ELHennawy Textiles

Audit Report
Surveillance 1

This report and all its content is confidential and remains the property of Intertek.

BA Audit Summary Report

Client ID#:

CMPY-060866
Client/Address:

ELHennawy Textiles
ASHMOON - MENOFIA

Audit Criteria:

ISO 9001:2008, OHSAS 18001:2007

Audit Activity:

Surveillance 1

Date(s) of Audit:

Menofia, Egypt:
22-Apr-2015

Report Issue Date:

26-Apr-2015

Auditor(s) (level):

Adel Bassiony (Lead Auditor, Menofia, Egypt)

Salah Keshtah (Auditor, Menofia, Egypt)
Nabil Bakry (Technical Expert, Menofia, Egypt)

Scope of certification:
Site: ELHennawy Textiles, Menofia, Egypt
ISO 9001:2008:
Production of Ready Made Garments
OHSAS 18001:2007:
Production of Ready Made Garments

OVERALL RESULT:

No Action Required

The management system was found to be fully effective. (no nonconformities issued)

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BA Audit Summary Report

Executive Summary

Strengths

Weaknesses
Opportunities
Threats

Clean & Safe Factory.

improvements have been done since last audit
All OFIs of Re-certification audit were covered effectively.
Occupational Health & safety Management System and QMS are effectively implemented against
the requirements of OHSAS 18001, ISO 9001:2008 relevant requirements & legal and other
requirements.
The system was supported by comprehensive documentation HSE manual, procedures, quality
plans and work instructions)
Documents covered all the requirements of OHSAS 18001 - ISO9001:2008 besides the company
documents.
Highly remarkable commitment of top management was seen,

Turn over of employees is relatively high

Open new markets via new trustable agencies

NA

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BA Audit Summary Report

Executive Summary By Category

The score descriptions are generic to all management systems and cannot be customized by the auditor, thus allowing for the consistency of
interpretation and standardization of audit results worldwide. The scores provided to your organisation are for benchmarking purposes only
and are based on the audit teams evaluation.

Management

Mature

Consistent evidence of management commitment, customer and/or interested party satisfaction, knowledge/awareness of policy and
objectives being demonstrated by the majority of staff. Responsibility and authority is evident and supported via data, trends and related
KPIs. Management reviews are complete and demonstrate support by the majority of personnel. Records are complete and demonstrate
positive trends inimprovement and lessons learned.

Internal Audits

Mature

Internal audits are being performed at planned intervals and are based on status and importance of the Management System. Data is
being collected analyzed and reviewed by senior management on a regular basis. There exists a link between the internal audit results
and the overall health of the Management System. Audit teams are trained, impartial and objective in their approach. Audit reports are
clear, concise and supported with applicable correction actions. Management is involved in the corrective action process ensuring timely
implementation and overall effectiveness of resolution.

Corrective Action

Mature

The corrective/preventive action process has demonstrated to be effective in practice. Data from sources such as customer and/or
interested party complaints, internal audits, warranty analysis, defects, internal metrics and supplier performance show stability over time
as the system matures. The process includes a thorough review of the effectiveness of the actions taken. There is evidence of problem
solving tools being used to support the process.

Continuous Improvement

Mature

Data streams are being used as sources to drive continual improvement over time. These may include management system policy,
objectives, and audit results, analysis of data, CAPA and management reviews. There is some evidence of advanced techniques being
used during the improvement cycle. Economic benefits have been realized.

Operational Control

Mature

Operational Controls are planned and developed. Planning of operational controls is consistent with all other Management processes.
Objectives, process requirements, needs for appropriate additional documents and resources, verification and monitoring activities and
records requirements have been determined, as appropriate. Processes and activities run consistently. Data is collected, and reviewed to
verify the effectiveness of operational controls with evidence of significant improvement trends. Some evidence linking to some key
business factors.

Resources

Mature

Resources required for the effective maintenance and improvement of the management system have been defined and deployed.
Improvements have been noted in areas such as customer and/or interested party satisfaction, continual improvement, and process
variation. Levels of competency have been defined and documented within the existing management system.

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Rating: 5=Benchmark 4=Mature 3=Meets Intent 2=Beginning 1=Not Evident

Follow-up on nonconformities issued at previous audit

Prior assessment resulted in no corrective actions.

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BA Audit Summary Report

Evidence Summary
The evidence the State of the Management system is summarized below:

Customer Performance / Satisfaction

The company has established and still Implemented the integrated management system effectively since 2010, Conformance, and legal
compliance of quality management system and OH&S management system (Q & OHS) were confirmed as per ISO 9001-2008 and 180012007 requirements. The top management is committed to quality, safety, customer satisfaction and the implementation of the management
systems. The system was adequately documented. Management System scope was adequately described in the manual. Q/OHS
processes were properly identified. Current issue of documents was available in all visited area. Reviewed records were legible, filed,
stored and protected. Interviewed personnel competence was satisfactory. Records & documents are adequate and covering all activities
of the company. Top Management commitment is proved via establishing SMART objectives, conducting deep management review.
Customer and interested parties focus is appearing via vision of the company and well communication with relevant authorities. The OHS
system is continually improved; it is complying with legal and other requirements applicable to company hazards and conforming to the
requirements OHSAS 18001-2007.The assessment covered the activities, e.g. Documentation, resources, risk assessment, top
management commitment, legal compliance, continual improvement, prevention of accidents and participation and consultation The
auditor evaluated the planning and effectiveness of QMS & HMS through interview, records verification and sampling methodologies. All
activities were assessed except the justified exclusions: 7.3, 7.5.2 & 7.5.4that were well justified: 7.3: Design and development was not
assessed since all specs are presented by the clients - 7.5.2: the validation of the processes was not assessed since all process &
products can be verified by sub sequence monitoring, 7.5.4: Customer property was not assessed since there were no dealing with
customer properties. No change in the scope of certification. It was evident that the quality, OHS management system are established,
documented, implemented and well maintained. Effective control on company operations is evident, Availability of adequate emergency
equipment & PPES. The company conducts drill tests periodically to evaluate emergency preparedness effectiveness. Conducting strong
internal audits, investigating near misses clearly, corrective actions for non-conformities were effective tools for continual improvements
Monitoring of the process related to the customer is achieved by reviewing customer requirements (contracts, orders), complaints,
satisfaction, etc). F-7505 is used on 6-monthly basis to measure customer & agencies satisfaction, Analysis show that all customers are
fully satisfied, e.g. Amr Hamdy, Hesham Salah; their satisfaction were measured in December 2014, Customer satisfaction is also
measured after each shipment via F 7502 as checked for Cogar Sport. Only two complaints were received in 2014 & 2015 so far and
handled properly as checked satisfactorily, e.g. the one of 16/1/2015 for delay shipment. Several Thanks letters have been received in
2014. Analysis of customer satisfactions shows positive trend in 2013 the ratio of satisfaction was 96% meanwhile the ratio in 2014 is
98%

Process for Monitoring and Maintaining Compliance with Legal and Other Requirements
OH&S monitoring and measurements were carried out as per procedure SP4501st issue dated 15/2/2010. OH&S measurements were
measured by outsourced valid environmental institute (Comprehensive Centre for scientific and environmental services on 15/12/2014.
OH&S measurement results report indicated full compliance with legal limits. Legal compliance was evaluated by HSE officers. Lights
intensity, heat stress, noises, total suspended particles, and air emission, humidity, ventilation & water were measured by a-m center.
Monitoring results illustrate full compliance with permissible limits of the environmental law, e.g. Solid particles (Result is 4.2/ Law limit 50
mg/m3)- Noise (80/90 db), CO (13.7/100) & heat stress; 20/30 degree. Analysis of potable water shows also an acceptable level of
measurements. No any asbestos material is used in the company as per the certificate of a-m center. Monitoring of the hazards associated
with the activities of the company is carried out by the OHSAS responsible weekly. Records are in place as checked via FS 4503; checked
for the whole locations inside the factory, e.g. stores, production line 12, administration, cutting, pressing and administration building. All
Results of the measurements are evaluated by the OHSAS management representative and found in limit of law.
Evaluation of compliance was carried out by analyzing the measurements & monitoring by HSE manager using a checklist quarterly via FS
4504; All measurements are analyzed effectively. In addition compliance was reviewed in the site and production areas by periodic
inspection as checked via a-m forms. Last evaluation took place on 31.03.2015
.

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Management System Performance (Objectives / Targets / KPIs / Trend Analysis)
Procedure P5802nd issue dated 15/1/2011 was established to identify quality Objectives & Procedure SP4331st issue dated
15/2/2010 for handling OHS objectives, Quality and safety objectives were set for 2014 cover all relevant functions and levels. The 8
Measurable Quality/HSE objectives that were set for 2014 were realized; including: installation of automatic firefighting system 
maintaining zero accident, increasing final product quality by 0.2% related to 2013increasing productivity by 10% related to year 2013
increasing customer satisfaction by 2% related to year 2013 as checked via F5801 & FS4331. Action plan for realization of targets was
established and implemented effectively as checked for the targets of the a-m objectives via F5802 & FS4331the programs located
responsibilities, stages and time intervals for achieving targets and followed up by M.R , For 2015: 5 Quality objectives & 6 safety objective
were set; including: upgrading the alarm system, getting advanced PPEs, always maintaining zero accidents, increase customer
satisfaction, increase sales.
Monitoring and measurements of the whole IMS done through internal audit, customer feed-back and management review as checked and
decisions are to be converted to corrective action as needed for improvement of the system. Procedure for corrective & preventive actions
is well implemented. Corrective actions take place from internal audit results, non confirming products, customer complaints, process
performance, near misses, HSE violations, improvements, management review and day to day operations, site inspections, drills, etc. 31
corrective actions were taken in 2014 (F888-5). Follow up of corrective actions are carried out as per CA log (F-888-6). Root cause was
investigated and follows up carries out. Two preventive actions were taken & carried out effectively in 2014. Data is collected and analyzed
for suitability and continuous improvement of product and QMS. Report of 2014 for the analysis of results of the process measurements
was satisfactorily assessed; purchasing 99%cycle tome, lead timeProduction 98%execution of production plans-non conforming
productsand Maintenance down times of machinesetc. Trend shows positive results d from the report of 31/12/2014 as checked
positively
Data is also analyzed for customer satisfaction; suppliers, management review factual decisions and overall projects and upgrading of
machines. trends show positive results

Assessment of Implementation related to Hazard or risk

Documented procedure SP431 issue 1 dated 15/2/2010 of OHS hazards identification & evaluation, Criteria were established to evaluate
risks associated with company activities and services based on likelihood and severity in the register form FS4312 (severity 1 very low 2
low medium 4 high 5 critical repetition 1 rarely 2 once yearly 3 once monthly 4 once weekly - -5 once dailyrisk factor 1
not need control 2-4 medium and need control, e.g. work instructions & PPEs 5-10 significant and need more control 12-20 more
significant more than 20 unutterable, e.g. administration is 2 & cutting is 5 and pressing is 5 , maintenance 2. Based on risk score/ level,
risk was classified into 3 levels. Suitable measures and controls were accurately applied. Hazards related to the company's activities have
been reviewed; the list was updated on 1/4/2015. It included all activities, e.g. as production operations, storing, pressing cutting 
packing and packaging administration building etc. he action to be taken was identified for all risk categories, e.g. printing machine
pressing & compressor. All activities are totally controlled via outstanding ventilation system, wearing PPEs, periodic measurements and
work instructions that organize the work-times in some areas.
Critical risks include mainly (heat stress, total suspended particles, noises, mechanical hazards, sewing hazards, lights intensity,
installments risks, working on heights, cutting hazards, painting activities, and electrical hazards, etc). Risks were evaluated taking into
consideration legal and other requirements, likelihood and severity. Risk degree was available for every hazard: low, medium and high.
Suitable measures and controls were applied. Risk assessment has been totally assessed and found satisfactory. All risks records were
subjected to review after near misses (no accidents were happened in 2014 or 2015 so far) as mentioned in the procedure.

Comparison of Results with Previous Audit Activity / Recertification Activity

Several improvements have been done in this contractual period; the implementation of the IMS system became totally effective, its
implementation is simple but efficient in addition to:
Housekeeping is getting much better in the factory, it is up to the level
All remarks of last audit were closed effectively
Depth of internal auditing & Management review was evident
Effective objective have been realized
Analysis of near-misses, incidents, etc is outstanding

Impact of Significant Changes (If Any)

NA

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Additional information / unresolved issues
Certification logos are not utilized
Exclusions are: 7.3, 7.5.2 & 7.5.4that were well justified: 7.3: Design and development was not assessed since all specs are presented
by the clients - 7.5.2: the validation of the processes was not assessed since all process & products can be verified by subsequence
monitoring, 7.5.4: Customer property was not assessed since there were no dealing with customer properties.

Communication / Changes during the audit (if applicable)

No changes have been occurred during the audit however the communication with the chairman, MRand the whole staff was outstanding
Procedure SP4431st issue dated at 15/2/2010 for communication, participation and consultation communication, External
communication log was checked satisfactorily, it is up to date FS44 31e.g. the one dated 21/3/2015 with industrial safety ,about review
of PPEs & the one dated at 11/12/2014 with Comprehensive Centre for scientific and environmental services about environmental
measurements. Internal communication is carried out through internal memo, advertising, telephones and e-mails. External
communications are done through faxes and phones and meetings. All External communications are registered accurately on FS4431
which is updated on 21/4/2015. Telephones of emergencies environmental sites are available and updated, e.g. environmental affairs
management in Monofya City. Communication with customer are done after each shipment in addition to effective utilization of customer
survey which is used to measure customer satisfaction quarterly as checked for several clients The employees are shared in
determination of the hazard identification and all issues relevant to OH&S system issues as checked via F-44304 dated 2/12/2015 &
11/3/2015 for discussing he risks, its advanced evaluation & PPEs; in addition to HSE monthly meetings which include 50%
workers/techniciansof its members last one was held on 3.4.2015

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Lead Auditor's Recommendation

Lead Auditor's Recommendation for ISO 9001:2008
The management system is in conformity with the audit criteria and can be considered effective in assuring that
objectives will be met. Continued certification is therefore recommended.
Lead Auditor's Recommendation for OHSAS 18001:2007
The management system is in conformity with the audit criteria and can be considered effective in assuring that
objectives will be met. Continued certification is therefore recommended.

Other or Additional Lead Auditor Recommendation

system is implemented simply but effectively

Client Acknowledgement
Acknowledged
By:

Mr. Abd Elkader Ashraf Khalil

ahmadabdallah@elhennawytex.com

Management
Representative
Name & Address:

Mr. Abd Elkader Ashraf Khalil

ahmadabdallah@elhennawytex.com

This report is based on a sample of evidence collected during the audit; therefore the results and conclusions include an
element of uncertainty. This report and all its content is subject to an independent review prior to a decision concerning the
awarding or renewal of certification.

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