ROVING QUALITY CONTROL SYSTEM

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What is Roving Quality Control ?

Control of in-line quality

Random inspection

Assurance at the needle point

Early identification of problems

not always the sewing operators fault

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Why do it ?

Reduce the amount of B grades

Improve the quality output of sewing operators

Find problems at the source not at end control too late

Use the quality resource where it can be most effective

Find out problems earlier and reduce costs

Increase the effective time and improve productivity

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What does this mean for Triumph

Vietnam?

The seventh (7th) in Triumph to have this training

The basis for a more sophisticated system with

PDAs later

The opportunity to improve quality quickly with

minimum costs

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Schedule

Training of key personnel (Theory) - Week 46

Commence a pilot project on 1 line - Week 46

Implementation of the pilot project (Practical) - Week 46

Continue implementation, problem solving - Week 46

Data input, control and distribution - Week 46

Follow up - TBC

Decision on expansion

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What tools are needed by the Roving QC?

Roving QC Daily SheetGreen & Red highlighters

Roving QC Daily Sheet

Clipboard

PencilTape measure

A good eye !!!!!!!!

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What do we need at the sewing operation ?

Operator Daily SheetOperator Daily Sheet

Sewing Specification

Green cone

Red cone

Operators Daily Sheet

AD page or Technical

Specification for the

operationOperation standard

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What documents are used ?

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TRIUMPH ROVING QC SYSTEM ROVING QC DAILY SHEET

ROVING QC NAME:- DATE : DAY: QC SUPERVISOR:

LINE:

Entered by QC Clerk

(Office use only) Operation

Style

Operator No

Qty inspected

Result X or

Defect qty/code rejected

Follow up

Remarks

Defect code: RM = Raw Material faults / holes; SC = Stains/Contamination; MD = Molding faults; PG = Seam/stitch pucker or gather; SB = Seam breakdown (non inclusion/cracking etc); SP = Seam position incorrect (twisting/stretched); SD = Stitch density/tension; PT = Poor trimming/thread ends; ND = Needle damage; GB = Incorrect garment balance; SE = Insecure or misaligned seams/edges; M = Measurement

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TRIUMPH ROVING QC SYSTEM OPERATOR DAILY SHEET (To be kept at the operators workstation at all times) Month: Line: Style: Operator No.: Operator:

Date Time 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15

Morning

Remarks:

Roving QC:

Line Ldr/Supvsr:

Sen. Line Ldr/PM:

Afternoon

Remarks:

Roving QC:

Line Ldr/Supvsr:

Sen. Line Ldr/PM:

Night

Remarks:

Roving QC:

Line Ldr/Supvsr:

Sen. Line Ldr/PM:

Remarks: If style changed, mark a # in the cell If leave, mark L in the cell Green = all pass Red = 1 major faults or 3 minor faults

If Green and no rejections, no signature needed; If green & some rejection QC signs: If Red, QC & Line Leader/Supervisor sign; If Red again immediately, Senior Line Leader/Production Manager signs

Defect code: RM = Raw Material faults / holes; SC = Stains/Contamination; MD = Molding faults; PG = Seam/stitch pucker or gather; SB = Seam breakdown (non inclusion/cracking etc); SP = Seam position incorrect (twisting/stretched); SD = Stitch density/tension; PT = Poor trimming/thread ends; ND = Needle damage; GB = Incorrect garment balance; SE = Insecure or misaligned seams/edges; M = Measurement

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How does the system work ?

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Production line

Roving QC

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TRIUMPH ROVING QC INSPECTION FLOWCHART

Equipment: Pencil, Highlighters (Green, Red), Measuring tapeFrequency: At lease once in each shift daily (morning, afternoon, overtime)

-Enter Month, Line, Style, Operator No, Operator-Enter Date, Line, QC Supervisor, QC

At the start of each day, refer to the QC Supervisor to the operations in need of special attentionAt the start of each day, refer to the QC Supervisor to the operations in need of special attention

Randomly select & check 7 samples from the finished bundle of 40 unitsRandomly select & check 7 samples from the finished bundle of 40 units

How many faults

How many faults

Return the bundle to OperatorReturn the bundle to Operator

In , colour the appropriate cell in Green

In , colour the appropriate cell in Green

Raise the Green coneRaise the Green cone

In , fill the result in relevant columns ()

In , fill the result in relevant columns ()

Return the defective pieces to Operator for repair

Return the defective pieces to Operator for repair

In , enter the relevant Defect code & quantity (eg 2/PT), colour the appropriate cell in Green, and sign it off

In , enter the relevant Defect code & quantity (eg 2/PT), colour the appropriate cell in Green, and sign it off

In , fill the result in relevant columns ()In , fill the result in relevant columns ()

Instantly inform and return defective pieces to Line Leader

Instantly inform and return defective pieces to Line Leader

Line Leader determines how to handle & request Operator to check the whole bundle & repair

Line Leader determines how to handle & request Operator to check the whole bundle & repair

In , enter the relevant Defect code & quantity (eg 3/PG), colour the appropriate cell in Red, & sign it off; Line Leader signs off

In , enter the relevant Defect code & quantity (eg 3/PG), colour the appropriate cell in Red, & sign it off; Line Leader signs off

In , fill the result in relevant columns ()In , fill the result in relevant columns ()

No fault

less than 3 minor faults

Raise the Red cone & move on to next OperatorRaise the Red cone & move on to next Operator

Once Operator finished checking & repairing, Line Leader calls QC to re-check

Once Operator finished checking & repairing, Line Leader calls QC to re-check

Request Line Leader to stop Operator & inform Senior Line Leader/ Production Manager

Request Line Leader to stop Operator & inform Senior Line Leader/ Production Manager

1st time

Line Leader, Senior Line Leader/ Production Manager solve the problem together

Line Leader, Senior Line Leader/ Production Manager solve the problem together

In , enter the relevant Defect code & quantity(eg 2/GB), colour the appropriate cell in Red; Senior Line Leader/ Production Manager signs off

In , enter the relevant Defect code & quantity(eg 2/GB), colour the appropriate cell in Red; Senior Line Leader/ Production Manager signs off

In the column Follow-up of , fill in the relevant Defect code & quantity

In the column Follow-up of , fill in the relevant Defect code & quantity

Keep the Red cone & move on to next OperatorKeep the Red cone & move on to next Operator

2nd consecutive time

After 2 consecutive Redand problem solved, QC checks Operator again

After 2 consecutive Redand problem solved, QC checks Operator again

1 or more major faults/3 or more minor faults

Move on to next Operator

Move on to next Operator

Revised 22/02/2007 CQA TIOL HKG

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Roving Quality Control Procedures or Work Instructions

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TRIUMPH ROVING QC SYSTEM

WORK INSTRUCTION - ROVING IN-LINE QUALITY INSPECTION (Roving QC)

Equipment: Pencil Highlighters Green, Red Measuring tape

Reports:

Frequency: At least once in each shift daily (i.e. once@morning, afternoon & overtime) Specific operations as frequently as directed

Related Parties: Roving QC, Line Leader/Supervisor, QC Supervisor, Senior Line Leader, Production Manager

Method:

1. At the start of each day, the Roving QC refers to the QC Supervisor to determine those operations which are in the Highest 3 or in need of close attention for some other reasons.

2. The Roving QC visits operators at random to eliminate any chance of them cheating the system.

3. On the , the Roving QC enters Roving QC name, Month, Line, Style, Operator No. and Operator. On the , the Roving QC enters Date, Day, Line, and QC Supervisor.

4. Roving QC randomly selects the latest 7 finished samples from the bundle of 40 still at the workstation, checks the work against the visual standard and specific requirements for: 4.1 Correct trim being used 4.2 Workmanship 4.3 General appearance 4.4 Measurement where the operation is elastication or there is a specified

measurement controlled by the operator 4.5 According to the number of faults, QC follows Step 5, 6 or 7

5. If no fault is found: 5.1 Roving QC returns the inspected garments to the Operator 5.2 Roving QC fills in the appropriate space on the with

Green highlighter 5.3 Roving QC fills in each column on the :

Operation abbreviation or code, Style, Operator No, Quantity Inspected, Result

5.4 QC raises Green cone at the work station and moves on to the next Operator

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1. If less than 3 minor faults are found: (a minor fault can be defined as a fault which will not result in customer rejection or return, but one that is not within the specification or tolerances required) 1.1 Roving QC returns the defective pieces to the Operator for repair 1.2 Roving QC fills in the appropriate space on the with

Green highlighter and enters the relevant Defect code and quantity as for example: 2/PT and sign it off

1.3 Roving QC fills in each column on the : Operation abbreviation or code, Style, Operator No, Quantity Inspected

Result , Defect qty/code, Remarks bundle number(if necessary) 1.4 Roving QC raises Green cone at the work station and moves on to the next

Operator

2. If 1 or more major faults / 3 or more minor faults are found: (a major fault can be defined as a fault that will definitely result in rejection by the customer and likely return) 2.1 Roving QC instantly informs the Line Leader/Supervisor to come to the operation

and returns the defective pieces to the Line Leader/Supervisor 2.2 Line Leader/Supervisor shall determine how to handle the defects and request the

Operator to check the rest of the bundle and rectify any further faults before permitting the bundle to continue down the line

2.3 Roving QC colours the Red, and enters the relevant Quantity and Defect code, for example: 3/SD and sign it off

2.4 Line Leader/Supervisor signs off on the 2.5 Roving QC fills in each column on the :

Operation abbreviation or code, Style, Operator No, Quantity Inspected Result , Defect qty/code, Remarks bundle number(if necessary)

2.6 Roving QC raises Red cone at the work station and moves on to the next Operator 2.7 Once the Operator has finished checking and repairing, the Line Leader/Supervisor

shall call the Roving QC back to the operator 2.8 Roving QC proceeds from Step 4 for the checked and repaired bundle 2.9 If no fault is found, proceed from Step 5;

If less than 3 minor faults are found, then proceed from Step 6; If 1 or more major faults / 3 or more minor faults are found, then proceed as follows:-

2.10 Roving QC requests the Line Leader/Supervisor to stop the Operator and informs the Senior Line Leader / Production Manager

2.11 Line Leader/Supervisor, Senior Line Leader / Production Manager solve the problem together

2.12 Roving QC colours the Red, and enters the relevant quantity and Defect code, for example: 4/SD

2.13 Senior Line Leader / Production Manager signs off on the

2.14 Roving QC fills the Defect code and quantity in Follow up on the

2.15 Roving QC keeps Red cone at the work station and moves on to the next Operator 2.16 Roving QC must ensure to check the Operator again after 2 consecutive Red 2.17 Once the operator has a Red, she must only be allowed to continue working

if a Red is immediately followed by a Green.

3. The Roving QC should particularly note the following points: 3.1 NEVER get involved with the Operator in trying to find out why the Operator is

wrong. That is the responsibility of Line Leader/Supervisor 3.2 NEVER wait at the operation whilst the problem is being resolved 3.3 NEVER try to suggest solutions to the Operator if anything goes wrong afterwards

you may be blamed 3.4 If you have any views about the cause or solution of a particular problem, the Line

Leader/Supervisor & QC Supervisor should be consulted and the matter left with them.

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WORK INSTRUCTION DAILY & WEEKLY CHECKING SUMMARY (QC Clerk)

DAILY:

1. At 16.00 or 2 HOURS before the end of the shift, the QC Supervisor collects the from all Roving QCs & submits them to QC Clerk.

2. In the computer file Roving QC Analysis, QC Clerk chooses the sheet Daily Chk Sumry of the corresponding day.

3. QC Clerk enters the Week commencing & Unit.

4. On the , the QC Clerk ignores the entries with no fault. For those entries with faults found , QC Clerk transfers the data to the Daily Chk Sumry, including: 4.1 Line, Style, Operator No 4.2 Total handled(Exceptions) and the number of different defects

The QC Clerk initials the box on the to indicate she has completed the entries for that sheet.

5. At 17:30 or 30 minutes before the end of the shift, the QC Clerk issues the Roving QC Analysis with completed Daily Chk Sumry to Factory Managers, QA Manager, Production Managers, QC Senior Supervisor, etc. through E-mail.

WEEKLY:

At 08:30 on Monday,

1. The QC Supervisor collects the which includes the data of the previous Saturday entered after 16:00 on Friday from all Roving QCs & submits to QC Clerk. Per the above steps, QC Clerk completes the Daily Chk Sumry of the previous Saturday.

2. The QC Clerk chooses the sheet Analysis only of the computer file Roving QC Analysis.

3. The QC Clerk filters the column Operator No & selects operators in the order of their number.

4. The QC Clerk copies from row A to row G for each operator.

5. The QC Clerk pastes into Wkly Chk Sumry by using Paste Special Values only.

6. In Wkly Chk Sumry, QC Clerk selects from Toolbar, Data-Sort-% Reject-Descending.

7. The QC Clerk issues the Roving QC Analysis with completed Wkly Chk Sumry to General Manager, Factory Managers, QA Manager, Production Managers, QC Senior Supervisor, etc. through E-mail.

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What reports are generated ?

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QSF TRIUMPH ROVING QC SYSTEM

Weekly Checking Summary (Exceptions) For email distribution0 Week Commencing 0

Line Style Operator No Total Checked (Exceptions) Total Rejected (Exceptions) % Reject (Exceptions) Day

A 1234 AS 14 8 57.14% MONA 1234 AS 14 2 14.29% TUEC 3456 BB 14 3 21.43% MONC 3456 BB 14 2 14.29% TUED 4567 CC 14 1 7.14% MOND 4567 CC 14 1 7.14% TUEA 1234 DD 14 6 42.86% MONA 1234 DD 14 1 7.14% TUEA 1234 IO 14 3 21.43% MONB 2345 DV 14 9 64.29% MONB 2345 DV 14 1 7.14% TUEA 1234 SS 14 1 7.14% MONA 1234 ER 14 1 7.14% MONA 1234 ER 14 1 7.14% TUEB 2345 GF 14 9 64.29% MONB 2345 GF 14 1 7.14% TUEB 2345 GG 14 7 50.00% MONB 2345 GG 14 1 7.14% TUEC 3456 GH 14 5 35.71% MONC 3456 GH 14 3 21.43% TUEB 2345 HH 14 1 7.14% MONB 2345 HH 14 2 14.29% TUEC 3456 HK 14 1 7.14% MONC 3456 HK 14 1 7.14% TUEB 2345 HU 14 1 7.14% MONB 2345 HU 14 2 14.29% TUEC 3456 II 14 7 50.00% MOND 4567 II 14 1 7.14% MONC 3456 II 14 1 7.14% TUED 4567 II 14 1 7.14% TUEA 1234 IK 14 9 64.29% MONA 1234 IK 14 2 14.29% TUEA 1234 IO 14 3 21.43% MONB 2345 IO 14 1 7.14% MONB 2345 IO 14 8 57.14% MONA 1234 IO 14 1 7.14% TUEB 2345 IO 14 2 14.29% TUEB 2345 IO 14 2 14.29% TUEC 3456 MM 14 1 7.14% MONB 2345 JJ 14 5 35.71% MONB 2345 JJ 14 2 14.29% TUEA 1234 JK 14 4 28.57% MONC 3456 JK 14 2 14.29% MONA 1234 JK 14 1 7.14% TUEC 3456 KJ 14 9 64.29% MONC 3456 KJ 14 1 7.14% TUEC 3456 LK 14 2 14.29% MONC 3456 LK 14 1 7.14% TUEC 3456 MM 14 1 7.14% MONC 3456 MM 14 1 7.14% TUED 4567 MY 14 1 7.14% MOND 4567 MY 14 1 7.14% TUEA 1234 OL 14 3 21.43% MONA 1234 OL 14 1 7.14% TUED 4567 PL 14 1 7.14% MON

Unit:

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Defect Codes

MeasurementM

Insecure or Misaligned Seams / EdgesSE

Incorrect Garment BalanceGB

Needle Damage (cuts)ND

Poor Trimming / Thread EndsPT

Stitch Density / TensionSD

Seam Position incorrect (twisting / stretched)SP

Seam Breakdown (non inclusion / cracking etc)SB

Seam / Stitch pucker or gatherPG

Molding FaultsMD

Stains and ContaminationSC

Raw Material Faults / HolesRM

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Defect Codes Major and Minor classification.

MAJORMissing OperationMO

MAJORMeasurementM

Careless Trimming

Insecure or Misaligned Seams / Edges

Incorrect Garment Balance

Needle Damage (cuts)

Poor Trimming / Thread Ends

Stitch Density / Tension

Seam Position incorrect (twisting /

stretched)

Seam Breakdown (non inclusion /

cracking etc)

Seam / Stitch pucker or gather

Molding Faults

Stains and Contamination

Raw Material Faults / Holes

MAJOR

MAJOR

MAJOR

MAJOR

MINOR

MAJOR

MAJOR

MAJOR

MAJOR

MAJOR

MINOR

MAJOR

CT

SE

GB

ND

PT

SD

SP

SB

PG

MD

SC

RM

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Some general rules and guidelines

At the start of the shift, every operator must be checked at least once morning, once afternoon and once on overtime, some will require extra checks from the previous days results

Roving QC should select the 7 most recently sewn pieces only

Roving QC should never attempt to solve a problem only identify and report and MOVE ON

Roving QC should never discuss the reasons for a problem with the operator

Roving QC should not become familiar with an operator

When faults are found, always return them to the operator for repair immediately

Roving QC must never become predictable, must be random checks

There must be no favourites

Line supervisor must solve the problem before calling the Roving QC back for a second check

Roving QC must concentrate on conducting as many checks as possible

Roving QC should be transferred to another line 2 to 3 months

Every red that appears on the Operators daily sheet, must be followed by a green before work re-commences

Two reds must involve the production manager

A red means an operation has stopped, so action is needed immediately

A red is not always the operators fault, just means a fault at that operation, so read the results carefully

Check the days results before the end of the shift, so that plans for the next day can be made

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Thank you..

Any Questions ?