What is FCCA (Factory capacity and capability Audit)?
The FCCA is the abbreviated form of Factory Capability & Capacity Assessment, which means Factory Output and Capacity Assessment. It is basically Wal-Mart’s own Code of Conduct Audit. Its purpose is to check whether the Factory’s Output & Production Capacity meet Wal-Mart’s Production Capacity and Quality Requirements. This Program is not focused on auditing an individual Product Category, but on specifically assessing all Suppliers & their Manufacturing Facilities, to confirm they comply with Wal-Mart Standards. FCCA stands for Factory Capability & Capacity Audit, it is a technical audit program which was developed to effectively identify the exact production capacity of a new or existing factory, it also helps the factory to enhance and provide a realistic system for quality and reduce quality problem, by doing this improved production efficiency and product value will be achieved. This program is specially used by WALMART throughout its supply chain which includes subcontracting and packaging facilities should comply with the standard. Effective measures for supplier’s production processes and quality safety evaluation being demanded by the brands and international buyers, they demand more effective way of evaluations. Proactive ways are being discovered by the factories to benchmark themselves and track progress against competitors and national standards. Significant shift has been observed towards greater transparency and the implementation tool for assessing continuous improvement. By implementing FCCA standard organization can improve and control its overall production processes risk and quality safety conditions to assure the confidence & satisfaction of their customers and other stakeholders. Factory can get the score after successful audit as it is a score-based audit and factory is approved if any factory meets the minimum score in audit which is required to get the approval as customers has set the acceptable score against the audit. FCCA is the customer-based audit program and is suitable for any organization i.e., large, medium and small considering improvement in its quality assurance practices and sustainability to meet the expectations of all stakeholders. FCCA audit is performed against the requirements of FCCA standard which assures safe, legal, quality effective, and controlled manufacturing process.
Process for FCCA Audit –
After finalization of agreement with client, IKON COMPLIANCE CONSULTANT’ experts visit to client’s premises and conduct the complete gap analysis of existing system against the FCCA code of conduct and discuss the gap report to the management, identified gaps could be in documents, implementation, employee’s awareness, customer code gaps. We commence work according to the agreed timelines as per final gap report and proceed for the audit once all the documentation, implementation, and other requirements are done. Our technical team provides complete assistance, support and cooperation throughout the process to make FCCA audit successful in first attempt. FCCA audit does not grant once-and-for-all, it must be re-audited before expiration of the certificate. After applying for the audit to the auditing body, they conduct the audit. After the successful conduction of audit, auditing body issues the report with score which is re-audited as per the score. After completion of audit cycle re-audit will be conducted.
What are the Benefits of FCCA Audit?
- Producing Walmart products that comply with the factory’s capacity, capability and quality requirements.
- Improved Transparency and Trust between Buyers and Suppliers.
- Improved Controls and Processes for Managing Product Quality and Safety.
- Supporting customers in developing a business relationship with Walmart and other large-scale retailers.
- Better Risk Management.
- Develop complete Quality Management system.
- Get new business opportunities from international Retailers.
- Helpful to retain the confidence of existing customers.
- Helpful to attract new customers.
- Improve quality performance.
- Improved Quality Management System Performance and product traceability.
- Globally accepted standard.
Evaluation Rating Criteria –
Rating Guide : Result
80-100%(A) : Good
60-79% (B) : Acceptable
00-59% (C) : Not Acceptable
What are the Focus points of FCCA?
- Factory Facility & Environment
- Quality Management System
- Incoming Material Quality Control
- Process and Production Control
- In-House Lab Testing
- Final Inspection
- People Resources and Training
- Traceability
- Supplier Control