project IIimplementation

of in-line traffic light systemof inspection

Title: -

In-Line Traffic Light System of Inspection

Objective : -

To build in quality at the point of operation through Traffic light system in order to reduce defects leading to reworking\ alterations and to improve factory efficiency.

Background:-

The project is specifically aimed at improving first time quality of the product by bringing precision and consistency in execution of operations, by making operators cognizant with their performance level and accuracy at specified intervals. This will lead to rise in efficiency of operators, resulting in growth in output of the factory; as well as reduction in number of defected pieces at the end of sewing lines, subsequently saving the time and the cost incurred by the company on their reworking and alteration.

Need for the project: -

REDUCING ALTERATION RATE - Higher alteration rate stands as a severe bottleneck in achieving an uninterrupted production flow, and adding up unnecessary production cost and time.

INCREASING OPERATOR EFFICIENCY - Operator efficiency is a very crucial factor in determining the attainment of specified target in production lines. Higher efficiency is directly proportional to better productivity.

QUALITY IMPROVEMENT- Quality is the one of the most important aspects which influences the salability of the product. Consumer satisfaction is highly based on the quality being offered. Thus it is very essential to have an avant-garde approach towards quality.

DESCRIPTION

The traffic signal system is based on three lights green, yellow and red. 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: GoodYellow:  Isolated defects found

Red:  Recurring defects or major defects found

In line QC has to check a minimum of 10 pieces in each visit of the work station. The In line controller will monitor the inspection and record it. The marking of lights are done as follows:

“If 9-10 checked pieces are found correct”

“If 8 pieces are found correct”

“If 7 or <7 pieces are found correct”

METHODOLOGY:-

PART I

Step 1: Studying of the productivity of the line with respect to the running style on a single day.

Step 2: Separation of defect-free and pieces with defects during end line auditing\ inspection.

Step 3: Classification and recognition of defects on the basis of intensity of occurrence.

Step 4: Calculation of total production and no. of pieces send back for rework\ alteration.

Step 5: Continuation of the process for a week (5 working days).

Step 6: Determination of average production and average percentage alteration.

PART II

Step 1: Putting of formats of Traffic Light System on critical operations (defined on the basis of maximum no. of associated defects)

Step 2: Checking of pieces and filling of formats with prescribed colors by In-line QC on hourly basis for the whole day.

Step 3: Calculation of total production and no. of finished pieces send for rework\ alteration in terms of percentage at the end of the day.

Step 4: Continuation of the process for 3 weeks

Step 5: Determination of average production and average percentage alteration per week.

Step 6: Comparison of the difference of average productivity and percentage alteration pre and post implantation of Traffic Light System.

IMPLEMENTATION

In accordance with our project, the In-Line Traffic Light System of Inspection got implemented in Line No. 1 loaded with:

Style no. – 312450

Buyer- STARDIVARIUS

Description- Dress

Order Quantity- 60000

*Prior to implementation of Traffic Light System of Inspection

DATE OUTPUT(LINE NO. 1)

DEFECTED PIECES

ALTERATION %

7-07-2014 1120 235 218-07-2014 1122 253 239-07-2014 1120 301 2710-07-2014 1118 256 2311-07-2014 1131 271 2412-07-2014 1145 255 22

TOTAL 6756 1571 140

Average production = 6756\6

= 1126

Average alteration = 140\6

= 23.33%

*Post implementation (1st week) of Traffic Light System of Inspection

DATE OUTPUT(LINE NO. 1)

DEFECTED PIECES

ALTERATION %

14-07-2014 1135 245 2215-07-2014 1142 257 2216-07-2014 1130 250 2217-07-2014 1132 222 2018-07-2014 1137 259 2319-07-2014 1128 212 19

TOTAL 6804 1445 128

Average Production = 6804\6

= 1134

Average alteration = 128\6

= 21.33%

*Post implementation (2nd week) of Traffic Light System of Inspection

DATE OUTPUT (LINE NO. 1)

DEFECTED PIECES

ALTERATION %

21-07-2012 1150 250 2122-07-2012 1155 230 2023-07-2012 1160 257 2224-07-2012 1158 219 1925-07-2012 1148 217 1926-07-2012 1152 220 20

Total 6923 1393 121

Average production = 6923\6

= 1154

Average alteration = 121\6

= 20.2%

*Post implementation (3rd week) of Traffic Light System of Inspection

DATE OUTPUT (LINE NO. 1)

DEFECTED PIECES

ALTERATION %

28-07-2012 1170 180 1529-07-2012 1175 149 13

30-07-2012 1180 152 1331-07-2012 1168 173 15

01-08-2012 1172 186 1602-08-2012 1178 149 13

TOTAL 7043 989 84

Average production = 7043\6

= 1174

Average alteration = 84\6

= 14%

*Post implementation (4th week) of Traffic Light System of Inspection

DATE OUTPUT (LINE NO. 1)

DEFECTED PIECES

ALTERATION %

04-08-2012 1205 131 1105-08-2012 1213 118 10

06-08-2012 1205 132 1107-08-2012 1228 129 11

08-08-2012 1218 129 1109-08-2012 1240 126 10

TOTAL 7309 765 64

Average production = 7309\6

= 1218

Average alteration = 64\6

= 10%

ANALYSIS: -

1st Week 2nd Week 3rd Week 4th Week108011001120114011601180120012201240

Average production post implementation

INFERENCES: -

1st week 2nd week 3rd week 4th week0

5

10

15

20

25

Average alteration % post im-plementation

1st week 2nd week 3rd week 4th week0

0.51

1.52

2.53

3.54

4.5

% Production rise post im-plementation

1st Week

2nd Week

3rd Week

4th Week

02468

101214

% Alteration reduction post implementation

COST- BENEFIT ANALYSIS

MAJOR DEFECTS ZONE(OPERATION)

NORMAL SAM ALTERATION SAM(AVERAGE)

COST

Bind neck all around 0.61 3 Rs 3Join piping @ armhole 0.31 2 Rs 2Binding @ zipper 0.47 2.5 Rs 2.5Attach zipper 0.81 4 Rs 4Tack zipper @ (bottom & top)

1.12 5 Rs 5

*Operational cost per minute = Rs 1.0/-

Average alteration cost = (3+2+2.5+4+5)\6

= Rs 3.30

PRE- IMPLEMENTATION

Alteration cost = No. altered piece\week * Average alteration cost

= 1575*Rs3.3

= Rs5197.5

POST IMPLEMENTATION

Alteration Profit

No. of altered piece\week Total alteration cost Alteration Benefit

1ST Week 1445 4678.3 519.2

2ND Week 1393 4596.9 600.6

3RD Week 989 3263.7 1933.8

4TH Week 765 2524.5 2673

Total Profit Rs. 5726.6

Production Profit

Rise in Production Operational Cost per Piece Production Benefit

1st Week 46 9.2 423.2

2nd Week 167 9.2 1536.4

3rd Week 287 9.2 2640.4

4th Week 553 9.2 5087.6

Total Benefit 9687.6

*Cost of employing In-line QC = Rs350 per day

For a period 4 weeks, it is (Rs350*24) = Rs8400

Gross Profit = (Rs 5726 + Rs 9687 – Rs 8400)

= Rs. 7013

LIMITATIONS

It is costly as we install it. Not easy for workers to understand. Requires a systematic and regular attention for updating the format. May create extra pressure on operators which could create adverse impact in the long run.

SCOPE

The formats can be put on each and every operation for complete minimization of alteration.

There can be a separate format for line supervisor as well; so that they also become careful about the defected operations.

Gross Profit= Alteration Benefit+ Production Benefit-Cost of Employing QC