验厂又叫工厂审核， 俗称查厂，简单地理解就是检查工厂。一般分为人权验厂(社会责任验厂)、品质验厂(质量技术验厂)、反恐验厂(供应链安全验厂)等等。很多客户希望供应商在质量、社会责任(人权)、反恐等方面的管理体系达到一定的要求，因此在下订单之前会自己或者委托第三方公证行检查工厂状况，在确认工厂没有大的、严重的问题存在后，才能够将工厂纳入为到合格供应商名单，才会下订单并长期合作。
验厂（工厂审核）是企业为了确保供应商或制造商符合其质量标准、社会责任和安全标准，而对工厂进行的系统性检查。验厂通常包括以下几个步骤：
1. 审核准备
确定验厂类型：有不同类型的验厂，例如质量审核、社会责任审核、环境审核等。根据需求选择合适的验厂类型。
准备审核清单：根据验厂类型，制定详细的审核清单，包括各项标准和指标。例如，质量审核会涉及生产流程、原材料、设备维护等，社会责任审核则关注工人权益、工作环境等。
2. 现场审核
文件审查：检查工厂的文件记录，例如营业执照、产品认证、员工合同、工资单、生产记录、质检报告等。
工厂环境检查：实地考察生产车间、仓库、办公区，查看环境卫生、安全设施、设备运转等。对于社会责任审核，还会检查工作条件、工人的工作时间和福利等。
生产流程审查：观察生产流程，检查原材料的管理、生产设备的运行情况、生产效率和质控环节的执行情况。
访谈：与管理人员和一线员工进行访谈，了解工厂的运营情况、管理制度、工人待遇等。
3. 质量控制
产品质量检查：随机抽样成品进行检测，验证是否符合质量标准和客户要求。
质控流程审查：检查工厂的质量控制流程，包括进料检验、生产过程检验和成品检验等环节的执行情况。
4. 社会责任审核
劳工权益审查：核实工厂是否遵守劳工法，是否存在童工、强制劳动、低工资或超时加班等现象。
健康与安全：检查工厂是否提供了安全的工作环境，例如是否配备消防设备、急救箱、员工是否接受过安全培训等。
5. 报告和跟进
审核报告：验厂完成后，审核员会出具详细的审核报告，指出工厂的优点、缺点和不合格项。
整改措施：如果发现不符合标准的地方，工厂需要制定整改计划并在规定时间内完成整改。
复查：有时会安排后续复查，确认工厂是否按要求进行了整改。
验厂的核心目的是确保工厂的生产能力、质量管理和社会责任水平符合采购方的要求，保障供应链的稳定与合规。
Factory inspection is a process used by companies to evaluate whether their suppliers or manufacturers meet required standards, such as quality, safety, social responsibility, or environmental regulations. Here’s a general guide on how to conduct a factory inspection:
1. Preparation for Inspection
Determine the Type of Inspection: Inspections can focus on different areas, including quality control, social compliance, environmental standards, or security. Identify what type of inspection is necessary based on your business needs.
Prepare a Checklist: Develop a comprehensive checklist based on the standards you want to inspect. This might include items related to raw materials, production processes, quality assurance, worker conditions, or safety practices.
2. On-Site Inspection
Document Review: Begin by reviewing key documents to ensure the factory is legally operating and maintains accurate records. These may include:
Business licenses
Quality control certifications
Employee contracts and payroll records
Production records and schedules
Health and safety documents
Factory Walkthrough: Conduct a thorough tour of the factory floor. Observe the overall cleanliness, organization, and safety of the environment. Check production equipment, workflows, and any potential hazards. Take note of:
The condition of machinery and tools
Organization of production lines
Stock of raw materials and inventory
Storage conditions for raw materials and finished goods
Production Process Review: Watch the production process in action to ensure that procedures follow best practices and meet quality requirements. This may include:
Raw material handling and storage
Manufacturing process flow and stages
Waste management and recycling
Efficiency and productivity monitoring
Interviews: Speak with management and workers to get insights into factory operations, worker conditions, and management’s commitment to meeting required standards.
3. Quality Control Inspection
Product Testing: Randomly select finished products for testing. Ensure they meet the quality standards required for your market. Testing could include functionality tests, safety tests, or visual inspections for defects.
Review of Quality Assurance Processes: Inspect how the factory manages quality control, including:
Incoming material inspections
In-process quality checks
Final inspections and testing
Non-conforming product handling
ISO Certifications: Check whether the factory has relevant quality certifications like ISO 9001 (Quality Management Systems), which can indicate a commitment to high-quality standards.
4. Social Compliance Inspection
Labor Practices: Verify the factory’s compliance with labor laws and international standards regarding worker rights. This may include:
Ensuring no child labor or forced labor is used
Reviewing work hours and overtime policies
Assessing wage compliance (minimum wage, overtime pay, benefits)
Checking for any discrimination or harassment issues
Health and Safety: Assess the working conditions and whether employees are provided with a safe environment, including:
Emergency exits, fire extinguishers, and safety signs
First-aid kits and access to medical care
Proper ventilation, lighting, and cleanliness
Personal protective equipment (PPE) for workers
Safety training for employees
5. Environmental Inspection
Waste Management: Inspect how the factory handles and disposes of waste, ensuring it meets environmental regulations. This includes:
Proper disposal of hazardous waste
Recycling and reduction of waste
Compliance with local environmental laws
Energy Efficiency: Check for efforts to reduce energy consumption and water usage, ensuring that the factory is implementing sustainable practices.
6. Report and Follow-Up
Create an Inspection Report: After the inspection, create a detailed report that highlights findings, both positive and negative. The report should clearly outline:
Areas that meet your standards
Non-compliant areas
Recommendations for improvements
Corrective Actions: If non-compliances are found, work with the factory to create a corrective action plan (CAP). This plan outlines how and when the factory will resolve the issues.
Re-inspection: Depending on the severity of the issues, a follow-up inspection may be necessary to confirm that corrective actions have been implemented.
The factory inspection process helps companies ensure that their supply chain meets regulatory and quality standards. It's an essential step to mitigate risks and ensure long-term partnerships with reliable manufacturers.