SOP/SEW/QA/006/2013 Issue -01

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Procedure For

Traffic Light Quality System

Issue Date Dept/ Sec/Unit Sewing Q.A Department

Designation Signature Reviewed & Approved By

General Manager

Written By SOP-Responsible

Table of Contents Page 1.0 Objective 1 2.0 Scope 1 3.0 Definition of Traffic Light Quality System 1 4.0 Procedure 1 4.1 Application 1 4.2 Defect, Color Code & Frequency of Q.C Visit 2 4.3 In Line Process Visit of Q.C, Color Code Flag Raising & Process Rectification 2 4.4 Data Accusation 3 4.5 Data Authentication & Verification 3 4.6 Data Interferences 3 4.7 Data Software Entry 3 4.8 Performance Data 4 5.0 Personal Qualification / Requirement 4 6.0 Control of Non Conforming Process 4 7.0 Control of Document 4 8.0 Control Record 4 9.0 Corrective Action & Preventive Action 4 10.0 Internal Audit 4 11.0 Training 5 12.0 Conclusion 5 13.0 Attachments 5 14.0 References 5

Page-1of 5 1.0 OBJECTIVE

TEXEUROP (BD) LTD is rising with its continuous Quality improvement journey, to grow and excel the organization as its mission. Our cooperative working environment involves all departments and all personnel have to work together in a team as a quality rally inside the entire company. This Traffic Light System procedure adopted as a tool of lean quality system, to produce highest quality apparels & achieve shorter lead time with lowest cost. As a proven quality control tool, it would increase the production capacity & strength the supply chain. Besides TEXEUROP (BD) LTD gives value of our stakeholders branding in USA & European retails chains, to present highly controlled quality apparels for end customers.

2.0 SCOPE The scope of this Traffic Light System emphasizes the sewing quality assurance, through in line individual process inspections. This inline process inspection shall be conducted as per controlled machine lay out plan and customers requirement. This inspection requires to verify the assembled accuracy apparel cut panels as per the style specification. This procedure also covers the rectification of the sewing process & also requires a re-inspection with a frequency.

3.0 DEFINATION OF TRAFFIC LIGHT QUALITY SYSTEM Traffic light quality system works in a similar fashion the transportation traffic light system works. Like the transportation system it includes three quality signal cards: green, yellow and red. In the production line each worker is characterized by a card and the card is being hanged above his/her head. Green is for good quality, yellow is for warning condition and red stands for stopping the production due to quality fault. Seven piece quality checking system has been implemented and the quality controllers were instructed to check the quality status every two hours interval and collect data of each worker on a regular basis.

4.0 PROCEDURE

4.1 APPLICATION Traffic Light Quality System is a visual control for highlighting quality issues in sewing line. When a worker produces quality product with zero defect, he or she is characterized by a green card. A worker who does a single fault out of the checked seven pieces, he or she is warned by a yellow card that indicates that he or she should be more careful about quality for the next time. But when any worker who does multiple faults, a red card is hanged above his or her head that indicates that this worker is producing several faults that should be corrected and an extra care should be taken to this worker. No defects/ Zero defect per 7 pcs inspected

1 defect per 7 pcs inspected

2 or more defects per 7 pcs inspected

Page-2 of 5 4.2 DEFECT,COLOR CODE & FREQUENCY OF Q.C VISIT

Below table is showing the stages of apparel Sewing Quality Assurance

4.3 IN LINE PROCESS VISIT OF Q.C,COLOR CODE FLAG RAISING & PROCESS RECTIFICATION

Below table is showing the frequency of Q.C Visit at the defective sewing in line process:

1st Check

Color of Flag

Time

2nd

Check

Color of

Flag

Time

3rd

Check

Color of Flag

Time

4th

Check

Color Of Flag

Time

0 Fault Green 1/hr None Green 1/hr

1 Fault Yellow 2/hr None Green 1/hr

1 Fault Yellow 2/hr 1Fault Red 2/hr None Yellow 2/hr None Green

1 Fault Yellow 2/hr 1Fault Red 2/hr 1 Fault Red & Stop

If 2 Red stop/ Inform QA Manager & Line Chief

2 or More Red

Red 2/hr None Yellow 2/hr 2 or More Red

Red 2/hr 1 or more Red

&Stop

Defect Found

Color code

Frequency of Q.C Visit

Signature

Action Required

None

Green Once Per Hour Q.C None

One

Yellow Twice Per Hour Q.C

Inform Operator Supervisor, Line Chief Production Manager to make necessary correction of the process.

Two or More

Red Three times per Hour Q.C

1. Show the correction method to the operator. 2. Involve the mechanic to solve sewing machine Problem. 3.If Operator cannot reach the quality level of the Process, sewing operator change is required. 4.If sewing machine trouble cannot be solved , need to be replace the machine. 5. If machine cannot be replaced stop the Machine operation.

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4.4 DATA ACCUSATION The Concerned Quality Controller shall generate Operator Quality Performance Report ( Form No F|QA|SEW|41 ) as per Attachment-1 . Which state as part A& Part B . The following informations shall be filled with the data form as per under mentioned required informations: (a) Operator Name , ID No , Unit no , Line no

(b) If Style change the marking round circle area shall be blank

(c) If machine problem the marking round circles area shall be blue color.

Below sample is self explanatory as stated:

A generated report of Operator Quality Performance Report ( Form No F|QA|SEW|41 )

4.5 DATA AUTHENTICATION & VERIFICATION

Operator Quality Performance Report (Form No F|QA|SEW|41) Shall be authenticated & must be verified by the Line Chief , Asst. quality Manager , Production Manager & Manager Q.A , as per the report requirement .

4.6 DATA INTERFERENCES The data interferences shall be together between Operator Quality Performance Report (Form No F|QA|SEW|41) & Quality Control In Line /Process wise Inspection Report ( Form No F|QA|SEW|17) as per the 7 pcs Inspection criteria .

4.7 DATA SOFTWARE ENTRY

To analyze the whole line defective level the data shall be analyzed after software entry on daily basis.

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4.8 PERFORMANCE DATA For annual performance evaluation the monthly generated Operator Quality Performance Report (Form No F|QA|SEW|41) shall be deposited to Human Resource to attach with personal file.

5.0 PERSONNEL QUALIFICATION / REQUIREMENT Recruitment for competent personnel, defined at recruitment policy of the organization.

6.0 CONTROL OF NON CONFORMING PRODUCTS

To monitor all types of non-conformance of sewing processes, its advised to report to Manger Production & Quality Assurance Manager for corrective & Preventive action . The product / with any kind of non Conformances must be investigated. Appropriate and timely corrective action must be taken according to the nature of the non-conformance. Non conformance of sewing process shall be documented as per defect codes (Annexture-1).

7.0 CONTROL OF DOCUMENT

All stages document of Traffic Light Quality System inspection must be controlled with individual identification stated information like Month , Operator name , Id No , Unit , Line no , Date , Style reference number , Operation Name /Code , Time & Color Mark , Daily Mark Nos summary.

8.0 CONTROL OF RECORD

All records shall be controlled as per the standard requirement .Which must be stored for a minimum (03) years. Although the test reports shall be generated in a computer software and stored also. Description of non-conformity, result of root cause analysis, list of possible corrective & Preventive actions, implementation monitoring and validation records, shall be kept by the Manager QA.

[ (a) (b) (c)

9.0 CORRECTIVE ACTION & PREVENTIVE ACTION

Any non conformance product is the factor of time loss & cost involvement. If any inconsistency found with any stages of cutting , first to find out the root cause if its a person even .There after analyze the cause of non-conformance & make the action plan.

If its a floor visit suggestion from any customer regarding the non-conformance the organization shall documented it as a record & must have the defined action plan also .

10.0 INTERNAL AUDIT

Internal audit shall be conducted periodically to ensure the followings:

To ensure that, the procedures in quality manual related to quality systems, related testing activities, are being followed. To ensure all deficiencies in the quality system and activities are documented through its corrective action process.

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This internal audit to analyze sewing process quality systems, policies, procedure, work instructions, analytical records and reports.

This internal audit shall be conducted with trained and knowledgeable official of the organization. 11. 0 TRAINING

A regular quality training program shall be conducted to improve the sewing operators performance to achieve the objective of this procedure . Implementation of the traffic light system for the improvement of quality level & overcome the deficiencies of the sewing process.

12.0CONCLUTION Traffic light system is a system that is easy to implement & enable the quality triggers to improve the quality status, reduced the cost, improve the lead time & strength the supply chain performance .

13.0 ATTACHMENTS

(i) F|QA| SEW|17- Quality Control In Line / Process wise Inspection Report (ii) F|QA| SEW|41- Operator Quality Performance Report (iii) Sewing Defect Codes (Annexture-1).

14.0 REFERENCES

(i) Enhancing lean supply chain through traffic light quality management system, Management Science letters 3 (2013) 867-878 .

End of the Document