80549V1 1EN+-+What+Good+Looks+Like+for+F&F+Suppliers PDF

2019
What Good Looks Like Guidance for

the Tesco Manufacturing Standard for
F&F Products
Version 1.1
SERVING SHOPPERS A LITTLE BETTER EVERY DAY

HAYWARD, LAURA
© Tesco Stores Ltd. All Rights Reserved. This document is supplied by Tesco for use of the immediate recipient.
Management commitment and control
The site’s senior management must be able to demonstrate that they are fully committed to the implementation of the Tesco Standard and to processes which
Section 1 facilitate continual improvement of product safety and quality management.
This is essential as without this commitment the site will not have the support necessary to deliver safe, legal and quality products for Tesco customers.
It is understood that during an approval audit, prior to any production for Tesco, test and trial results may not have been completed on Tesco products or production.
.
Item Detail What Good Looks Like
Quality policy The site must have a documented quality The quality policy is displayed around the site at key employee locations.
policy which states the site’s intention to
consistently produce safe and legal products
of the specified quality, whilst ensuring that
all customer obligations and requirements
are met.
This must be:

 signed by the person with overall
responsibility for the site
 effectively communicated to all site
employees
Resource and The site’s senior management must provide Structure charts show details of the technical, quality, cleaning, and maintenance and training teams.
organisational the human and financial resources to
structure produce safe and legal products at the right
1
quality for Tesco, maintain Good As well as Senior management cover the site are able to demonstrate they have sufficient cover for operatives
Manufacturing Practices and meet the who are responsible for CCPs.
requirements of this Standard.
There is quality representation at senior level management meetings and this should be independent of
An organisational structure chart must be in production and other areas with commercially linked KPIs.
place showing management responsibilities
and authority.
Details of deputising cover for personnel

with responsibility for legal, safety and
quality issues must be documented.
Management Systems must be in place to ensure that the Sites which are part of a larger company share the learnings from their management reviews across the group.
review and management team regularly review the This review may form part of regular scheduled management meetings, where the Technical / Quality
corrective action Good Manufacturing Practices on site; this department provide information on site performance e.g. Key Performance Indicators (KPIs).
will include the safety, legality and quality of
product supplied to Tesco.
The senior management team must ensure

that any corrective actions resulting from the
review are implemented in a timely and
effective manner.
Management The site must have systems in place to An up to date Tesco contacts list is in place.
notification ensure that the relevant Tesco Technical
contact is notified of any safety, legality and At the first sign of an issue, the site must contact their Technical Manager at the earliest opportunity
quality issues that are identified with
product, that directly affect or may have the
potential to affect Tesco product. The Tesco
Technical contact must be involved in the
2
final decision for handling affected Tesco

product.
Your Tesco Technical contact must be

informed as soon as possible, of any
enforcement notices, pending prosecutions,
judgements, or approaches from the media
etc., where there may be an impact on Tesco
product, our reputation or the site’s ability to
supply. This may include the following,
although this is not an exhaustive list:
 Product Safety enforcement
 Environmental enforcement
 Health and Safety enforcement
 Contact with the Media
 Anonymous internal or external
contact, e.g. “whistle-blower”
3
Key performance The management team must measure key

indicators performance indicators and establish actions
to improve following regular analysis in key
areas such as, although this is not an
exhaustive list:
 ‘On Time’ Shipment Performance.
 Customer Quality Performance
Customer Complaints
Representation The most senior operational manager Unless they are deputising, Tesco would be looking for representation during audit from roles relating to
during audit for available on site at the time of the audit must manufacture of product and processes.
Tesco participate in the opening and closing
meetings. Examples include:
•Production manager
Other relevant representatives must be •Site manager
available as required during the audit. •Quality assurance manager
•Operation manager
•Technical manager
It should not include representation from finance, HR and health & safety colleagues
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Quality management
Quality management of manufacturing processes ensure that safe and legal products are consistently produced to the agreed specification and desired quality. This
is fundamental in supporting the required due diligence of all processes.
Section 2
Internal auditing assesses the effectiveness of site procedures and policies in maintaining the safety, legality and quality of products. It supports the identification of
the potential need for procedural change or employee retraining is required and enables continuous improvement.
Quality The site must have a Quality Management Quality Management Systems are made up of key policies, procedures and specifications to ensure product safety,
management System (QMS), which is maintained and legality, quality and customer requirements are understood and can be met, as well as the monitoring and reviewing
system regularly reviewed. The QMS must contain activities, and the records to demonstrate these requirements have been met in practice.
procedures and records as required by this
standard. The level of detail required in the documents of a Quality Management System will generally reflect the level of
complexity of the processes and the risk they present to the product. For example, in low complexity operations, it is
A member of the management team must unlikely that a lot of documentation will be needed, and the level of detail in the documents will also be low.
be assigned to manage the Quality
Management requirements More complex operations will need to implement a more detailed system that will require more documentation,
because there is more to consider in relation to product safety, legality and quality with more variables with the
The manual must be in place and available potential to impact the product.
to key employees and integrated in to day
to day operations. It is important that, where used, documented procedures are available to the staff responsible for carrying out the
activity, and this is usually best in the location where the activity is carried out. For example, procedures for carrying
out raw material intake quality checks should be available in the intake area
Document All documents related to legality, quality
control, and product safety must be adequately Individual version numbers and dates of issue should be included on all site documents (for document control purposes).
completion controlled, authorised and the correct All copies of the previous version must be removed and destroyed other than the original ‘master copy’ which must be held
and retention versions must be in use. in a central location in a controlled manner
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Alterations to records must be It is important that all ‘live’ documentation related to legality, quality and product safety has a history of changes and this
appropriately authorised and a change log can be in the form of a separate document. However a good way to log changes is in the document itself, which allows a
maintained. reader to immediately see how the document has developed and improved over time. It also means that you don’t need to
update and re-issue a second document at the same time
All records must be accurate and fully
complete.
Documents and records need to be retained to ensure sites can produce full traceability of product. The amount of time
All documentation and records must be documents and records need to be retained is dependent on many factors including product life & any legal requirements
retained for a defined period with
consideration given to:
 any legal or customer
requirements
 the product life
 specific Tesco requirements
This photo shows a document to remind
All documentation and records must be
staff to complete records correctly.
available for auditors.
It is also used as a training aid.
It highlights the most common faults

found by auditors when looking at
records. These are: the use of dittos,
missing information, no actions being
recorded where required for out of
specification tolerances, over writing and
unexplained gaps (e.g. for break time).
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Internal Internal audits of the quality system must Internal audits is a broad term covering a number of different methods of checking compliance with policies,
audits verify whether activities comply with the procedures and standards, with appropriate record-keeping. Ideally internal auditing systems will be a combination
documented procedures, policies and work of these methods, and the approach can vary based on the complexity of the processes. It could be a simple daily
instructions to ensure product safety,
cross-check or countersigning of records by a suitably competent person, for example in smaller sites with low
legality and quality are maintained.
numbers of employees, this can be appropriate for assessing hygiene standards and records.
Internal audits must be completed to a
schedule at a defined frequency
throughout the year.
Audits must be conducted by trained

auditors who have good knowledge of the
processes and area being audited.
Another method is to carry out a full traceability exercise with a cross-check on associated procedures, training
records etc.at every stage of the process. An internal assessment against the requirements of the Tesco Food
Manufacturing Standard must be carried as mentioned in clause 2.11 and 2.12, however other equivalent food
safety standards can be used in addition to this.
Internal audits can be used as a tool for driving positive competition across shifts and departments
Internal Internal audits must include an assessment It is good practice to spread internal audits throughout the year rather than covering all topics in one go. This
audits of all site activities against this Tesco ensures that the site is being assessed frequently and allows the audits to go into more depth. However there may
minimum standard as a minimum. be topics that have more or less significance in your process or industry, so you may decide to audit these more or
requirements less frequently, as long as they are assessed sufficiently seasonally as a minimum
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The auditor must identify where the site is

non-compliant during the audit.
Audit reports must be available and detail

non-conformances and recommendations.
These must be brought to the attention of

the person responsible for the activity
audited.
Timescales and corrective actions must be

agreed by both parties. The completion of
corrective actions must be verified.
Third Agreed corrective actions arising from any As part of your sites due diligence we would expect that any non-conformances raised by any third party or other
party/Tesco technical audits conducted by third customer audit is acted upon in a timely manner.
audits parties/Tesco must be implemented in
agreed timescales and verified.
8
This would be evidence of management commitment
9
Ethical trading and agency labour
The requirements in this section are the minimum global requirement for Tesco. It is included in this manufacturing standard as it is commonly the case that a
technical visit is the first stage of approval.
Section 12 In addition the site must register with SEDEX (where required by the relevant Tesco operating country). Sites rated High or Medium Ethical Risk require an ethical
audit conducted by a Tesco recognised auditor. If rated as High, the site must have an audit prior to supply and every year. If rated as Medium, the site must have an
audit within 6 months and then every 2 years. All non-compliances raised in an ethical audit must be resolved within the timeframes outlined in the Corrective Action
Plan.
In addition the site must have employment agency controls to ensure that legal requirements in the operating country are met and all employees are fairly and
equitably treated.
Ethical trading – The site must be aware of and have SEDEX membership is current with up-to-date Self-Assessment Questionnaire (SAQ).
Requirements for procedures in place to comply with
Tesco Tesco Requirements for Suppliers Ethical audits are conducted and followed up as appropriate.
60388 - Ethical trading requirements.
For detailed guidance please visit https://www.tescosuppliernetwork.com/mod/ouwiki/view.php?id=1098
The site must have a procedure in
place to ensure they keep up to date
with applicable legislation, e.g.
minimum wages, insurances, health
and safety standards.
ETI base code The site management must have
compliance knowledge and comply with the
Ethical Trading Initiative (ETI) Base
Code.
If you see any obvious ethical issues

such as:
 Suspected child labour
 Verbal/physical abuse
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Please send an alert within 24 hours to

the Responsible Sourcing Team,
copying the Technical Manager, on:
For all sites:
ethicalalerts@tescohk.com
Management of The site must have procedures in

agencies place to demonstrate that they
manage employment agencies.
Identification of The site and the agency must be able
agency personnel to identify the individual agency
personnel that are on site at any time.
The site and agency must be able to
identify what job each agency
employee is doing in any one day.
Protector Line Protector Line posters are displayed in
staff areas.
Protector Line If you use Protector Line you must
comply with the Tesco Requirements
for Suppliers 60418 – Protector Line.
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Environment, water and waste management
Section 21
Consideration of the environment ensures that the site operation is compliant with the law, and not having an undue impact on the environment which is positive
for the planet, the reputation of the supplier and Tesco. It can also drive efficiency by reducing wasteful activities.
Environmental A site specific environmental policy The environmental policy should be displayed around the site at key employee locations and can be communicated to staff
policy must be in place, detailing by one or more of the following methods:
responsibility for meeting local •Company handbook
legislative requirements, •Induction pack
minimising overall environmental •Key information on the back of staff security passes
impact and how this is measured. •Company video in the canteen
•During induction training
Employees need to be aware of this policy and understand the company’s commitment to it.
This policy should identify potential environmental risks and contaminants, how those will be controlled, how the site
operations adversely impact on the surrounding local environment.
It should also take into account:

•Waste control
•Recycling
•Use of water
There should be a person who is accountable for this policy This may include a consultant with knowledge of this area
Environment The site must have a system for The Environment Management System considers waste control, recycling, use of water etc.
management managing its environmental
system impact, commonly known as an
Environmental Management
System.
It must ensure environmental risks

are identified and managed, and
must include, as a minimum:
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 potential environmental
risks are identified and
controlled
 control measures for
potential contaminants
are reviewed regularly to
ensure they are effective
 site operations do not
adversely impact on the
surrounding local
environment
Water plan There must be a schematic plan of A water plan needs to include the following plus details of any water treatments in use:
all water circuits within the site •water tanks
which is reviewed annually. •filtration
Potable and non-potable water

It needs to be managed & reviewed by a person responsible for services i.e. Maintenance or environmental manager.
lines must be identified
throughout the site.
This plan should be reviewed on a regular basis or following changes to any building structure or equipment layout
Dead ends on potable water lines
must be eliminated.
Water Where water treatments are in Automated controls and an alarm mechanism are in place to indicate if levels fall outside set limits.
treatment place they must be monitored to
ensure they remain effective An example of an effluence treatment plant can be seen in the photo below.
through monitoring of critical
parameters.
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Water Following treatment more than

Treatment 80% of the water used must be
recycled within the factory.
Water storage Water storage facilities must be Where water is stored for periods of time, the water system is regularly flushed (e.g. taps are run) at defined frequencies.
constructed from suitable
materials, of a suitable size, and Risk based microbiological testing undertaken on all sources of stored water to confirm the effectiveness of controls.
designed to exclude light and pest
entry.
Legionella is a bacterium (germ) found in the environment. It can cause two types of illness:
Controls must be in place to
prevent Legionella within any • Legionnaires’ disease, which is a pneumonia (lung infection), and can often be a severe illness.
storage facility or equipment
where water may be stored for • Pontiac fever, which is a milder flu-like illness.
periods of time.
A Legionella bacterium is widely distributed in the environment and has previously been found in ponds and rivers.
Equipment may include the Problems arise when it contaminates man-made water systems, such as the water in air conditioning cooling systems, hot
following, although this is not an and cold water systems in buildings, cooling towers and other artificial water systems.
exhaustive list:
 staff showers The most common way to get these illnesses is through inhaling water droplets from a contaminated water system
 air conditioning units containing bacteria.
 emergency showers
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 cooling towers Where water is stored for periods of time we recommend that the system is regularly flushed. For example taps and
showers are run at a frequency identified by the water quality risk assessment
Waste water Waste and effluent management

and sewerage must comply with local legal
requirements.
Sewage disposal must not

compromise product safety or
employee health. Waste water and
sewer drains must not be vented
inside the facility.
Waste Where recyclable materials are
segregation collected the site must have a
system in place to ensure effect
segregation.
15
External areas and site security
Section 6
Maintenance of the site boundary and the external areas, combined with good site security, minimises the risk of accidental or unauthorised personnel access. It also
reduces the potential for contamination, adulteration or damage to the products as well as minimising the risk of pest infestation and entry to the facility.
Scope Item Detail What Good Looks Like
Base Site boundaries The site must comply with local The site is surrounded by secure fencing and is monitored by security cameras.
regulations regarding approval or
registration of premises and site
usage.
Boundaries must be clearly defined

and where appropriate have
adequate perimeter fencing.
A site plan must be available.
Base External The external areas must be

maintenance maintained in good order. Vegetation is more than
Where buildings are surrounded by

one metre from
grassed or planted areas, they must production and storage
be regularly tended, well-
maintained and free from items that buildings
could potentially harbour pests.
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The areas immediately surrounding

buildings on site must have
adequate drainage to prevent
pooling of water and allow for
cleaning.
If the external maintenance is the

responsibility of another party (e.g.
neighbouring site, landlord or local
authority etc.) the site must work
with those parties to ensure external
areas do not pose a risk.
Base External External units (including silos, All external structures are sited on a sealed base to help prevent pest ingress.
storage units containers and tanks) must be kept
locked and have restricted access.
This picture shows a portable office unit sited
directly on a hard surface, preventing access for
rodents. Where units are higher off the ground
the base of units should be sealed to prevent
rodent access. The siting of units on soft ground
or loose aggregates is not recommended as this
can provide a habitat in which rodents can
live/burrow
Base Photographic The use of photographic/recording Visitor and contractor procedures include a declaration of any intended use of photographic/recording
recording equipment must be controlled. Only equipment.
equipment equipment authorised by the site
must be permitted on site.
Base Control of All visitors and contractors must Entrance to the site is via a manned security barrier/check point.
visitors and report on arrival and sign in prior to There is a list of approved contractors who have been briefed on the appropriate site controls.
contractors entering the production and storage
areas. Proof of identity must be
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required for persons unknown to the

site.
All visitors must be accompanied at A simple form for all contractors to
all times. complete when entering the site. This
contractor has also been issued a bright
All visitors and contractors must be
yellow jacket ensuring visibility at all times
required to read, understand and
accept health, hygiene and safety and easy distinction from other workers.
rules prior to entering the product
handling, production and storage
areas.
A system must be in place to

adequately supervise visitors and
contractors. This must include a
manager being accountable for their
movements.
Base Control of Access to production and storage A security guard is on site.

employees areas must be restricted to
authorised personnel. A controlled access security system is in place near the security guards for all employees e.g. swipe cards
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Employees are encouraged to challenge unknown visitors.
19
Design and construction of premises
Section 7 Good factory design and construction minimises the risk to the product of physical, chemical or microbiological contamination, while providing the correct
conditions for production and storage in a safe and efficient working environment.
Consideration should be made for the safe flow of product through the facility. This will allow for management controls to be effective, whilst ensuring health and
safety requirements for workers are achieved.
External The structure, fabric, location and layout of

structure and buildings must not pose a risk to the product
fabric (e.g. contamination).
The structure, fabric and all external doors

must be effectively proofed against pests.
Where strip curtains are fitted they must be full

length (but not in contact with the floor),
intact, and kept clean.
Building For sites outside of the EU a valid building

certificates approval certificate covering all
20
floors/buildings that has been issued by the

relevant government body must be available
on request.
All buildings must be designed for industrial

use only and must not be mixed-use buildings,
or shared buildings where there is a fire risk to
workers, please refer to 60007 - Shared (multi-
tenant) or mixed-use buildings.
Internal Walls, floors, ceilings, staircases, drains and
structure doors must be designed and maintained to
allow effective cleaning.
All aspects of the site structure must be

maintained in a good condition to prevent
foreign object risks and/or risks to workers.
21
Drains Drains must be accessible for cleaning. A drain plan is available for the site.
Lighting Lighting in all areas must enable safe working

and good visibility. Adequate lighting must be
in place above product inspection areas.
Electrical There must be a documented contingency A back-up generator, while an ideal solution should the electricity supply fail, is a very expensive investment. As
supply plan in place for if the electrical supply fails. an alternative, sites should consider other ways to plan for this eventuality. For example adjusting hours of
production to accommodate scheduled power outages is perfectly acceptable as a contingency plan. Any
contingency plan must be documented
Ventilation Heating, ventilation and extraction systems
and must be effective at preventing excessive dust.
extraction
An air extraction system must be in place
where processes and operations create
hazardous gases e.g. soldering stations.
Environment Where the control of the environment is
controlled required, as determined by risk assessment,
areas construction and fabrication of walls, floors
and ceilings must be suitable for this purpose.
A programme of environmental monitoring

must be in place including temperature and
humidity control.
Services All services must be designed from material All pipework and electrical cabling is enclosed.
suitable for the purpose and appropriate to the
area where used, intact and allow easy and
effective cleaning.
This must include, if present, although this is
not an exhaustive list:
 pipework for water/gas/compressed
air
 electrical cabling/conduit/sockets
22
 ventilation ducting,
compressors/pumps, fire sprinkler
systems
Storage areas Storage areas must be fit for purpose and The space around the materials allows someone to walk around it and inspect without having to move anything.
maintained in a clean and hygienic condition.
Materials must not be stored directly in contact

with the floor or against the walls to allow
inspection, prevent contamination, and
prevent pest harbourage.
23
Chemical All chemicals, including cleaning

storage chemicals, glues and resin stock must be
stored externally in a separate building to
production and bunded.
All chemicals used on factory must have a

‘Material Safety Data Sheet’ (‘MSDS’).
Where the MSDS indicates potential risk to

the employees, a documented risk
assessment must have been carried out
to determine and manage all Health and
Safety risks. As well as MSDS being posted on this board, other health & safety notices and guides can also be posted to
further support the requirements
For any risks that have been identified a

risk reduction action plan must be in place
and operational.
External External waste containers must be covered. Four types of waste container can be seen in this image. All are covered and tidy. No evidence of debris can be
waste storage They must be managed to ensure a tidy pest seen around the area, minimising the risk of pest activity.
free environment.
24
Design and construction of equipment

Section 8
Good design and construction of production equipment minimises the risk of contamination or damage to the product and ensures products are manufactured
safely, to a consistent quality.
Base Design, All equipment must be properly specified, The location of equipment is important and care should be taken in the siting of equipment, so as not to
construction commissioned, checked against local pose a risk to product and operator safety. E.g. Too close to walls and doorways expecting operators to
and location legislation for suitability and risk assessed crawl under or climb over in an unsafe manner.
for product safety prior to use. The
equipment must also be suitable to
produce to the agreed specification.
25
Equipment must be designed,

constructed and located to enable
cleaning, maintenance, and servicing.
Base Equipment in Equipment which is not being used must
storage be stored so as not to pose a risk to the
product.
Base Guards on Guards must be fitted and used on Eye guard fitted to a buttonhole machine. The same type of guard can be used on all 'fixed cycle'
machinery equipment where there is a risk posed to machines including button sew machines and bar- tack machines
personnel. This may include although this
is not an exhaustive list:
 eye guards
 finger guards
 fly wheels
 grinder wheels
 pulleys
 sewing machine needle guards
 hot air guns
26
27
Operational hygiene and cleaning programme
Section 22 Control of site hygiene and cleaning minimises the risk of product contamination and helps prevent the accidental use of defective materials.
Planning and training for the control of operational hygiene and cleaning ensures that the appropriate resources are in place to maintain the correct standards of
hygiene at all times, reducing the risk of product contamination.
Cleanliness Equipment and facilities must be

maintained in a clean condition
appropriate to its function.
Cleaning equipment, including mops,

must be fit for purpose, in good
condition, easily cleanable and not
pose a risk of foreign object
contamination.
There must be a suitably competent

person accountable for overseeing all
cleaning functions and the standards
achieved.
Cleaning personnel must be trained in

the use and handling of chemicals and
against cleaning procedures.
Clean and tidy Personnel must be responsible for Communication and posters up on walls regarding good housekeeping.
working areas maintaining a clean and tidy working
area. Working areas should be kept today and clean as is appropriate to the product/process taking place in that area.
Employees should be made aware of their responsibilities to keep their work space clean and tidy.
This must be fully communicated to
and understood by all employees. This notice reminds staff of good housekeeping rules within the production environment.
28
Cleaning Cleaning schedules must be

schedules determined by risk assessment and be
in place across all areas. The risk
assessment must be used to
determine the level and frequency of
cleaning required and the equipment
that must be used.
The schedules may include, although

this is not an exclusive list:
 specific equipment
requirements
 when to clean (e.g. between
batches, between shifts,
daily, weekly, monthly etc.)
 when cleaning is required to
support segregation controls
29
Maintenance
Section 24
Maintenance of the structure and fabric of the buildings and equipment minimises the risk of contamination or damage to the product. Effective equipment
maintenance supports the manufacture of products to a consistent quality.
Equipment and Any maintenance or repairs to the

facilities structure and fabric of the building or
equipment must be completed to a
satisfactory standard.
Preventative There must be a planned preventative The PPM can include physical maintenance, or visual monitoring of equipment condition and reporting when
maintenance maintenance (PPM) programme that maintenance is required. Visual monitoring could be carried out by competent operators as part of regular start-up
programme covers all equipment critical to safety, checks, after shift changes or after cleaning.
legality and quality, which is fully
implemented. All the equipment used on site that might have the potential to affect safety, legality or quality should be on a PPM
schedule.
Maintenance programmes should be based on risk assessment (likelihood of breakdown and impact of breakdown
considering the product safety and business impact) and take into account information provided by the equipment
manufacturer/supplier, e.g. recommended checks, frequency of checks.
30
Maintenance/ A system must be in place to record all

engineering maintenance work requested and PPM
records work completed.
Work must be prioritised and completed

in the agreed timescales.
Procedures must be in place to manage

work not completed within agreed
timescales.
Engineers / Repairs to or servicing of equipment must

mechanics be completed by site
engineers/mechanics, approved
contractors or the equipment
manufacturer.
Contamination Risk assessments must be completed It is good practice to schedule maintenance activities outside production hours. Where this is not practical, removing
control prior to work commencing to ensure the equipment for maintenance to an area away from product, or using screening to protect the product and other
product and packaging is not put at risk. equipment are ways to prevent contamination.
Engineering activities must be controlled.

For example welding, drilling, riveting and
soldering must not take place on
equipment while it is being used for
production or on any equipment
immediately adjacent, unless suitable
hygienic screening is in place
Temporary Temporary repairs must be controlled to
repairs ensure product is not put at risk.
31
The material used must be suitable e.g.

no sticky tape, no cardboard
A timescale for a permanent repair must

be established and checks performed to
ensure this is achieved.
Maintenance Maintenance workshops and associated Engineering areas are a concern as engineering can produce dangerous foreign bodies such as metal swarf, and they
workshops and areas must have good standards of may contain materials that are not suitable for a produce handling environment.
tools fabrication, hygiene and housekeeping.
Measures must be taken to ensure that Controls may include, locating engineering areas away from production and storage areas, control of access to the
engineering areas do not pose a engineering area and placing swarf mats at their entry points, and at workstations used for drilling / grinding /
contamination risk to the rest of the site. welding.
This may include for example, although Wherever possible, engineering work should take place away from production areas and it is good practice to keep
this is not an exhaustive list: tools in the engineering area. Where this is not practical, tools should be adequately cleaned prior to being taken into
 isolated from production and open product areas.
storage areas
 secure access Ideally engineers don’t wear the same clothes in the workshop as they wear in packing areas, if there is a risk of
 swarf mats at their entry points contaminating the product. Consideration can also be given to changing footwear to reduce the risk of foreign
objects such as metal shavings, particularly where walkways pass over packing lines, although these types of
Tools must be kept clean, well walkways should be avoided generally anyway
maintained and replaced when
necessary.
Tools and parts must be controlled. A

system must highlight and initiate an
investigation if a tool or part is missing.
Product containers and Tesco trays must

not be used as general storage containers
in these areas.
32
Pre and post The site must ensure that prior to starting
work checks any maintenance activities all product is
removed from the area.
33
After engineering work has been

completed, a system must be in place to
assess cleaning requirements prior to use
in production.
Where a cleaning requirement is

identified it must be undertaken before
production commences and must be
recorded.
Equipment must be checked and signed

back to production by the engineer and
production QA (depending on sites
procedures) following work and any
necessary cleaning.
34
Pest management
Section 23
Effective preventive pest management programmes minimise the risk of infestation to the site and contamination of the product, protecting the business and
the brand. To achieve this it is essential that the correctly skilled resources are available to monitor the site routinely and also rapidly respond to any issues which
occur.
Pest control The pest control programme must be

programme available, based on a documented risk
assessment and should include the
following:
 the product
 the material included
 the location and the type of
premises
 the process
 inspection schedule
The pest control provider may be a

specialist or a trained employee.
35
Service During each visit or inspection,
record/visit activity/action reports must be completed
report and include the following:
 all observations of pests or
evidence of pest activity
 recommendations for action by
the site
 details of any chemicals used
 pest proofing requirements
 poor hygiene/housekeeping
conditions
 access difficulties or lost/missing
baits
 signatures from the nominated
manager or deputy
Management A trained and competent company
accountability employee must be accountable for the
pest management programme and that
the specification is complied with, e.g.
frequency of inspections.
Where paperless, electronic or online

systems are used, the designated
individual and any nominated deputies
must have access to the system and have
knowledge of its content/workings.
Pest Pest monitoring points must be
monitoring appropriately positioned by risk and they
must be robust, tamper proof, and
secured to walls or floors to prevent
removal.
36
Employee facilities and personal protective equipment
Section 9 Provision of suitably controlled employee facilities ensures that the risk of contamination to the products is minimised.
Personal and protective clothing where applied appropriately is there to both protect the product from contamination, and protect the employee or visitor when
carrying out potentially hazardous tasks.
Employee Employee facilities (including rest areas, This image show clean, well maintained staff facilities
facilities toilets and locker areas) must be provided
and maintained in a clean and hygienic
condition.
Toilets Toilets must be segregated and enclosed

from production and storage areas.
Hand wash sinks and drying facilities must

be present.
37
Hand washing signs must be displayed in

toilet areas.
Toilets must be ‘fit for purpose’ for the

nationality and gender of staff, whilst being
maintained in a clean and hygienic
condition.
Consumption Consumption and storage of personal food

and storage of must only take place in designated areas.
personal food
Canteen and Where a site provides canteen facilities,
staff rest areas staff rest areas or a food service the area
must be clean and fit for purpose.
These areas must not be used for

production or storage.
38
Drinking water Drinking water must be provided for all

employees.
This water must be safe and clean for

human consumption and a certificate of
potability from the provider must be
available.
Smoking Smoking must not take place in production

and storage areas, offices and workshops
with direct access to production and
storage areas when it poses a risk to the
product. This photo shows a smoking
area that is in good condition,
Smoking areas must comply with local covered and away from
legislation.
production areas
Where provided, smoking areas must be

maintained in a clean condition and have
appropriate fire safe bins. Smoking debris
must not be disposed of on the floor.
39
Staff transport All vehicles used for staff transport must

meet the relevant local legislation relating
to safety.
Drivers must possess the required licenses.
Employee All sites must have a dedicated space to Lockers have sloping tops and are raised off the floor.
changing allow employees to leave their own
rooms and belongings and to change into and out of Hooks are provided outside lockers for outdoor clothing.
lockers PPE where required.
Visitors and management enter production and storage areas through the same route as staff.
Where lockers are used they must be kept
clean and in good condition, and not be
used to store food.
40
Footwear Footwear must be suitable, clean and No open-toe or high-heel footwear are worn.
appropriate to the activity being carried
out.
Personal The requirement for PPE must be The PPE risk assessment fully considers the intended use of the product and the subsequent supply chain steps.
protective determined by a thorough and
equipment documented risk assessment.
(PPE) PPE for hazardous activities are stored in well ventilated areas.
PPE and uniform must be maintained in a
good condition, and be clean and hygienic.
PPE must be worn for any hazardous

activities. PPE for hazardous activities must
be stored securely with restricted access
and only used for the intended tasks. This
may include although this is not an
exhaustive list:
 ear protectors (e.g. loud
workshops such as knitting, boiler
rooms and embroidery)
 chain mail gloves (e.g. cutting
processes using exposed blades)
 rubber gloves (e.g. handling of
chemical, laundry and applying
adhesives)
 face masks (e.g. operations
generating dust or fibres)
 footwear – (e.g. raw material
receipt/storage.)
Frequency of changing PPE must be

defined according to the risk of
contamination of product.
41
Training
Section 10 Effective and relevant training and regular skills assessment ensures that all staff are able to carry out their tasks safely and competently, resulting in the production
of safe, legal and consistent quality product.
This applies to employees (both permanent and temporary), contractors and visitors.
Training The site must ensure that all Employees should be fully trained and supervised in their role until they can demonstrate full competency. The site should
personnel performing work also offer regular refresher training for all job roles.
relating to product safety,
legality and quality are
competent to carry out their
activity, through training, work
experience or qualification.
The competency must be

verified (e.g. through evaluation,
examination or testing).
If required by local legislation, a

valid and up to date operator
certificate/license must be
available for all employees who
operate specific equipment (e.g.
boiler or lift).
Induction All relevant personnel, including There is a defined time period after inductions whereby new starters have a training buddy or extra supervision.
agency, temporary staff and
contractors must have a
documented and recorded
induction training programme
prior to commencing work and
42
be adequately supervised
throughout the working period.
The induction may include the

following, although this is not an
exhaustive list:
 product safety
 chemical safety
 foreign object controls
including metal
detection procedure
 health and safety
 site specific procedures
(e.g. pinch gauge
testing).
In the event that the induction

content is updated or changed,
all personnel must be trained in
all updated or changed sections.
Trainers Training must be delivered by Trainers have received training delivery training e.g. Train the Trainer.
competent and capable
personnel.
Language The level of language Sites check the level of language understanding using a literacy test.
understanding must be known
for all personnel (including Where appropriate, sites can translate instructions into the languages that are spoken by their employees. This supports
agency or temporary personnel). understanding and ensures consistency. The photo below shows and example of a multilingual sign.
The site must provide

information, instruction, training
and supervision in an
understandable format for all
workers, irrespective of their
national origins, first language or
literacy.
43
This may be translated

documents, pictorial training
aids, use of a translator.
The level of understanding must

be aligned with the importance
of their role.
Training Records of all training must be A training matrix is used to show which employees are trained in which activities.
records available. Where training is
undertaken by agencies on The matrix identifies employees who are untrained, in training, trained and able to train others.
behalf of the site, records of the
training must be available.
This must include as a minimum:

 the name of the trainee
 the date of the training
 the title or course
contents, procedures
covered
 the training provider
 evidence of successful
training
 copies of certificates
may form part of these
records e.g. Safe use of
chemicals
 signature of trainer
 signature of trainee
indicating that they Training should be pre-planned, managed and recorded for each employee in a manner that is easy to understand and
have understood the follow.
training
44
 when refresher training This schedule shows planned training in a variety of areas to be conducted over the course of a year. The records for these
is required should be held in the training files.
The competency of employees

must be reviewed at defined
intervals and re-training
undertaken where necessary.
Where competency tests are

used, wrong answers are
reviewed with, and corrected by
the trainee to demonstrate full
understanding.
Job Documented and agreed work Job descriptions should be available in the appropriate language for that person and should include responsibilities around
descriptions/W instructions and/or job quality of product.
ork Instruction descriptions must be available
for all personnel. Where deputy roles are assigned for key roles within the site, each key member should be aware of their job description and
have a copy of the deputy job description so that they are aware of their job role if deputising.
All personnel must have a clear
understanding of what is Some roles may use a job description as documented evidence of a working procedure as what is expected as part of the
expected of them in their job process.
roles.
45
Personal health and hygiene
Section 11
Good personal health and hygiene management on site minimises the risk of the contamination of the site and product, and assists in maintaining a clean, healthy
and safe environment for those working on site.
Personal Effective personal health and

hygiene hygiene standards must be in place
at the site.
All personnel, visitors and This picture shows

contractors must be required to H&S site rules in
read, understand and accept health,
hygiene and safety rules prior to local language for
entering the product handling, visitors and
packing and storage areas. contractors clearly
displayed
Personal items Where personal medicines must be

kept on the person at all times, these
must be suitably controlled to
ensure they cannot contaminate the
product
Jewellery Personal jewellery must not pose a It is best practice to document any jewellery that is being worn by staff
potential foreign object risk to the
product.
Jewellery may be permitted for

medical or religious reasons based
on risk assessment.
46
Jewellery must not be worn during

the metal detection process.
Plasters All cuts and grazes on exposed
skin must be covered.
Procedures for Procedures must be in place for A spillage kit is readily available on site.
clearing illness managing any bodily fluid spillages
in the e.g. vomiting, and bleeding within If bodily fluid spillages occur (e.g. vomit, blood), procedures can include that it is cleaned immediately, including floors,
workplace the production and storage areas. packing lines and equipment. If dedicated equipment is not used to clean the spillage, the site can ensure the equipment
is completely cleaned or disposed of afterwards. The spillage can be prevented from spreading by stopping people and
equipment movement in the area, which can be done by cordoning off the area or supervision of the area during
cleaning. Procedures can also detail steps for segregation and rejection of contaminated product.
First Aid All First Aid rooms, where provided,

must be clean and reasonably
equipped. They must be able to both
treat and allow a worker private rest
in the case of either a basic injury,
illness or awaiting the arrival of
external medical assistance.
A First Aid room must be provided if

required by local legislation.
Well-equipped First Aid boxes must

be available throughout site and
appropriately trained First Aid
personnel must be available. The
site must ensure that the contents The image below shows a well-stocked first aid box
are in date.
47
Raw material and packaging supplier management
An effective supplier approval and management process ensures that sites receive safe and legal material, of the desired quality, from reputable suppliers. This in
turn reduces the risks relating to safety, legality and quality to the finished product and consumer.
Section 3
It is essential that the site takes the responsibility to manage the risk within their raw materials and supplier base with respect to quality, provenance and responsible
sourcing, to enable customer trust in the supply chain.
Supplier An effective raw material and A helpful risk assessment rating value for raw material suppliers should be generated based on:
selection and packaging supplier selection system •Inherent risk of the material
risk assessment must be in place for all raw materials •Number / volume of materials supplied
suppliers. •Supplier history
All raw material supplier selection

must include assessment of the
exhaustive list:
 ability to deliver to the
required specification
 capacity to deliver to the
volume requirements
 supplier performance
history (e.g. percentage of
rejections at delivery,
response to rejection or
issues, likelihood of
substitution or fraud)
The raw material supplier approval

process must be reviewed annually.
48
Supplier Any raw material, component or Records should be kept of approved raw materials suppliers and their assessment against relevent aspects. This may
approval and packaging supplier to the site must include:
monitoring be approved prior to supply and ability to deliver to the required specification
reviewed annually. capacity to deliver to the volume requirements
supplier performance history (e.g. percentage of rejections at delivery response to rejection or issues, likelihood of
The approval and monitoring substitution or fraud)
process must be based on the
outcome of the supplier selection The raw material supplier approval process must be reviewed annually
process and include one or
combination of the following For some lower risk suppliers, you may choose to evaluate a supplier with a self-assessment. This can ask suppliers to
depending on the level of risk confirm their compliance with the relevant safety, legal and quality criteria of an appropriate standard
identified:
 a valid certification to an
appropriate standard
49
 a site visit to ensure all

selection criteria can be
achieved
 a supplier ‘self-audit report’
which includes all
requirements detailed in
the relevant Manufacturing
Module detailed in this
standard, which has been
reviewed and corrective
actions followed up
Documented records must be

maintained to demonstrate the
above approval process has been
conducted for all approved
suppliers.
50
Contingency Where contingency suppliers are

suppliers used these must be assessed to
ensure there is no risk to the safety,
legality and quality of the finished
51
product, or any reduction in

traceability.
Details of any contingency supplies

must be recorded, and your Tesco
Technical contact must be informed
and provide documented
authorisation prior to using these
materials.
Approved Details of all raw material, There is a re-approval process in place for ongoing suppliers.
supplier list component and packaging
suppliers, and the raw materials and Approved supplier lists must be kept up to date to ensure visibility and control of the supply base
packaging they supply, must be kept
on an approved supplier list.
52
Raw material All raw materials and components,

and packaging including packaging, must have an
and agreed specification, including the
specifications relevant Tesco requirements, that is
signed by both the Tesco supplier
and the raw material supplier.
General Any key production which is Any material re-entering the site from offsite production should be treated as a raw material to make sure that
requirements manufacturing is completed to the right specification.
for secondary outsourced must be declared to
sites the Tesco Technical Contact and For products where the Tesco/F&F brand is identifiable sites must:
Retain a full list of all outsourcing facilities used for Tesco product
must be declared during the
Retain documentation as evidence that Tesco are aware of any outsourcing including the product outsourced and the
audit. facility used
Retain evidence that the outsourcing facility has received an audit conducted by a Tesco approved auditor
Retain evidence that any outsourced product is treated as a raw material when it returns for further processing
All secondary sites must be
approved by either:
 Where the Tesco Brand

is identifiable on the
product the tier 2
factory must be
approved through a
Tesco Non-Food audit
conducted by a Tesco
approved auditor.
Where the Tesco brand is not
identifiable, the tier 2 factory
must be approved by the tier 1
factory in the same way that raw
material and packaging suppliers
are approved and receive
ongoing assessment, annually as
a minimum.
53
For products where the Tesco/F&F brand is not identifiable sites must:
Retain a full list of all outsourcing facilities used for Tesco product
Retain documentation as evidence that Tesco are aware of any outsourcing including the product outsourced and the
facility used
Retain evidence that the outsourcing facility has received a full annual visit by the site
Retain evidence that any outsourced product is treated as a raw material when it returns for further processing
Ensure any
outsourcing
is identified
on your
process
flow
Homeworkers All use of homeworkers and offsite Any off site production must be declared to Tesco and have written approval from your Tesco technical contact.
production must be declared to
Tesco with written approval from For further information on vulnerable workers (i.e. home workers etc.) please visit out Ethical Trading What Good Looks
the Tesco Technical Contact Like site
available on request.
Requirements Sites must comply with all
for Tesco relevant Tesco Requirements
documents. For example,
although this is not an exhaustive
list:
60391 – Restricted Substances in

Textiles
54
60284 – Responsible Sourcing of

Wood and Wood Products
60366 – Raw Cotton Sourcing
60373 – The Approval of Leather
Materials
55
Foreign object control
Section 15
Control of foreign objects, including needles, blades and scissors, present in the production area minimises the risk of contamination or damage to the products
manufactured. Control also minimises the risk of causing subsequent injury or harm to the consumer.
Foreign The site must have a documented risk When risk assessing for foreign object controls things that you may want to consider are:
object assessment and corresponding •Start up checks should identify if equipment is damaged in any way.
controls and effective procedures in place to •It is good practice to have procedures in place for the purchasing of small items so that where possible they are metal
risk eliminate (as far as practically detectable.
assessment possible) all potential foreign object •It is good practice to inspect any area where wire scourers or brushes have been used.
hazards. •Swarf mats are placed on the ground for engineers to walk over on exiting the workshop area. Debris caught on the
bottom of the shoes or boots is transferred to the mat and does not enter the factory. The mat should be regularly
The risk assessment may include the changed to ensure it remains effective.
following, although this is not an •It is good practice to keep the contents of first aid boxes to the minimum required so as to minimise the risk of potential
exhaustive list: product contamination.
 the production process •Alternatives to staples and drawing pins are used wherever possible
 level of maintenance for •Paperless systems eliminate the need for staples and paperclips in a factory environment. However they can be
equipment expensive and alternative methods such as collation of documents in clean plastic wallets or using A1 sized pre-printed
 glass record sheets can also be good.
 plastic •PPE should be supplied to the site without any unnecessary packaging that could pose a foreign object risk. For example
 wood card inserts, rubber bands and pins.
 metal (e.g. staples) •Disposable PPE and liners should be removed from their packaging and stored in clean containers.
•Pens should be one piece with no lid and no clear plastic parts
Where any material identified as a •For sites where metal detection is used consideration should be given to the use of metal detectable pens.
potential foreign object is used in the
process or integral to the product it
must be suitably controlled to prevent
contamination.
Product packaging or distribution

trays/crates etc. must not be used to
store other materials (e.g. nuts, bolts,
tools, chemicals).
56
Foreign When a foreign object is identified, or

object detected, the source of the material
investigation must be fully investigated. Where
possible this investigation must be
used to instigate corrective and
preventative action to reduce the re-
occurrence of the contamination.
Records of any investigation must be

kept.
Sharps The site must have controls in place to All knives/scissors issued are individually numbered, or marked with the user name.
cover knives, blades, scissors, snips,
57
tweezers and other metal Sharps are accounted for on a register at the start and end of production.
equipment/tools.
Knives and blades are stored on shadow boards, magnetic holders or in secured, clean storage.
The controls must include, although
this is not an exhaustive list:
 only site issued sharps in use
 controlled sharps are This demonstrates a very simple and effective process
uniquely identified for the control of issuing new cutting blades in a cutting
 no snap blades room. A record is established for each different type of
 knives and blades must only blade and size/length of blade. As each blade is issued
be used for the task for which
they were designed the date, quantity, name and signature are recorded
 sharps must be accounted for along with the balance of blades remaining in stock.
and the condition checked When a new box of blades is issued the balance must
and recorded (start and end
of production as a minimum) read zero.
 blade changes must be
recorded
 metal equipment must be
tethered to the
workbench/table or the
person
 knife and blade sharpening
must take place away from
packing areas and equipment
must be returned in a clean
condition
 sharps must not be permitted
in personal lockers
 in the event of breakage or
loss, all parts must be
accounted for and the
incident logged. Corrective
action must be taken to
prevent re-occurrence.
58
 in the event of breakage or

loss a system must be in place
to identify and control
potentially contaminated
product.
Pins, drawing Pins, drawing pins, staples or
pins, staples paperclips must not be used in any
or paperclips part of the manufacturing unit or any
office that has direct access into a
production area.
Glass Where possible glass (including Shatterproof covers on all strip lighting.
windows and equipment) in
production and storage areas must be
eliminated and replaced with suitable
alternatives.
A procedure must be in place for the

management of glass and hard plastic
breakages.
59
Wood The use of wood within the site must This image shows a good example of layer separation between pallets and product. In this example the product is
be minimised where possible. placed into boxes with lids which protects the product from contamination from both the pallet and other boxes
stacked on top.
Controls to minimise the risk from
wood can include:
 layer separation between
wooden pallets and product
 coverage of materials stored
under wooden pallets on
racking systems
 removal and segregation of
broken wooden pallets etc for
repair or disposal
 identification of where
wooden pallets are permitted
within the site
Wooden pallets, boxes, containers etc

must be in a good condition and not
pose a contamination risk.
60
Calibration and verification
Section 17
Calibration and verification of measuring and monitoring equipment critical to product safety, legality and quality minimises the risk of manufacturing defective,
unsafe or illegal products.
Master list Equipment that is critical to product safety,

legality or quality must be calibrated. The This type of form can be used to maintain a
site must maintain a master list of comprehensive list of all pieces of equipment that
equipment to be calibrated. require calibration either externally or internally. The
last date when that specific piece of equipment was
The master list/calibration matrix must calibrated and the next date calibration is required
include: can be recorded to ensure that this requirement is
 serial numbers and/or ID numbers maintained on a continuous basis.
of equipment
 frequency of calibration These records can also be maintained as an additional
 date of last calibration
means of demonstrating the process is managed
 date next calibration is due
 frequency of internal verification
 acceptable equipment tolerances
61
Equipment All equipment specified on the Master List

calibration must be calibrated to National Standards,
to at least the minimum frequency
recommended by the equipment
manufacturer.
Calibration must be conducted across the

equipment’s normal operating range.
Calibration certificates and records must be

available and up to date.
Equipment All critical measuring and monitoring Verification checks should be undertaken at pre-determined points e.g. Middle and end of shift and at the start of
verification equipment must be verified by a trained each new production run or at time intervals throughout the shift. This should be done on all equipment critical to
person, on a frequency dictated by risk product safety and at a schedule determined by risk assessment for equipment used for monitoring quality and
assessment. legality.
Records must be maintained.

Inaccurate Equipment that is operating outside of It is good practice to have a procedure in place to identify corrective action required if measuring equipment is found
equipment specified limits must be taken out of out of calibration.
service, replaced or repaired.
The procedure should include quarantine and confirmation testing of all stock produced since the last good test.
Documented corrective action must be
evident where inaccurate measuring or A contingency device for critical control equipment such as metal detectors should also be available if equipment
monitoring equipment has been used. becomes out of service.
Where inaccurate equipment is identified

during production, product must be re-
checked or inspected using accurate
equipment, prior to supply.
A contingency or back-up device must be
available in the event that a measuring
device associated with a critical control
62
point, or legal measurement is out of

service or away for repair.
63
Transport
Section 25
Management of transport providers and vehicles ensures that products are protected during transport and that the risk of contamination or damage to the product
is minimised.
Transport All vehicles used for transportation must

be well maintained and in good hygienic
condition to ensure the product safety,
legality and quality of materials is not
compromised.
Transport includes that of, although this

 raw materials
 packaging
 work in progress
 finished goods
Procedures must be in place to minimise

the risk of cross contamination (including
taint) during transportation and ensure
product is transported as per the product
specification.
Third parties If a third party haulage contractor is used,

all the requirements above must be
defined within a contract or Service Level
Agreement (SLA) and effectively
managed.
This must also include storage facilities

where used as part of the contract.
64
Loading Where materials are susceptible to

weather damage, vehicles must be
loaded and unloaded in covered bays or
the materials suitably protected.
65
Security Procedures must be in place to ensure

product is held under secure conditions
during transport.
66
Customer complaints, product withdrawal and recall, and incident management
Investigation and analysis of customer complaints can increase product quality, supports continuous improvement and can prevent minor issues progressing into
major incidents, which can all affect customer trust, as well as put them at risk.
Section 5
Effective management of emergency situations enables appropriate decisions and communications to be made by authorised people, resulting in the protection of
customers, the product and business continuity.
Complaints A complaints policy and procedure A policy and procedure for complaint handling must be in place. It is advisable that the site also set a
procedure must be in place. threshold that triggers a full review of their policy when a defined number of complaints linked to a product
or production line is reached
This must be part of the site incident
management procedures where A defined number of complaints linked by complaint type, product or production line will trigger a review.
necessary.
67
Complaints All complaints relating to product

handling manufactured for Tesco must be
procedure captured on a record and be given a
unique reference. The record must
include:
 the product information
 the nature of the complaint
 the method of reporting (e.g.
phone, email, media)
Complaints from all sources must be

covered in the procedure. These must
include, although this is not an
exhaustive list:
 customer representatives
(e.g. technical managers,
buyers, support office)
 stores (store returns,
distribution centre rejections)
 retailer customer complaints
departments
 law enforcement bodies
 output from internal or
customer quality assurance
processes e.g. testing panels
 site internal departments
(e.g. operational
departments)
 customs and export reports
Complaint All complaints must be investigated in

handling and detail.
investigation
68
The complaint handling procedure

must identify what steps are taken
depending on the type of complaint
(e.g. foreign object, printing, quality,
make-up etc.)
The investigation must determine

whether the complaint is product
specific (isolated) or is an issue which
is likely to affect more than one
product.
Full records must be kept and the

outcome of the investigation
promptly reported to relevant
personnel and departments.
Corrective actions must be effective to

prevent a re-occurrence. Mechanisms
must be in place for briefing corrective
action with the relevant departments.
Where requested the full corrective

actions must be reported to Tesco.
Complaint Complaint levels and trends must be Complaint numbers and type are tracked against units sold.
monitoring and monitored. If there is an increase in
trend analysis the severity or number of complaints, Complaint trend information is graphically displayed on notice boards at suitable locations.
an investigation must be prompted.
Information from trend analysis of

complaints must be communicated to
the site management, production
teams and your Tesco Technical
contact.
If complaints are received on other

brands produced by the factory, which
69
may affect the safety or legality of

Tesco product, the site must report
this to Tesco.
Incident Procedures must be in place to An Incident Response Protocol is a useful tool which helps co-ordinate action in the event of an incident
management manage all incidents and potential and, dependant on your production facility, could include the following information:
emerging issues which could affect •Roles and responsibilities of the Rapid Action Team
product safety, legality and quality. •Meeting plans
The procedures must include a •Incident Escalation plans
defined incident management team. •List of external stakeholders and suppliers to contact
•Record Keeping
Issues could include the following, •Out of Hours protocol
although this is not an exhaustive list:
 disruptions to operations and Each Incident Response Protocol will differ depending on business size, production volumes and risks
distribution, water and associated with the product. Suppliers are encouraged to develop an Incident Response Protocol bespoke
energy supplies, labour and to their facility
communications
 fire, flood and other natural
disasters
 sabotage and malicious
contamination
 vandalism and terrorism
 product safety, legality and
quality issues
The likelihood of the occurrence of

the identified issues must be risk
assessed. A communication plan must
be in place to manage potential
incidents.
If an agent or supplier deals with

Tesco on behalf of the manufacturing
site, the agent or supplier must have
emergency situations in place. There
must be no delay in providing
70
information to Tesco as a result of this

being completed via an intermediary.
Contacts Key contact information must be This photo shows a template for a key
maintained. contacts list. The list should be updated on
a regular basis and can be used in the event
Contact information (both working of an incident or issue where Tesco need to
hours and emergency out of hours) be contacted.
must include the following, although
 internal contacts
 Tesco
 suppliers of both raw
materials and services
 local government and
enforcement bodies
Any issue that impacts on supply

or affects the brand integrity must
be reported to Tesco.
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Withdrawal and The site must have a system in place

recall plans to enable the effective withdrawal and Withdrawal and recall plans:
recall of products should this be
required (e.g. where safety and/or There must be a process in place which details how a site will deal with the withdrawal or recall of a product.
legality or quality is in doubt or there is
a reputational risk). This process should include the following:
•Who to contact when an incident arises
The procedure must include in detail, •Compiling an Incident Log
although this is not an exhaustive list: •Investigating the incident and agreeing corrective actions
 how to report an incident to •Completing an EPW form
Tesco
 the full process of traceability Traceability can be managed through a system that uses barcodes to trace a product/ingredient through
identifying key points in production and distribution. There are a number of companies that sell traceability software and
production and distribution consultancy services that may be suitable for your production site.
 how product will be
withdrawn or recalled from
distribution and sale
All affected product must be located

with 24hrs/48hrs depending on
geographical location.
Reconciliation of product must be

verified against production records.
The withdrawal/recall of Tesco brand

products from Tesco stores will be
managed by Tesco.
Any communication with external

bodies, Government or enforcement
agencies, regarding Tesco branded
products must be co-ordinated by
Tesco.
Mock recall and A mock recall or mock incident must
incident be undertaken by the site to test the
management effectiveness of the system and the
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incident management team

understanding of the recall
procedures.
The test must occur annually as a

minimum. Out of hours tests must
occur at least every 2 years.
If a mock recall is undertaken this

does not replace the need for a
traceability test.
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Product safety and risk assessment
Section 11 Risk assessment of manufacturing processes ensure that safe and legal products are consistently produced to the agreed specification and desired quality. This is
fundamental in supporting the required due diligence of all processes.
The site must ensure that a risk assessment has been carried out on all products prior to sampling or product development. The site must also have systems and
procedures in place throughout the development and manufacturing of the product that ensures the product meets the agreed specification and Tesco
requirements l on a continuous basis.
Risk An effective, accurate and documented risk It is good practice to take in to account all the risks when producing a product. This could be done using the
assessment assessment based programme must be in following:
place. This must include detailed procedures, •FMEA (Failure Mode Effect Analysis) process
clearly recording the process and •'What if' analysis - identifying threats and hazards
responsibilities. For example: •Likelihood and severity table - how likely is it to happen and how severe would it be?
 the embellishment on a product •Restricted Substances lists (see document below)
does not affect the functionality of
the zip fastening
 metal trims on a product to be used
in the sun and come into contact
with the skin do not conduct the
heat of the sun
 cultural or political messages
This programme must be reviewed at a pre-

determined frequency (annually as a
minimum) or prior to changes of
product/process which may affect product
safety.
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All products must adhere to the General Product Safety Directive (GPSD).
Risk A completed children’s ‘Product Risk

assessment Assessment Form’ must be available.
(Children’s
products) Where risks have been identified, there must
be clear evidence that these have been
discussed and actions agreed with the Tesco
Technical Contact.
Evidence must be available to demonstrate

all planned actions and controls have been
fully implemented.
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76
Product development, product specifications and style files
Product design and development procedures, including risk assessment, ensure that new products, processes or changes to product, packaging or manufacturing,
results in the production of safe and legal products, consistently to the agreed specification.
Section 4
Detailed, accurate specifications ensure that safe, legal products are supplied to the agreed quality.
Design and Where a site is involved in all stages

development of sample development evidence
must be available to demonstrate
the following:
 designs must be reviewed
prior to production
 samples must be reviewed
to check they meet
specification prior to
sending to the customer
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Pattern For all garments except knitwear
Management evidence must be available that all
patterns have been downloaded
directly from TQC.
If the site does not have access to

TQC evidence must be available
that all patterns have been
downloaded directly from TQC by
the supplier and shared with the
site with no amendments.
These photos show patterns being checked for

accuracy in a dedicated pattern room
78
Pattern For knitwear and non- garment
Management sites where the site creates their
(knitwear and own patterns from the initial
sample, the patterns must be
non-garment
checked for accuracy to
sites) requirements and that they allow
for inconsistencies in raw
materials.
All patterns must include

assessment of the following and
include records of this, although
• all patterns are fully
checked for accuracy before
releasing into production
• shrinkage tests for both
washing and steam must be
carried out on a minimum of 10%
of every dye lot (sewn products
only)
• patterns must be
amended for different shrinkage
bands to control measurements
(sewn products only)
• before and after washed
measurements are recorded on a
measurement chart for laundry
wash products
• the Children’s Product
Risk Assessment must be available.
 all records are clearly
dated and maintained
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Automated If the site uses a Computer Aided

pattern and Pattern System the site must
cutting ensure all Tesco approved patterns
have the following information
machines
visible:
 Style number
 Block ref number
 Size
 Notches
 Grain line
 Seam allowance
 Date
 Signature
Mannequins
(Clothing, All mannequins used must be
Sites should have Tesco approved
Maintenance approved Tesco stands.
mannequins and also appropriate CAD
audits only)
facilities in sample rooms
Tesco Certified TCGTs are required at supplier

Garment level rather than site so can
Technologist therefore be:
 on site at the time of the
(Clothing,
audit
Maintenance  contactable by phone at
audits only) the time of the audit
The site must hold copies of the

certificates for all TCGTS and have
them available on request.
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For more details contact the in-

country Tesco Technical Contact.
Packaging The performance and durability
performance of packaging must be tested
through, for example:
 transit trials
 drop tests
 endurance tests
 vibration tables
 stack testing
Packaging design and testing

must consider how the product
is stored e.g. in store or direct
to customer.
Records must be kept and

available on request.
Pre-production Prior to the start of any bulk The meeting includes:
sample and production of a new style a Pilot  review and approval of pre-production sample quality
meeting Lot/Size set/Sample is made either  risk assessment
on a production line, dedicated  components and packaging materials status
pilot line or a sample room using  machinery and equipment status
the correct machinery that will be  review of any customer testing
used in bulk production and the  Tesco secondary site approval status
 updates of master and production schedules
correct quality raw materials.
 managers from all
departments attend
 records are kept
 actions of risk analysis are
discussed
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 evidence of corrective
actions taken following
meeting
Approved Sites must ensure all approved

Samples samples are well managed.
For Tesco production both the

red and green seal must be
available for inspection with full
records of any changes made
during the sealing process.
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Green seal samples must be taken from the first production of the launch of
the product. The Green Seal sample must be approved and signed by the
relevant Tesco Technical Manager and kept on site for future reference
Product claims Where product claims are made Documented evidence must be maintained to support all on-pack claims – this may include intake checks, traceability and
documentary evidence must be processing records etc. Any changes to materials / materials suppliers, product formulation or process should be reviewed in
available on site to substantiate the context of their potential impact regarding on-pack claims before making any changes.
these.
Horizon scanning and the use of TACCP is recommended where a known issue is likely to arise
Claims may include, although this
 Organic
 Fairtrade
 100% cotton
 ‘Anti-bacterial’
Copies of any product testing

internal and external and/or
certification must be kept and held
in the ‘Style File’ or with the
specification.
Legal Legal aspects of all products must
requirements have been addressed and
documented in the specification
and Style File. Examples of
legislation are, although this is not
an exhaustive list:
 EN17
 Nightwear
 Draw Cords
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Agreed Agreed specifications must be in The below images show agreed specifications for display in the production area
specifications place for each different
design/product. These must
include the raw materials,
construction details and
packaging.
Copies of the specifications must

also be accessible at all relevant
production areas.
Specifications must be agreed in

writing by both parties (electronic
signatures acceptable).
Production The product specifications must be
specification held in a master ‘Style File’ which
and style file must include where applicable by
product type the following:
 Purchase Order (PO)
details
 embellishment/printing
standards (including both
design, colour and
position)
 size chart or grading chart
(Footwear)
 make up specification
 raw material specification
and standard
 laundry wash colour and
handle approved
standards (where
applicable)
 bulk component/trim
approval card
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 label and packaging

details.
 product claims
documentation
 Children’s Product Risk
Assessment form
(mandatory for children’s
products including pinch
setting and pull test
reports and copy of metal
detection records)
 all comments related to
the review and approval of
all samples (Green and
Red Seal Workbook)
 product risk assessment
pilot lot/size set/sample production
records
Factory specific Where internal site specific Individual version numbers and dates of issue (for document control purpose).
specifications specifications are used they must Changes to the product result in revised specification issued with a new version number and date. All copies of the previous
be controlled and accurately version must be removed and destroyed other than the original ‘master copy’ which must be held in a central location in a
reflect the current Tesco controlled manner.
specification.
All samples and associated

documentation to be retained for
10 years, or as agreed with your
Tesco Technical Contact.
Using Tesco Where your Tesco business unit
Quality specifies you must use the Tesco
Quality Connect, the supplier must
Connect use employees who are trained to
correctly operate the system and know
where to access policies and
documents relevant to the
products.
85
The following information must be

up to date, although this is not an
exhaustive list:
 supplier and site details
that all alerts have been
acknowledged
86
Process control
Adequate controls, monitoring and records covering raw material and packaging, work in progress, packing, processing, finished product, processes and equipment,
Section 13 through to the despatch of finished product, and including the management of out of specification materials, prevents inadequate, faulty, unsafe or illegal goods
from reaching the customer.
Critical path Key critical path dates based on It is important to make sure that your production plan fits with the Tesco Critical Path and that any concerns or issues are
management the Tesco critical path shared with Tesco so that both supplier and Tesco can work together to make sure everything runs smoothly from goods
(CP) and requirements must be available on in to delivery and there are no delays. This process can also help to improve efficiencies within the factory by measuring
site and include the following,
production output hourly and taking action to improve and optimise production potential
although this is not an exhaustive
planning list:
 Identified for each
individual purchase order
 Communicated to all
relevant personnel
 Records kept
 Performance reviewed
A system must be established to

inform Tesco where revised dates
have to be established.
A production planning system

must be established to ensure
each order is planned into
production based on the CP dates
and the estimated production lead
times.
Output is measured hourly and action taken to improve and optimise production potential.
Production efficiencies and
Operator performances must be
87
measured to ensure production

lead times are met.
Order of A flow diagram or site plan must be A flow diagram or site plan covering all steps in the manufacturing operation must be in place. This may be generic but it
operation prepared to set out all aspects of is critical that all process steps are included and identified by product.
the manufacturing operation,
from raw material receipt through
to processing, storage and
distribution. The diagram must
include:
 plan of premises and
equipment layout
 raw materials flows
 sequence and interaction
of all process steps
 critical control points
 process delay e.g. setting
 outsourced processes and
subcontracted work
 rework and recycling
 key segregation
All documents must be validated,

signed and dated.
88
Raw material All incoming raw materials must be The site can segregate simply using a labelling system that is clear and understood by all workers.
intake controls held in a dedicated and clearly
89
identifiable quarantine area until

the inspection, testing and colour
continuity processes have been
completed.
The site must have documented

procedures in place for the
inspection, testing and colour
assessment of all batches and/or
dye-lots of raw materials.
The inspection, testing and colour

assessments must be conducted
against the ‘Tesco Textile
Performance Standard’, the
relevant ‘Tesco Fabric Standard’
and the ‘Tesco Approved Bulk
Submission Standard’.
All orders for raw materials used

must clearly specify the need for
them to be ‘Phthalate Free’ as per
document 60391 Restricted
Substances in Textiles.
Compliance to this must form part

of the intake approval process.
All raw materials used must be

stored separate to any phthalate
containing raw materials.
Intake records must be retained

and be available on request.
90
Raw material Fabric inspection machines must In many situations a factory may be only a manufacturing unit in the form of a CMT (Cut, Make & Trim) supplier, where the
intake controls – be of a suitable standard, including raw material is ordered and initially delivered to a 'head office' for approval, then forwarded on for manufacturing. In this
fabric only lighting that allows the process to case the factory must be aware that they can only use a raw material if it has been through the approval process, for this
be carried out effectively. All
reason the raw material must be clearly identified as approved and documentation must also be available to clearly
machines must be regularly
demonstrate this.
calibrated and records and
samples must be retained to
demonstrate this.
A minimum of 10% of each fabric

batch must be subjected to the
following intake checks, although
this not an exhaustive list:
 a visual inspection
process that must be to
an established inspection
standard, such as the ‘4
point system’.
 in-house testing on every
These examples demonstrate fabric inspection aids. The process route for the fabric approval process is clearly
batch for colour fastness,
shrinkage, spirality where displayed. In addition, very clear guidelines on different types of fabric
facilities are provided.
 the moisture content of faults that require identification during the inspection process are displayed in both examples
all yarns must be checked
against specification
using a calibrated
moisture probe
 all fabric must be clearly
marked up for faults on
delivery
Records must be maintained and

available.
If the inspection and cutting is

conducted centrally the site must
91
have documentation to show that

minimum of 10% of each batch
has been inspected
100% of all embellished fabric

must be inspected for
embellishment quality and
attachment security.
All fabric approval details from one batch of fabric all held together in one folder. This could include colour continuity
swatches, the fabric weight sample, shrinkage results and even the physical inspection records.
This is an example of a 'moisture

content probe' that can be used
for measuring the moisture
content within a cone of yarn
92
Raw material All yarn and fabric delivered must

intake controls – be accompanied by test reports
fabric and yarn from either an accredited
only laboratory as listed in the Tesco
Testing Manual or Tesco approved
internal laboratory
Where no test reports are delivered

with the bulk fabric or yarn then
the fabric or yarn must be held in
the quarantine area. The fabric or
yearn can only be released once
the necessary tests have been
conducted by an accredited
laboratory and the results
received.
Fabric or yarn can only be released

when the test reports meet the
specification within the allowed
tolerances.
93
Raw material All yarns and jersey knitted fabric

intake controls – must be weighed on delivery and
yarn and knitted checked against the delivery
fabric documentation.
The image below shows incoming yarn. Each is protected by a ploy bag and they are sorted by colour
Raw material A minimum of 10% of all PU and
intake controls – leather must be checked against
PU and leather an approved swatch sample at
intake for:
 thickness
 colour
 quality
Laminated PU and leather must be

checked for thickness using a
calibrated thickness gauge and
adhesiveness for the laminated
layer tested by using a peel test.
Records must be maintained and

available.
94
Raw material All trims and accessories must be

intake controls – checked against an approved
trims and sample for:
This demonstrates a very good
 quantity
accessories system of establishing an approval
 quality
 size card for each style. An approved
 colour sample of every trim in each
colour & label is attached to a
board. These can be used as
For multiple trims such as buttons, standards as part of the visual
poppers, rivets etc. a minimum of inspection for the bulk approval
10% of each delivery must be process
inspected
Raw material All ‘dyed to order’ trims and For dyed to order trims and accessories, colour tolerance /shade and colour fastness must be checked against approved
intake controls – accessories must undergo the samples for each roll/cone/bag of every dye batch and must be recorded.
dyed to order and following tests:
 colour fastness for each All trims must have clear identification in storage areas. Racks/pallets should be used for trims storage
coloured trims
dye batch.
 colour tolerance against
the approved colour
sample for each roll, cone
or bag from every dye
batch and continuity
between each roll, cone or
bag.

available.
Raw materials For all raw materials sourced from
from the market market the site must undertake
place testing and be able to produce
evidence of chemical compliance.
Records must be kept.
95
Intake controls All materials, components or

– secondary product that is the result of
site production outsourced production must
be subjected to the same
intake checks as raw materials.

available.
Storage of raw All raw materials must be
materials, stored in conditions that meet
packaging and the specification.
equipment
Where external storage of raw
materials, packaging and
equipment is unavoidable,
items must be secure,
protected from deterioration,
contamination and pests, and
must be inspected or
decontaminated prior to use.
This includes all Tesco reusable

product crates/trays.
Non-conforming Non-Conforming materials must There is a dedicated and permanent quarantine area with restricted access
materials be rejected at intake. Where this is
not possible these materials must
be ‘quarantined’ and identified.
96
A segregated area must be

identified for the quarantine of
non-conforming raw materials,
packaging or finished products.
Where a computer based system is

used, this must render the material
quarantined and unavailable for
use.
This area is clearly

identified and is very tidy,
however to improve this it
would be better to locate
in a separate area to the
approved fabrics and to
make more secure.
Hold and release A documented procedure for risk

assessment must be in place to
manage the release of
quarantined raw materials and
packaging.
97
The risk assessment may include

the following, although this is not
an exhaustive list:
 the issue that led to
holding the material
 the intended use of the
material
 the significance of the
issue
Records must be kept of products

on hold and released. This must
include as a minimum:
 checks to ensure all
affected product has
been isolated
 total quantities
 identification codes
 the time and date raw
materials or packaging is
put on hold and released
who released the raw materials or
packaging, and under what
conditions (e.g. reworking,
processing as normal, extra
checks, rejecting to supplier,
disposal etc.)
Stock rotation A stock rotation system must be in In general, stock should be used in the order that it is received by the site, according to the first in, first out (FIFO) principle.
and material place to ensure that raw materials Where FIFO is not appropriate, there are other ways to monitor stock to ensure that it will be of the correct quality at the time it is
control received first are be used first (first despatched, e.g. visual inspection, first expiry, first out (FEFO).
in – first out.) In the event that
other factors determine which
order stock is used evidence of
that decision-making must be
available, e.g. first expiry – first out
Part-used raw Opened or part used raw materials
materials batches (including any used for
development work) must be
98
effectively controlled including

labelling, reclosing, covering
(where possible) and protected
from the environment.
Segregation Where required, suitable
during storage segregation controls must be used
and processing to reduce the risk of cross
contamination, especially where a
product claim is being made on the
final product. for example dark
fibres onto light, ‘Organic’ or
‘Fairtrade’.
Chemical Where any hazardous It is good practice to have the following segregation controls in place to manage any risk of cross-contamination:
management chemical, glues and resins used •Organic raw material stored separately
•Raw materials with product claims e.g. provenance, fairtrade, organic cotton
during in production are transferred •Part used material stored in the lower levels of warehouse racking
production from its original container it •Flammable materials stored outside
must be correctly labelled with
the contents, appropriate
hazard warning label and used The glues/resins have been transferred from their original bulk
containers into clearly marked, easy to handle containers. These are
for their intended use only.
further stored on an easy to manage trolley for easy movement and
safe storage. This process also shows a glue/resin being further
transferred into a smaller container that will control the amount
being released during the production process. Also note the
provision of a funnel to assist in the transfer of the glues/resins
when required
This is a good practice for the safe transfer of glues/resins from

their central storage to the production area on a daily basis
99
Oil Storage, showing movable trolleys to allow use within other areas
of the factory, but these also are able to contain any spillages
Machinery Each production line must be

checks checked for manufacturing
quality, machine settings and
technical requirements against
all required specifications
before production starts.
100
Records must be kept.

Work in progress Work in progress (WIP) must be
clearly labelled with internal use
and product details and protected
from contamination where
necessary.
Moisture content Where humidity is identified as a Humidity could be identified by the site as a seasonal risk or all year round in certain areas of the world.
potential risk to the product the This process must be applied whenever humidity reaches a level that puts the product at risk from mould or damp issues.
moisture content must be checked
throughout the production
process at defined points and prior
to despatch.
Full records of issues identified and

corrective actions put in place
must be kept and available.
Product If the finished product
deviation deviates from the agreed
specification your Tesco
Technical contact must be
notified and the product
must be quarantined
pending risk assessment.
Tesco must be notified

immediately of any illegal
and/or unsafe products
which have been produced
and despatched.
101
Process If the product or process

deviation deviates from specification or
set procedures, then root
cause analysis and correct
actions must be taken and
documented.
Tesco must be notified

immediately of any illegal
and/or unsafe products which
have been produced and
despatched.
Production Trays/containers of work in

trays and progress or finished product
containers must be fit for purpose.
Production Trays/containers of work in
trays and progress or finished product
containers must be blue plastic.
Packing All Tesco product must be packed A dedicated packing area for Tesco product, to avoid cross contamination. The area should be maintained by way of a
in a dedicated area which is clean, “clean as you go” policy. Lighting should be protected to avoid glass contamination; it must also be of an acceptable
tidy and has good lighting. brightness.
 Packers must pack one
style, size and colour at a
time.
102
 All packaging labels must It is important to have good processes in place within the packing area to ensure that all product gets packed into the
be stored securely and correct packaging with the correct labels applied. This means ensuring that the line is cleared of previous packaging and
independently by style labelling prior to starting the packing of a new product.
size and colour and
issued/used on a style, The image below shows employees packing one style/size/colour at a time
size and colour basis.
 An approved packing
standard must be
available within the
packing area.
 Packers must be issued
with bar-code numbers to
check on a size/colour
basis.
 At the end of packing for
each style, colour and size
batch all spare/un-used
labels must be returned to
the secure storage with
records kept
At the end of the contract all
remaining packing labels must be
returned to central stores with
records kept.
Packing with pins The site must not use pins to pack
Tesco product.
Where another customer requires

their goods to be packed with the
use of pins, this must be carried
out in an area enclosed and
segregated from Tesco product.
Product release The site must ensure that only
product that meets the agreed
specifications is released for
despatch.
103
The site must ensure that product

is not released for despatch unless
all agreed procedures have been
followed.
Product returns A system must be in place to
manage product which has been
rejected at either pre-shipment or
distribution centre and is returned
to the site.
Product rejected by Tesco for

quality reasons may only be
reworked and/or re-delivered to
Tesco following authorisation by
your Technical contact.
Re-labelling of returned/rejected
products may only be carried out
with written approval from your
Tesco Technical contact.
104
Needle control
Section 14 This module ensures that the factory has robust needle controls in place and therefore reducing the risk of production contamination, injury to our customers and
damage to our reputation.
Needle control All types and sizes of needles used in any type of
machine, including knitting machines, or hand
held ‘swift tag gun’, used in any section or area of
the production process, must be controlled. This photo is of the needle breakage form at a sites
supervisor station and shows the one in one out
The needle management process must include the working well. Each supervisor is given 10 replacement
following, although this is not an exhaustive list: needles each shift and cannot get any more unless
they produce 10 broken needles (in the plastic bags)
 needle allocation must be controlled by
an authorised person and recorded on the sheet.
 needles to only be exchanged with the

same type
 new and used needles must be stored
securely
 stock replenishment must be on a strict
‘New for Old’ exchange
 all needle records must be kept for a
minimum of 1 year from shipment
Please refer to Tesco Requirements for Suppliers

60121 – Needle control for textiles.
105
This photograph shows a well-controlled and managed

process for the centralised stock of all needles. These
must be held in a secure location and managed by an
authorised person. By having central stocks managed
by another responsibility will give a more robust
process. This must also be further supported by a
'Stock Control System' which can be used when the
process is audited.
106
Hand sewing Any hand sewing operation on a product

needles and must be agreed with the Tesco Technical
tools controls Contact at the product development stage.
Where products require a hand sewing

operation the needles and any tools required
must be controlled.
Hand sewing on repairs is not acceptable.

This shows a good practice of establishing individual hand sewing kits, each box/container contains a set
amount of tools. These are individually issued to an operator, the operator signs as confirmation the kit is
Please refer to Tesco Requirements for
complete, upon return at the end of each working day, the 'kit controller' signs as a confirmation the kit
Suppliers 60121 – Needle control for textiles.
has been received as complete.
This form can be used to manage the issuing and control of hand workers kits. The total amount of kits
established must be recorded along with details of what each kit carries. N.B. Each kit must carry the
same contents.
107
When a kit is issued by the controller the hand worker must check that all contents are in the kit and sign
for the receipt. Upon return the controller must ensure the kit is complete before signing as confirmation
Broken needle There must be a detailed procedure in place

control to manage broken needles on the production
floor.
 If a needle breaks, all parts must be
accounted for before a new needle is
issued.
 If all parts of the needle cannot be
found then the immediate vicinity
must be checked with a magnet and
any product or part product, within
the same vicinity, must be fully metal
detected. If all parts have still not
been located then the issuing of a
new needle must be approved by an
authorised person. All parts of the
broken needle must be securely
attached to a ‘Broken Needle Record
Form’ along with details of date,
machine and operator.
 All broken needle control records
must be kept for a minimum of 6
years from shipment, or as agreed
with your Tesco Technical Contact.
Please refer to Tesco Requirements for

Suppliers 60121 – Needle control for textiles.
108
Metal detection
Metal detection minimises the risk of metal contamination present in the product and is supplementary to the foreign object control policy and procedures. It is
imperative that the site does not rely on metal detection to remove the risk of metal contamination. The site must have procedures and processes in place to control
metal within the factory and therefore only use metal detection as a final check.
Section 14
The site must have systems in place for setting up, operating and testing metal detectors. The detectors must be located at the end of the manufacturing process
after the final packing of the finished product. Trained staff must operate the metal detectors. The site must retain records of equipment set up, calibration, testing,
servicing and the details of any metal rejections.
Metal detection Metal detection must be carried out

where determined by risk assessment or
requested by Tesco.
All sites must be able to produce a full

Risk Assessment to show why they either
do or do not have metal detection in
place.
Metal detection is required where there

is a risk of metal contamination to the
product.
109
Metal detection Metal detection equipment used must

equipment be ‘Ferrous Only Metal Detectors’ and
must be in good working order.
At a minimum the metal detection

equipment must comply with the
exhaustive list:
 metal detectors must be a
conveyor belt type, with an
audible alarm if metal is
detected.
 the conveyor belt must stop if Examples of how to ensure the MD can only be restarted by a responsible person
the alarm goes off and must not
automatically restart.
the machine can only be re-set by a key
switch, which is held by the person
responsible for the department. The key
must not be left in the machine or with
the machine operator. The metal
detector must be capable of detecting
an approved ‘Ferrous Test Standard’
supplied by the metal detector supplier,
at any point in the metal detector
aperture.
Metal detection Any new metal detectors must be purchased Equipment must be upgraded to improve detection sensitivity where advances in detection are developed.
equipment from a Tesco approved supplier (See Tesco
‘Clothing Technical Manual’).
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Hand held Where hand-held metal detectors are

metal used due to size or bulk of the item
detection there must be a detailed procedure
followed when performing the checks.
Examples of hand held metal detectors
Metal detector The metal detector must be located in a The finished goods warehouse is separated from the production area by a solid wall.
location dedicated and clearly identifiable area at
the end of the natural process flow of
the product and be as close to the point
of despatch as possible. The product
must have all labels, swing tickets and
packaging attached prior to going
through the metal detector.
The site must have control in place to

ensure the product is protected from
potential metal contamination after
metal detection.
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The location must be approved by the

metal detector manufacturer with
records kept and available.
Metal Free Zone
The exit/feed off side of the metal detector
must be a ‘Metal Free’ area.
The product should only enter the finished

goods warehouse through the metal
detector with the finished goods warehouse
separated from production area by a solid
wall.
The location must be approved by the metal

detector manufacturer with records kept and
available.
The product must have all labels, swing

tickets and packaging attached prior to
going through the metal detector.
112
Example floor plans
Positive The factory must employ a positive

Release release system when transferring
product from the metal free zone to the
finished goods storage.
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Product must not be released from the

metal free zone until the next 9 point
system check has been conducted
successfully.
The factory must conduct the 9 point

system check every 2-4 hours.
Metal detector All operators must be trained against the
operators manufacturer’s instructions in the
correct usage of the metal detector.
All operators must have been trained in

the internal procedures for metal
detection including the quarantining and
release of product. Details of this
training must be recorded and kept.
Operators must not wear metal jewellery
and accessories in close proximately to
the metal detection process.
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Metal detection The site must have a documented

equipment and procedure in place for metal detection.
use and At a minimum this must include the
records following, although this is not an
exhaustive list:
 risk assessed method for
determining the best way to
check the metal detector is
functioning correctly
all tests and system checks must be
recorded and the records, readily
available
Using a test standard holder will give the 3 vertical

levels of the metal detector aperture (Top, Middle &
Bottom). Other practices are possible by using metal
free plastic wood or polystyrene blocks that will
allow the test standard to sit in the middle and top
of the aperture.
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Metal detection The metal detector must be serviced at It is generally not possible to calibrate metal detectors but they do need to be serviced regularly.
equipment regular intervals (minimum annually).
maintenance Details of the services must be recorded The whole system needs to be checked e.g. sensitivities, rejection, fail safes etc.
and retained.
All new metal detection system installations should be checked by engineers from the equipment
supplier.
Evidence of satisfactory installations should be verified and documented before production

commences.
Systems should be revalidated in the event of their being relocated within the manufacturing
environment and on an annual basis thereafter.
The system must be serviced at regular intervals, either through a service contract entered into
with the manufacturer, or on site engineers trained by the manufacturer. Documentary evidence of
training must be retained. A stock of suitable spare parts should be maintained
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Metal detection If metal detection equipment is in use

equipment and fails (whether failure to detect a test
failure piece or failure to reject product) all
product or materials that have been
checked since the previous positive test
must be quarantined and retested
through a unit that has been verified to
be working correctly.
Tagging at A procedure must be in place for garment

Source factories that attach security tags to the final
product. The procedure must include the
following , although this is not an exhaustive
list:

 Security tags must be stored
securely and only issued by a
designated, responsible person
 Security tagging must take place in
a designated area within the metal
free area
 Security tags must be counted in All security tags should be put into the
and recorded Assigned staff issues security tag to the bin/box with tagged worker's name to avoid
 Left over security tags must be tagging workers base on PO quantity/daily containment
counted out, balanced against the
tagged product and recorded metal detection quantity/necessary quantity
 Records must be kept for inspection to each tagging worker with record
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Security tag must be attached at the

segregated area inside the metal free
A tagging standard must be available at the zone
attaching area
Metal detection Where metal detection is used the site

– must comply with the requirements as
Requirements detailed in Tesco Requirements for
for Tesco Suppliers 60375 - Foreign object
detection.
118
Count
Control of product size or count ensures that the product is correct and legal when sold to the consumer.
Section 14
It is understood that during an approval audit, prior to any production for Tesco, traceability tests cannot be completed on Tesco products or production, but can be
completed on similar products.
Count control Procedures must be in place to ensure that the correct Dedicated personnel are in place to count the items on the line or better still automated systems are in
numbers of items are present in the pack when a place to ensure the count is correct.
number has been declared.
If a visual inspection is conducted by an operative at the end of the line, wherever possible, packaging
Documented checks of product count must be in should be designed in such a way that a low count can be visually identified
place.
Equipment Where relevant all automated content control
settings and equipment must have adequate security devices so
security only authorised personnel have access to alter
settings.
119
Product labelling and coding
Section 19
Control of product packaging, labelling, promotional labelling and coding ensures that the correct product or components are packed into the correct outer
packaging, along with the correct user instructions where applicable. Accurate coding or labelling enables an entire batch to be recalled in the event of defective
products being released for sale.
Packaging Packaging supplied to the

supplied to production line must be
production controlled and checked to
ensure it is correct and for the
right product.
The material and labels must

be stored in a controlled area
until issued to the production.
Records of packaging supplied

to the packing line must be
maintained.
Control of Barcodes on all packaging Barcodes are verified using scanners or in store for validation and the till receipt is checked and retained.
barcodes must be checked against Tesco
issued information before the
packaging is used.
120
On line printed bar codes must

be checked and recorded at
regular intervals.
121
Product inspection and analysis
Section 20
Product inspection and analysis is required to demonstrate that products meet safety and legality requirements and comply with the Tesco specification.
In-Line In-line examination during the production Findings are used in some form of ‘Traffic Light’ system to identify areas of production that require continuous
Examination process must be carried out by dedicated, attention.
fully trained in-line examiners operating
within the production lines.
Each production line must be checked for

manufacturing quality, machine settings
and technical requirements against all
required specifications.
In-line examiners must be dedicated and

not conduct processes such as ‘thread
ending’.
Any out of specification findings must be

recorded by the in-line examiner.. Both
corrective and preventative actions must
be agreed and implemented to prevent re- This shows the use of a 'Mathbirk' for the use of carrying out an in-line examination process for the production of
occurrence with records available. socks.
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Tesco Certified There must be the appropriate number of There must be an appropriate number of TCQC's on site. For further information and advice for your specific site,
Quality qualified Tesco Certified Quality Controller please refer to your in country Tesco technical contact.
Controller (TCQC) on site as agreed with Tesco, with a
(TCQC) minimum of one per site.
(Clothing and
footwear only) The site must hold the certificates for all
TCQCs and have them available on request.
End of line End of line examination must be conducted The images below show end of line examinations in clean, well lit environments by fully trained employees
examination at the end of production by dedicated and
properly trained examiners. The ends of
line examination must include the
exhaustive list:
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 100% of all production must be

examined against the green seal
product
 products are checked inside and
out for finished appearance
 thread ends are treated as faults
 the surface of all inspection tables
must be white and in good
condition
Any out of specification findings must be

recorded by the in-line examiner. Both
corrective and preventative actions must
be agreed and implemented to prevent re-
occurrence with records available.
124
This shows a good examination station, the lighting is

very good, the surface of the table's white, there is
system of recording targets and output.
Records of findings are recorded on forms held within

the folders on the worktop and the examiner is not
carrying thread trimmers
This shows a well-equipped examination station for

the inspection of socks to ensure all required
specifications are being met through the use of a
'Mathbirk' and foot templates
125
This workstation uses illuminated frames to

examine for any faults in the yarn and knitting
process of hosiery.
End of line If pressing and/or packing take place after

examination the examination process the site must be
able to demonstrate that the pressing and
packing is conducted consistently to a
standard agreed with Tesco.
Non- All non-conforming products identified by This shows a very clear system of segregating examined products that have been passed and rejected. The passed
conforming the end of line examiner must be products go into the large blue box, whilst the rejected products are placed in the boxes under the tables and
products segregated from other product in an sorted by fault category.
identifiable quarantine area.
All faults must be marked and the non-

conforming products organised by fault
category for corrective action.
126
Rework The site must have a process in place for

assessing any out of specification WIP or
final product and either approving,
rejecting or reworking the material.
Where rework is permitted and used, this

must be appropriately controlled, must not
negatively affect product quality, safety or
legality, and the final product must meet
the Tesco specification.
Where rework is permitted, it must all be

traceable.
End of line All faults found must be recorded by the
examination end of line examiner and analysis
reporting, conducted to identify any potential
monitoring and operations and/or operators with quality
trending results issues.
Records must clearly demonstrate that

quality issue trends are being reduced.
Measurement All finished product must be subjected to a This shows a dedicated workstation for a measurement auditor to work in, it is located next to the pressing area
checking measurement check. where products can be selected on a random basis when they have been left to hang and recover to 'room
temperature'. A file can also be seen where all approved size charts can be held with the measurement audit
results.
127
The measurement check must be against

an approved size chart and conducted by
fully trained operators.
Any product that is outside of the required

measurement standards must be clearly
identified and segregated.
For textile products the measurement

check must be completed once the product
has had 24hours to recover to room
temperature after it has been finished,
pressed and ticketed.
For further information on how to measure

socks and hosiery please see the Tesco
Clothing and Footwear Manual.
Measurement The measurement check for children’s
checking products must ensure that any critical
measurements identified in the Children’s
Risk Assessment are monitored and
documented.
Final inspection End of line examination must be conducted
room in a dedicated inspection room. The room
must have the following, although this is
 Good lighting
 Reference sample and relevant
documentation
Necessary equipment
Final inspection Production boards must be displayed.
room
128
Product testing Finished product testing must be

completed to ensure compliance with
Tesco style file. The frequency and type of
testing must be followed as defined in the
Tesco style file and testing matrix in the
Tesco Fabric Manual.
Testing may include some or all of the

exhaustive list:
 physical performance
 chemical composition
 colour performance
Testing External laboratories and their testing
laboratories methods must be accredited by their
country national accreditation body an
internationally recognised country body or
industry accreditation.
Routine quality control checks which are

completed in an on-site laboratory
environment such as measuring, quality
sampling etc. must be agreed with the
Tesco Technical Contact.
Procedures must be in place for reporting

of testing results.
The procedure must include what action

and investigation is required in the event of
out of specification results.
Testing Procedures must be in place for the
monitoring and monitoring of compliance to all
trending specifications and, where applicable, trend
analysis to spot issues which are increasing.
Pre-shipment Prior to the shipment of any finished goods This picture shows a good example of a dedicated inspection room with good lighting and samples available.
accepted all production must go through a
systematic AQL process.
129
quality level
(AQL) This must be carried out by dedicated and
properly trained AQL in- house factory
auditors, against the required Tesco AQL
level, as defined in the Tesco Clothing
Manual.
The AQL process must ensure, although

 100% of packed product is
subjected to the AQL process.
 an approved finished, packed
standard must be available to the
AQL auditors.
 the inspection process must
include the finished appearance
including sewing/knitting, fabric
and accessory quality against the
approved standard.
 a percentage of the AQL sample
must be measured against the
approved size chart.
 all rejected batches must be 100%
reinspected.
 all 100% re-inspected batches
must go through the AQL process
again
 records of each AQL audit must be
maintained and these records
analysed to show overall quality
performance.
 checks against the risk assessment
Pre-shipment The AQL process for children’s products
accepted must include checks for all safety issues
quality level identified in the Children’s Risk
(AQL) Assessment.
130
Seconds During any inspection process of finished

goods, any goods that are deemed to
outside the Tesco specification and are not
repairable must be categorised as
‘Seconds’. The control of these must
include the following and be in accordance
with the Tesco Terms and Conditions:
 any potential products classed as
‘Seconds’ must be clearly
segregated at any inspection
process.
 any potential ‘Seconds’ must be
individually clearly identified by
fault category/reason.
An analysis of the amount and type of

‘Seconds’ must be completed on a regular
basis.
Finished All product disposal routes must be agreed All indications of the Tesco identity is removed from or masked on surplus stock donated to charitable
product with your Tesco Technical contact. organisations.
disposal and
surplus stock Any rejected product must be securely
disposed of through an authorised route. In
countries where secure disposal is not
possible the Tesco packaging must be
removed or defaced.
Prior to any surplus stock being made

available for purchase by site staff, Tesco
branded packaging must be removed or
defaced.
Where it is not possible to remove the

packaging, the barcode and all references
to Tesco must be removed or permanently
masked. This includes the Tesco name,
131
address, trademarks and any other

indications of the Tesco identity.
Where surplus stock is donated to

charitable organisations, the site must
ensure the product is adequately controlled
by the organisation.
132
Traceability
Section 14 Traceability systems enable all raw materials, components, work in progress, packaging and finished products to be identified and fully traceable to source.
It is understood that during an approval audit, prior to any production for Tesco, traceability tests cannot be completed on Tesco products or production, but can be completed
on similar products.
Traceability The site must have a system in place to enable all ) Procedures must be in place to trace a finished product back to the raw materials and packaging used.
system raw materials to be traced to a batch or order The traceability system must enable all raw materials, components, work in progress and packaging to be
number. identified and fully traced back to source. The traceability must also include at what stage these raw
materials and components were used in the manufacturing process. The site must have systems that fully
If finished product codes are applied to the identify and locate all finished product during storage and despatch, including where these products have
product, procedures must be in place to trace a been despatched to.
finished product back to the batch of raw
materials and packaging used. 2) These are the documents needed to verify a traceability exercise.
Product safety and quality management

•Product safety manual with product safety and risk based management plan, training and scope
Raw material, packaging and outsourced process supplier management

•Copies of all raw material and packaging specifications
•Supplier audit risk assessment and schedule
•Audit reports and corrective action plan (including 3rd party information)
•Incoming raw material and packaging records including any testing, intake quality checks, vehicle
condition checks, goods receipt information, COCs, COAs, certificates to prove source or claims of
materials.
•Copies of Tesco Approved/Known Supplier lists (where appropriate)
Finished product specifications

•Approved Tesco Finished Product specification
Process controls
•All product controls and records relating to the production and packing run
133
Weight, volume, size and count checks

•All records relating to the control of weight, volume or count throughout the production run
Product labelling and coding

•All records relating to the control of labelling and coding throughout the process
Product inspection
•All quality and inspection records relating to the quality of the finished product throughout the process.
Finished products testing results.
Transport
•Vehicle cleanliness records
•All despatch records to depot
Lot identification Identification of raw materials, work in progress,

packaging and finished products is adequate, to
ensure traceability within all site processes.
Internal test of Sites must carry out an internal audit (minimum

traceability annually) to test traceability systems.
Reconciliation of Where a finished product claim has been made, Reconciliation is part of the process where the site establishes the amount of products produced and
volume or reconciliation of the volume or quantity of key where these are at a given time. It establishes how many units were produced and how many were
quantity of stock materials or components (related to the claim) despatched, on stock, held, disposed-of and so on. This is only relevant in TTFMS where product claims
items related to a must be tested once per year as a minimum and have been made.
product claim the results must be retained for inspection.
134
Work study and production engineering
Section 26 Production engineering and work studies assist the site in improving performance and efficiency, resulting in potential savings and reduced costs.
The site organisational structure will include personnel with the skills required to both determine and implement the efficiencies from improved manufacturing
methods.
Industrial If the site has undergone Industrial

Engineering Engineering assessment,
implementation and training with
Tesco they must be able to
demonstrate that they are adhering to
the ways of working put in place.
135
Spinning
Module A
136
Woven, knitted and true knitwear
Module B Effective management of the procedures to control raw material receipt, yarn inspection and the weaving or knitting process, ensures that all fabrics produced,
consistently meet the agreed specification and are protected from deterioration.
The site will have systems in place to assess the quality of incoming yarns against the agreed quality parameters, carried out by suitably trained personnel. Any out
of specification materials will be isolated and controlled. Suitable conditions for weaving or knitting will be maintained.
Yarn All ‘batches/dye-lots of yarn must be

inspection inspected, tested and colour assessed by
and testing trained staff on receipt, according to
procedures and against an Approved
Inspection Standard and Specification.
Intake records must be retained.
Checks must include:

 colour
 cleanliness
 yarn count
 moisture content using a
calibrated moisture probe
 strength as appropriate
 records of the above inspection
and testing must be maintained.
137
Dyed yarn All incoming yarns must be checked that

Colour they are in tolerance for colour against an
assessment / approved standard.
continuity
All incoming yarns must also be checked
for continuity between batches. To do
this the site must ensure the following are
in place, although this is not an
exhaustive list:
 a well maintained light box
 the inspection employees must
have a copy of the Tesco
approved colour standards
available.
Records/samples must be maintained for

each roll/cone from every batch/dye lot.
138
Re-winding The site must have a system in place for

yarn the rewinding of any yarn onto another
cone.
The site must be able to demonstrate that
the process ensures that the original yarn
information is transferred from the
original cone to the new cone with no
mixing of batches.
For example the quality/reference

number identification sticker is
transferred to the new cone.
Yarn All yarn must be conditioned before use.
preparation
for weaving/
knitting
Yarn All yarn must be conditioned and exposed

preparation to ambient conditions for a minimum of
for true 24 hours before use.
knitwear
All plain fabric knitting machines must
have positive feed and tension controls
139
Fly The site must ensure that the weaving

management workshop is temperature controlled and
that fibre fly is extracted and removed
from the atmosphere (fly management).
There must be a ‘Fly Management’

process in operation. (i.e. fibre fly is
extracted from the atmosphere).
Where ‘Organic’ or ‘Fairtrade’ yarn is used

in the same environment as normal yarn
the process used for fly management
must ensure that there is no risk of cross
contamination
140
Pre - Finished For greige or pre-finished fabric must be

fabric 100% inspected for faults and, where
appropriate, marked up before use or
despatch.
The inspection process must be to an

established inspection standard, such as
the ‘4 Point System’ and an accept/reject
total points standard must also be
established.
All finished fabric stocks are stored

correctly, protected and clearly marked.
141
Yarn and fabric preparation, dyeing fabric, yarns and products and finishing
Effective control of the systems, processes and procedures operating within the dyeing process, ensures that all products produced consistently achieve and maintain
Module C
the agreed specification for the standard of dyeing. Control also minimises the risk of deterioration or damage to the products.
The site will have systems in place to control the dyes and chemicals in use within production and their subsequent disposal. The dyeing will be carried out by trained
staff in a dedicated area, using equipment that is maintained in good working order. Reference fabric or product standards as well as recipe cards and shade
standards will be available. An examination process will be carried out following the completion of the dyeing by dedicated and properly trained examiners.
Lab dye All recipes must be mixed in a clean,

recipe dry, organised and ventilated area and
preparation there must be controls to ensure the
correct formula:
 digital scales must be used
 approved ‘Recipe Cards’ and
the original ‘Shade Standard’
must be available for each
colour used in the print
 digital colour QC equipment
is used to check shade
matching e.g. colour
spectrophotometer
Bulk Dye All recipes must be mixed in a clean, Digital colour QC equipment is used to check shade matching e.g. colour spectrophotometer.
recipe dry, organised and ventilated area and
preparation there must be controls to ensure the
correct formula:
digital scales must be used
approved ‘Recipe Cards’ and the
original ‘Shade Standard’ must be
available for each colour used in the
print
 digital colour QC equipment
is used to check shade
142
matching e.g. colour

spectrophotometer
Preparation The process must be carried out in a
and bulk dedicated, well lit and clean area. The
dyeing equipment used must in good working
order with programmable controls and
regularly maintained.
To ensure the correct and good quality

is established the following must be in
operation:
 there must be an approved
‘lab dip’ available within the
dyeing section for each colour
being dyed
 there must be a light box
available to the dyeing
department
 colour continuity cards must
be maintained stating date,
quantity and dye lot number
the final fabric or products must be
stored off the floor in a clean and dry
area
In Process Sites must ensure documented in
Inspection process checks are carried out before
proceeding to finishing. These may
include the following, although this is
 Weight
 Visual colour inspection
Handle where required
Finishing Based on the risk to product sites must
ensure the following are in place:
143
 for processes such as sueding

or brushing, comparative
standards must be available
 an approved fabric or product
standard must be available.
 the final fabric or products
must be stored off the floor in
a clean and dry area
 For chemical finishes where
product performance claims
are made recipes must be
followed to chemical
manufacturers instructions
Final A representative sample from
Inspection every yarn dye lot must be
inspected for colour continuity,
levelness and colour fastness.
All dyed fabric must be 100%

inspected against the approved
standard.
Fabric to be inspected using the ‘4
point system’ and an
accept/reject total points
standard must also be established
there must be an approved
Fabric An examination process must be
Colour carried out following the
continuity completion of the dyeing by
144
dedicated and properly trained

examiners. The examiner must
have an approved ‘Colour
Standard’ for each colour being
examined.
Yarn/Fabric The colourfastness and physical
performance properties of the dyed fabric must be
tested.
The full inspection process must be to

an established inspection standard
with
Records available that clearly
demonstrate that corrective and
preventative actions have been taken.
145
Module D Printing fabric and panels
Effective control of the systems, processes and procedures operating within the printing process, ensures that all fabric or products produced consistently achieve
and maintain the agreed specification for the standard of printing. Control also minimises the risk of fabric or products being produced with incorrect colour or print
or incomplete curing.
The site will have systems in place to control the use of dyes, inks or chemicals. Printing will be carried out in a dedicated, well lit and clean area using equipment
which is in good working order and regularly maintained. Trained personnel will carry out detailed examination of the products following the completion of
printing. Out of specification materials will be controlled, isolated and clearly identified.
The recipe must be reproducible, scalable

Strike off for bulk production, and documented
The site must be able to demonstrate that

the strike off has been approved by Tesco
UK, prior to production.
Recipe All recipes must be mixed in a clean, dry,
preparation organised and ventilated area and there
must be controls to ensure the correct
formula:
 digital scales must be used
 approved ‘Recipe Cards’ and the
original ‘Shade Standard’ must be
available for each colour used in
the print
146
Printing The printing must be carried out in a

dedicated, well lit and clean area. The
printing equipment used must be good
standard, in good working order and
regularly maintained.
To ensure the correct and good quality is

established the following must be in
operation:
 an approved ‘Strike Off’ and
Recipe Card must be available
within the printing section for each
design printed
 print continuity cards must be
maintained
 size grading must be available for
panel prints
 final fabric or panels must be
stored off the floor in a clean and
dry area
Curing To ensure consistency in the print finish the
curing process must be carried out under a
controlled manner against the documented
curing conditions required for that print:
 the curing equipment temperature
and drying cycle times must be
tested a minimum of twice per day,
at the beginning and end of each
shift or at the beginning and end of
a new print run and records
maintained
 the temperature testing must be
done by the use of a digital probe
Print Print durability must be checked at the
durability beginning and end of each print run
and following the change to any
147
approved process conditions or recipe.

Samples and records must be
maintained that also allow for
traceability.
An examination process must be

carried out following the completion of
the dyeing by dedicated and properly
trained examiners. The examiner must
have an approved ‘Colour Standard’ for
each colour being examined.
Print The colourfastness and physical properties
performance of the print must be tested.
The full inspection process must be to an

established inspection standard with
Records available that clearly demonstrate
that corrective and preventative actions
have been taken.
148
Cutting
Module E Control of the cutting procedures reduces the likelihood of problems in the production process, ensuring an acceptable and consistent standard of bulk cut
material for supply to the construction stage. Cutting control minimises the risk of production of poor quality finished products.
The site will have systems in place that ensure that equipment is suitably maintained and controlled. All cut work will be inspected by suitably trained personnel to
an agreed quality standard. Records of these inspections will be retained
Process and Where the cutting process is carried out

equipment manually with the use of band
knives/straight knives/rotary knives or
die press cutters, there must be the
following:
 markers attached with
adhesive tape / spring side
clamps / weights. Not pins
 sufficient operating space
between tables
 as this is segregated activities
band knife working areas must
have, a clear and defined
barrier between the factory
floor and the dedicated area for
band knife work
 all electrical cables for cutting
equipment must be suspended
away from the cutting blade
 all cutting operatives using
knives must use protective
gloves
 straight knife operators must
stand next to the table.
Operators must not climb onto
the tables
149
This demonstrates good working conditions and also the

establishment of a safe working area for a band knife cutter,
the red/white poles and chain create a dedicated area which
will stop the operator being accidentally knocked by any person
passing the area
150
In the below photo the cutter is wearing a 'chain mail glove, on the left hand for protection when cutting, this is a
requirement of the standard, he is also wearing a face mask to protect against fine fibres in the air. Also note the
use of basic clamps to hold the lay during the cutting process, this will help towards good quality and the electrical
cable held in the air so that it does not lie on top of the lay.
The use of a 'Rotary Cutter' is very common in the manufacturing of knitwear, note the operator in the photo below
is using a 'chain mail glove' for protection and the electrical cable is held from above so that it does not lie on the
table.
151
All cut templates are identified and

securely stored
This demonstrates another simple

safety feature for band knives when
they are not is use, the block
protects the sharp blades from a
person accidentally cutting
themselves.
152
Cutting Dies All ‘Cutting Dies’ must have very clear

style number and size markings.
All ‘Cutting Dies’ must have notches to

define the size of each cut pattern
piece.
Number of layers being cut must not

cause difference in shape or quality.
Well organised, and easy to manage

die cutting area. All cutting dies have a
very clear and dedicated area to be
stored in which both ensures good
efficiency and reduces quality cost
failures
153
Leather cutting done using a two handed

pneumatic cutting press. Every cut bundle is
numbered. The machine is in a good
position and there is a waste bin to collect
bi-product waste.
154
This demonstrates the only type of die

cutter Tesco can accept, the operation can
only be completed by the use of two hands
which ensures that there is no possibility of
the operator being injured during the
cutting process.
Equipment In addition to the use of the ‘Base If Lay Markers not used in cutting all cut parts are clearly identified
(Textiles Requirement’ equipment the factory
only) uses Computerised Cutting/Vacuum
Tables with computer produced Lay
Planning and Lay Markers. In addition to
the above ‘Base’ requirements this must
be further supported by the following:
 lay markers are ‘heat adhesive’
155
Check and/or Where checked or striped fabrics are What is meant by a 'controlled' is that it is accurately known how many pins have been issued and the system is
stripe used and require matching by the use of auditable.
matching independent ‘pins’ then the use of these
(Sewn ‘pins’ must be controlled. The process This is best achieved by establishing 'kits' which contain a set amount of pins in a secure box. When a 'kit' is issued the
products must be auditable to demonstrate operator receiving must check that the quantity is correct before signing for them. The record must also identify when
only) compliance with the requirements and the 'kit' was issued and which table the kit is being used on. Following the cutting of the lay, a complete 'kit' containing
records must be maintained. the correct amount of pins must be returned to the controller who must verify the correct quantity that was issued by
signing the record sheet.
When fabric spreading is completed
and awaiting cutting, all pins points
must be protected/covered.
Laying up To ensure that the quality of cut work
produced by the cutting room will not
generate problems in either the
production process or with the quality of
finished products, a ‘cut work quality
control process’ must be operational,
this must include the following:
 pre-laying checks are carried
out on lay-markers and issued
fabric
 no more than 10cm or as
defined by the knife depth to
maintain quality of the cutting
shape by preventing
movement of the fabric
 shade lots are separated by
colour continuity system
 fabric rolls used in each lay are
from the same dye lot/batch
 where rolls from different dye
lots/batches are used in same
lay, each roll is separated by
coloured paper
 elastomeric fabrics must be
relaxed for a minimum of 24
hours before spreading. Other
156
knit fabrics must be relaxed for

a minimum of 12 hours.
Good examples of fabric
 fabric relaxing must take place
on the correct equipment relaxation.
157
Quality To ensure that the quality of cut work Ticketing process for the cut work
control produced by the cutting room will not
system generate problems in either the
production process or with the quality of
finished products, a ‘cut work quality
control process’ must be operational,
this must include the following:
 cut work is inspected against a
‘master’ pattern (top, middle
and bottom ply of every main
body part)
 each cut piece is individually
ticketed with size, ply and lay
number to give total
traceability
 any re-cut work is 100%
inspected
158
 following inspection and

ticketing all cut work must be
stored in an organised and
controlled manner
159
Fusing, laminating, heat transfer prints and embellishment
Module E
Effective control of the fusing, laminating or heat transfer of prints/embellishments process ensures that an acceptable bond to the main fabric is achieved and the
product performs to the agreed Tesco specification.

Fusing / Well maintained equipment, set to the
laminating correct conditions, must be used in the
equipment construction of the product.
To ensure this, data and documentation

must be available to demonstrate the
following:
 each interlining must have
recommendation reports from
the supplier available detailing
conditions to set machine to.
The site must validate the
recommendations before
production
 equipment must be ‘check
tested’ at least twice a day for
time and glue line temperature
with thermo strips and a
stopwatch. The number of
‘thermo strips used will depend
on the width of the fusing belt,
however, a minimum of two
must be used, whilst on wide
belt machines three must be
used at the edges and centre
 ‘check testing’ records are
maintained
160
This shows a typical example of the type of Fusible Test Report that should be obtained from the
fusible interlining supplier for each order. This will give clear instructions as to the
recommended interlining quality, the required settings of the fusing machine, the fusing time
and the pull strength test results required to give a high quality bond.
161
A good example of retaining thermal strip testing records. The three strips from each test
carried out 3 times per day are attached to the form and the pass/fail is signed off by a
supervisor.
Fusing For products where glue line

laminating temperature is critical, bond strength
process tests must be carried out.
Fabric shrinkage and colour change is

assessed for every fabric batch/dye lot
(sewn products only).
Durability wash test are carried out on

each batch and fused stock is held on a
‘positive release system’ until wash test
results are confirmed (sewn products
only).
162
Heat Well maintained equipment, set to the

transfer correct conditions, must be used where
equipment heat transfer prints or embellishments
are used.

following:
 each print/embellishment
must have recommendation
reports from the supplier
available detailing conditions
to set machine to. The site
must validate the
production
 an approved standard is
available to show the
position/location of the
transfer print/embellishment
on each design by size
 all machines are ‘check tested’
at least twice a day for time
and glue line temperature with
thermo strips and a stopwatch
 ‘check testing’ records are
maintained
163
Heat Well maintained equipment, set to the

transfer correct conditions, must be used where
equipment heat transfer prints or embellishments
are used.

following:
 each print/embellishment
must have recommendation
reports from the supplier
available detailing conditions
to set machine to. The site
must validate the
production
 an approved standard is
available to show the
position/location of the
transfer print/embellishment
on each design by size
164
 all machines are ‘check tested’
at least twice a day for time
and glue line temperature with
either thermo strips or a peel
test and a stopwatch
‘check testing’ records are maintained
Heat Carbon paper testing for uniform

transfer pressing must be carried out twice a
process day for any new shape/style.
Fabric shrinkage and colour change is

assessed for every fabric batch/dye lot
(sewn products only)
Durability wash test are carried out on

each batch and heat transferred stock
is held on a ‘positive release system’
until the wash test results are
confirmed (sewn products only)
165
Sewn and knitted products
Module F Control of the manufacturing process ensures that all products produced consistently meet the agreed specification and are correctly labelled and identified.
The production area will be clearly defined and organised enabling the smooth flow of raw materials, work in progress and finished product during the process.
Systems will be in place to ensure the area is fully cleared of product, labels and packaging before moving onto the next production run. The site will have systems in
place to manage the issue and application of labels to the product, preventing incorrect label application.
Label The site must be able to demonstrate that the This clearly shows a well organised and secure storage of labels on the production floor. Labels are issued
management correct care code/product number labels are from the central stores based on actual cutting/knitting data then held in clearly identified storage
inserted into every individual product on a containers within a secure cupboard. Each individual size label has its own draw within each container.
continuous basis. These can then be issued onto the production line on a 'bundle by bundle' basis. Also note there is a
recording system to control stocks
All labels and hangtags must managed as follows:
 labels must be stored securely on the
production floor and issued onto the line by
the same quantity, size and colour as the
work being introduced into production with
records kept
 operators inserting labels must be issued
with a copy of ‘product numbers’ for the
style in production
 replacement labels issued due to loss,
damage or incorrect issuing must be issued
on a controlled basis and records kept
 all spare labels issued to production line
must be returned to secure storage with
records kept
 at the end of contract all remaining labels
must be returned to the central warehouse
with records kept
166
Production Systems must be in place to demonstrate that both

feed on the receipt of cut work and the feed onto the
production line is controlled. This must include,
although not an exhaustive list:
 the cut work must be accompanied by a
copy of the cut work inspection report
 checks to ensure all cut work parts have
been received and fed onto the production
line
 cut work fed on to the production line in
either block, bundle or single product form
must carry some form of identification
showing style, size colour and lay number
details
 all cut work from each lay must be fed on to
the production line before the
commencement of the next lay
Records must be kept and available.

Production Systems must be in place to demonstrate the yarns
feed on issued conform to the specific product specification.
(Knitting, This must include the following, although this is not
Socks and an exhaustive list:
Hosiery)  a copy sample and a copy of the
specification located at each knitting
machine
 evidence that the issued yarn count and lot
numbers correspond with the product
specification before use
167
Popper, rivets Where popper, rivet and press stud attachment Examples of attachment section with
and press occurs the site must ensure: raised partition
stud  attachment machines must be pneumatic
attachment and not manual
 machines must be serviced on a regular
basis with records to demonstrate
 the type and manufacturer of the
attachment used matches the machine
 machines are segregated from the
 production floor to reduce the risk of metal

contamination
 pinch gauge settings are established at the
beginning of the contract with records
available
 a physical standard of the positioning is
available at each machine.
 all machines are positioned on a ‘gridded
floor’ to allow for the capture of any spilt
parts
168
169
Popper, rivets Where popper, rivet and press stud attachment

and press occurs for children’s products the site must ensure:
stud  the attachments are purchased from a
attachment – Tesco nominated supplier. (For further
children’s information please see the Tesco Clothing
products Technical Manual or Footwear Technical
Manual)
 all machines used must be electronic or
pneumatic and approved and serviced
under a service contract by a Tesco
nominated supplier
 pinch gauge testing must be completed by
trained staff minimum hourly with records
kept
 technical data sheets must be established,
approved by Tesco at pre-production, and
available at every machine
 a documented procedure is available and
details the action required when any pinch
gauge DPC testing identifies a failure
Button Lockstitch button attach machines must be used
attachment with thread wipers.
All button machines must be serviced on a regular

basis with records kept.
A physical standard of the positioning must be

available at all machines.
170
Button Pull strength tests, as specified in both the Tesco

attachment – Clothing Technical Manual and the product risk
children’s assessment sheet, must be conducted.
products
Thread Thread ends must be removed prior to the final A thread ended physical standard must be established and the thread ending operation must be part of the
ending examination throughout the sewing process by normal production process.
either ensuring machines are set up correctly, the
use of thread trimmers or dedicated employees. Where examiners/inspectors are required to also trim thread ends the inspection operation usually becomes
an operation to look for thread ends rather than looking at the actual quality of the finished product. An
examiner/inspector must be totally focused on looking at the quality of the construction and the quality of
the raw materials for faults and defects. By removing the responsibility of thread ending this will help to
ensure focus on quality.
171
Spot cleaning Spot cleaning must be done with the use of water
and a detergent.
If the nature of the stain or base material requires a

cleaning chemical to be used, the cleaning area
must be well ventilated and the chemical(s) must be
kept in a designated store with restricted access.
Spot cleaning All spot cleaning carried out on children’s products

must be done with only water.
172
Product laundry and wet and dry processing
Effective control of the systems, processes and procedures operating within the laundry, finishing and pressing process, ensures that all products manufactured
consistently achieve and maintain the agreed specification for the standard and that the correct finish/handle is achieved. Control also minimises the risk of any
health and safety or environmental incidents occurring.
Module G The site will have systems in place to ensure that chemicals/detergents are correctly mixed in a clean, dry, organised and well ventilated area. Dry finishing will be
carried out in a dedicated area, separated from the production area. Suitable PPE will be available for all employees carrying out dry finishing operations. Trained
personnel will carry out quality control checks on finished products. The site will carry out documented checks on effluent which is discharged from site.
N.B. Stonewashing is not allowed for any children’s products.
Wash Control systems must be in place to ensure all To ensure that all chemicals/detergents are mixed to the correct and required formula which in turn will
chemicals chemicals/detergents are correctly mixed to ensure the correct finish/handle is achieved, there must be good controls systems operating in a clean, dry,
preparation required formula: organised and well ventilated area:
•All chemicals must be measured on digital scales.
 all chemicals must be measured on
•Approved Recipe Cards/Recipe Cards. A reference card detailing the specific combination of
digital scales
dyes/chemicals to be used in a specific process, including the original must be available for each colour used.
 approved ‘recipe cards’ must be •All employees involved with the process must be issued and wear the required Personnel Protective
available for each colour used Equipment (PPE) which at minimum must include eye goggles, protective gloves and masks
173
Bulk washing Laundry must be carried out in a dedicated, well

lit and clean area using equipment with
programmable controls that is in good working
order and regularly maintained.
 a ‘job card’ must be available, for the
specific product being laundered that
shows machine settings and cross
references the required recipe
 the laundered products must be
organised and stored, off the floor, in a
clean and dry area
Drying To ensure consistency the drying process must

be carried out in a dedicated, well lit and clean
area using drying equipment standard with
programmable controls that is in good working
order and regularly maintained.
 a ‘job card’ must be available, showing
machine settings for the specific
product being dried
 the laundered/dried products must be
organised and stored, off the floor, in a
clean and dry area
Quality A quality control system must be in place in the
control laundry area to ensure all washed products meet
system specification and must include the following:
 an approved ‘Fabric/Handle Hanger or
Product’, for each product, must be
available
 there must be an approved ‘wash
blanket’ available for each product
 there must be a light box available to
the drying department
 colour/wash continuity cards with
machine number and date must be
maintained for each batch
174
 dedicated and properly trained

examiners carry out quality checks at
the end of the process
 colourfastness and physical properties
of the washed product must be tested
to ensure they still meet specification
(or agreed exceptions)
 records must be maintained
 unacceptable results must have action
plans in place showing measures have
been taken to reduce quality issues
Abrasive The material used to carry out the abrasive
material (Dry process must not contain any Crystalline Silica.
finishing)
The factory must be able to demonstrate this
requirement through ‘Certificates of
Conformance’ and/or independent test reports
that cross reference with stock identification.
Location (Dry The dry finishing area must be located area would be best located in a separate building
finishing) separately from the rest of the factory by a
physical barrier such as a wall.
Blasting No Blasting using sand or other particles is
system permitted on site. – see requirements document
60455.


175
Pressing & Boarding
Module G
Pressing Where pressing is required, at a minimum, ‘hand

(Textiles steam irons’ that product dry steam and vacuum
only) tables with a strong vacuum must be used:
 the pressing area must be clean with
sufficient lighting
 all table covers must be clean and
changed frequently
 the process must take into account the
nature and composition of the fabric
 a pressing standard for each style must
be available to the pressing operatives
 after pressing, stock must be stored so it
doesn’t crease
This shows a very well let and clean pressing area
176
This pressing area shows how 'laser lights' can be used to identify the finished size/shape of the product. These
also assist the presser in achieving the required specification on a more efficient method.
This demonstrates a press cover in a very good condition, it is clean and due to a good vacuum system is also
dry. It is also well fitted through the use of a 'drop down' frame, which means there is no need for the use of
pins, string etc. for attachment.
177
Boarding Where boarding is required, at a minimum, an
electrically heated form of the appropriate board
size must be used:
 the boarding area must be clean with
sufficient lighting
 a boarding standard for each style must
be available to the boarding operatives
 after boarding, stock must be stored so
it doesn’t crease
178

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2019

What Good Looks Like Guidance for

SERVING SHOPPERS A LITTLE BETTER EVERY DAY

Item Detail What Good Looks Like

This must be:

Details of deputising cover for personnel

The senior management team must ensure

final decision for handling affected Tesco

Your Tesco Technical contact must be

Key performance The management team must measure key

Item Detail What Good Looks Like

It highlights the most common faults

Audits must be conducted by trained

The auditor must identify where the site is

Audit reports must be available and detail

These must be brought to the attention of

Timescales and corrective actions must be

This would be evidence of management commitment

Item Detail What Good Looks Like

If you see any obvious ethical issues

Please send an alert within 24 hours to

Management of The site must have procedures in

Item Detail What Good Looks Like

It should also take into account:

It must ensure environmental risks

Potable and non-potable water

Water Following treatment more than

Waste water Waste and effluent management

Sewage disposal must not

Scope Item Detail What Good Looks Like

Boundaries must be clearly defined

A site plan must be available.

Base External The external areas must be

Where buildings are surrounded by

The areas immediately surrounding

If the external maintenance is the

required for persons unknown to the

A system must be in place to

Base Control of Access to production and storage A security guard is on site.

Employees are encouraged to challenge unknown visitors.

Item Detail What Good Looks Like

External The structure, fabric, location and layout of

The structure, fabric and all external doors

Where strip curtains are fitted they must be full

Building For sites outside of the EU a valid building

floors/buildings that has been issued by the

All buildings must be designed for industrial

All aspects of the site structure must be

Lighting Lighting in all areas must enable safe working

A programme of environmental monitoring

Materials must not be stored directly in contact

Chemical All chemicals, including cleaning

All chemicals used on factory must have a

Where the MSDS indicates potential risk to

For any risks that have been identified a

Design and construction of equipment

Scope Item Detail What Good Looks Like

Equipment must be designed,

Item Detail What Good Looks Like

Cleanliness Equipment and facilities must be

Cleaning equipment, including mops,

There must be a suitably competent

Cleaning personnel must be trained in