4M : Corrective Action Plan

Factory Name : No Name Set Date : November 26, 2020

Involved Production Line / Department : Fty Area Product Type : Swimwear

Quality Issue / Workmanship M1 M2 M3 M4 Solution / Target / Completed Date Prefentive Action

Problem / Defect Rate - OQL Root Cause ( 5 Why ) (CAP & acceptable standard)
finding Man Machine Material Method
N.C #2.3 1st Why : Lighting that used is not sufficient to meet the standards of Lack of understanding management and staff QA/ No Lux meter or if fty have lux meter , the equipment Lighting Equipment Not standard for Buyer - No S.O.P and work Instruction Posted on each area Conduct management review and factory management should 1. Make a Training for check lighting before start working
buyer requirements. Technical about Standard Lighting (Buyer Regulation) (lux meter) is not yet calibrated by 3rd party. Requirement. - No Daily Checklist conducted by PSO. set up a QA department, that function for make S.O.P and 2. Conduct Daily Checklist for Lighting Standard.
Insufficient lighting at 2nd Why : No instruction / Standard Lighting Procedure based on maintaince the QA System and Internal Audit. 3. Conduct Internal Audit.
a. Accessories Room buyer requirement / regulation that posted on each area.
b. Fabric W/H 3rd Why : There is no department that is responsible for developing
c. Accessories W/H standard operating procedures, especially for lighting
d. Sample Room standard based on buyer requirement.
e. Folding Area 4th Why : The factory management has not yet concentrated on the QA
f. Packing Area system.
5th Why : Management review not yet conducted.

N.C #4.3 1st Why : Person in charge not fill with completely the fabric identification Lack of undestanding PIC on warehouse area about - N/A - N/A - Training not yet evaluatedby QA department. - Identification training needed by QA Department, especially 1. Make a Training for how to fill the report.
label. how to fill the report production/ fabric identification for "how to fill the report". 2. Conduct training evaluation.
Fabric identification label without 2nd Why : Training "how to fill the report" is not yet evaluated. label. - Make evaluation for every training that conducted by QA 3. Control the report on production floor by QA Department.
lot number. 3rd Why : QA Department not yet maintaince the training evaluated and Department.
- QA Department must control all the report and internal
training needed schedule. identification card/label.
4th Why : The factory management has not yet concentrated on the QA
system.
5th Why : Management review not yet conducted.

N.C #5.5
Cutting Panel storage rack without
Identification label
1st Why : No identification card/label. Lack of understanding PIC document control for cutting - N/A - No Identification label/card for cutting panel rack - No SOP for labeling the cutting panel Storage. - Review buyher rquirement list for QA System and make procedure 1. control the production report by QA Dept.
2nd Why : label / identification card has not been made for cutting panel storage panel rack identification label. storage. list needed based on each point buyer requirement / regulation. 2. Conduct internal audit by QA department.
by QA Department. - Conduct the trial for every new SOP that made by fty based on
3rd Why : lack of understanding PIC Document control about identification rack buyer requirement.
- Make evaluation for the SOP and review by QA department.
for cutting panel. - Make a training for PIC who will be fill the report or identification
4th Why : No procedure for cutting panel rack identification. card/label.
5th Why : Management Review not yet conducted. - QA Department must control all the report and internal
identification card/label.

N.C #5.11
Reference Sample at cutting area
had no PP comment and sign of
authorized person
1st Why : No checklist for PP sample attribute. Lack of understanding QA inhouse and Spv Cutting about - N/A - No complete list for reference sample made by fty - No SOP for Reference sample - Make SOP for reference sample and review. Conduct socialization and be reminded during the PP meeting so that all
2nd Why : QA department does not provide a complete list of reference sample. reference sample regulation. - Make a complete list form for refrence sample. reference samples are well equipped and covered with complete
3rd Why : Lack of understanding QA inhouse and Spv Cutting about reference - Conduct the training for SPV and QC about reference sample. documents in accordance with the respective buyer's regulations.
sample regulation.
4th Why : No SOP for Reference Sample.
5th Why : Management Review not yet conducted.

N.C #7.1 1st Why : No Work Instruction posted for carton placed regulation. Lack of understanding packing personil. - N/A - No Pallet - Training not yet evaluted by QA department - Review the SOP and Training for packing Area about garment contamination 1. Posted Work Instruction
2nd Why : SOP at packing area not yet running well. - No Work Instruction - SOP not yet running well. - Make work instruction and posted at packing/ finishing area 2. Daily checklist for condition of production floor ( cleanliness and
3rd Why : Training not yet evaluated. - Control by QA department and conduct internal audit. tidiness of the production area)
Cartons at packing area were placed 4th Why : No SOP evaluation from QA department.
on the floor and were not tidy 5th Why : there is no managament review conducted.

N.C # 7.3 1st Why : No SOP for calibration equipment and calibration schedule & list. Lack of understanding PSO about calibration system and - N/A - fty doesn't have calibration list and schedule - SOP not yet established for calibration system. - Review the SOP and Training for calibration equipment by 3rd party. 1. Make calibration equipment list and schedule.
2nd Why : lack of understanding by PSO. regulation based on buyer requirement. - Control by QA department and conduct internal audit.
Mini Boiler at pressing area had no 3rd Why : No training calibration for equipment.
certification 4th Why : No identification training needed.
5th Why : There is no management Review.

N.C #7.8 1st Why : No Work Instruction posted for garment storage regulation. Lack of understanding finishing personil. - N/A - No cover provided - Training not yet evaluted by QA department - Review the SOP and Training for finishing Area about garment contamination 1. Posted Work Instruction
2nd Why : SOP at finishing area not yet running well. - No Work Instruction - SOP not yet running well. - Make work instruction and posted at finishing area 2. Daily checklist for condition of production floor ( cleanliness and
Containers of finished products were 3rd Why : Training not yet evaluated. - Control by QA department and conduct internal audit. tidiness of the production area)
not covered 4th Why : No SOP evaluation from QA department.
5th Why : there is no managament review conducted.

N.C #7.12
Cartons at finishing/packing area
were placed on the floor directly
(no pallet)
2nd Why : No Work Instruction posted for finish good storage regulation. Lack of understanding packing personil. - N/A - No Pallet - Training not yet evaluted by QA department - Review the SOP and Training for packing Area about garment contamination 1. Posted Work Instruction
2nd Why : SOP at finishing/packing area not yet running well. - No Work Instruction - SOP not yet running well. - Make work instruction and posted at packing/ finishing area 2. Daily checklist for condition CTPAT area.
3rd Why : Training not yet evaluated. - Control by QA department and conduct internal audit.
4th Why : No SOP evaluation from QA department.
5th Why : there is no managament review conducted.

MANAGEMENT REVIEW IT SHOULD BE CONDUCTED TWICE IN 1 YEAR AND AND ATTENDED BY ALL STAFF AND MANAGEMENT RELATED TO THE PRODUCTION SYSTEM, AFTER THAT QA DEPARTEMENT MUST BE FOLLOW UP THE PROGRESS AND RECORD BY DOCUMENT INCLUDING EVIDENCE.
Remarks: Made by : BAYU IRAWAN