TRAFFIC LIGHT

IN LINE QUALITY INSPECTION SYSTEM

RFT support program

 • Visual management.
TRAFFIC
LIGHT • Easy for anyone at a glance to be able to
establish the quality level of a T1.
SYSTEM
• Solid quality foundation suitable for all T1
suppliers.

• Formal / structured approach to in-line quality

control.

• Adjustable depending on the current level of

quality.

Red
BENEFITS
• Problems are
detected early.

• Increase productivity

• Higher RFT

• On Time Delivery

• Reduce costs

14/03/2012 5
THE
SYSTEM
VISUALLY
DEFINES Green indicates that Quality meets
THREE the customers Standard.

QUALITY
LEVELS Yellow: indicates that a minor fault
has been found and caution is
required.

Red: Indicates that the Quality

Standard does not meet the
customers standard.
STATUS
GREEN
• From a sample of 7 pieces no defects were found.

• The operator is therefore achieving the required

standard.

OK • Green indicator in place

• The QC will move on to the next operation.

STATUS • From a sample of 7 pieces one defect was found
YELLOW to be defective.

• It is considered to be a minor defect and would

not cause a customer complaint.

• Details passed to the line supervisor for action.

Warning • Status changed from Green to Yellow

• QC moves to next operation

• If the same defect is found during subsequent

inspections move to Red.
STATUS
RED • From a sample of 7 pieces two or more minor faults
were found or one major fault.

• Details passed to the line supervisor for immediate

action

• Status changed from Green or Yellow to Red.

Danger
• The fault classed as major is outside of the customers
specification and would cause customer
dissatisfaction.

• Two minor faults count as a major fault.

HEADCOUNT
REQUIRED
• Tight Control: Applicable to manufactures that have
unstable end of line quality performance.

• Requirement: 1 QC to 24 Sewers. Enables in-line

QC’s to carry out a minimum of 2 audits per day per
operator.

• Ratio: Can be adjusted, dependent on the sewing

lines / groups quality performance.
 RED
Danger
MEANS
Stop
DANGER
Rectify
Follow Up
and
Sustain
HUGE OPPORTUNITY TO REDUCE
COSTS

LOST
Flag design
 Traffic light roll out plan

Phase one All Strategic suppliers

Phase two All Regional Strategic suppliers

Phase three All Core Suppliers

ME will have baseline efficiency data.

Approach
Measure the efficiency gains and Wrong first time data.

Target 75% of all production must be covered by year end 2017

Daily reports to Production

Reporting
Monthly reports to Management
THANK YOU