FACTORY CAPABILITY ASSESSMENT v.
0006
Report No.
Report Date Supplier Initial Assessment
0
SUPPLIER/FACTORY DETAILS
Factory Name 0
Address of Assessed Factory (District-City-
0
Province-Country)
Assessment Date
Product Range
FINAL SUMMARY
Detail : Factory strengths / weaknesses; Recommendations for improvement / development
Monthly Capacity:
Core Capabilities:
CONCLUSIONS AND RECOMMENDATIONS
Major non-compliance identified - improvements required prior to
FAIL orders being placed or further orders committed to. A reassessment is
required.
CORRECTIVE Issues identified which require corrective action. Improvements to be
ACTIONS actioned within 3 months and a follow-up reassessment required.
No evidence of major non-compliance or serious corrective actions
MEETS
required. Factory appears to maintain good controls over production
STANDARDS
and quality systems.
Factory Assessed By Factory Assessment Auditor / Report Authorized By
Manager
Name : Name : Name :
Title : Title : Title :
Date : Email : Email :
Date : Date :
PBA-FM-034 v 1.0
Factory Capability Assessement (FCA)
For factory new to PB, this form should be returned to PBA Quality Team
Supplier Name:
PB Division(s) Supplying to:
Compliance Person Name: Phone: Email:
Factory Name:
Factory Address:
Number of Employee: Main Products:
Factory(not Supplier)Main
Customers(list 3)
Name and Title of the Person
Filling this Form:
1. Raw Material inspection /Auditing Requirements Factory Self Assessment PBA Rating Comments / Evidence
(Rating: 1,2or NA)
1.1 Lightbox is used for color and fabric inspection 0/1/2/NA 0/1/2/NA
1.2 Fabric inspection machine with proper back-lighting 0/1/2/NA 0/1/2/NA
1.3 Dedicated fabric color specialist 0/1/2/NA 0/1/2/NA
1.4 List your top 3 fabric suppliers [Name/location-province/location-country] Fabric Supplier 1
Fabric Supplier 2
Fabric Supplier 3
1.5 In house testing lab 0/1/2/NA 0/1/2/NA
Please specify which tests are performed
1.6 Color continuity records maintained 0/1/2/NA 0/1/2/NA
1.7 Fabric quality inspection performed and documented 0/1/2/NA 0/1/2/NA
1.8 Trims quality inspection performed and documented 0/1/2/NA 0/1/2/NA
1.9 Trim cards approved by responsible person and distributed to all quality auditing areas 0/1/2/NA 0/1/2/NA
1.10 Passed/rejected materials are clearly identified and segregated 0/1/2/NA 0/1/2/NA
1.11 Stock control records complete and up-to-date 0/1/2 0/1/2
1.12 Fabric/trims test reports complete and up-to-date 0/1/2 0/1/2
Total 0
twos 0
ones 0
zeros 0
TOTAL POSSIBLE 0
Total Score - Raw Material Inspection (%) #DIV/0! #DIV/0!
2. Production Requirements
2.1 Factory laid out in logical manner 0/1/2/NA 0/1/2/NA
2.2 Production lines laid out in an efficient manner 0/1/2/NA 0/1/2/NA
2.3 Proper lighting in cutting, sewing and packing areas 0/1/2/NA 0/1/2/NA
2.4 Dedicated sample making facilities 0/1/2/NA 0/1/2/NA
2.5 Packing area is of adequate size and well organized 0/1/2/NA 0/1/2/NA
2.6 In-house computer grading and marker making capabilities 0/1/2/NA 0/1/2/NA
2.7 WIP/bundling tracking system in place 0/1/2/NA 0/1/2/NA
2.8 Equipment is well maintained 0/1/2/NA 0/1/2/NA
2.9 Are folders and guides used to assist fabric and garment alignment 0/1/2/NA 0/1/2/NA
2.10 Factory workshop makes their own tools (eg, folders) 0/1/2/NA 0/1/2/NA
2.11 Reasonable standard of housekeeping is maintained 0/1/2/NA 0/1/2/NA
2.12 Supervisor-to-operator ratio 0/1/2/NA 0/1/2/NA
2.13 QC-to-operator ratio 0/1/2/NA 0/1/2/NA
2.14 PBA approved mannequins are used to fit product prior to approval of bulk production 0/1/2/NA 0/1/2/NA
2.15 Equipment calibration records complete and up-to-date 0/1/2 0/1/2
2.16 Equipment maintenance records complete and up-to-date 0/1/2 0/1/2
2.17 Equipment/machinery list complete and up-to-date 0/1/2 0/1/2
2.18 Production work instructions complete and up-to-date 0/1/2 0/1/2
2.19 Are all operations done in-house? 1/2 1/2
2.20 If no, what are they?
2.21 Sub-contractor factory assessment reports complete and up-to-date 0/1/2 0/1/2
2.22 Do they have sufficient capacity and right machinery to handle our volume? -- 0/1/2
Total 0
twos 0
ones 0
zeros 0
TOTAL POSSIBLE 0
Total Score - Production (%) #DIV/0! #DIV/0!
Page 2 of 10 PBA-FM-034 v 1.0
Factory Capability Assessement (FCA)
3. Quality Requirements
3.1 Storerooms / warehouses well organised and goods clearly labelled 0/1/2/NA 0/1/2/NA
3.2 Approval samples visible to all work stations 0/1/2/NA 0/1/2/NA
3.3 QC supervision in each production area (eg. cutting, sewing, packing) 0/1/2/NA 0/1/2/NA
3.4 In-line quality and measurement audits performed and documented 0/1/2/NA 0/1/2/NA
3.5 End line quality and measurement audits performed and documented 0/1/2/NA 0/1/2/NA
3.6 Final inspections include quality audits of labels and packaging 0/1/2/NA 0/1/2/NA
3.7 Packing method and carton quality/weight audited and documented 0/1/2/NA 0/1/2/NA
3.8 Each customer's products are clearly segregated & marked once packing is complete 0/1/2/NA 0/1/2/NA
3.9 Accurate records maintained for samples 0/1/2/NA 0/1/2/NA
3.10 Preproduction meetings held for all new styles 0/1/2/NA 0/1/2/NA
3.11 Cutting room quality audits performed and documented 0/1/2/NA 0/1/2/NA
3.12 Detailed product specs established for all product being manufactured 0/1/2/NA 0/1/2/NA
3.13 Product specs easily accessible to all work stations 0/1/2/NA 0/1/2/NA
3.14 PBA Quality Manuals available and up-to-date 0/1/2 0/1/2
3.15 Sample checking records complete and up-to-date 0/1/2 0/1/2
3.16 In-line and end line quality audits complete and up-to-date 0/1/2 0/1/2
3.17 Do their quality match with the quality requirement of the product that we plan to put in the factory? --
0/2
Total 0
twos 0
ones 0
zeros 0
TOTAL POSSIBLE 0
Total Score - Quality System (%) #DIV/0! #DIV/0!
4. Safety Requirements
4.1 Studs safety controls and documentation 0/1/2/NA 0/1/2/NA
4.2 Metal tool safety controls and documentation 0/1/2/NA 0/1/2/NA
4.3 Broken Needle safety controls and documentation 0/1/2/NA 0/1/2/NA
4.4 Metal/needle detection equipment and documentation 0/1/2/NA 0/1/2/NA
Total 0
twos 0
ones 0
zeros 0
TOTAL POSSIBLE 0
Total Score - PBA Product Safety Requirements (%) #DIV/0! FAIL
FCA RATING #DIV/0! #DIV/0!
Comply with PBA product safety? #DIV/0! Final rating changes to FAIL
What certificates have they obtained? (e.g. Disney, WRAP, etc.)
When was the last time the factory has undergone our Social Compliance audit?
PBA QC Comments Product categories being produced by the factory
Product complexity level acheved by the factory
Workmanship quality observed in random inspection
Other comments
Page 3 of 10 PBA-FM-034 v 1.0
FACTORY CAPABILITY ASSESSMENT PBA-FM-034 v 1.0
Category Results - No. of questions scored
Total Score Total Score (%)
2 points 1 point 0 point
1 Raw Material Requirements 0 0 0 0/0 #DIV/0!
2 Production Requirements 0 0 0 0/0 #DIV/0!
3 Quality System Requirements 0 0 0 0/0 #DIV/0!
4 Safety Requirements 0 0 0 0/0 #DIV/0!
TOTAL 0 0 0 0/0 #DIV/0!
FCA RATING #DIV/0! #DIV/0!
Final rating changes to
FINAL RATING Comply with PBA product safety requirements? #DIV/0! FAIL
PBA-FM-034 v 1.0
Digital Images
1. Description of photos 2. Description of photos 3. Description of photo
4. Description of photos 5. Description of photos 6. Description of photo
7. Description of photos 8. Description of photos 9. Description of photo
PBA-FM-034 v 1.0
0-Do not have or in poor conditon
1-Available, in accepable condition
2-Available, in excellent condition
N/A
Factory laid out in logical manner
Production lines laid out in an efficient manner
Proper lighting in cutting, sewing and packing areas
Dedicated sample making facilities
Packing area is of adequate size and well organized
In-house computer grading and marker making capabilities
WIP/bundling tracking system in place
PBA approved mannequins are used to fit product prior to approval of
bulk production
Equipment is well maintained
Are folders and guides used to assist fabric and garment alignment
Factory workshop makes their own tools (eg, folders)
Reasonable standard of housekeeping is maintained
Supervisor-to-operator ratio
QC-to-operator ratio
Equipment calibration records complete and up-to-date
Equipment maintenance records complete and up-to-date
Equipment/machinery list complete and up-to-date
Production work instructions complete and up-to-date
Sub-contractor factory assessment reports complete and up-to-date
PBA Quality Manuals available and up-to-date
Sample checking records complete and up-to-date
In-line and end line quality audits complete and up-to-date
Are all operations done in-house?
Do they have sufficient capacity and right machinery to handle our
volume?
Do their quality match with the quality requirement of the product that
we plan to put in the factory?
0-Not available or in poor conditon
1-Available, in accepable condition
2-Available, in excellent condition
Not Applicable
0-None
1-Part of the facotry
2-The entire factory
NA
0-less than 50% of production lines
1-50%-79% of production lines
1-more than 80% of production lines
NA
0-Not available or in poor conditon
1-Available, in accepable condition
2-Available, in excellent condition
NA
0: less than 50% of equipment is well maintained
1: 50%-79% of equipment is well maintained
2: >80% of equipment is well maintained
NA
0-Not available
1-Occasionally use when needed
2-Always use when needed
NA
0-The factory does not make their own tools
1-The factory makes some of their own tools
2-The factory makes all of their own tools
NA
0-Poor housekeeping condition
1-Acceptable housekeeping condition
2-Good housekeeping condition
NA
0- Larger than 1:30
1- Between 1:20 and 1:30
2- 1:20 or below
NA
0-Not available or in poor conditon
1-Available, in accepable condition
2-Available, in excellent condition
1-Some operations are out-sourced
2-All operations are done in-house
0-No sufficient capacity nor right machinery
1-Not readily available but can be arranged in a reasonable timeframe
2-Readily available
0-Their quality is way below/above our requirement
2-Match
