SPC Traffic Light System

Clothing Apparel

Traffic Light System

AimThe Aim and Purpose is to build in quality at the point and to quickly identify problem areas in order to reduce defects working and to improve factory efficiency.

• Also to measure Quality Performance as a % Age for:• - Each Operator• - Each Line• - Factory Overall

ProcessThe traffic signal system is based on three lights red, amber and green. The lights are used to symbolize the quality status at the operation and make supervisor aware of where problems are occurring and give the in line controllers an idea where they have to spend more time. Green Good Amber Isolated defects found Red Recurring defects or major defects found In line QC has to check a minimum of 10 pieces each visit to the work station. The In line controller will monitor the inspection and record it. The traffic lights must work in sequence unless the frequency of defects it too high.

• Quality Performance is calculated positively. Example 5% defect is expressed as 95% Quality Performance.

TRAFFIC LIGHT SYSTEM

If the inspector finds.

Defects Found Colour Code Frequency of QC

Visit

Signatures Action Required

None Green Once per Hr QC None

One Amber Twice per Hr QC Supervisor Inform Operator & Supervisor

Two Red Three times HR QC Manager /

Line Manager

Operator shown correct method. Involve

mechanic?

Two or More 2 Red Stop Operation

1

st

Check

Colour Time 2nd

Check Colour Time 3

rd

Check Colour Time 4

th

Check

Colour Time

0 fault Green 1 HR None Green Etc.

1 fault Amber 2 HR None Green 1 HR Etc.

1 Amber 2 HR 1 Red 2 HR None Amber 2 HR None Green

1 Amber 2 HR 1 Red 2 HR 1 Red &

Stop

If 2 Red

Stop /

Inform

QC

Manager

& Line

Manager

2 or

more

red

Red 2 HR None Amber 2 HR Etc.

2 or

more

red

Red 2 HR 1 or

more

Red &

Stop

Etc.