客投诉体系,并记录召回计划。

2.0.4 Critical Factory QC team is independent from Production pision. (重 要)工厂 QC 团队是独立于生产部门。

2.0.5 Production management and QC team discuss and work together in solving Quality issues/ concerns. Documented 生产管理和 QC 团队讨论和共同努力在解决质 量问题/关注的问题。(记录)

2.0.6 Factory has systems and procedures in place to control the risk of physical, chemical and biological contamination that may damage the product and personnel as well. 工厂有制度和程序能控制物理、化学和生物污染风险,可能会损害产品和人员。

2.0.7 Factory conducts risk assessments to identify hazards from chemicals, raw materials, process equipments and tools. 工厂进行风险评估,以识别危险化学品、原材 料、工艺设备和工具。

3.0 Incoming Materials Control 进料控制

3.0.1 Proper first in-first out FIFO system on materials are practiced. 料实施先进先出(FIFO)体系。

3.0.2 Factory has procedures for quality inspection on incoming raw materials, accessories and components. 工厂有对进仓原物料、配件和部件质量检验的程序。

3.0.3 Incoming and outgoing material quantities are monitored and documented. 进料和出货的物料的数量进行监测和记录。

3.2.4 Factory has specifications for purchased materials. 工厂有采购物料规范。

3.2.5 Factory has documented process and reference samples that ensure incoming raw materials conform to specifications. 工厂有文件程序和参考样品以确保进仓原料符 合规格。

3.2.6 Critical Factory has proper system on material segregation to avoid accidental contamination from rejected items. (重要)工厂已适当的对物料隔离体系, 不合格的项目隔离以避免意外污染。

3.2.7 Factory properly separate good quality items from rejects and identifies non-conforming rejects materials for replacement. 工厂适当隔离良品(不良品), 并确定不良品(拒绝)更换。

3.2.8 Facility's storage areas have sufficient lighting, well ventilated and clean surrounding. 厂房的存储区域周围有足够的照明、通风和清洁。

3.0.9 Materials, components and accessories are properly stacked and identified with tags / labels and off the floor. 材料、部件和配件的妥善堆放并有标记/标签并与 地板隔离。

3.0.10 Critical Chemicals and maintenance substances are properly marked and stored to prevent risk of contamination. (重要)化学品和维修的物质妥善标识和储存, 以防止污染的风险。

3.0.11 Color relevant materials such as fabrics, genuine leather and synthetic PU/ PVC, trims and accessories are sorted by lot numbers. 颜色有关的材料如布料、 真皮及合成聚氨酯/聚氯乙烯、装饰及配件按批号储存。

4.0 Process and Production Control 过程和生产控制

4.0.1 Does factory have work area only for Product Development? 工厂是否有产 品开发工作区?

4.0.2 Does factory PD study and apply product safety features, evaluates patterns, moulds and samples during product design and development? 在产品设计和开发工厂产 品开发的研究与应用是否有产品安全功能、评估模式、模具和样品?

4.0.3 Does Product development includes packaging design and tests that conforms to industry standard ISTA 产品开发包括包装设计和测试以确保符合行业标准(ISTA.

4.0.4 Does factory PD perform assembly time-study on product and develop easy ways to use for consumer benefit? 工厂产品开发在产品执行组装时间研究,产品开发和 简便的方法使用的消费者受益呢?

4.0.5 Factory has documented Production procedures at each stage of operation. 工厂有每一个阶段的运作生产程序文件。

4.0.6 Factory has documented Quality procedures at each stage of operation. 厂有每一个阶段的运作质量程序文件。

4.0.7 Does factory conduct Pre-production meeting prior to start of production? 工厂是否实施进行生产前的预产会议?

4.0.8 Are production and quality supervisors present during Pre-production meeting? 目前在预产会议有生产和质量主管?

4.0.9 Critical Are critical quality and safety checks reviewed, identified, and actions for improvement documented during Pre-production meeting? (重要)是 至关重要的质量和安全检查、审查,确定,并采取行动加以改进记录在预产会议?

4.0.10 Does factory conduct “ pilot-run ” , review product quality against specification sheet and document results with corrective actions prior to production? 工厂是否进行试运行”,检讨对产品质量的规格表和文件在纠正行动之前生产?

4.0.11 Is quality of item acceptable on current production? Check 3 or 4 completed products from production floor. 质量是可以接受的项目就目前的生产呢?

(从生产区检查 3 4 个成品).

4.0.12 Was in house lab-testing performed on current production? Request for test copies)内部实验室测试是否实施当前生产测试?(要求测试的副本)

4.0.13 Does factory QC compare first piece samples with approval sample and specification sheet? 工厂 QC 是否比较首件样品抽样检验和批准的规格表?

4.0.14 Are there adequate approved samples, first piece samples, reference samples and work instructions to provide workers with proper guidelines? 是否有足 够的核准样品、首件样品、参考样品和为工人提供适当的作业指导书?

4.0.15 Does factory use defective/ reject samples to demonstrate examples of common defects? 工厂使用有缺陷的/不合格样品是否普遍例子?

4.0.16 Critical Does Quality Control have authority to stop production if quality of products did not meet specification? (重要)如果产品质量不符合规格质 量控制是否有权停止生产?

4.0.17 In-line inspections IPQCare performed by QC at every operation process. 在巡检(IPQC)所执行品管在每一个操作过程。

4.0.18 Does factory use statistical process control SPC for quality?工厂 使用统计过程控制?(质量统计分析)

4.0.19 Factory QC inspects per standard AQL or as per industry standards.工厂 品管检验按照标准 AQL 或按照工业标准。

4.0.20 Factory performs 100% functionality check on final products?工厂最终产 品实施 100%功能性确认?

4.0.21 Does factory use corrective actions and root cause analysis methods?Please provide examples)工厂是否使用的纠正措施和根本原因分析方法呢?(请提供例 子)

4.0.22 Does factory have guidelines in place to ensure packaging is correct for product? 工厂是否有指南以适当确保包装是正确的产品?

4.0.23 Does packing area have enough space to perform packing functions properly? Is it clean and organized? 包装区是否有足够的空间用来履行包装职能?它是清洁和有组 织的?

4.0.24 Packed cartons are stored in enclosed area not exposed to sunshine and wet weather. 包装纸箱都储存在封闭区域内没有暴露于阳光和潮湿天气。

4.0.25 Does factory track and document on-time ship performance?工厂是否有跟 踪和文件准时出货职能?

4.1 Suppliers and Sub-contractors 供应商和分包商

4.1.1 Does factory have a documented supplier selection and approval process? 工厂是否有供应商选择和批准过程文件?

4.1.2 Does factory track, evaluate and document material's supplier reliabilityperformance?工厂是否跟踪、评价和文件物料供应商的可靠性(效能) ?

4.1.3 Does factory have an established, documented quality procedure and does factory evaluate, monitor sub-contractor quality performance and reliability? 厂是否有建立质量记录的程序和工厂评估、监测分包商的质量性能和可靠性呢?



以下是FCCA质量管理体系审核所需文件/证件清单,供参考:

1、工厂简介 Brief introduction of factory

2、营业执照 Business license

3、公司组织架构图 Organization chart

4(公司)厂区/厂房平面图 Factory’s plane figure-factory floor plans

5、生产工序流程图 Production process chart

6ISO9000证书及最近一次外审报告ISO 9000 certificate and the last external audit reports

7、质量手册 Quality manual

8、程序文件 Procedure

9、质量计划 Quality program

10、文件更改收发记录 Documents control records

11、员工培训计划 Worker training plan

12、员工质量培训记录 Worker quality training records

13、内部审核计划、记录 Internal audit plan and records

14、订单评审和客户关注程序及记录 Order review and customer focus procedure and records

15、客户投诉处理记录 Complaint handling procedure and records

16、纠正与预防措施记录 Records of corrective actions and preventative actions

17、仪器设备清单、内外校记录报告Testing/measuring equipments calibration records

18、设备维护计划和记录 Equipment maintainence plan and records

19CE/EMC/相关的产品测试化验报告CE/ EMC/ Relevant product lab test reports

20、其它相应有效的安全证书Other corresponding valid safety certificate

21、开发设计控制程序Design control procedure

22、设计计划或任务书及审核记录 Design planning and input review record

23、验证和确认记录 verification and validation records

24、设计产品检测报告 design testing and record

25、设计输出(技术文件,物料单, 包装、使用说明)Design output (technical file, BOM, Packing and using description)

26、设计变更记录 ECN



WM-ES验厂审核,有关消防安全的结果,有以下三种消防橙色结果:

•Orange Fire Safety 橙色消防安全

•Orange Fire Safety–CAP 橙色消防安全整改计划

•Orange Fire Safety–2 橙色消防安全-2

取得以上三种消防安全审核结果的工厂:

––可以接订单,但处于预审阶段的工厂除外

––可以出货

––供应商与其下属工厂应密切合作共同整改任何关于消防安全的违规。

如果工厂未能对消防问题进行任何整改或整改不完善可能会导致:

•Red–Unauthorized Fire Safety 红色消防安全不通过

红色-消防安全不通过的工厂:

––订单/出货可能取消

––工厂再进行一次完整范围WM-ES验厂审核并取得可接受结果(黄灯或绿灯)之前不能接新的订单。

 



沃尔玛人权验厂对工时的要求及违规情况



沃尔玛人权验厂对工时的要求:

-工厂应具备完善的工时系统,准确记录所有员工的工作时间。

-每周总工作时数不得超过72小时(6/7)

-24小时总工作时数不得超过14小时。

-不接受综合计时但接受一个工资支付周期以内的调休

-工厂应遵守营业地的地方标准,采用合理的工作时数。

-工厂应该朝每一工作周60小时的目标努力(至少每七天有一天休假日)



沃尔玛人权验厂常见的高风险工时违规情况:

A、不完整/不一致的考勤系统

-计件,计时或, 月薪或临时工人等工人无工时记录

-手工考勤无明确的上下班时间及员工每日签核

-不完整的工时记录

-不一致的工时记录

B、严重超时加班

-单日工作时间超过14小时

-每周工作时间超出72小时

-倒班工作的工人24小时内累计工作时间超过14小时



沃尔玛人权验厂影响消防橙灯问题点



以下一些问题会导致沃尔玛人权验厂结果为消防橙灯,供参考:

1、三合一厂房;

2、工厂及宿舍没有安装烟感器;

3、没有(不是)安装带电的安全出口、应急灯和逃生指引等消防设施;

4、生产厂房没有消防部门出具的备案记录;

5、工厂没有提供厂房建筑工程竣工验收报告;

6、工厂储存危险化学品车间及库房没有设置相应的安全设施,如防渗漏的二次容器;

7、工厂没有在化学品仓库外安装洗眼台;

8、工厂没有培训合格的急救员;

9、工厂在生产过程中产生的废弃物,没有给有相关的资格的处理单位处理;

10、生产及生活污水染物的排放,没有经过当地的环境保护部门批准;

11、工厂没有建立ODS(臭氧层破坏物质)清单;

12、工厂没有建立温室气体排放(直接和间接)盘存清单;

14、工厂没有制订应急程序,处理环境事故,应急程序应包括(紧急反应计划)经过培训的紧急团队和定期演练。

工厂需要严格按照沃尔玛人权验厂新标准好验厂准备,确保顺利通过沃尔玛人权验厂。



WM-ES验厂之火灾预防消防安全问题

工厂应该严格执行消防安全要求,确保工厂有足够的消防设施,并得到正确的维护,处于正常工作状态,以确保员工的安全得到保障。

以下是WM-ES验厂有关火灾预防的消防安全问题,供参考:

未安装烟感器

烟感器安装数量不够

危险化学品或易燃化学品存储不当

在建筑物内吸烟

配电箱处于危险状态或维护不当(配电盒的盒盖维护不当,如无合格的内盖)



沃尔玛人权验厂对食堂和宿舍的要求

沃尔玛人权验厂,对食堂和宿舍的要求可参考:

食堂:

卫生许可相关证件,从业人员健康证证明以及卫生培训记录;

有足够的通风;

地板不能打滑;

配备有盖的垃圾桶;

生食与熟食分开储存;

如需储存易腐食物,需配备冷冻柜;

饭菜是否留样;

食堂的每个楼层都应该有医药箱;

餐厅都要有:逃生平面图;

有消防应急疏散图,各种疏散标志应急灯等齐全,备有消防警铃,灭火器,消防栓等消防设备。



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