Factory Production Control (FPC) audits are a crucial part of the ISO 17065 Type 5 ‘product certification process’. These audits help ensure that the manufacturers of construction materials, fire-safety products and fire-protection systems implement control measures into the manufacturing cycle and conform to the applicable standards and regulations the relevant parties and authorities set. FPC audits verify that a factory’s quality management system and production processes align with the applicable requirements and standards.
Fire-safety-product and fire-protection-system certification is a process by which a third-party organisation evaluates the construction material, product, or system to determine if it meets the specified requirements and standards relevant to the product specifications and end use. The certification process is designed to assure the end-users that the product is compliant, performs as intended or claimed and meets the set standards. The FPC audit is an essential part of this certification process as it verifies that the factory producing the product can consistently deliver products that meet these standards.
Why are FPC audits important?
FPC audits are essential for several reasons:
- To ensure that the products produced in a factory fulfil certification requirements and are safe for consumers, which is vital for protecting public health and safety.
- To ensure consistency for what was produced for initial type testing (ITT) and certified is the same as that produced and sold to consumers, enhancing the manufacturer’s reputation.
- To define any area in the production process that needs improvement, allowing manufacturers to make necessary changes and improve the quality of their products.
- Finally, FPC audits are often required by regulatory bodies or authorities having jurisdiction, like the Civil Defence, Fire Department, Standards Organisations, or Municipality, to grant product registration or approval.
- Many countries worldwide, including in the Middle East, mandate that products are certified by a conformity assessment body (CAB) following the ISO 17065 Type 5 technical schedule or certification scheme. This certificate is required for fire-safety products and fire-protection systems sold in certain countries or regions. With product certification, manufacturers can consciously market their products and access the targeted markets without restrictions.
What happens during an FPC Audit?
During an FPC audit, the auditor will evaluate the quality management system and the factory’s production processes to determine if they align with the relevant requirements and standards. The auditor will also inspect the factory’s facilities, plant, machinery, equipment and production lines to ensure that they are in good condition and can consistently produce products that meet the necessary standards.
The auditor will also review the factory’s quality-control procedures and inspect samples of the products produced in the factory. This helps to determine if the factory can consistently produce products that meet the identified applicable and required standards.
The auditor will also review the factory’s documentation, including its quality manual, procedures and records. This supports ensuring that the factory has a robust quality management system in place and that it can consistently produce and reproduce products that meet the necessary quality standards, and that the products manufactured are always the same as the certified product that was initially tested and certified by the certification body providing the product certification and assurance.
Finally, the auditor will hold discussions with the factory’s management and staff to get a better understanding of the production process and the quality management system. This helps to identify any areas in the product knowledge that may need improvement and to determine if the factory has the necessary resources, skills and competencies, and capabilities to produce products that meet the set standards.
What are the key aspects of an FPC audit?
The critical aspects of an FPC audit include the following:
- Evaluation of the factory’s quality management system and production process and addressing all areas needed to produce the certified product, starting with raw material selection to dispatch finished goods.
- Examining raw material suppliers, inspection records, calibration of inspection equipment and customer complaints records.
- Verify product traceability and any relevant formulas to produce the product to be certified.
- Inspection of the factory’s facilities and equipment.
- Witness the production and selection of samples of the products produced in the factory, if needed.
- Reviewing the factory’s documentation, including its quality manual, procedures and records.
- Interviewing and meeting factory management and staff.
These aspects comprehensively evaluate the factory’s production process and quality management system and determine if the factory can consistently produce products that meet the applicable standards.
The FPC surveillance audits are carried out annually to ensure the requirements are maintained for which conformity has been evaluated. After conducting the FPC audit, the auditor will issue a report detailing the findings and recommendations. Suppose the manufacturer is complying with the scheme and audit requirements. In that case, it will be presented to the decision committee for proceeding with the next steps in issuing or renewing the certification. If the manufacturer is found to be non-compliant, they will be required to implement corrective actions to address the issues identified during the audit. The manufacturers consider these findings as a health check of their businesses as part of their continuous improvement journey.
What are the benefits of an FPC audit?
The benefits of an FPC audit include the following:
- Improved product quality: FPC audits help identify areas in the production process that may need improvement, allowing manufacturers to make necessary changes and improve the quality of their products.
- Improved production processes: FPC audits can help to identify areas in the production process that may need improvement, allowing manufacturers to make necessary changes and improve their production processes. This can help to increase efficiency, reduce costs and improve the quality of the products produced.
- Product Consistency: FPC audits ensure that manufacturing controls are adequately addressed to ensure conformity of product through consistent raw materials used, process controls routines and inspections (in-process and final)
- Enhanced reputation: FPC audits ensure that the products produced in a factory meet the necessary quality standards, enhancing the manufacturer’s reputation. This can help to increase customer confidence and trust in the products produced by the factory.
- Compliance with regulations: FPC audits help ensure that the factory products comply with the relevant prescribed codes, regulations and standards. This is important for protecting public health and safety and helps to ensure that manufactured goods can be sold in certain countries or regions.
- Increased market access: Regulatory bodies often require Type 5 product certification per the provisions of ISO 17065, which includes FPC audits, to grant product certification. This certification is required for products to be registered and sold in certain countries or regions. With product certification, manufacturers can market their products and be unrestricted in terms of the markets they can access.
In conclusion, ISO 17065 Type 5 product certification and the required FPC audits are crucial in the product certification process. FPC audits help ensure that the products produced in a factory are consistent, conform to and meet the relevant and required standards, and assure the end-users that the products are consistent and of high quality. Manufacturers typically embrace and take FPC audits seriously with an understanding that audits are a good learning exercise and like a health check for a producer as part of continuous improvement. These audits ensure that their production process and quality management system align with the relevant requirements and standards to secure and maintain product certification for gaining greater access to existing and new markets.
Emirates Safety Laboratory (ESL) is an independent testing and certification body providing ISO 17025 accredited testing to over 90 test methods and certification to over 600 methods and norms. ESL Testing Laboratory is accredited by the International Accreditation Centre (IAS) from the United States of America (USA). ESL Certification is accredited by Emirates International Accreditation Centre (EAIC), operating from the UAE and additionally by GCC Accreditation Centre (GAC), working from the Kingdom of Saudi Arabia, following ISO 17065 Type 5 to provide product certification. ESL is recognised as a notified body by both the Ministry of Innovation and Advanced Technology (MOIAT) in the UAE and Saudi Standards, Metrology and Quality Organisation (SASO) and is a member of the European Group of Organisations for Fire Testing, Inspection and Certification (EGOLF).
If you would like to understand more about our FPCs, testing or certification services, you can contact one of our technical experts by writing to Ask@EmiratesLaboratory.com
About the Author
David Campbell is General Manager for Dubai Civil Defence’s Emirates Safety Laboratory, educated in Applied Sciences - Fire Technology, Fire Engineering and Environmental Sciences – Natural Resource Management and Digital Transformations with 33 years working in the sector of which the past 13 years supporting the Middle East region, specialising in Electrical Safety and Fire Compliance (active and passive systems), Testing, Inspection, Certification (TIC) and Advisory.
