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Overview
Complete
Gibson Toes Manufacturing Company / Footwear / 21 Dec 2018 / Quentin Morgan
Factory Audit ChecklistConducted on21st Dec, 2018BySafetyCulture Staff
Inspection score
87.72%
Failed items
1
Created actions
2
Supplier Name
Gibson Toes Manufacturing Company
Product Category
Footwear
Location
41-47 Ocean St N, Bondi NSW 2026, Australia
Conducted on

21st Dec, 2018

11:19 AM +08

Prepared by
Quentin Morgan
Failed items
1
Audit / Quality Control
Are clear procedures given to each operator and to the QC staff, for each job?
No
Notes
Some operators were not given proper instructions and were not aware of some quality control measures in place.
Actions
2
SafetyCulture Staff created a High priority action for jason@gibsons.com
To do
21st Dec, 2018 11:21 AM +08
Kindly use some digital maintenance checklists to ensure that all of your machines are in good working condition to prevent injuries and accidents. You may find amazing sources here: safetyculture.com/checklists
Audit / Maintenance
Are there checklists for maintenance? Do they seem to be followed?
SafetyCulture Staff created a Medium priority action for jason@gibson.com
To do
24th Dec, 2018 11:20 AM +08
Kindly provide updated inventory records.
Audit / Production
Is pre-production inventory well organized?
Audit
1
2
87.72%
General Information
Date established

8th Dec, 2008

Total annual sales
$10 Billion
No. of Employees
10,000 workers
No. of Quality Control Employees
179
No. of Operators
500
No. of Machines
3,000
Quality Control
1
90.00%
Does the supplier has a quality system?
Yes
Does the factory communicate requirements to its suppliers on its POs (or other documents)? Are these requirements clearly listed?
Yes
Are incoming QC results recorded in a formal report?
Yes
Are conform samples available to workers in production and QC areas?
Yes
Are clear procedures given to each operator and to the QC staff, for each job?
No
Notes
Some operators were not given proper instructions and were not aware of some quality control measures in place.
Does final QC occur before or after packing is completed?
Yes
Are there QC staff solely dedicated to final QC? How many? Do they only do QC, or also a finishing operation at the same time?
Yes
Are final QC results recorded in a formal report?
Yes
Is the first-pass yield displayed on a wall, and tracked day-by-day and line-by-line?
Yes
Are numbers and details of customer complaints displayed on a wall?
Yes
Cost Control
100.00%
Are top managers (general manager, production manager, finance manager, sales manager, QC manager) part of the owner’s family? Or are they professional managers?
Yes
Are there several empty floors?
Yes
Can you see recent investments in expensive machinery?
Yes
Notes
Not really empty but a potential warehouse for more stocks.
Photos
Are there idle machines?
Yes
Maintenance
1
50.00%
Is equipment failure down time calculated?
Yes
Are there checklists for maintenance? Do they seem to be followed?
No
Notes
They lack records on equipment maintenance.
Actions
To do
Kindly use some digital maintenance checklists to ensure that all of your machines are in good working condition to prevent injuries and accidents. You may find amazing sources here: safetyculture.com/checklists
Visual Control
100.00%
Is the number of pieces per labor hour displayed on a wall, and tracked day-by-day?
Yes
Is the amount of scrapped material displayed on a wall, and tracked day-by-day?
Yes
Is the total unit cost displayed on a wall, and tracked day-by-day?
Yes
Degree of "Lean-ness"
0.00%
Can you see a lot of inventory kept before production and kept between each production step?
No
Notes
They told me that inventory checks are being done once a week. For me it is really important to do an inventory to check what supplies were received or which items did not pass standards.
Production
1
93.33%
Before a new product is launched, are some jigs/tools prepared by the engineering department?
Yes
Is pre-production inventory well organized?
No
Actions
To do
Kindly provide updated inventory records.
Is work-in-process inventory stored in a predictable way, or do people need to look around to find what they need?
Yes
Where do the components used in production come from? How long does transportation take?
Yes
Is production organized as a continuous flow, without any work-in-process inventory visible in the workshop? (best)
Yes
Is there a kanban system? (very good)
Yes
Is there a production planning, with details for each workshop, and updated every day? (good)
Yes
Is there no production planning at all? (worst)
Yes
Is there a list of approved subcontractors, who can take over part of the job? For which process steps?
Yes
Is there a power generator?
Yes
Is equipment failure downtime calculated?
Yes
Are there checklists for maintenance? Do they seem to be followed?
Yes
Is the proportion of on-time shipments displayed on a wall, and updated at least weekly?
Yes
Is the time to make one piece, from start to finish, displayed on a wall, and updated daily?
Yes
Can you see a lot of inventory between each production step?
Yes
Compliance
83.33%
Are there enough fire extinguishers (in workshops, dormitories)? Are they accessible, and up to date?
No
Notes
There were some scattered fire extinguishers which are outdated and not functional. These equipment must be disposed properly or else might cause potential risks.
Photos
Are there enough emergency exits? Is it possible to lock them? Are they used as storage areas?
Yes
Do workers have appropriate personal protective equipment (gloves, masks, glasses, safety boots)?
Yes
Are there enough first-aid kits? Are they available and full?
Yes
Does production generate a lot of waste? Is this waste treated?
Yes
Has the factory invested in energy-efficient equipment?
Yes
Summary of Findings
87.50%
General organization in the factory
Average
Notes
The organization was good but there were minimal adjustments that need to do such as maintaining records of inventory checks and equipment inspection.
Working environment (light, noise..)
Good
Motivation of top management
Good
Ease of mutual understanding
Average
Notes
This was reflected because some staff were not given instructions. Some are not aware of some quality control measures.
Can they make our product?
Yes
Notes
With the equipment and strategies that I have seen, I am confident that they can make high-quality products. They just need to make some improvement on how they streamline their work processes.
Do they have enough capacity?
Yes
Do they already sell to our country?
Yes
Do they understand our standards?
Yes
Completion
Full Name and Signature of Inspector/QC Manager
Quentin Morgan
21st Dec, 2018 11:39 AM +08
Photos