The Home Depot Quality System Audit. * Example Report * North America Latin America

Transcription

1 The Home Depot Quality System Audit * Example Report * North America Latin America Europe & Middle-East Asia & Asia Pacific India info@proqc.com

2 Presentation Rev. Dear lient, Pro Q International was engaged to help factory XXXXXXX comply with The Home Depot Supplier Requirements. The Home Depot was planning to audit the factory and the goal of this engagement was to ensure that the factory passed the rd party audit and became an approved supplier to The Home Depot. Pro Q started this project in July 18, 2017, by conducting an Initial Evaluation based on The Home Depot Quality System Assessment requirements at supplier XXXXXXXXXXXX. The scope of the initial assessment covered following: hapter 1: Product Finish ontrol hapter 2: Paint ompliance hapter : Packaging Assessment hapter 4: Quality System Assessment The rd page of this document, Initial Audit Summary, provides the results of the Initial Assessment, with level of compliance for each hapter. The green bar shows the level of compliance with the requirement while the yellow and red bar show the level of incompleteness and non-compliance with the requirement respectively. On August 1, 217, Pro Q established a orrective Plan in sheet orrective Plan Follow- Up based on the findings of the Initial Assessment conducted on Juy 18, The sheet presents 1 violations, each describing the content of the Violation, including the corresponding elements of The Home Depot's requirement, a proposed orrective, target date to complete the corrective action and actual date of completion. The orrective Plan was presented to representative members at the factory XXXXXX. Since the factory did not have any knowledge about the requirements of The Home Depot, it was clear that the project leader at Pro Q International would have to lead them with coaching, preparation of documentation, training and monitoring. The page Documentation is the list of documents Pro Q developed and provided to the factory as foundation for the system. In total 12 policies, 8 procedures and around record templates were developed during the phase of coaching. The project was completed in 6 visits to the factory XXXXXX, each visit had an update of the current level of completion as described in the page AP Progress. Photos of evidence of completion were also added under Photo. On August 0, 2017, 2 month after beginning, Pro Q International completed corrective action for 1 violations, around 100% of open violations. Pro Q also conducted a pre-audit to ensure that all members at the factory were ready to receive the final audit from a designated rd party audit firm. The factory XXXXXX was audited by a rd part audit firm and got a score of 87% which is sufficient for the factory XXXXXX to become an approved supplier for The Home Depot. The Home Depot QSA 2/49

3 Initial Audit Summary Rev. 1 Supplier Name Audit Date Report No. 2017//9 XXXXXXXXX SUPPLIER'S INFORMATION LIENT'S INFORMATION NAME : XXXXXXXX NAME : XXXXXXXX ADDRESS : XXXXXXXX ADDRESS : XXXXXXXX XXXXXXXX XXXXXXXX IT : XXXXXXXX IT : XXXXXXXX OUNTR : XXXXXXXX OUNTR : XXXXXXXX PHONE : XXXXXXXX PHONE : XXXXXXXX FAX : XXXXXXXX FAX : XXXXXXXX SUPPLIER'S PERSONNEL PARTIIPATING Mr./Mrs. XXXXXXXXXXXXXXXX Title: XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX Mr./Mrs. XXXXXXXXXXXXXXXX Title: XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX Pro Q PERSONNEL Mr./Mrs. XXXXXXXXXXXXXXXX Title: XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX AUDIT RESULTS I N PRODUT QUALIT FINISH SSTEM ONTROL ASS 0.00% 25.00% 75.00% PAKAGING ASSES 16.67% 16.67% 66.67% PAINT OMPLIA 25.00% 12.50% 62.50% PRODUT FINISH O 16.67% 0.00% 8.% PAINT OMPLIANE PAKAGING ASSESSMENT QUALIT SSTEM ASSESSMENT 0.00% 10.00% 20.00% 0.00% 40.00% 50.00% 60.00% 70.00% 80.00% 90.00% % I N REOMMENDATIONS Systems are effective, you could start or continue business with this supplier System is acceptable, with minor nonconformities, you could use this supplier, and keep pushing them to improve it. System has some major issue, you could temporaly use this supplier and request immediate corrective action in case of long term business. There are serious major issue in this supplier that could impact in your business The better solution will be to source for another supplier The Home Depot QSA /49

4 The Home Depot ompliance orrective Plan Progress PRO-02 The Home Depot QSA ompliance Job Number Visit Date Auditor's name Open NF losed NF % Man-days XXXXXXXXXXXX Aug, 1 XXXXXXXXXXXX Aug, XXXXXXXXXXXX Aug, 8 XXXXXXXXXXXX Aug, 1 XXXXXXXXXXXX Aug, 16 XXXXXXXXXXXX Aug, 25 XXXXXX % 2 XXXXXX % 2 XXXXXX % 2 XXXXXX % 2 XXXXXX % 4 XXXXXX % 4 100% 90% 80% 70% 60% 50% 40% 0% 20% 10% 0% Aug, 1 Aug, Aug, 8 Aug, 1 Aug, 16 Aug, 25 losed NF Open NF The Home Depot QSA 4/49

5 Documentation Rev. 1 Supplier Name Audit Date Report No. 2017//9 XXXXXXXXX A= Policy & Regulation; B = Procedure; = Record Template ategory Name English Name hinese A Quality Manual 质量手册 A Decomposition and evaluation of quality policy and goal 质量方针与目标的分解与测评 A ontinuous improvement Team organization hart 持续改善小组组织结构图 A Inspection Standard(IQ, IPQ, FQ) 检验标准 ( IQ, IPQ, FQ) A ISTA1 Testing Standard ISTA1 测试标准 A Packing material Inspection Specification 包装材料的检验规范 A THD Packing SBA 家得宝包装 SBA A Standard about the Lead content of Oil paint(16 cfr 10) 有关油漆铅含量的标准 ( 如 16 cfr 10) A Quality Management Responsibility 质量管理体系 / 控制关键人员职责 A Factory Organization hart 公司组织架构图 A Quality Organization hart 品管组织架构图 A SP 检验数据统计与分析记录 B Document ontrol Procedure 文件控制程序 B Recording ontrol Procedure 记录的控制程序 B Management Review Procedure 管理评审程序 B Human resource Management Procedure 人力资源管理程序 B Production facility configuration and management and work environment contr生产设施的配置和管理及工作环境控制程序 B Product realization planning control Procedure 产品实现的策划控制程序 B ontrol procedure relating to customer processes 与顾客有关的过程的控制程序 B Design and development control Procedure 设计和开发控制程序 B Procurement control Procedure 采购控制程序 B Production and service provision of control and confirmation Procedure 生产和服务提供的控制和确认程序 B ustomer property management Procedure 顾客财产管理程序 B Product protection Procedure 产品防护程序 B Monitoring and measuring device control Procedure 监视和测量装置的控制程序 B ustomer satisfaction measurement Procedure 顾客满意度的测量程序 B Internal audit Procedure 内部审核程序 B Product monitoring and measurement Procedure 产品的监视和测量程序 B Nonconforming product control Procedure 不合格品控制程序 B Data analysis and control Procedure 数据分析控制程序 B orrective and preventive measures control Procedure 纠正和预防措施控制程序 B SOP for each process 各工序包括包装的作业指导书 / 规格要求 B ustomer complaint handling Procedure 客户投诉处理程序 B ontinuous improvement procedure 持续改进制度 B EN procedure 工程变更程序 B Supplier Management and review Procedure 供应商管理评审程序 B Equipment calibration Procedure 仪器设备校验程序 B Equipment maintenance Procedure 设备维修保养程序 B Packaging material sample management system 包材样品管理制度 B olor printing package color plate to retain the provisions of the update 彩印类包材色板的更新保留规定 B Loading Procedure 装柜程序 B Paint process control management system 油漆过程的控制管理制度 B In-coming Appearance color Inspection Specification 进料外观颜色检查管理制度 B Porcess Appearance color Inspection Specification 过程外观颜色检查管理制度 B Final Appearance color Inspection Specification 成品外观颜色检查管理制度 B Light boxes, color cards and other management system 灯箱, 色卡等管理制度 B Swatch color sample update management system 色板色样更新等管理制度 B Wood products storage and workplace management regulations 木制品存放及工作场所的管理规定 B Pest control Procedure 虫鼠控制程序 B Traceability program for wood products 木制品的追溯性程序 Management review Record 管理评审记录 Internal Audit Record 内部质量审核记录 /N The Home Depot QSA 5/49

6 Documentation Rev. 1 Supplier Name Audit Date Report No. 2017//9 XXXXXXXXX ategory Internal audit failed report ustomer complaint handling Record ontrolled list of documents EN record Supplier review Record Equipment maintenance Plan Equipment maintenance Record Package-like packing list Loading record Swatch color sample list Pest control Record Traceability record for wood products Moisture detection records A= Policy & Regulation; B = Procedure; = Record Template Name English Document delivery, change, destruction records ontinuous improvement Record(5S, Q, training etc.) Training Record Production lead time Record Inspection record of First sample piece New product development record BOM Sheet Material Procurement ontract (ontains THD Requirements) Inspection Record(IQ, IPQ, FQ) SP Record Measuring instrument alibration Plan Nonconforming product handling Record Shorten the production cycle plan orrective and preventive Record ISTA1 Testing Record Inspection record of package material Exterior color inspection inspector training and assessment records Name hinese 内部审核不合格项报告客户投诉处理记录受控文件清单文件收发, 变更, 销毁记录持续改进记录 ( 如 5S, Q, 培训等 ) 培训记录出货交期记录首件样品检查记录新产品开发记录 BOM 表工程变更记录供应商评审记录材料采购合同 ( 包含 THD 要求规定 ) 检验记录 ( IQ, IPQ, FQ) 检验数据统计与分析记录计量仪器校准计划设备维修保养计划设备维修保养记录不良品处理记录缩短生产周期计划纠正预防记录 ISTA1 测试记录包装材料的检验记录包材封样的清单装柜记录外观颜色检查检验员的培训和考核记录色板色样清单虫鼠控制记录木制品的追溯性记录水分检测记录 /N The Home Depot QSA 6/49

7 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 1 Section 2: ontinuous Improvement Facility had tracked production plan to check if it was finished on time, but the production lead time was not measured and lead time reduction plan was not feasible. Section 2: ontinuous Improvement Requirements A07 1.heck the real deadline 2.Develop a lead time reduction plan then put it into effect.train the related workers The facility has set up realistic lead time reduction plan; implements the plan with records. XXXXXXX 25-Aug-17 lose The Home Depot QSA 7/49

8 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 2 Section 2: ontinuous Improvement Training had been provided for staff according to training plan but was not sufficient nor implemented effectively. For example: 1) Facility representative claimed that oral training had been provided for operators about AR/I activities, but relevant training records were not available. Train related staff on this issue losed since August 0. The facility has trained the operators about AR/I activities and line stoppage rules, and maintained the records. XXXXXXX 0-Aug-17 lose Section 2: ontinuous Improvement Requirements A09 The Home Depot QSA 8/49

9 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved Section : Quality System 2) Facility representative claimed that oral training had been provided for operators about line stoppage rules when defective materials were identified, but relevant training records were not available. Section : Quality System Requirements A16 Train the related staff on this issue losed since August 0. The facility has trained the operators about AR/I activities and line stoppage rules, and maintained the records. XXXXXXX 0-Aug-17 lose The Home Depot QSA 9/49

10 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 4 Section 4: Purchasing Approval assessment was not conducted for some key suppliers (e.g. password lock supplier: bojiaya etc.).(p) Section 4: Purchasing Requirements A20 1. Assess the supplier immediately 2.Train the related staff losed since August 15. The facility has conducted the approval assessment for the password lock supplier bojiaya. XXXXXXX 15-Aug-17 lose The Home Depot QSA 10/49

11 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 5 Section 4: Purchasing 1) Inspection standard was not established for some incoming materials (e.g. flannelette and plasterboard etc.). 2) AQL defined for all inspection items of password lock was 1.0, but IQ used AQL(2.5) to inspect the appearance of password lock. (P) 1. Develop the incoming inspection rules on carpet and fireboard; unified the sampling standard on e-lock 2. Train the related staff The facility has established the inspection standard for flannelette and plasterboard. In addition, the facility has trained the IQ employees about AQL, and maintained the record. XXXXXXX 0-Aug-17 lose Section 4: Purchasing Requirements A21 The Home Depot QSA 11/49

12 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 6 Section 4: Purchasing D - Paint ompliance Ongoing performance assessment based on the quality, on time delivery and service etc. was not conducted for some suppliers (e.g. password lock supplier: bojiaya and screen printing supplier: lashing etc.).(p) Section 4: Purchasing Requirements A22 D - Paint ompliance Requirements D11 1.Assemble the supplier of e-lock and silkscreen on service etc. and annual assemble 2.Train the related staff losed since August 15. The facility has conducted ongoing performance assessments for some suppliers (e.g. password lock supplier: bojiaya and screen printing supplier: lashing etc.). XXXXXXX 15-Aug-17 lose The Home Depot QSA 12/49

13 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 7 Section 4: Purchasing Some key suppliers (e.g. password lock supplier: bojiaya etc.) were not registered in approved supplier list.(p) Section 4: Purchasing Requirements A2 1.Assemble the supplier was mentioned, if it was passed, list it in supplier list. 2.Train the related staff to identify the supplier. Some key suppliers (e.g. password lock supplier: bojiaya etc.) have been registered in approval supplier list. XXXXXXX 25-Aug-17 lose 8 Section 4: Purchasing Facility representative claimed that process/product change would be informed by suppliers and facility also would communicate the change with customers and get approval, but relevant implementation records were not available. (P) Section 4: Purchasing Requirements A25 1. Explain to the supplier that if they need to change the product, they should notify the facility first 2. Train the related staff. Purchasing dept. should received the change letter from suppliers The facility has updated the purchasing process. Records available prove EN process is effectively followed. XXXXXXX 25-Aug-17 lose The Home Depot QSA 1/49

14 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 9 Section 4: Purchasing Some incoming steel plates and flannelettes etc. stored in warehouse were not identified with necessary information (e.g. PO/batch number, quantity, incoming date and inspection status etc.) to ensure the traceability. Section 4: Purchasing Requirements A26 1.Mark the steel and carpet with labels 2.Train the related staff Some incoming steel plates and flannelettes etc. stored in warehouse have been identified with necessary information (e.g. PO/batch number, quantity, incoming date and inspection status etc.) to ensure traceability. XXXXXXX 10-Jul-17 lose The Home Depot QSA 14/49

15 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 10 Section 5: Inspection and test- Process ontrol Most operating parameters of necessary production processes were well controlled by facility, but the line speed of the powder coating process and the shot blasting time of the shot blasting process etc. were not effectively monitored and relevant monitoring records were not properly documented. Section 5: Inspection and test- Process ontrol Requirements A0 1.The group leader should supervise the records 2.Train the staff on importance of the data losed since August 15.The line speed of powder coating process and shot blasting time of shot blasting process etc. have been effectively monitored and relevant monitoring records were properly documented. The facility used the document to record the first product and confirmed. XXXXXXX 15-Aug-17 lose The Home Depot QSA 15/49

16 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 11 Section 5: Inspection and test- Process ontrol Most finished goods stored in warehouse were not identified with necessary information (e.g. order number, quantity, production date and inspection status etc.) to ensure traceability. Section 5: Inspection and test- Process ontrol Requirements A6 1.Mark the goods in warehouse immediately 2.Train the staff to use the correct labels to identify the goods. All finished goods stored in warehouse have been identified with necessary information (e.g. order number, quantity, production date and inspection status etc.) to ensure traceability. XXXXXXX 25-Aug-17 lose The Home Depot QSA 16/49

17 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 12 Section 5: Inspection and test- Process ontrol IPQ had conducted in-process inspection for all production processes, but some inspection records were not properly documented, for example: 1) In-process inspection records were not properly documented for assembling process. 2) In-process inspection records were not properly documented for metal working process on the auditing day. 1.heck again everyday by group leader and keep records 2.Train the inspectors The facility has set up documented inspection records for assembling process and metal working process, and started to maintain records. XXXXXXX 0-Aug-17 lose Section 5: Inspection and test- Process ontrol Requirements A42 The Home Depot QSA 17/49

18 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 1 Section 6: ontrol of Test equipment E - Product Finish ontrol Some measuring equipment (e.g. micrometer: serial number and light box etc.) was not calibrated and relevant calibration certificates were not available. Section 6: ontrol of Test equipment Requirements A46 E - Product Finish ontrol Requirements E08 1.alibrate the micrometer and light box immediately 2.Train the staff The facility has obtained the calibration certificate of the micrometer. XXXXXXX 0-Aug-17 lose The Home Depot QSA 18/49

19 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 14 Section 6: ontrol of Test equipment Facility representative claimed preventative maintenance had been conducted for the measuring equipment and most of them ran in a good condition, but relevant preventative maintenance records were not properly documented. Section 6: ontrol of Test equipment Requirements A48 1.Perform preventative maintenance on the equipment mentioned and keep records 2.Train the staff The facility developed the annual equipment preventative maintenance plan. Moreover the preventative maintenance records have been properly documented. XXXXXXX 0-Aug-17 lose The Home Depot QSA 19/49

20 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 15 Section 7: ontrol of Nonconforming Product Some non-conforming and/or idle finished goods were not identified and yet they were stored together with good ones in finished goods warehouse. Section 7: ontrol of Nonconforming Product Requirements A49 1.Settle the non-conforming goods and mark the clearly 2.Train the staff losed August 0. The facility has developed rules for the storage of the non-conforming goods and idle finished goods have been identified and distinguished from good ones. XXXXXXX 0-Aug-17 lose 16 Section 8: orrective and preventive orrective and preventive action was not conducted for all rejected key incoming materials (e.g. electric magnet etc.) and relevant records were not available. Section 8: orrective and preventive Requirements A54 1.Fill in the corrective and preventive action document for electric magnets as the process requires, and confirm by facility 2.Train the staff APAs for electric magnet have been documented and records are available. XXXXXXX 20-Jun-17 lose The Home Depot QSA 20/49

21 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 17 Section 10: Handling, Storage, Packaging, & Delivery Some WIPs of shelf manufacturing process and metal working process which were stored in workshop were not identified with necessary information (e.g. order number, production stage, quantity and production time etc.). Section 10: Handling, Storage, Packaging, & Delivery Requirements A61 1.Identify the process label immediately 2.Train the staff The WIPs of shelf manufacturing process and metal working process which were stored in workshop have been identified with necessary information (e.g. order number, production stage, quantity and production time etc.). The facility checked them by 5S. XXXXXXX 0-Aug-17 lose The Home Depot QSA 21/49

22 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 18 Section 10: Handling, Storage, Packaging, & Delivery Most WIPs of shelf manufacturing process, some WIPs of assembling process and finished goods were found stored directly on the floor in the workshop and without effective protection measures. Section 10: Handling, Storage, Packaging, & Delivery Requirements A62 1.Use a carpet or canvas on the floor immediately 2.Ruled it as a process.train the staff losed since August 15. All semi finished goods and finished goods has been stored on the carpet or canvas and with effective protection measures. XXXXXXX 15-Aug-17 lose The Home Depot QSA 22/49

23 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 19 Section 2 packaging quality control capability Packaging material inspection specifications were established, but which only had the material test requirement and didn t contain the performance test requirements. Section 2 packaging quality control capability Requirements B04 1.Inspect the cartons via a performance test 2.Train the staff. Study the HD s requirements deeply The facility has updated the inspection process and added the performance test in. XXXXXXX 25-Aug-17 lose 20 Section 2 packaging quality control capability Standard samples of packaging structure (e.g. corrugated board of master carton etc.) were not established by facility. Section 2 packaging quality control capability Requirements B06 1.Get the standard samples of packaging structure 2.ensure the sample load in good environment and marked.study the HD s requirements deeply The facility has established the standard samples of packaging structure(e.g. corrugated board of master carton etc.). XXXXXXX 25-Aug-17 lose The Home Depot QSA 2/49

24 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 21 Section 2 packaging quality control capability Renewing plan was not established for color standards of packaging materials and also relevant renewing actions were not conducted. Section 2 packaging quality control capability Requirements B10 1.set up the sample form and ensure each item. 2.Study the HD s requirements deeply. losed since 0. The facility has renewed plan for color standards of packaging materials and conducted the relevant renewing action. XXXXXXX 0-Aug-17 lose 22 Section 2 packaging quality control capability Facility didn t know any about THD packaging requirements (e.g. Supplier Reference Guide etc.). Section 2 packaging quality control capability Requirements B11 1.Meet THD packing requirements 2.Train the staff base on SRG.Study the HD s requirements deeply The facility has arranged training about THD packaging requirements for all relevant employees and management and maintained the training record. XXXXXXX 0-Aug-17 lose The Home Depot QSA 24/49

25 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 2 D - Paint ompliance Lead content requirement was not set for each individual incoming paint color (e.g. coating powder etc.) and each kind of incoming painted components (e.g. screen printing products etc.). (P) D - Paint ompliance Requirements D02/D10 Update the purchase order with color/ item and component losed since August 0. The facility has updated the purchase order with color/ item and component, and the lead content requirement has been set. XXXXXXX 0-Aug-17 lose The Home Depot QSA 25/49

26 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 24 D - Paint ompliance IQ just carried out random lead content verification for the incoming paint color (e.g. coating powder etc.) and incoming painted components (e.g. screen printing products etc.). (P) Doing lead test on the powder and silkscreen Get the lead report from the supplier losed since August 0. The facility has obtained the lead report from the supplier. XXXXXXX 0-Aug-17 lose D - Paint ompliance Requirements D04/D12 The Home Depot QSA 26/49

27 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 25 D - Paint ompliance Production control sheet just defined the color of coating powder used during the production, but which didn't include other information (e.g. supplier/brand name, model#, and lead content information etc.). (P) D - Paint ompliance Requirements D05 hange the production control sheet, list such information (supplier name, model# and lead content) The facility has updated the BOM list, making sure of the power information. Moreover the facility has changed the production control sheet to include other information (e.g. supplier/brand name, model#, and lead content information etc.). XXXXXXX 0-Aug-17 lose The Home Depot QSA 27/49

28 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 26 D - Paint ompliance Workers just checked the color of coating powder before use, but other information (e.g. supplier/brand name, model#, and lead content information etc.) was not verified. D - Paint ompliance Requirements D06 1.Set up the new rules and include all the power information as THD requires. 2.Train the related staff The facility has updated the painting checklist, include the power information. And Inspector verifies the proper paint used against all the information included in the product control sheet. XXXXXXX 0-Aug-17 lose The Home Depot QSA 28/49

29 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 27 D - Paint ompliance Facility just carried out lead content test for finished goods according to customer requirements and lead content sampling test was not set in finished goods inspection standards.(p) D - Paint ompliance Requirements D07/D1 Be certain of THD requirements, do lead content test every 4 months and keep the reports. losed since August 0. The facility has maintained the lead content test report according to THD requirements. Moreover Lead content sampling test was set in Final Quality heck process for every lot. XXXXXXX 0-Aug-17 lose 28 D - Paint ompliance Line clearances have been done for the changing over of the powder coating process, but lead content was not checked for related products after the changing.(p) D - Paint ompliance Requirements D08 Testing THD products more than 5 times each year after changing lines, and keep the reports. losed since August 0. The facility has set up the process document and ensuring to clear the painting lines every time after changing. XXXXXXX 0-Aug-17 lose The Home Depot QSA 29/49

30 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 29 E - Product Finish ontrol Facility had obtained some reference samples to inspect the finish of the materials and products, but necessary facilities (e.g. spectrophotometer or AAT gray scale comparison chart Purchase the gray scale comparison etc.) were not available.(p) chart. losed since August 0. The facility has purchased the AAT gray scale comparison chart. XXXXXXX 0-Aug-17 lose E - Product Finish ontrol Operation and Awareness Requirements E06 The Home Depot QSA 0/49

31 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 0 E - Product Finish ontrol Inspectors had been validated by a Munsell Farnsworth test to ensure that they had enough capabilities to conduct the color visual check, but the score was not below 16. (P) E - Product Finish ontrol Operation and Awareness Requirements E07 Retest the inspectors Update the SOP as required losed since August 0. The facility has trained and retested the inspectors via a Munsell Farnsworth test, and the score of all the inspectors was below 16. XXXXXXX 0-Aug-17 lose The Home Depot QSA 1/49

32 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 1 E - Product Finish ontrol Standard samples just kept by Q and randomly placed at the inspection area. Moreover, no designated area with good condition was established to store the standard samples. E - Product Finish ontrol Sample Management Requirements E10 Designate a special space to store the samples The facility has maintained the standard samples in designated area with good condition. XXXXXXX 0-Aug-17 lose The Home Depot QSA 2/49

33 orrective Plan Follow-Up PRO-02 The Home Depot QSA ompliance orrective : after the visit in orrective lose Date lose=solved 2 E - Product Finish ontrol Renewing plan was not established for reference samples which were used to inspect the surface appearance and color of necessary incoming materials, semi-finished goods and finished goods etc. and also relevant renewing actions were not implemented. E - Product Finish ontrol Sample Management Requirements E11 Marked the sample with item / date and confirmed person, set up the process such as who take the charge of the samples The facility has established the sample renewing plan, and color of necessary incoming materials, semi-finished goods and finished goods etc. and also relevant renewing actions were implemented. XXXXXXX 0-Aug-17 lose The Home Depot QSA /49

34 Photo Evidence PRO-02 The Home Depot QSA om How is was before How it became after correction the production lead time was not measured and lead time reduction plan was not feasible. Photo 1-1: Production lead time reduction plan Photo 1-2: Production lead time reduction plan Facility representative claimed that oral trainings had been provided for operators about AR/I activities, but relevant training records were not available. Photo 2-1: Training records Photo 2-2: Training records The Home Depot QSA 4/49

35 Photo Evidence PRO-02 The Home Depot QSA om How is was before How it became after correction Facility representative claimed that oral trainings had been provided for operators about line stoppage rules when defective materials were identified, but relevant training records were not available. Photo -1: Training records Photo -2: Training records Approval assessment was not conducted for some key suppliers (e.g. password lock supplier: bojiaya etc). Photo 4-1:Approval assessment Record Photo 4-2: Approval assessment Record The Home Depot QSA 5/49

36 Photo Evidence PRO-02 The Home Depot QSA om How is was before How it became after correction 1) Inspection standard was not established for some incoming materials (e.g. flannelette and plasterboard etc). 2) AQL defined for all inspection items of password lock was 1.0, but IQ used AQL(2.5) to inspect the appearance of password lock. (P) Photo 5-1: In-coming Inspection standard Photo 5-2: In-coming Inspection standard & inspection records Ongoing performance assessment based on the quality, on time delivery and service etc was not conducted for some suppliers (e.g. password lock supplier: bojiaya and screen printing supplier: lanhong etc). Photo 6-1: Ongoing performance assessment Record Photo 6-2: Ongoing performance assessment Record The Home Depot QSA 6/49

37 Photo Evidence PRO-02 The Home Depot QSA om How is was before How it became after correction Some key suppliers (e.g. password lock supplier: bojiaya etc) were not registered in approval supplier list.(p) Photo 7-1: Approval supplier list Photo 7-2: Approval supplier list Facility representative claimed that process/product change would be informed by suppliers and facility also would communicate the change with customer and get approval, but relevant implementing records were not available. (P) Photo 8-1: EN processrecord Photo 8-2: EN record The Home Depot QSA 7/49

38 Photo Evidence PRO-02 The Home Depot QSA om How is was before How it became after correction Some incoming steel plates and flannelettes etc stored in warehouse were not identified with necessary information (e.g. PO/batch number, quantity, incoming date and inspection status etc) to ensure the traceability. Photo 9-1: Identified label of raw materials Photo 9-2: Identified label of raw materials Most operating parameter of necessary production processes were well controlled by facility, but still line speed of powder coating process and shot blasting time of shot blasting process etc were not effectively monitored and relevant monitoring records were not properly documented. Photo 10-1: Production process control record Photo 10-2: Production process control record The Home Depot QSA 8/49

39 Photo Evidence PRO-02 The Home Depot QSA om How is was before How it became after correction Most finished goods stored in warehouse were not identified with necessary information (e.g. order number, quantity, production date and inspection status etc) to ensure the traceability. Photo 11-1: Identified Label of finished goods Photo 11-2: Identified Label of finished goods 1) In-process inspection records were not properly documented for assembling process. 2) In-process inspection records were not properly documented for metal working process on the auditing day. Photo 12-1: Documented inspection records Photo 12-2: Documented inspection records The Home Depot QSA 9/49

40 Photo Evidence PRO-02 The Home Depot QSA om How is was before How it became after correction Some measuring equipment (e.g. micrometer: serial number and light box etc) were not calibrated and relevant calibration certificates were not available. Photo 1-1: alibrated plan & calibration certificate Photo 1-2: alibrated plan & calibration certificate Facility representative claimed preventative maintenance had been conducted for the measuring equipment and most of them ran in a good condition, but relevant preventative maintenance records were not properly documented. Photo 14-1: Preventative maintenance records Photo 14-2:Preventative maintenance records The Home Depot QSA 40/49

41 Photo Evidence PRO-02 The Home Depot QSA om How is was before How it became after correction Some non-conforming and/or idle finished goods were not identified and stored together with good ones in finished goods warehouse. Photo 15-1: Identify the idle finished goods Photo 15-2: Identify the idle finished goods orrective and preventive action was not conducted for all rejected key incoming materials (e.g. electric magnet etc) and relevant records were not available. Photo 16-1: orrective and preventive action Photo 16-2: orrective and preventive action The Home Depot QSA 41/49

42 Photo Evidence PRO-02 The Home Depot QSA om How is was before How it became after correction Some WIPs of shelf manufacturing process and metal working process which were stored in workshop were not identified with necessary information (e.g. order number, production stage, quantity and production time etc). Photo 17-1: Identified label of WIP of shelf manufacturing process Photo 17-2: Identified label of WIP of shelf manufacturing process Most WIPs of shelf manufacturing process, some WIPs of assembling process and finished goods were found stored on the floor directly in workshop and without effective protection measures. Photo 18-1: Stored without effective protection measures Photo 18-2: Stored with effective protection measures The Home Depot QSA 42/49

43 Photo Evidence PRO-02 The Home Depot QSA om How is was before How it became after correction Packaging material inspection specifications were established, but which only had the material test requirement and didn t contain the performance test requirements. Photo 19-1: Packaging material inspection requiremen Photo 19-2: Packaging material inspection requirement Standard samples of packaging structure (e.g. corrugated board of master carton etc) were not established by facility. Photo 20-1: Standard samples of packaging structure Photo 20-2: Standard samples of packaging structure The Home Depot QSA 4/49

44 Photo Evidence PRO-02 The Home Depot QSA om How is was before How it became after correction Renewing plan was not established for color standards of packaging materials and also relevant renewing actions were not conducted. Photo 21-1: Renewing plan and action Photo 21-2: Renewing plan and action Facility didn t know any about THD packaging requirements (e.g. Supplier Reference Guide etc). Photo 22-1: THD packaging requirements Photo 22-2: THD packaging requirements and training The Home Depot QSA 44/49

45 Photo Evidence PRO-02 The Home Depot QSA om How is was before How it became after correction Lead content requirement was not set for each individual incoming paint color (e.g. coating powder etc) and each kind of incoming painted components (e.g. screen printing products etc). (P) Photo 2-1: Lead content requirement Photo 2-2: update purchase order and BOM IQ just carried out random lead content verification for the incoming paint color (e.g. coating powder etc) and incoming painted components (e.g. screen printing products etc). (P) Photo 24-1: the lead report Photo 24-2: the lead report The Home Depot QSA 45/49

46 Photo Evidence PRO-02 The Home Depot QSA om How is was before How it became after correction Production control sheet just defined the color of coating powder used during the production, but which didn't include other information (e.g. supplier/brand name, model#, and lead content information etc). (P) Photo 25-1: Production control sheet Photo 25-2: Production control sheet Workers just checked the color of coating powder before the using, but other information (e.g. supplier/brand name, model#, and lead content information etc) were not verified. Photo 26-1: Verify the lead content information Photo 26-2: Verify the lead content information The Home Depot QSA 46/49

47 Photo Evidence PRO-02 The Home Depot QSA om How is was before How it became after correction Facility just carried out lead content test for finished goods according to customer requirements and lead content sampling test was not set in finished goods inspection standards.(p) Photo 27-1: lead content sampling test documented Photo 27-2: lead content sampling test documented Line clearances had been done for changing over of powder coating process, but lead content was not checked for related products after the changing.(p) Photo 28-1: lead content checked record Photo 28-2: lead content checked record and SOP The Home Depot QSA 47/49

48 Photo Evidence PRO-02 The Home Depot QSA om How is was before How it became after correction Facility had obtained some reference samples to inspect the finish of the materials and products, but necessity facilities (e.g. spectrophotometer or AAT gray scale comparison chart etc) were not available.(p) Photo 29-1: AAT gray scale Photo 29-2: AAT gray scale Inspectors had been validated by Munsell Farnsworth test to ensure that they had enough capabilities to conduct the color visually checking, but the scoring was not below the16. (P) Photo 0-1: onduct the color visually checking for inspectors Photo 0-2: onduct the color visually checking for inspectors The Home Depot QSA 48/49

49 Photo Evidence PRO-02 The Home Depot QSA om How is was before How it became after correction Standard samples just kept by Q and randomly placed at the inspection area. Moreover, no designated area with good condition was established to store the standard samples. Photo 1-1: standard samples area Photo 1-2: standard samples area Renewing plan was not established for reference samples which were used to inspect the surface appearance and color of necessary incoming materials, semi-finished goods and finished goods etc and also relevant renewing actions were not implemented. Photo 2-1:Renewing plan Photo 2-2: Renewing plan and Standard sample managementprocedure The Home Depot QSA 49/49