RM-QAFA PROCESS TRAINING

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Presenter : Rakhi Vashisht

Sr. Manager – Raw Material Assurance
 Quality Management System:
Embed a culture of quality
Utilize continuous improvement as a pillar of the performance engine to deliver on guest experience
Mitigate risk and empower vendor to own product quality
Enabled by technology

TIER 2
RAW MATERIAL –
CLAIM MATERIAL ASSESSMENT
QUALITY ASSURANCE FACTORY ASSESSMENT
(CMA)
(RM-QAFA)

Who: Who:
Designated Tier 2 Fabric Suppliers & Factories Designated Tier 2 Fabric Supplier & Factories

What:
To assess quality management system and
manufacturing risks of a Tier 2 factory servicing
Target Owned Brand’s apparel business
What:
To assess capability of a Tier 2 factory to
handle claimed materials, ensuring risks are
identified and effectively mitigated around
guest-facing raw material claims on Target’s
Owned Brand products
 .

Raw Material – Quality Assurance Factory Assessment

(RM-QAFA)

Raw Material Assurance

Mar’2021
 Agenda

• QMS alignment

• RM-QAFA (Objectives & scope)

• Assessments stages (Preparation/Self-Assessment/ Verification/

Closure)

• Module, Methodology & Assessment Process

• Questionnaire, Observations method & answers types

• Q&A

Key Definitions: QMS
Quality Control
(QC)
Meeting quality by
checking for defects
Goal = Detection
Focus = Product
What it is:
Fabric inspection, machine
inspection, Product Testing,
Corrective Action
What it isn’t
Process, MCP, Preventative
Action, QA
Quality Management System
Quality Assurance
(QA)
Improve quality by being
proactive and preventative
Goal = Prevention
Focus = Product + Process
What it is:
Preventative action, CAPA Audits etc
What it isn’t:
Inspection, 100% guarantee, QC
Quality Management
System (QMS) QMS
1
System comprised of quality
strategy, planning, resources
Quality
and activities to improve the
organization as a whole; Assurance
governed by a set of policies
and procedures.
Quality
Goal = Strategy beyond QC / QA to Control
an integrated systems approach
Focus = Product + Process +
Organization(s) + Data/ Technology
What it is:
It is more than just documentation…
it is effective implementation & Continuous Improvement
execution
Continuous Improvement is a central
priority for a QMS – PDCA Continue to Evolve from a QC/QA to a QMS Organization
What it isn’t: Not ISO 9000 Target’s Quality Management System (QMS) principles,
within an established culture of quality.
 Quality Management System

1Quality
From one size fits all From lack of visibility in product
development
To differentiated approach
aligned to business needs Quality To planning for end to end
Strategy Planning preventive risk mitigation
throughout product life cycle

Voice of
customer

From a focus on Quality Control

Quality Quality From inconsistent skills and
through Lab Testing Activities Resources expertise

To continuous improvement To specialized capabilities to

focusing on delivering quality by match needs, both internal and
being proactive and preventive external

Enabled by Technology
 RM-QAFA
What is Raw Material – Quality Assurance Factory Assessment (RM-
QAFA)?
It’s a factory assessment, managed by Raw Materials Assurance
team (RMA) via nominated 3rd party to review factory’s
manufacturing process & quality management systems that ensure
consistent quality & assess risk in supply chain i.e. fabric suppliers
serving Target's apparel business.

* The process is conducted through on-site assessments, verification

& validations.
 RM-QAFA Objectives
Objectives-
1. To ensure continuous & reliable supply of quality materials meeting Target’s
guest expectations.
2. Mitigate quality & supply chain risks.
3. Provide a differentiated view of the matrix with full transparency
through digitized version of assessment i.e. Inspectorio Rise platform.
4. To validate suppliers have required processes, methodology and capability to
supply flawless materials meeting Target guest expectations.
5. To ensure adherence of raw materials to US Safety & regulatory requirement.
6. Reduce enterprise risk by ensuring that factories don’t follow malpractices
during manufacturing.
 RM-QAFA SCOPE
aaaaaaa Out of scope
In scope
• Individual spinning mills
• Vertical set up (Fiber to garment)
* scope covers all processes except garmenting
• Embroidery units
• Composite mills (Fiber to fabric)
* scope covers all processes including spinning • Washing units

• Non composite mills or individual

process units registered in Target’s
VMM
* scope covers process units like weaving, knitting,
dyeing, printing, brushing, special finish etc.
 RM-QAFA Stages
1. Preparation
Factory to arrange required documents in advance in Inspectorio.
Instructions/Templates are available at Inspectorio Rise.

2. Initiate self-assessment
New suppliers/factories - GRMT/Fabric Sourcing to direct to initiate self-assessment.
Existing suppliers/factories –RMA team to inform fabric suppliers/ factories to submit
a self-assessment around 60 days before expiration date.

3. Verification assessment
RMA to review self-assessment, if overall score meets Target’s minimum
requirement, it gets assigned to 3rd party for onsite verification assessment.

4. CAPAs follow-up & closure

After verification assessment, a report with CAPA gets auto generated.
RMA to review CAPAs and follow up on closure directly or via 3rd party.
 Preparation
Documents to prepare -
• Plant layout diagram
• The manufacturing process flow diagram
• Manufacturing Control Plan (MCP)
• Machine list
• Factory capacity
• Factory capability
• Business intelligence form (same as submitted to GRMT/ fabric
sourcing)
• Supplier vetting form (same as submitted to GRMT/ fabric sourcing)
• Claimed material assessment (CMA) report (If applicable)
 RM-QAFA Module
The assessment is designed to determine the existence and
effectiveness of appropriate Quality Control Systems” & validate
capacity & capability to ensure that the factory has the necessary
equipment, processes and process controls to produce materials
intended for Target Owned brand products.

The sections included in the assessment are:

1. Site Conditions
2. Quality Management System
3. Raw Material Controls
4. Pre-Production Process
5. Process Control
6. Production Management
7. Equipment & Maintenance
 RM-QAFA - Methodology
• Document Review – The assessor will review procedures, work
instructions, and supporting records. This review is conducted at the
locations in the factory where the procedures and work instructions are
being implemented, where the records are being generated and retained.
Key emphasis is on effectiveness of processes mentioned in documents.

• Observations – The assessor will visit all areas of the factory and
observe that defined processes and procedures are being followed as
well as observing general factory conditions. Again, here emphasis is to
ensure that work practices & SOP being executed effectively at factory
floor.

• Interviews – The assessor will interview worker/staff responsible for

carrying out the assigned task to validate awareness level and
effectiveness of processes. These will be informal interviews carried out
at the work location in the factory. Assessor will also interview senior
management to understand their vision & mindset.
 RM-QAFA Process
• Opening meeting – The assessor will meet with factory management and review the
audit scope and process. Factory should share any challenge/ concerns upfront during
this meeting like permission to use for photo/video at specific area.

• Factory your – The assessor will tour the factory from the incoming material area to the
finished product warehouse. During the tour assessor will make general observation and
identify the areas of the factory where he/she will return to conduct the detailed portions of
the assessment. The tour helps the auditor visualize the factory layout to optimize
subsequent activities.

• Sectional assessment – The assessor will visit the specific areas of the factory covered
within the scope and utilize the methodologies described above to assess compliance.

• Draft findings – The assessor will then need a private area to review his findings and
prepare the draft for review during the closing meeting.

• Closing meeting – The assessor will present the draft findings to factory management. In
case of any disagreement on assessment observation, factory should reach out to RMA team
within two weeks of assessment,
 Assessment score
on making & CAP Follow-up Plan
Stage 1 Stage 2 Stage 3
QMS / On- On-
CAPA Desktop Continuous site assessme site assess
Overall Score Overall Color Explanation Decision Review/ improvement nt ment
Rating Evidence (partial (full
review plan
scope) scope)
90 calendar
95.00 to 99.99% Purple Exceed Good to work days - -
expectations from assessm
ent date
90 calendar
80.00 to 94.99% Green Meet Good to work days - -
expectations from assessm
ent date
60 calendar Within 6
60.00 to 79.99% Yellow Needs Continue to work days - months -
(for existing supplier) improvement Act on CAP from assessme from assessm
nt date ent date

60 calendar Within 6
60.00 to 79.99% Yellow Needs Can add to matrix days - months -
(for new supplier) improvement Act on CAP from assessme from assessm
nt date ent date

- Look for back up fabric supplier 30 calendar Within 3

59.99% and below - Act on CAP on priority days months
Red Critical - Reassessment after 3 months, if - - from asses
(for existing supplier) from assessme sment date
supplier doesn't elevate to Yellow, nt date
drop it from matrix

- Can not add in matrix

59.99% and below - Drop from potential supplier list or
Red Critical - Supplier can reapply - - - -
(for new supplier)
for assessment after 3 months after
doing necessary improvement
 Examples
Site Conditions :
Q - Is the factory clean, organized, have sufficient lighting,
proper ventilation, gets pest control done at defined interval & is
maintained in a way to prevent mildew/mold growth.
Guidance –
• Check if site conditions are well maintained, which may include below but not limited to:
Only necessary items at kept at workplace/ Items are arranged to sustain efficient work flow/ Production & related areas
must be clean & organized.
• Standards are set for a consistently organized workplace with every item, equipment, material properly identified with
labels.
• Locations are marked to keep trolleys, trays, equipment etc.
• Designated areas for material storage must be effectively maintained.
• Periodic internal audit is planned & executed to ensure site condition as per above mentioned expectations.
• Check for evidence of effective pest control in the factory.
• Factory must have a procedure for prevention and control of mold and mildew which includes, regular checking of factory
premises, manufacturing & storage areas & appropriate frequencies for sanitization.
• Production and storage areas must have acceptable ventilation/air circulation, no leakages and dehumidifiers installed (if
applicable) to maintain the appropriate humidity level for the product type being manufactured.
Where dehumidifying areas exist, this must be monitored daily to ensure acceptable humidity levels are maintained.
• Light levels must be sufficient for production (Min. 550 Lux) ,Inspection Areas – 750 Lux, Packaging Areas - 300 Lux
& Loading/Unloading Areas - 150 Lux
 Examples
Quality Management System :
• Management commitment
• Document & sample Control
• Record retention policy, process and control
• Automation focus
• Efficiency & competitive advantage drive
• Policy in case of non compliances of product quality, safety & regulatory requirements
• After sale service and attention to Voice of customer
• Continuous improvement / Right first time approach
• Periodic performance review

Q - Does factory management have a clear vision/plan for future

growth, which is documented and shared/displayed with the wider
organization.
Guidance - Check if there is a plan in place for measurable outcomes & specified timeframe.
Check if modernization of production factory, innovation, R&D, infrastructural improvements, technology, data based decisions
(integrated technological solutions like IOT) are part of plan.
Check if management review quality dashboards/analytics & invest in digitization.
Check if management has plan to provide resource for efficiency optimization.
Check if there are plans for improvement of quality/efficiency & production matrix.
Check if factory/supplier has sustainable developmental goals with respect to material, process etc.
Check if there are effective plans for human capital management.
 Examples
Training :
• Training Curriculum appropriateness and its intent
• Trainer pre-qualification
• Basic Onboarding / Operational Trainings
• Critical to Quality trainings
• Trainings for Continuous improvement
• Training effectiveness

Q - Does factory have a robust training program for new employees,

refresher courses & special training for chemical or claimed material
handling.
Guidance –
• Does factory have a proper training manual, training calendar & adherence to it.
• Does factory have defined training frequency & requirement listed which function/employee should attend which kind of training.
• Does the factory employee understand the purpose of and requirement of special material (claimed material) to maintain product
content integrity.

Claimed Material - Product claims can be of various types, one of them is raw material claims, where mostly sustainable raw materials are
called out in product or packaging. At Target, based on company policy, following material types are in focus for making claims:
• Cotton (Organic, Supima, US Cotton etc.)
• Recycled fibers (rPET, recycled cotton, recycled acrylic etc.)
• Forest based materials
• Down/feather
RMA team manages Claimed Material Assessment (CMA) for above materials, which is valid for one year and a separate CMA is required
for each material.
 Examples
Raw Material Controls :
• Receiving inspections of raw materials i.e. Cotton / Yarn / Fabric
• Storage Controls of raw materials i.e. Cotton / Yarn / Fabric
• Receiving & storage controls of dyestuff and accessories
• Receiving & storage controls machine parts etc.
• Identification/ Segregation & Traceability Control

Q - Is factory aware of product specifications, quality standards & US

Safety and Regulatory requirements for all incoming raw materials,
components or sub-assemblies. .
Guidance –
• Check if team managing raw material have product specification details with them.
• Check if team managing raw material is aware of US Safety & Regulatory requirements specific to the product being
handled (applicable for finished fabric factories).
• Check if team managing raw material is aware of any restricted countries/regions of raw material origin by US federal
agencies or based on Target cotton policy.
• Check if supplier/factory has signed any affidavit to not source raw material from specific countries for Target or agreed to
follow Canopy pledge (specially applicable for annual assessment).
 Examples
Pre-Production Process :
• Risk Assessment
• Process Flow Chart / Route / Engineering
• Manufacturing Control Plan
• Supplier management (Pre-Qualification)
• Sub-Contracted process (Pre-Qualification)
• Raw Material Pre-qualification

Q -Does the factory have a competent technical department / resource to

consistently review design, material, label claim (if applicable), safety &
regulatory requirements specified by the customer against plant capability
before initiating any sample development request.
Guidance –
• Interview the concerned team to understand their role and responsibility and level of competence if they are conversant with design,
material, label claim (if applicable), safety and regulatory requirements specified by customer.
• If concerned team can really assess the potential challenges for any new product development considering factory capability
assessment.
 Examples
Process Control :
• Calibration of equipment of inspection, measurement
• In-house product test capability (Laboratory)
• Non-Conforming Material control
• Quality Control activities
• Quality Assurance activities
• CAPA Process

Q -Does the factory follow appropriate "Manufacturing Control Plan

(MCP)" containing testing, inspection, gauge controls & critical to quality
controls for all production processes & is it consistent with relevant "Process
flow Diagrams".
• Guidance –
• Observe the MCP is process specific, including process input and output & being executed on the factory floor.
• MCP must include but not be limited to below key elements:-Process steps, what's controlled, specification limits,
• measurement methods, control methods, sample size, frequency, who measures, where recorded, decision rule or
• corrective action, and SOP number (specified).
• Factory production and quality team must have and use the MCP in overseeing their production during all inspection and check points.
• Additional requirement for high risk product should be clearly listed (ex product with functional claims)
• For outsourced processes, the sub-supplier/contractor must have an effective MCP for outsourced manufacturing processes.
• Check if the MCP controls contain at least those quality parameters which connect with Target quality requirements.
• Understand the focus and intent of implementation of controls mentioned in MCP if they are only covering detection (in terms of test and inspection) or also covers
the preventative approach by encircling occurrence controls in terms of gauge settings and critical to quality controls.
 Examples
Production Management :
• Production Layout
• Material movement
• Production planning
• Production record keeping
• Gauge controls reporting
• Recipe control
• Production handling routines

Q -Does the factory conduct finish goods inspections & if there are records
to support final Inspections at packed roll for delivery stage.
Guidance –
• What % of finished goods gets inspected.
• Does factory maintain finished goods inspection records & if it can be traced back in case of issues.
• In case of issues, is there any corrective action taken & if records are maintained for such actions.
• Does factory has defined authorization to know who makes the decision, in case of issues.
• Check if training records are available.
• Check if inspectors are trained how to handle/escalate issues.
• What's the frequency & % of re-inspection.
 Examples
Equipment & Maintenance :
• Equipment working condition
• Preventative maintenance
• Maintenance SOP
• Emphasized on safety
• Focus on quality maintaince & improvement

Q -Does the maintenance team get regular visibility for production quality
issues to mitigate them from maintenance perspective.
Guidance –
• Check if maintenance team attend quality meeting on regular basis.
• Check if quality issues are categorized based on reasons like material, maintenance, training etc.
• Ask for examples, if maintenance team have modified their preventive maintenance schedule based on learnings from quality meeting.
 Question & Answer Types

Question types: Answer types:

1. Standard questions 1. Based on adherence level
Meet
Partially meet
Ex – Does not meet
Does factory do visual inspection of N/A – If question is not applicable
incoming material. * More details are on next slide

2. Parent-child question (there Ex –

Are work instructions appropriate considering intent of implementation
is a sub question based on covering all production processes in accordance to process flow
answer type of standard diagrams.

question)
2. Based on participation
Ex- Yes –
Parent Q - Is factory's lab certified for No –
Target.
Child question - Does lab follow procedure Ex –
of consolidating test report with third party Is factory's lab certified for Target.
without fail + additional required tests are
conducted at

Note : Questions have different weightage.

 Adherence based scoring
MEETS: A factory meets the intent of the questions per the criteria in the resource
guide.
Examples:
• Factory consistently meets the expectations of the question and resource guide
• Factory has implemented an effective process that is appropriate for their product
categories

DOES NOT MEET: The factory does not have a process or records to meet the intent of
the question and criteria in the resource guide.
Examples:
• Factory does not consistently meet the expectations of the question and resource
guide
• Factory does not have sufficient evidence to demonstrate and support the effective
execution of the process
• Required processes for the specific product category are missing, incomplete, and/or
not effective
• Factory has attempted to implement a process but it does not meet the requirements
of the question and resource guide

PARTIALLY MEETS: The factory meets the majority of the criteria in the question and
resource guide and only minor discrepancies are identified.
Examples:
• After review of the process and supporting records, minor inconsistencies are
identified
• Inconsistent execution of a process is observed
• Process is being executed but supporting evidence is inconsistent
 RESOURCE GUIDE
Resources will be provided after the
training:
• Recordings
• Survey Link
• Testing platform credentials from
Inspectorio

REMINDER:
CMA process training by RMA team on Mar 11 th @11:00 am – 12:30 pm HKT
(English).

Technology training by Inspectorio team on Mar 11 th @03:00PM – 04:00PM HKT

(English)

Technology training by Inspectorio team on Mar 12 th @11:00 AM – 12:30 PM HKT

(Chinese)
 Queries??
For any Questions or queries, please feel free to
contact us at RMA@target.com