factory audit overview - renaissance...

Soft-lines/Textile Factory Capability Audit

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

Rev: June 27, 2012

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: [email protected]

Agent/Vendor: KHQ Investment

Factory producing Kirkland Signature items

YES NO

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 Re-audit necessary.

Score: 99%-85% with critical

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 months and will be verified at next audit.

Score: Less than 85% - 70%

Audit Valid for 3 months from date of audit. Corrective Action Plan required. CAP must be completed prior to the re-audit within 3 months

Score: Less than 70% - 60%

No Certification Re-audit within 60 days. Shipment may be held depending on audit results regardless if Critical defect is present or not

Score: Less than 60%

Total Score 88.39 %

Date of Audit: November 28, 2012 Auditor: Md. Abdullah Al Mamun Talukder

mailto:[email protected]



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

an order to starting production) 90 days

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

Major Machinery: Manufacture Date:

Quantity: Remarks:

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? **

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)

Yes No N/A

2.) Are needle guards used? ** Yes No N/A 3.) If needle guards are used, are they used consistently on

all machines? ** Yes No N/A

4.) Is there a needle replacement policy in effect? ** If so, explain this policy below in remarks:

Yes No N/A

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:

A-3 It was noted that approximately 90% of the needle guard of the sewing machines are not in appropriate height.

A-4 (Remarks)

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 the parts of the broken needle found and registered, if not then the garments of that particular 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

Product being manufactured? **

Yes No N/A

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?

working toilets

hand washing stations

first aid kits / stations

fire extinguishers

floor free from debris

Yes No N/A

4. Does the general housekeeping appear tidy and is it

overseen by appointed management?

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

7. Did you see documentation that all production machines are on a

maintenance schedule and a maintenance team was in place?

Yes No N/A

8. Were all machines and equipment calibrated and checked to run

efficiently and are maintenance records readily available? **

Yes No N/A

9. Did you see that all machines/equipment/fixtures

were suitable to produce the intended product?

Yes No N/A

10. Did you see evidence that the factory has a well

organized maintenance team that could immediately

respond to a machinery breakdown or emergency?

Yes No N/A

11. Did you confirm that telephones were available

for employees in case of emergency?

Yes No N/A

12. Did you confirm electronic communication systems were in place?

(PC’s with word processing, spreadsheet and e-mail capabilities).

Yes No N/A

13. Are isles kept clean and free of debris?

Yes No N/A

14. Does factory provide a separate area for workers

break time and eating, away from the production area?

Yes No N/A

15. There is no evidence of smoking, eating or drinking in the

production area?

Yes No N/A

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


B-8 (remarks)

Factory has updated calibration certificates for the measuring devices e.g, measuring tapes, Pull test machine, weighing balance Light boxes, physical testing equipments (crocking meter, washing machine).

C. QUALITY CONTROL SYSTEM

1. Is factory operating a formal & written internal quality

control procedure? **

Yes No N/A

2. Are there adequate internal training programs provided

for all quality control personnel involved?

Yes No N/A

3. Are there adequate traceable training records for factory

personnel?

Yes No N/A

4. Are the factory’s Q.C. personnel certified or assessed

before they perform their job as outlined in the Q.C. procedures?

Yes No N/A

5. Has management defined its quality control objectives? If so, are those objectives clearly understood by personnel?

Yes No N/A

6. Does the factory use international, national, client’s,

or its own approved standards to perform in-house

quality control? Explain in remarks.

Yes No N/A

7. Does the factory have a detailed written plan

demonstrating how safety requirements on products are

checked in-house?

Yes No N/A

8. Do detailed Factory Records reflect that products are properly

checked in accordance with customer requirements &

specifications prior to proceeding to the next production process?

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

quality policy, quality consciousness and the

importance of the quality assurance concept?

Yes No N/A



Rev: June 27, 2012

11. Does Q.C. personnel have knowledge and expertise on

products to be made?

Yes No N/A

12. Are all QA staff a separate team and different personnel from

the trimming and inspection teams?

Yes No N/A

13. Is there an adequate number of QA staff to deal with the quality

and quantity of spot-checking?

Yes No N/A

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


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.

C-7 It was noted that factory checking some safety requirement on products like pull test and snap button test without any detailed written plan.

C-6 (remarks)

Factory use international standard like 4 point system for fabric inspection, roll to roll shade check, AQL- 0.65 for accessories inspection, traffic light system followed in sewing inline and 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

specifications before use? **

Yes No N/A

2. Are raw materials properly labeled, stored and traceable?

Yes No N/A

3. Are raw materials kept in controlled storerooms/areas to

avoid theft, loss and any deterioration of quality?

Yes No N/A

4. If raw materials need inspection before use in production,

are they properly inspected and are records maintained

and traceable?

Yes No N/A

5. Is the inspection sampling schedule adequate and can the

quality of the product be guaranteed with confidence?

Yes No N/A

6. Are inspection records maintained to prove products

meet all requirements?

Yes No N/A



Rev: June 27, 2012

7. Are there written inspection instructions available

as guidelines to 3rd

party inspectors?

Yes No N/A

8. If testing equipment is needed during inspection, is there a

sufficient quantity of equipment in order to do so in timely

manner?

Yes No N/A

9. Does the factory have a system for lot control of

raw materials that requires oldest date to be pulled first for

use, “First in/ First out”?

Yes No N/A

10. Does the factory have a policy and procedure for inspecting

incoming fabric?

Yes No N/A

11. Are incoming and outgoing raw materials registered to prevent intermingling?

Yes No N/A

12. Are raw materials kept in controlled storerooms to avoid theft,

loss and deterioration of quality?

Yes No N/A

13. Does the factory possess a fabric inspection machine? If so, is there a policy/procedure for it’s usage on all material?

Yes No N/A

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

mixing?

Yes No N/A

16. Are different shade lots of fabric well separated in order to avoid

mixing?

Yes No N/A

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


D-1 (remarks)

Factory use international standard like 4 point system for fabric inspection, roll to roll shade check, AQL- 0.65 for accessories inspection



Rev: June 27, 2012

D-7 (Remarks)

Factory preserves approved samples, Pre Production meeting minutes, Fabric construction details, Measurements as a reference for the auditors.

E. IN PROCESS QUALITY CONTROL

1. Are all toolings fully tested and evaluated with all

measurements and safety issues?

Yes No N/A

2. Are samples of pilot run, or approved client samples

carefully reviewed by engineers and/or quality staff to see that

all safety aspects are being met?

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

production? **

Yes No N/A

5. Is there any documentation from either engineering,

Q.C. department or top management to authorize

mass production?

Yes No N/A

6. Are there line patrols by quality controllers or other

means to monitor the compliance of the product to

meet safety requirements? **

Yes No N/A

7. Does factory use international or other approved

standards to carry out in-process inspection? Are

there records?

Yes No N/A

8. Do records reflect the action taken on the rejected

lots?

Yes No N/A

9. Do records show rejected lots are well identified and

segregated from accepted lots?

Yes No N/A

10. Is there a system or policy in place for permanently removing

non-conforming manufactured items?

Yes No N/A

11. Are there clearly written criteria/instructions

available for employees to follow?

Yes No N/A

12. Are there approved samples attached to all areas

to give inspectors or workers a guideline?

Yes No N/A

13. Is the inspection and test equipment reliable to

verify the conformance of the semi-finished final product?

Yes No N/A



Rev: June 27, 2012

14. Are the inspection defects charted, analyzed, and

monitored to improve the problems encountered?

Yes No N/A

15. Are QC supervisors and management easily identifiable? (e. g. QC supervisors and management wear certain colored vest/shirt

uniforms, other than badges)

Yes No N/A

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


E-8, E-9 Factory does not preserve any defect rework reports. However, factory preserves inspection reports along with defect quantities.

E-11 Working instructions are not given in pressing area.

E-12 No reference sample found at ironing area.

E-15 QC supervisors or personnel were not provided with identification uniform to be worn for easy identification.

E-16 Factory has no physical segregation between accepted cut panels and rejected cut panels. 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

final inspection on merchandise? **

Yes No N/A

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

they properly filed and traceable to review quality of products?

Yes No N/A

4. Are customer drawings/specifications readily available

from quality control or posted on each line? **

Yes No N/A

5. Does factory perform internal mechanical tests on finished

goods to safeguard the product’s quality? If so, note below

how often.

Yes No N/A

6. Are there records to show factory has regularly performed

such mechanical safety tests?

Yes No N/A

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

pulled for internal review and inspection?

Yes No N/A

9. Are there normal procedures that require acceptable

inspection reports in order to authorize and shipment of products?

Yes No N/A

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

compare finished product at different stages of production run

for customers order? – beginning, middle or at the end of

production run?

Yes No N/A

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

of the finished garments?

Yes No N/A

14. If some operations are sub-contracted out, will the factory send its

QC to the sub-contractor’s site for monitoring the quality and are

the out-inspection records readily available?

Yes No N/A

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

*N/A answers will not be factored into the Maximum Points Available



Rev: June 27, 2012

F-5 (Note) Factory performs internal mechanical tests on finished goods. Besides this, factory has an

internal lab where factory is doing physical and chemical tests.

F-14 (Remarks)

Factory has no operations which are subcontracted out, however they do embroidery which is 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

products from being packaged into master cartons for another order?

Yes No N/A

3. Is there any control to prevent any defective or rejected

products from being packed into master cartons? **

Yes No N/A

4. Are semi-finished products well segregated from final

finished products in the packing area?

Yes No N/A

5. Are finished approved products packed promptly for best

manufacturing process in order to avoid dust and dirt? If not, are they properly stored and protected until packing?

Yes No N/A

6. Do workers wear gloves, hats/caps, shoe covers when

necessary?

Yes No N/A

7. Is there an established and posted packing procedure for product

according to the customers specific requirements?

Yes No N/A

8. Is the weight of packed master cartons randomly checked to

avoid product shortages? If not, is there a procedure to avoid

the possibility of shortages?

Yes No N/A

9. Are packed master cartons well stored in a covered area or a

good shelter to keep from exposure to climate conditions which

could compromise final appearance or structural integrity?

Yes No N/A

10. Is there equipment to use for stamping the date code, lot code,

and case number?

Yes No N/A

11. Does the facility have a working barcode scanner to verify

that the barcode on packaging is correct?

Yes No N/A

12. Does the facility have a policy for storing and stacking

finished cartons prior to shipment? **

Yes No N/A

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

Certified engineers and are those maintenance records readily

available?

Yes No N/A

15. Are cleaning liquids and agents properly stored to avoid catching fire

or being inhaled by workers?

Yes No N/A

16. Are scales used to accurately obtain the carton weight? If so, how

often are those scales calibrated? Answer in remarks below.

Yes No N/A

17. If laundry or washing machines are used, are there any written

procedures for wastage water treatment?

Yes No N/A

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


G-8 Factory has randomly checked weight of packed master cartons to avoid

product shortages but no records maintained to track or cross check product

shortage.

G-10 There is no equipment to use for stamping the date code, lot code, and case

number.

G-16 (Note) Calibrated weight measuring scales used for obtaining carton weight.

G-17 (Note) Factory does not have any washing plant. But factory have an effluent 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?

If so, are those procedures clearly understood and implemented

by factory personnel and are records readily available?? **

Yes No N/A

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

good product?

Yes No N/A

5. Is there a corrective action procedure for non-conforming

materials? **

Yes No N/A



Rev: June 27, 2012

6. Can the factory demonstrate how they handle non-conforming

materials such as product that fails the mechanical tests? If so,

does this demonstration coincide with its written procedure?

Yes No N/A

7. Can the factory supply solid proof to guarantee non-conforming

materials/products are unquestionably segregated from conformed

production and will not intermingle?

Yes No N/A

8. Does the factory have a process for notification to client when

non-compliant product is identified as being introduced into the

production run?

Yes No N/A

9. Is it found that there are no workers wearing garments identical to

garments being produced?

Yes No N/A

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


H-2 Alter/reject/ Ok garments are not segregated at all the production process. Factory has

provided alter/reject box in sewing, finishing section but it is not functional. Worker are not

aware about alter/reject box.

H-3, H-4

Non conforming materials are segregated at all stage but no proper marking system found to

identify the non-conforming product. In sewing section factory has provided separate

alter/reject box but no identification found at those box.

H-5 Factory does not track the re-work activity and non conformance products to ensure re work

quality.

H-7 Factory does not have a process for notification to client when non-compliant product is

identified as being introduced into the production run.

I. COMMUNICATION, DOCUMENTATION CONTROL AND WORK MOVEMENT

1. Does factory management and key staff understand English

sufficiently to ensure communication with vendor/US Rep/Retailer?

Yes No N/A

2. Is there an adequate and formal system for receiving and

applying line drawing, procedures, design change?

Yes No N/A

3. Are approved line drawings and specifications used properly,

filed in chronological sequence and traceable?

Yes No N/A

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

provide adequate supervision and specifications to ensure

compliance to the requirements of client’s standards? **

Yes No N/A

6. Does the factory conduct a 100% inspection on all subcontracted

work? **

Yes No N/A

7. Does factory have clear written instructions to its departments,

delegating authority to stop production if the products do not

meet the safety requirements of client’s standards?

Yes No N/A

8. Is technical information clearly identified to QA personnel with

adequate controls to insure process is replicated throughout

the production run?

Yes No N/A

9. Does factory have a policy for keeping all client’s technical

project information confidential?

Yes No N/A

10. Does the factory have an efficient policy to notify the client and

advise/discuss any failure on processing problems?

Yes No N/A

11. Does the factory retain copies of internal test reports? If yes, note type of test reports in remarks section.

Yes No N/A

12. Does the factory retain copies of external test reports? If yes,

note type of test reports in remarks section.

Yes No N/A

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

comments attached?

Yes No N/A

15. Do records show that regular pre-production meetings are held

before a new style is put into production?

Yes No N/A

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


I-5, I-6 (Note) Factory has no operations which are subcontracted out, however they do embroidery from their sister concern Southeast textile ltd and Anam clothing limited.



Rev: June 27, 2012

I-12(remarks) Factory perform external test through 3

rd party testing company (Bureau Veritas / SGS etc) for

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

resolving customer/product complaints? **

Yes No N/A

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

non-conformity?

Yes No N/A

5. Is the corrective and preventive plan communicated with the

customer?

Yes No N/A

6. Are there traceable records for the handling of complaints?

Yes No N/A

7. Do records show that the corrective and preventive actions

are properly conducted and monitored to client satisfaction?

Yes No N/A

Rating: Handling of Complaints:

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

Total Score for Section J: ( 3 ) / 3


J-1 (Remarks)

It was noted that, factory does not face any complain from their client yet.

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

have appropriate paperwork? **

Yes No N/A

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

Other countries? **

Yes No N/A

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

Production. **

Yes No N/A

Rating: Trans-shipment Information

( 8 ) out of 8 Critical items rated as "YES" = ( 24 ) points

Total Score for Section K: (24 ) / 24


K-1

Its confirmed by last shipment documents Verification of Costco Canada, PO #45009992,Style No# Harg 1003/1004/1005/1007,Total cartons : 2000 ; that 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.

4. Does the factory possess any other accreditations?

Yes

Yes

No

No

N/A

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.

2. Factory has in house testing facility to conduct test for product’s safety and 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

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.

SUMMARY OF THE POINTS THAT THE FACTORY ACHIEVED

SECTIONS Maximum Points

Available

Total Points

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

Control, Work Movement 13 13

J. Handling of Complaints 03 03

K. Trans-Shipment Information -

Critical Points 24 24

Total Points Available 181 (B)

Total Points Achieved 160 (A)

Audit Result: Total Score in %=88.39

(A/B X100%)



Rev: June 27, 2012

Digital Photo Records

Factory Outlook Factory Name Dyeing section

Dyeing finishing Chain mail gloves used in Cutting

section

Sewing 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

facility

Fabric relaxation area Cut panel numbering



Rev: June 27, 2012

Cut panel stored in separate boxes

color wise.

Printing section. Fusing section

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

garments

Test card for calibration Metal

detector



Rev: June 27, 2012

Weighing balance for Cartons Bar code scanner Broken needle register

Button pull test machine Dummy used for fitting

confirmation

Light box

Traffic light introduced in the sewing

section.

Fabric inspection machine Shade band Band knife cutting machine

Separate boxes found for alter / reject

/ okay in sewing section.

Workers are keeping damage cut

panel bundles in same table where cut

panel inspection taking place.

Needle guard are not in appropriate

height.

factory audit overview - renaissance...

Documents