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Youth Wear (0-6/7X) Source Certification Action Plan

Charitha Salgado ( Regional Manager)& Mam


Name of factory: Name
( Thailand PI Manager)
TY Fashion (Cambodia) Auditor

Licensee responsible: Organization Haddad Apparel Group Ltd (USA) & Thailand Office
Haddad Organization
National Road No 51,Srah Po Date YW certification
Date of
Factory address: Village,Phsardek Commune,Ponhealeu request was received by 4th April 2013 5th April 2013
audit:
District , Kandal Province ,Cambodia EMO
Certification type Production type:
Name Menchie Lacsamana ACTIVE Small Parts
No-Small Parts
Single Point Contact
(Prod. Safety Mgr.)
Status : "CERTIFIED"
NOT Attached
Attached
E-mail Ca_menchie@tyfashion.com.tw CONDITI No Small
CERTIFIE
Phone # 855-765025702 ONAL Parts Attached
D
Re -inspection Date:
Name Mary Jayne Francisco Certification
Point Person Back up Date
E-mail Ca_jayne@tyfashion.com.tw
Phone # 855-11411053 Auditor's Signature

Policies
Has the factory documented policies that follows LS&CO YW product Agreed
safety guidelines on the following and signed by top management Completion
Observations Recommendations completion
date .
Yes No date
1 Embedded Object Policy
Metal staples, pins and other sharp objects that could Levis Safety policy to
contaminate product (Cutting, Sew or Finish) are manage all of embedded
forbidden. object has been developed
& sign by the top
management on the 28th
Jan 2013 . But Found the
use of Some staples in
Finishing department .

X
2 Needle control (Broken and Replacement needle policy and process)
Needles controlled by supervisor (Issue new and collect The factory has a clear
broken needle and fragments). policy for needle
replacement procedure .The
main stock of needle are
kept locked in the
production floor with a
separate person issueing
the needles to workers &
suppervisors .

X
Employees not allowed to have extra needles or pins. Added in the Needle control
policy saying the workers &
staff are not allowed to
have extra needles
,unaccounted needles &
pins were not found during
the factory inspection,

X
All parts of needle - taped together as to form needle All parts of needle - taped
straight again on needle log. together in the needle
replacement report
X
3 Broken needle fragment search
Tunnel-type metal detector (Country specific) Factory Has a total of 2
Note: Japan requires 100% product inspection through Metal detectors (Brand -
tunnel metal detector. Hashima) in the unit that
they make haddad Levis
production,
x
Needle fragment search process flow chart MUST be Flow-chart according to the
followed. Levis YW requirements has
been developed on the 28th
Jan 2013

X
4 Pull test perfomed according to LS&CO. YW (0-6-7X) product safety Factory had not made any
requirements. Levis styles yet . They do
Pull test ( 20.2 LBS) for
other Brands ( Carters &
H&M) & understand that
Levis Requirments of
20.23LBS.

N/A

Factory shall not be certified if any item highlighted is not met.


6 Training of workers and supervisors (All who touches YW product while in Thailand Haddad PI
process). Manager & Regional PI
Manager had conducted the
“Train the Trainer" to
Factories Single point
person & for a team on the
9th Nov 2012 . Safety Team
had trained the workers &
suppervisors from 27th Dec
12 untill the 15th Jan 2013 ,

X
7 Mechanic's training and certification by equipment and sundry approved The factory is requesting an
supplier (YKK). approval for Non-metal
attachment, therefore no
YKK involvement
N/A
8 Auditor/Inspector training and certification (In-line and Final Audit) 103 staff of In-line, End-line,
final inspectors & auditors
were not trained on YW
safety requirement on the
12th - 15th Mar 2013 .

X
9 100 % In-line inspection and 25 unit/5 carton Final Audit process policy. 25 units /5 carton safety
inspection policy has been
developed on the 28th Jan
2013
X
10 Use of stones NOT ALLOWED. No Stone policy was
developed on the 28th Jan
2013
X
11 Perlite / Diatomaceous Earth "D.E." ARE ALLOWED for YW product (0- No Stone policy was
6/7X) ONLY if product is 100% inspected after the pockets are cleaned developed on the 28th Jan
with exception of Adjustable Waist Band "AWB" YW (0-6/7X) product. 2014
Perlite and D.E. can be use in AWB ONLY if slits are basted closed.
X
12 Equipment and Sundries used only from LS&CO. approved supplier Factory had not made any
(i.e.YKK). Levis styles yet .
N/A
13 All sundries attachments to be tested according to LS&CO. YW (0-6/7X) Factory had not made any
product safety requirements. Levis styles yet .
N/A
14 Sundries control: receiving QC log, issuance to floor log, floor return Sundries control procedure
inventory. with the daily issues & daily
return inventory according
to the Levis YW process
had been developed In jan
2013

X
15 Policies shall be in local language and available for workers to read All policies are in
Chinees , English & Khmer
(Cambodian)
X
16 Policies legibly displayed and updated in factory conspicuous location. All Policies were posted in
all production areas .
X
17 YKK zippers (Pre-cut zipper tape or Chain zipper, sliders, zipper stop, etc.) Factory had not made any
and YKK zipper equipment MUST be use for YW (0-6/7X) product. Levis styles yet .but the
management understand
that they have to use YKK
pre-cut Zippers for YW
styles
N/A
18 Implement a safety control process for zipper, zipper stop making, zipper Factory had not made any
slider and their application that complies with LS&CO.'s YW (0-6/7X) Levis styles yet .but the
product safety requirements. management understand
that they have to use YKK
pre-cut Zippers for YW
styles
N/A

Equipment /Tools
Does the factory have the following equipment /tools for testing, porcess Completion Date
control, manufacturing, and metal detection ready for use? Yes No Observations Recommendations date agreed completed
1 Foreign Metal Seach (Tools and method)
Tunnel metal detector (This Factory Currently Has 2
requirement is Country specific, where product is Metal detector (Hashima) in
manufactured or where product will be shipped requires the unit where Haddad levis
100% inspection of product using Tunnel Metal detector are going to be made,
(i.e. Japan)).
X

Factory shall not be certified if any item highlighted is not met.


Iron ball of 1mm (required to verify tunnel metal 1.0 MM card is used to
detector when use). calibrate the
mechines.mechine has
been calibrated every 2
hours , records were kept
for review.

x
Broken needle fragment search flow chart and needle
control process
flow chart MUST be followed.
Are any of the following tools or method Broken needle fragment
being use to search foreign metals? 1) search flow chart had been
Tunnel or hand held metal detector 2) devolped according to the
Magnet 3) YW requirments
Visual check-Rip seam
X
2 Pull test machine
Only bench type "SafQ" accepted. Factory already has a in-
house Saf-Q bench type
x pull test machine
Standard methodology (test 2 units per contract size of Safety Team understand
2000 units and one additional units for every 1000 units the Levis YW new
thereafter). requirement of 21 LBS & 2
Pcs testing for the first 2000
pcs & the I pcs each for
each additional 1000
depending on the order qty
during the final inspection,

X
Calibration procedure 15 LBS weight is placed to
calibrate the Machine daily
X
3 Snap-O-meter (Americas and Europe Only) The factory is requesting an
approval for Non-metal
attachment, therefore SNAP
– O –Meter is not required

N/A
Standard methodology (test 5 units from each machine The factory is requesting an
"3 snap test and 2 Un-snap". approval for Non-metal
attachment, therefore SNAP
– O –Meter is not required

N/A
Calibration procedure The factory is requesting an
approval for Non-metal
attachment, therefore SNAP
– O –Meter is not required
N/A
4 Electric machines
Digital Caliper (to check Pinch setting) . Factory has a in-house
Digital Caliper
X
Control process in placed for usage of dies (According
to sundries and machine type).

5 Pneumatic machine
Rotation / interference test (snap the snap together and
rotate the two parts "the stud and the socket") . N/A Not In Asia
Compressed air checked by YKK for adequate pressure
and air supply.
N/A Not In Asia
6 Washing machines with "no stones used on YW product" poster No Stone policy was
developed in Jan 2013
X
7 Cross and Lock stitch equipment (sew-on buttons). Factory uses cross &
lockstitch machines for the
attachment process , 23
Machines in-house
X
8 YKK chain zipper roll equipment (i.e. zipper top and bottom stop machine,
etc.) Factory had not made any
Levis styles yet .but the
management understand
that they have to use YKK
pre-cut Zippers for YW
styles
X
9 Recommended YKK equipment test for zippers and process being use Factory had not made any
(i.e. Digital Caliper, Micrometer, forms, etc.) Levis styles yet .but the
management understand
that they have to use YKK
pre-cut Zippers for YW
styles
X

Factory shall not be certified if any item highlighted is not met.


Training
Verify each one of the items listed below though GIFW process, and Completion Completion
management interview. Yes No Observations Recommendations if any dates agreed date
1 Employees demonstrate proficiency on Needle control, broken needle Thailand Haddad PI
procedure, safe attachment identification, unusual odor in garment, and Manager & Regional PI
other foreign objects (metal staples, pins, stones, perlite, D.E., etc.) in Manager had conducted the
LS&CO. YW (0-6/7X) product. “Train the Trainer" to
Factories Single point
person & for a team ( 6
members)on the 9th Nov
2012 . Safety Team had
trained the workers &
suppervisors from 27th Dec
12 untill the 15th Jan 2013 &
special training to the QC
on 12th -15th Mar 2013

X
2 Laundry operators demonstrate proficiency in the YW (0-6/7X) product No Stone policy was
safety requirements related to laundry. (No stones allowed in YW (0-6/7X) developed in Jan 2013 .but
process, No perlite or Diatomaceous earth for YW (0-6/7X) with adjustable washing was not done in
waist band, product with Snaps to be washed with snap open and zipper TY Garments.
close, snap test after drying process.)
N/A
3 Operators in Cutting area are proficient on YW (0-6/7X) product safety 49 people From cutting
requirements (i.e. No pins or metal staples allowed, material with unusual section were trained on YW
odor to be evaluated for chemical residue, etc.). requirments on the 29th
Dec 2012
X
4 In-line inspectors demonstrate proficiency on YW (0-6/7X) product safety 103 staff of In-line, End-line,
requirements. (i.e. safe attachment, embedded objects "needles,, pins, final inspectors & auditors
metal staples, zipper stop, NO stones, perlite or D.E.. on adjustable elastic were not trained on YW
waist band unless busted closed , etc. safety requirement on the
12th - 15th March 2013 .

X
5 Mechanics demonstrate proficiency on YKK equipment maintenance, 5 Mechanics were trained
calibration, and proper snap/button/rivet/zipper attachments on YW (0- on YW requirements on the
6/7X) product safety requirements. 12th Mar 2013

X
6 Employees who work with Tunnel metal detector demonstrate proficiency 6 members were trained on
in it's operation and calibration procedures. the 8th Feb 2013.
X
7 Product Safety process assigned employee/manager demonstrate Thailand Haddad PI
proficiency on steps that need to be taken if an unsafe attachment is Manager & Regional PI
found while performing daily machine test (Pinch /Pull /Interference Manager had conducted the
/Snap /Visual) and proper calibration procedures of tools being used. “Train the Trainer" to
Factories Single point
person & for a team ( 6
members)on the 9th Nov
2012

X
8 Product Safety manager and Facility manager understand and document Product Safety manager
the YW (0-6/7X) product safety process control documents monthly. and Facility manager
understand the YW process
clearly .
X
9 Product Safety manager demonstrate proficiency in the YW (0-6/7X) Single point person &
product safety requirements, and knows how often he/she is expected to Factory manager had
review documentation and safety process. checked and reviewed the
YW documented process
weekly & monthly as
required

X
10 Sundries manager understand and practice the sundries control policy. (i.e Stores Manager & one more
Verification of right sundry for the right garment before issuance, person whos in-charge of
die/socket control for snap/button machines, and inventory return if excess haddad styles had been
at end of day etc.). trained about YW
procedures & Sundries
issues on the 8th Feb 2013

X
11 A process to keep a buffer of trained employees ready to support factory had not recruited
employee absenteeism in the YW production line in maintained. any new workers since 15th
Jan 2013
X
12 Factory have a system for retraining its employees in YW (0-6/7X) Factory has a training
requirements? (annual recommended). schedule to re-training all
workers & staff every 6
months .next re-training is
due in June/July 2013
X

Factory shall not be certified if any item highlighted is not met.


13 Has the factory manufactured LS&CO. Youth wear (0-6/7X) product in the Factory had not made any
last 6 months? Levis Style up-to-date .
X
14 Factory maintains a minimum of 3 management staff trained by a Certified Management had set-up the
trainer (Licensee, External Monitor or LS&CO staff) at all times. product safety team that we
wanted with 6 management
staff. They were provided
with the TTT by Haddad
regional team members on
the 9th Nov 2012.

X
15 YKK trained in-line inspectors, supervisors, workers making and applying Factory had not made any
zipper and zipper stop (i.e. proper procedure to make and apply zipper, Levis styles yet .but the
zipper stop) and detection of unsafe zipper or zipper stop. management understand
that they have to use YKK
pre-cut Zippers for YW
styles

16 YKK trained mechanics to properly maintain and adjust zipper making and Factory had not made any
zipper stop application equipment (i.e. zipper stop pinch value and Levis styles yet .but the
location, etc.) management understand
that they have to use YKK
pre-cut Zippers for YW
styles

Records
Records shall be audited for accuracy and completeness in the areas Complete
described below. Write observations and recommendations in the
pertinent column when records are not complete or accurate. Agreement Completion Completion
to complete items checked as "No" in the complete column shall be dates agreed date
discussed with management at the closing conference to agree to thier
completion dates. Yes No Observations Recommendations if any
1 Training records of Management, trainers, and Quality/Product Safety Thailand Haddad PI
Mgr.; Employees, Supervisors, Auditors, In-line inspectors Manager & Regional PI
Manager had conducted the
“Train the Trainer" to
Factories Single point
person & for a team ( 6
members)on the 9th Nov
2012 . Safety Team had
trained the workers &
suppervisors from 27th Dec
12 untill the 15th Jan 2013 &
special training to the QC
on 12th -15th Mar 2013

X
2 Training records and certificates shall have participant's name, date of all training record details
training, topics cover, and trainer's name were clearly documented .
X
3 Training and certification records given by YKK technicians to mechanics, The factory is requesting an
Inspectors, QC Mgr. approval for Non-metal
attachment, therefore no
YKK involvement
N/A
4 GCR and DS records for LS&CO. YW (0-6/7X) production Factory had not made any
Levis Styles with
attachments yet so GCR &
DS still not followed,
N/A
5 Initial equipment installation records including, date, name of YKK The factory is requesting an
technician, List of Die number with corresponding attachment, air approval for Non-metal
compressor capacity sign off by YKK technician for pneumatic machines. attachment, therefore no
YKK involvement
N/A
6 YKK sundries attachment machine maintenance and calibration test log at The factory is requesting an
each machine (floor verification). approval for Non-metal
attachment, therefore no
YKK involvement
N/A
Electric snap/button machine pinch setting and The factory is requesting an
calibration test log. approval for Non-metal
attachment, therefore no
N/A YKK involvement
Pneumatic snap/button machine rotation/ interference
test log. Note:
rotation/interference test is perfromed by snap the snap
together and rotate the two parts (the stud and the socket) to
insure there is no interference between the legs and that the
components couple flatly.
N/A Not In Asia

Factory shall not be certified if any item highlighted is not met.


Zipper stop application machine calibration test log (i.e Factory had not made any
zipper stop pinch setting and application location Levis styles yet .but the
checked). management understand
that they have to use YKK
pre-cut Zippers for YW
styles
N/A
7 Calibration log/records: (Tunnel type metal detector, Digital Caliper for Metal detector machine
Electric machines ONLY); Snapometer, Pull tester. Note - Only calibrated using 1 MM.
bench type pull tester allowed.
X
8 Sundries Control: P.O. request-packing slip verification for accuracy of Sundries control procedure
order; quality check documention of sundries received (confirmation with with the daily issues & daily
techpack/BOM); sundries issuance to floor control and returns. return inventory according
to the Levis YW process
had been developed In jan
2013

X
9 Broken needle log (operator's name,machine type and #, date, needle Unaccounted needles were
type, operation, supervisor's signature when replacing needles and broken Not found in production .
needle pieces taped to form complete needle). Needle stock was accurate
with the actual issuance , ,

X
10 Other Foreign objects log (packer's knife breakage, hang tag gun's needle Proper equipment control
control, etc.). log in all departments.this
was monitorted daily by the
safety in charge .
X
11 Inline 100% inspection log for Y/W (0-6/7X) product In-line & end-line checking
was done 100 % & the
reports were kept for review

x
12 Final Audit log/records Final check-ups were done
using AQL 2.5
X
13 Records review performed by facility Mgr. and Product Safety/ Quality Single point person &
Mgr. documentation. (Monthly review is expected by factory manager and Factory manager has
weekly review by single point contact after certification is granted). checked and reviewed they
YW documented process
weekly & monthly as
required
X
14 Ragged garment's records (a garment MUST be kept on file for 5 years for Ragged garments
every incomplete needle found in record "Broken needle log"). procedure is Included in
the YW policys
X
15 Equipment performance records reviewed every 4 hrs.
YKK electric snap/button machine and/or YKK No Levis Styles are made
pneumatic snap/buttonmachine (SPC form) up-to-date
N/A
Zipper stop application machine. No Levis Styles are made
N/A up-to-date
Tunnel metal detector (if used to avoid ragging garment Metal detector & Hand held
when needle fragment are not found) needle detector machines
were calibrated using 1 MM
matal Ball card,

X
Pull Tester (use pull test frequency from training 15 LBS weight is placed to
materials). calibrate the Machine daily
X

Comments/Remarks:

Factory shall not be certified if any item highlighted is not met.


1). Any Facility certified/approved for YW (0-6/7X) production without small parts attached can not be use to source product with small parts attached. Factory will need to be certified
for production with small parts attached.

2). Certification types and definitions:


ACTIVE "CERTIFIED" :
A facility is classified as Active when it has been newly certified and each time it passes a quarterly certification inspection after having produced LS&CO
Youthwear 0-6X/7X products during the preceding 90 days.

CONDITIONAL:
A facility is classified as conditionaly certified if highlighted items in yellow from the audit form above are not met and agreement by facility management is
confirmed to be address within 10 days after audit was performed.

NOT CERTIFIED:

The facility can not be certified for LS&CO Youthwear 0-6X/7X product if any of the audit list items are not met in full. Production may not be placed at this
facility unless the audit perfromed qualifies for conditional certification. Under such circumstances conditionl certification terms will apply.

Conditional certification Items


Country specific requirement (Requirement(s) that must be met if it’s a Country requirement/Standard/Law or best practice).
Mandatory Items

Factory shall not be certified if any item highlighted is not met.