Factory Manufacturing Audit (FMA)
To perform a relevant audit, we need some samples and/or photos of products technically equivalent to what the factory would have to produce.
A detailed report is issued by the auditor, supporting his assessment of the factory´s capacity to deliver to your specifications. The report is based on the pieces of information listed below.
- General information about the factory
- General working, hygiene and safety conditions
- Storage condition (cleanliness, organization, safety)
- Cutting condition (efficiency calculations, fabric preparation, machines, safety)
- Sewing organization (machines, flow and quantity of in-process inventory)
- Packing organization (organization, flexibility)
- Work flow with number of workers in each service/line, and management organization
- Production capacity of the factory, and of each production line
- Production tracking and scheduling systems
- Average cycle time and necessary production lead time
- Main suppliers (transport time to factory)
- Sampling equipment (software, machines) and staff
- Sampling room capacity and uses
- Experience of sewing operators
- Quality control actors (operators vs. supervisors vs. QC service)
- Quality control procedures (inputs-operations-outputs)
- Organization and accessibility of customer approvals files (samples, components, lab dips…)
- Average complexity level of products observed in workshop and in showroom
- Quality standards (Oeko-Tex Standards, ISO9000 series…)
- Other audits previously passed. Names of major customers
Pre-Production Review (PPR)
In China, the development samples are often made in a sample room, by very experienced technicians and in conditions that are different from mass production. This can cause last-minute surprises.
This service takes place before the bulk fabric is cut. It consists of the elements listed below.
- Reporting of fabric and accessories arrival status.
- Visual control of fabrics: weight/m², color, handfeel.
- Forecast of production timing (starting date, assigned capacity, daily output, and finish date).
- Checking with production supervisors whether they think the style is feasible in conformity with the approved samples. For each issue raised: making a test in the workshop, and reporting the exact results.
- Checking all the issues listed by the client and reporting results.
If you ask the factory to make small series before bulk production, we can also control their conformity. It is often a very good solution to prevent problems in bulk production.
Note of caution: these series are useful in checking that a style is industrially feasible only if they are made in the workshop (not in sample room).
Fabric & Accessories Control (FAC)
 Our textile engineer can run some tests on fabrics and accessories while in the factory.
These controls mainly comprise: defect rate, weight/m², shrinkage, color fastness, color shading, and hand feel.
For visual inspection of fabrics, we use the 4-point system, as defined by the ASTM D5430-04 standard (issued by the American Society for Testing and Materials).
Penalty points are given for each defect, in function of its size and significance.
We can also control fabric quality based on other criteria, as defined by clients.
For advanced tests, we work with recognized laboratories that have all the requisite equipment. We invoice their services at cost. We can also pick materials randomly for you.
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