NORTHERN UNIVERSITY BANGLADESH

Knowledge for Innovation and Change

A REPORT ON INDUSTRIAL TRAINNING ECHOTEX COMPANY Ltd.

A report on industrial training is submitted to the department of
Textile Engineering in partial fulfillment of the credit requirement
for the B.Sc. in Textile Engineering Degree by Northern University
Bangladesh.

Submitted by:
Md. Rayhan Kabir
Student ID: EBTX-
33180303397
Md. F.M.Tanvir Ahmed
Student ID: EBTX-
33180303399
Md.Mustain Billah
Student ID: EBTX-33180303416
Md. Asim Howlader
Student ID:EBTX-33180303410
Supervisor copy

Supervisor
Md.Shahjalal
Lecturer
Northern University Bangladesh

DEPARTMENT OF TEXTILE ENGINEERING

Northern University Bangladesh
i
August 2021

ii
 NORTHERN UNIVERSITY BANGLADESH
Knowledge for Innovation and Change

A report on industrial training is submitted to the department of

Textile Engineering in partial fulfillment of the credit requirement
for the B.Sc. in Textile Engineering Degree by Northern University
Bangladesh.

Submitted by

Student Name Student ID

Md. Rayhan Kabir EBTX-33180303397
F.M.Tanvir Ahmed EBTX-33180303399
Md. Mustain Billah EBTX-33180303416

Md. Asim Howlader EBTX-33180303410

project work submitted to the department of Textile Engineering in partial fulfilment of

the credit requirement for awarding the Bachelor Degree in Textile Engineering by the
Northern University Bangladesh (NUB)

Supervisor

Md. Shahjalal
Lecturer

Northern University Bangladesh

DEPARTMENT OF TEXTILE ENGINEERING

 Letter of Transmittal

Date: 00.08.2021

Md. Shahjalal

Lecturer (Dept. of Textile Engineering)

Northern University Bangladesh (NUB)
Subject: Submission of industrial training
report.
Dear Sir,
With due respect, we the students of Textile Engineering, Northern University
Bangladesh (NUB) have successfully completed our project program. In this stage we
are submitting our project report on industrial training report as part of our B.Sc. in
Textile Engineering requirement that bears three (03) credit hours under your
supervision. We are submitting this report for our academic purpose only.
Please be kind enough to evaluate this dissertation with your valued suggestions.
Sincerely yours

Md. Rayhan Kabir

ID:33180303397

F.M. Tanvir Ahmed

ID: 33180303399
Md.Mustain Billah
ID: 33180303416
Md: Asim Howlader
ID:33180303410
 DECLARATION

We Md.Rayhan Kabir, ID No: 33180303397, F.M.Tanvir Ahmed,ID No :

33180303399,Md.Mustain Billah ID No: 33180303416,Md:Asim Howlader,
ID:33180303410 student of Northern University Bangladesh of Department of Textile
Engineering, hereby declare that the thesis entitled “Study on the Investigating the
Minimization of DHU% by Applying Traffic Light System”is my own work and has not
been printed, published or submitted as research work, thesis or publication in any form in
any university, research institution, etc. in Bangladesh or abroad.

Date : …/……/……. -------------------------

Md. Rayhan Kabir
ID:33180303397
B.Sc. in Textile Engineering

F.M.Tanvir Ahmed
ID: 33180303399
B.Sc. in Textile Engineering

Md. Mustain Billah

ID: 33180303416
B.Sc. in Textile Engineering

Md: Asim Howlader

ID:33180303410
B.Sc. in Textile Engineering
 Letter of Approval

This research work entitled submitted by Md. Rayhan Kabir ID No.33180303397, F.M.
Tanvir Ahmed ID No. 33180303399, Md. Mustain Billah ID No.33180303416 , Md:
Asim Howlader ID:33180303410 of Department of Textile Engineering, was carried out
under my supervision and has been accepted as satisfactory for the partial fulfilment of the
requirements for the degree of Bachelor of Science in Textile Engineering (Apparel
Manufacturing Technology).

Date……………………. (Supervisor)
Md. Shahjalal
Lecturer (Dept. of Textile Engineering)
 Acknowledgement

At first, our gratefulness goes to Almighty Allah to give us the strength and ability to
complete the industrial training and this report. You have made our life more beautiful and
peaceful. May your name be exalted, honored, and glorified all over the universe.
Now we wish to take this excellent opportunity to thank a lot of people who have assisted
and inspired us in the completion of my training period.
We sincerely thank Md. Shahjalal, Lecturer, Northern University Bangladesh and Md.
Tanjim Hossain, Assistant Professor & Head,Department of Textile Engineering for their
continuous encouragement and valuable suggestions.
We would like to thank the management of the Echotex ltd. For giving us the opportunity
to do the industrial training successfully and also their valuable suggestion. Our deepest
appreciation goes to Md Radoyan Ahmed AGM (Garments),Echotex ltd.for his
permission to conduct our industrial training without which it would be uncompleted. The
generous support is greatly appreciated. Also, like to thank executives, senior executives
and other officials of Echotex Textile Ltd. for helping us to complete industrial training
successfully. Our gratitude also goes to the employees of Echotex Ltd. for their sincere co-
operation, support and valuable advice.
Last but not least, thanks go to our precious family for their never-ending love and inspire at
every stage of our life.
Fig: Factory location Chondra,pollibidut,Gazipur
 Fig: Factory layout

Fig: factory outlook picture

 ABSTRACT

Garments styles are changing rapidly. Also the fast changing economic conditions such
as global competition, declining profit margin, customer demand for high quality
product, product variety and reduced lead time etc. had a major impact on manufacturing
industries. The demand for higher value at lower price is increasing and to survive,
apparel manufacturers need to improve their operations through producing right first time
quality and waste reduction. Unless buyer expectations and requirements are met, it
would be very difficult to survive or to grow. Therefore, quality is becoming a vital key
to successful growth of a company. Reworks in the garments industry are a common
work that hampers the smooth production rate. In the project work, how a traffic light
system in sewing floor can be used to detect defects at source level is described. At first a
T-shirt production line was selected for applying traffic light system. Then all the
operators’ performance was rated with green yellow and red mark as per the amount of
defects found. The operators were motivated as they would get incentives according to
their performance with green signal. The performance was checked for one month for
each operator in the sewing line. The operators got more green signal that is the defect
amount was decreased in the line gradually. Thus we get more improved quality
garments by worker motivation.
 . Table of Contents

Chapter Topic name Page No

1 Introduction 1

1.1 Introduction 1-2

1.2 Objectives: 2

2 Traffic Light System 3

2.1 Garments Inspection System 4

2.2 Initial Inspection 5

2.3 In-line Inspection 6

2.4 Final Inspection 7

2.5.6 Total Acceptable Product (TAP) & Acceptable 8

Quality Limit (AQL) & Uses of AQL
2.7 Finishing 9

2.8 Inspection Sampling Plan 9-10

2.9 AQL (Acceptable quality label) 11-12

2.9.1 Types of AQL System Followed in Apparel 12

Industry
2.9.2 AQL Chart for Garment Industry 13

2.9.3 Traffic Light System 14-15

2.9.4-5 Working Procedure & Features of traffic light 16-19

system
2.9.6-7 Traffic Light Symbol & Basic concept of Color 20-21
Light Card
2.9.8 How to fill/use 21-22

2.9.9 Employee Motivation 23-24

2.10 Quality Management System 25
3 Experimental Design 26

3.1 Short Sleeve Polo Shirt 27

3.2 Operation breakdown of Polo shirt 27

3.3 Outline of project work 28-29

3.4 Experimental data 30-36

4 Result & Discussion 37

4.1 Graphical representation of for operator Kadu Azad 38

4.2 Graphical representation of for operator Fahim Farhan 39

4.3 Graphical representation of for operator Mahmudul 40

4.4 Graphical representation of for operator Sujon Parvej 41

4.5 Graphical representation of for operator Rony Mia 42

4.6 Graphical representation of for operator Soniya 43

Khatun

4.7 Graphical representation of for operator Sumi Akhter 44

5 Conclusion 45

5.1 Conclusion 46

5.2 References 47
 CHAPTER-01
INTRODUCTION
Introduction: -
In the todays fashion world garment style has a wide range product with rapid changing. Also
the fast changing economic conditions such as global competition, declining profit margin,
customer demand for high quality product, product variety and reduced lead time etc. had a
major impact on manufacturing industries. The demand for higher value at lower price is
increasing and to survive, apparel manufacturers need to improve their operations through
producing right first time quality and waste reduction. Unless buyer expectations and
requirements are met, it would be very difficult to survive or to grow. Therefore, quality is
becoming a vital key to successful growth of a company. Reworks in the garments industry
are a common work that hampers the smooth production rate. Rework is a vital issue for poor
quality product and low production rate. Stitching operations (with respect to cutting and
finishing) needs high skill as well as quality work, because of difficulty associated with
repairing of products sewed with wrong specifications. We have to give more attention to
stitching than to cutting and finishing. Here, how a traffic light system in sewing floor can be
used to detect defects at source level is described. Like other quality inspection tools, the
traffic light inspection system is widely used in garment quality inspection. This system is
used to stop producing defect at the source. This is a random inspection system. Traffic light
system is more effective in controlling shop floor quality than other quality tools because of
its visual communication. At the same time, it measures operator’s performance level in
quality. No operators like be presented themselves as lower quality makers. They concentrate
on quality aspect during stitching garments. The format used for displaying as well as
recording audit report. The format is very simple to use and to understand. The format is
printed on a slightly thick A4 sheet and hanged on the sewing machine. In this system quality
auditor visit operator’s workplace 4 times in a day (considering 8 hours shift day) and
inspects stitched garments and fill circles with color according to the inspection result. In the
initial stage when this format had been introduced by JC Penny for their supplier, they
instructed to inspect 7 pieces from the stitch garments and if auditor found any defective
piece respective circle to be filled by RED color. If red color is marked on the inspection
sheet, all stitched pieces must be checked by an auditor. And operator needs to be explained
about the quality expected from him/her and how to get that expected quality. In some case,
operators need more practice to get right quality pieces. Factory QAs later modified sample
size, the rating criteria and added yellow color keeping purpose right. The sample size is
reduced as a quality auditor does not get 7 pieces at a time of inspection at most of the
workstations.

This happens due to low work in process (WIP) in between two workstations. I have recently
visited a factory in composite knitting industry ltd. and found that factory uses Traffic Light
System. Inspection formats in the floor were spread over to all machines. Traffic light system
is the most effective inspection tool to reduce defect generation at source. This is a random
inspection system. Traffic light system is more effective in controlling shop floor quality than
other quality tools because of its visual communication. At the same time, it measures
operator’s performance level in quality. No operators like to be presented themselves as lower
quality makers. They concentrate on quality aspect during stitching garments. Inline checking
system will alert operators in concentrating their job. If less number of defective seam is
1
made,

2
less the time will be lost in repairing it. It also helps in other way. May be at the start of the
style an operator do not understand the specification, an interaction with quality inspector
will make an operator clear about the quality requirement. Traffic Light System is designed to
flag the problem at source and allow immediate corrective action rather than all potentially
defective product to continue to be manufactured.

Objectives: -

1. To execute the operator’s rating

2. To reduce the defect of garments
3. To margin the operator performance in quality.
4. To ensure that rejection rate of each process are minimized and controlled.
5. To reduce sewing DHU% and process defects percentage.
6. Tracking operators sewing quality and operator wise defects.
 Chapter: 02
Literature Review
Garments inspection system: -
Inspection is the act of looking at something closely in order to learn more about it, to find
problems, to see if rules are being followed and things are in their proper condition. Buyer
Inspection System in garments sector is mainly divided into three. Some buyers maintain four
Inspections which called Pre-Final Inspection. It takes place before Final Inspection. Main
Inspections are as below:

Fig: 2.1 Garments Inspection System

Initial Inspection:
It’s very important for Quality Control Department to carry out Initial Inspection after first or
trail cutting of 200 to 500 pieces covering all sizes & colors. It is to compare with approved
sample & ensure to be conformance of requirements. It’s very important to get a smooth
production as it’s the time to find out & solve the problems which may cause during
production. A meeting can be held after this Inspection named First Bulk Review Meeting.
See image of First Bulk Review Meeting below.

Fig 2.2 Fast bulk review mitting

In-line Inspection: -
Inspection means checking the quality of work or a product. Inline Inspection means checking
the quality of the product in the process instead of checking at the end of the process when
product is completely made. Inline inspection in a garment factory means checking of semi-
stitched garments or partially stitched garments while pieces are still inside the line and all
sewing operations are not yet stitched.

Inline inspection is also known as roving quality checking or roaming quality checking. Inline
inspection is done for 100% of garments or certain percentage of total stitched pieces. Various
format of inline checking exits in the garment stitching.

Fig: 2.3 Inline inspection report

Final Inspection:
Final inspection consists of inspecting finished garments from the buyer’s point of view;
size measurements, form fitting (putting garments on the proper size manikins to see if they
properly fit labeled sizes); and live modeling if necessary (again to see if the garments
properly fit the labeled sizes). Final inspection may occur before or after garments are packed
in poly bags and cartons. If it is done after garments packed, then proper size and style
markings on the package can also be checked.

Fig:2.4 Final Inspection in Garment Industry

Total Acceptable Product (TAP) & Acceptable Quality Limit (AQL):

TAP means the number of acceptable products in a lot. On the other hand, AQL means
maximum acceptable capability or rejected % of products in a lot.

Example
10,000 dozen T-Shirts have AQL of 4%. Then find out TAP of that lot.
Here,
100 dozens T-Shirts have acceptable limit = 4 dozens
1 dozen T-Shirts has acceptable limit = 4/100 dozen

10,000 dozens T-Shirts have acceptable limit = (4/100) X 10,000 dozens

= 400 dozens

Therefore,

TAP = (10,000 - 400) dozens

= 9600 dozens

Generally in garment industries, inspections are made 1%, 1.5%, 2.5%, 4%, 6.5%, 10%, etc.
This depends on the buyer’s requirements.

Uses of AQL:
In this system, sample is selected by random sampling technique from a lot. After proper
inspection, the decision is taken whether the lot will be accepted or rejected. This is
applicable for raw materials to finished products inspection as well as garments. This system
is popular and used widely in the world trade.

Acceptable sampling system consists of 5 parts:

 Lot size
 Sample size
 AQL
 Accept number
 Reject number
Customer’s choice is given priority in this system. It is the customer who decides whether the
goods will be inspected at AQL of 1.5%, 2.5% or so on. They generally give preference to
the major defects (such as oil mark, holes, torn, etc) i.e. which at a glance seems to be odd for
use. They also give the direction on sampling technique.
Finishing
In garments industry finishing is a process which consists of pressing or ironing, folding
and packing of garments. Among them, by pressing we remove unwanted crease or wrinkles
from garments. Again folding is done by ironing. After pressing, the process used to fold the
garment in a required size and shape is called folding.

Types of Packing and Folding

There are four types of packing and folding for shirts, they are mentioned below:

1. Stand up pack
In which collar is folded and kept at 900 angles with the body.

2. Semi-stand up pack
In which collar is folded and kept at 450 angles with the body.

3. Flat pack
In which collar is folded and completely laid flattened on the body.

4. Hanger pack
In which shirt is supplied in box by hanging on a hanger.

Inspection Sampling Plan: -

During Final Inspection, we need sampling plans. There are several sampling plans available
with 4 features that separate them from others. It’s quite not possible to describe in brief. We
need read lots in books regarding Inspection Sampling Plans. These are:
1. AQL (1.0, 1.5, 2.5, 4.0, 6.5)
2. Type (Normal, Tightened, Reduced)
3. Plan (Single, Double)
4. Level (I, II, III)
The following Inspection Plan is in the most of Bangladeshi Factories.
1. AQL = 2.5

2. Type = Normal
3. Plan = Single
4. Level = II
 Fig:- 2.5 single sampling plan AQL

Few buyers don’t follow any AQL for their Inspection System. Instead of AQL, they follow
percentage of defective goods in the Order. If any defect of product exceeds 3%, then the
goods will be rechecked for those defects.
See the sheet in image that few buyers use as Final Inspection Report based on percentage of
defects.

During these inspections, various types of reports & records are seen & followed such as
Quality Risk Assessment Report, Fabric Visual Inspection Report (4 Point System), Fabric
Wash Test Report, Fabrics GSM, Spirality & Shrinkage Test Report, Fabric Relaxation
Report, Lay & Marker Check Report, Cut Panel Measurement Report, Process Control Report
(7 pieces), Traffic Light System, Hourly Q. C. Pass Production Report, Hourly Final
Inspection Report by factory QC, Inline Inspection Report by factory QC, Pre-final Inspection
Report, Pre-production Meeting Record, Loose Metal Control Register, Pull Test Record,
Nickel & Ferrous Test Record, Shade-wise Country Plan & Shade Record, Hourly Internal
Quality Audit, Corrective & Preventive Plan, Monthly Worker Training Program, Production
Reporting & planning, Shipping Documentation etc.
AQL (Acceptable quality label):

Goods in a sample are tested at random, and if the number of defective items is below the
predetermined amount, that product is said to meet the acceptable quality level (AQL). If the
acceptable quality level (AQL) is not reached for a particular sampling of goods,
manufacturers will review the various parameters in the production process to determine the
areas causing the defects.

As an example, consider an AQL of 1% on a production run. This percentage means that no

more than 1% of the batch can be defective. If a production run is composed of 1,000
products, only 10 products can be defective. If 11 products are defective, the entire batch is
scrapped. This figure of 11 or more defective products is known as the rejectable quality limit
(RQL).

The AQL is an important statistic for companies seeking a Six Sigma level of quality
control 503, which is a quality-control methodology developed in 1986 by Motorola, Inc.
AQL is also known as the acceptable quality limit.

KEY TAKEAWAYS:

 The acceptable quality limit (AQL) is the worst quality level that is tolerable for a
product.
 The AQL differs from product to product. Products that might cause more of a health
risk will have a higher AQL.
 Batches of products that do not meet the AQL, typically based on a percentage
measurement, are rejected when tested during pre-shipment inspections.
The faults or defects which are found during inspection are mainly classified into four
categories:
Critical: Must be 100% accurate. There is no range.
Major: Normally 2.5%
Minor: Normally 4%
Slight: Normally 6.5%

1. Critical Defects: Defects, when accepted could harm users. Such defects
are unacceptable. Critical defects are defined as 0% AQL.
2. Major Defects: Defects usually not acceptable by the end-users, as they are likely to
result in failure. The AQL for major defects is 2.5%.
3. Minor Defects: Defects not likely to reduce materially the usability of the product
for its intended purpose but that differ from specified standards; some end users will
still buy such products. The AQL for minor defects is 4%.

Types of AQL System Followed in Apparel Industry: -

There are total six types of acceptable quality level (AQL) system followed in garment
manufacturing industry which are pointed out in the below:
AQL-1.0%,
AQL-1.5%,
AQL-2.5%,
AQL-4.0%,
AQL-6.5%,
AQL-10%.
AQL Chart for Garment Industry: -
An acceptable quality level (AQL) chart have presented in the below to facilitate the easy
understanding of the above discussion.

Sample Acceptable Quality level

Lot or Batch size size Code Sample 2.5 4.0 6.5
Letter Size Ac Re Ac Re Ac Re
2–8 A 2 0 1 0 1 0 1
9 – 15 B 3 0 1 0 1 0 1
15 – 25 C 5 0 1 0 1 0 1
26 – 50 D 8 0 1 1 2 1 2
51-90 E 13 1 2 1 2 2 3
91-150 F 20 1 2 2 3 3 4
151-280 G 32 2 3 3 4 5 6
251-500 H 50 3 4 5 6 7 8
501-1200 J 80 5 6 7 8 10 11

1201-3200 K 125 7 8 10 11 14 15

3201-10000 L 200 10 11 14 15 21 22
10001-35000 M 315 14 15 21 22 21 22

Fig: 2.6 AQL Chart for Garment Industry

Traffic Light System: -

Traffic Light system is a very effective quality control system in garments sewing line. Every
garment factory aims to achieve a minimum DHU level possible. A new framework is the
Traffic Light System which helps to reduce the work-pressure on the quality department and
improving the level of quality in sewing lines at the same time. Thus, such a Traffic Light
system (TLS) system can prove to be a boon for apparel manufacturing. Traffic Light System
(TLS) is a quality system designed to identify problems and involve help from management to
solve the problems. This is a “Pareto” based system which focuses on solving the 3 highest
occurring faults daily. The system incorporates the key fundamentals necessary for any system
successful:

 Clear standards and tolerance.

 The ability to track a problem back to the source.

 Reporting and process discipline.

 TLS will transit the vendor to a Right First Time (RFT) mentality and culture.

Objectives of Traffics Light system in Sewing:

 Tracking operators sewing quality and operator wise defects.

 To monitor the level of quality in sewing lines through a different approach to

Traffic Light System.
 To reduce sewing DHU% and process defects percentage.
 Fig: 2.7 Marking System In Traffic Light System

Traffic Light system

In-line Auditors together with Technicians should prepare “Quality Specification” cards for
every operation. When the operator fully understands what is required and completed three
garments with the right quality, this is agreed with the operator and a sample selected out of
the above three is attached. The agreement & the approval of the sample sign off by the
Operator, Production Supervisor, Technician and Mechanic on Quality Specification sheet in
the presence of the In-line Auditor. This is then hanged on the stand located on every machine
set at an eye-level for ease of viewing.
Working Procedure:

Traffic Light System is a visual control for highlighting quality issues in sewing line. Traffic
light quality system works in a similar fashion the transportation traffic light system works.
Three different color cards are placed in each operator’s place. Green indicates that Quality
meets the customers Standard. Yellow indicates that a minor fault has been found and caution
is required. Red indicates that the Quality Standard does not meet the customer’s standard
requirement.

Fig: 2.8 Traffic Light System

One Inline Quality Checker is to be allocated for every line of particular style or cover 15 or
20 Workstations. She/he has to check the semi-finished garment pieces from current bundle
once in an hour or two. Pieces will be taken randomly and check all the quality parameters
required for that operation. Stitches per inch, seam width, sewing allowance, correct trims and
their placement and measurement etc. are to be verified by the Inline Quality checker. While
inspecting, depending upon the quality level, color cards are placed on their machine.

The red card is given for those, who are identified by the line supervisor have produced 5 or
more defective item out of ten pieces inspected. The yellow card is given to those who are
identified by the line supervisor have produced 2 or more defective items out of ten inspected.
The green card is given if no reworks are found. This can motivate the worker to produce
good quality products. It is also an indication of how and which operator is going wrong to the
production in charge and quality supervisor. They can monitor from any corner of the floor
easily.
 Fig: 2.9 Traffic Light System In Garments Factory

Traffic Light Auditor Role in Sewing Line

There is an assigned traffic Light Auditor every 2 or 3 sewing lines who works as a roaming QC
and control the traffic light system. A traffic light Auditor has the authority to stop the machine,
the machine have to be stopped when auditor put the red light indicator in front of an operator.
Traffic Light Audit system
In-line Auditor (Quality Monitor) starts the day work with “Patrol Inspection” of which he/she
checks 3 components/pieces from each and every operation. The Patrol Inspection should be
completed within fifteen (15) minutes of starting the day. In-line Auditor turns the Traffic Light
Cards (TL Cards) into respective colors according to the result of the Patrol Inspection.

Zero defects – Green

One defect - Yellow
Two or more defects – Red

Action on Traffic Light

Auditor turns the Traffic Light Cards ( TL Cards ) into respective colors according to the
result of the Inspection.
Green-Appreciate & ask to continue the Operation

Yellow- Inform to operator & Production Supervisor to increase the attention & the
level of her own inspection

Red -Stop the operation. Inform to Operator, Production Supervisor to identify the
problem & solve it with the help of Mechanic & Technician.

The result is marked on the Traffic Light Chart or Daily In-line Audit Sheet. In-line Auditor
makes the normal random audit route as follows by considering the 3 highest defect making
operations / Critical operations on the previous day. Two visits for top 3 defect making
operations / Critical operations in two hrs (a quarter of a shift)
One visit for other operations in two hrs • It is marked on the “Daily Inline Audit Sheet”

In-line Auditor then inspects each operation as per the random audit sequence four times per
day.
In each visit to an operation, Inline Auditor selects 7 pieces /components randomly and checks
them

The Traffic Light Chart ( TL Chart ) is updated with the color given for the visit.

The relevant record is made on the “Daily In-line Audit sheet” with fault code.

No. defects out of 7 checked components, Mark as “  ”.

Actions taken for Red dots by the Supervisor / Technician and the team are noted down on the
reverse side of the “Daily In-line Audit Sheet”.
If any operation gets a Red dot, In-line Auditor makes a 2nd visit to audit the relevant
operation again in the same quarter.
At the end of the day, In-line The auditor summarizes the quality performance of the operation
and it is marked on the “In-line Quality Performance” board hanged in front of the line.
The top three (3) operations that made highest no. of defectives, are marked together with
relevant fault code on the “Daily In-line Audit Sheet” and “RFT Meeting Minute” as inputs for
the RFT meeting.
In-line Auditor provides the following information

No. of Red dots for the shift / a day with fault code.

No. of defectives found & no of components audited at the In-line Audit.

Top three operations making the highest no of defectives with fault codes as per the In-line
audit result.
Top three operations making highest no. of defectives with fault codes as per the End-line
inspection result.
No. of seconds garments

Features of traffic light system

 Random inspection system widely used in sewing section to produce defect free
garments at sewing floor.
 More effective in controlling shop floor quality than other quality tools because of
its visual communication.
 Measure operator performance as well as to maintain raw material supply from
MCD.
 Introduced by JC Penny for their supplier.
 7 piece garments are checked and evaluated.
 times checking in 8 hours shift.
Traffic Light Symbol:

Traffic light system is the most effective inspection tool to reduce defect generation at source.
This is a random inspection system. Traffic Light System is designed to flag the problem at
source and allow immediate corrective action rather than all potentially defective product to
continue to be manufactured.

 Green light: When no defect found.

 Yellow light: When 1 defect found.
 Red light: When 2 defects found.

Basic concept of Color Light Card

Green Light Card:

 Allows the garments to proceed.

 If 1 defect found in next inspection, then replaced by Yellow Light Card.

Yellow Light Card:

 Quality team should assist the operators actively to solve the quality problems when
yellow card is attached.

 If no defect is found in follow up visit then replaced by green light card.

 If 1 defect is found in follow up visit then replaced by red light card.

Red Light card :

 WIP or Products cannot be passed to the next stage

 The whole team has to be involved for solving the problem.

 If successfully pass the consecutive two inspection then replaced by yellow card.

 Process is stopped for continuous red light to solve the problem.

Advantage of Traffic Light System

 To improve the quality standard of the product.

 To find out the reason of the problem to the needlepoint.

 To maintain the smooth supply of the raw material.

 To measure the rating of the operators.

 To provide the increment and the other facilities based on operator’s performance.

 To accelerate the production flow.

Disadvantage of traffic light system

 Unnecessary raw material supply if wrong light is selected.

 Chance of wrong operators rating in case of QA’s mistake.

 Chance of wrong light card hanging by mistake.

How to fill/use: -

The format is used for a single operator or workstation. A single sheet will keep record for
the whole month for an operator.

1. A Line Controller has to fill details such as Operator Name, Process Name, Line
Number, Floor and name of the month. Inspection instructions have been given on the
format itself with Root Cause.
2. The format is displayed covering27 days (whole month). In a sewing line, this Traffic
Light Inspection Card has to put in all sewing machines.
3. In a working day, LQC will do five times audit. 1st& 2nd audits will be conducted in
all sewing processes/machines.
4. Rest 3 audits will be done in critical operations only.
5. LQC will mention Root Cause for the defects, as Man, Machine, Material and Method.
6. He will mark Green, Yellow and Red marking if gets zero, 1 or more than 1 defects
respectively.
7. Floor QA Manager shall follow-up with the findings and take necessary corrective
actions for each audit fails.
 Fig: 2.9.1 Traffic light audit system
The above format is used for a single operator or workstation. A single sheet will keep the
record for the whole month for an operator. As a quality auditor, on the first day of the month,
you have to fill details such as Operator name, Operation name, Line number, Floor number,
and the name of the Month. Inspection instructions have been given on the format itself with
rating procedures. The format is displayed in two sections to cover 31 days (whole month).
Write the date in the cells of the top row. Each column contains 4 circles, represents four
inspections in a day. Number of pieces to be checked and limit of number of defect pieces for
color code change slightly differs in different factories depending upon the quality level they
target. 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. The extra care may be in a way that he or she should
be trained for that operation or if there have any problem, could be solved. In the garment
industry quality control is practiced right from the initial stage of sourcing raw materials to the
stage of final finished garment. For textile and apparel industry product quality is calculated
in terms of quality and standard of fibers, yarns, fabric construction, color fastness, surface
designs and the final finished garment products. However, quality expectations for export are
related to the type of customer segments and the retail outlets.
Employee Motivation: -

The system offers that, the best worker and the best line that scored highest should be honored
by the management and some incentive should be given to them for their outstanding
performance. The system also offers that, they should also be honored by being put a best
quality badge for the whole month so that they could feel proud and all other workers could
inspire to achieve the highest quality level. It is practiced by lot of factories nowadays and they
find improvement in employee performance. System offers that, the best worker and the best
line that scored highest should be honored by the management and some incentive should be
given to them for their outstanding performance.

Fig: 2.9.2 Traffic light inspection process

Fig: 2.9.3 Traffic Light System In Sewing Line

Fig: 2.9.4 Traffic guide line for operator

Quality Management System: -
Quality management is the act of overseeing all activities and tasks that must be accomplished
to maintain a desired level of excellence. This includes the determination of a quality policy,
creating and implementing quality planning and assurance, and quality control
and quality improvement.
Quality management strives towards the achievement of quality in everything one does.
Quality means conformance to customer requirements. In to-days highly competitive
economy, business must face the challenge of continually improving the quality of the goods
or services. A number of systems, measures & techniques are used so that only quality goods
are produced in the first place and defects do not originate at all. If they occur at all, there
must be corrective action so that they are eliminated in the preliminary stage and would not
reappear. For increasing productivity in garment industry need strong quality management
system. Here flow chart of quality management system are given for apparel industry.

Fig: 2.9.5 Quality Management Principles

 CHAPTER-3

Experimental Design
Short Sleeve Polo Shirt:

Fig: 3.1 Short Sleeve Polo Shirt

Operation breakdown of Polo shirt: -

Collar Mark
↓
Placket Join
↓
Band Join
↓
Placket Box
↓
Collar Join
↓
Back Tap Join
↓
Back Topsin
↓
 Label Join
↓
Sleeve Joint
↓
Cuff Joint
↓
Side Seam
↓
Body Hem

↓
Button Hole
↓
Button Attached

Outline of project work: -

Traffic Light System is a visual control for highlighting quality issues in sewing line. Traffic
light quality system works in a similar fashion the transportation traffic light system works.
Three different color cards are placed in each operator’s place. Green indicates that Quality
meets the customers Standard. Yellow indicates that a minor fault has been found and caution is
required. Red indicates that the Quality Standard does not meet the customer’s standard
requirement. Following is the flow chart of project methodology

Study the present alteration rate and method to rectify the alterations.
↓
Discuss with higher management and suggest traffic light system.
↓
Prepare the traffic light formats.
↓
Hang the format on each machine of the operator.
↓
Continue the system for one month.
↓
Study the alteration rate after implementation of traffic light system.
↓
There was a high rate of alteration.
↓
 The type and cause of defects could not be identified correctly.
↓
Time is taken for a style to move out of the line increased.
↓
A monthly format was made for every operator in the line and was hung on his/her Machine.
↓
A QC checked a bundle of 7 pieces produced on a bi-hourly basis and marked the Format
appropriately- 2 or more pieces’ defective – RED, 1-piece defective – YELLOW, NO
piece defective – GREEN.
↓
Once QC completed one round of the line, the supervisor made the round and checked the
format.
↓
If the supervisor found red on any format, then he would tell the operator to stop the
Operation and tell him/her the correct procedure to carry out the operation.
↓
After the supervisor corrected the operator the same operator altered the pieces found
Defective by him.
↓
At the end of the month, the formats were reviewed and the operator with a good Performance
was rewarded with the monitor incentive.
↓
Then the performance report was analyzed and present graphically with green, red, yellow
color.
 Experimental data:
Operation Name Placket Joint Month April-21
Operator Name Kadu Azad Sewing Input D
Operator ID 1860 Line 3
STANDARD OF TRAFIC
LIGHT SYSTEM
GREEN/OK YELLOW/Observation RED/Problem
Very poor Quality Very poor
Stitching method OK Need to train operator Need to
attention Stitching wrong
Quality method OK improve the Quality
method stop the Operator

Total
Total
Date 1st 2nd 3rd 4th 5th 6th 7th 8th Inspection DHU %
DHU
HR HR HR HR HR HR HR HR Qty
01.04.21 0 0 1 0 80 1 1.25
02.04.21 0 3 1 0 80 4 5
03.04.21 FRI
04.04.21 1 3 1 80 5 6.25
05.04.21 0 0 1 80 1 1.25
06.04.21 1 0 1 0 80 2 2.5
07.04.21 2 1 0 80 3 3.75
08.04.21 1 0 0 1 80 2 2.5
09.04.21 3 1 0 1 0 80 5 6.25
10.04.21 FRI
11.04.21 0 1 L 2 1 80 4 5
12.04.21 1 0 U 0 1 0 80 2 2.5
13.04.21 1 0 N 2 0 80 3 3.75
14.04.21 0 2 C 0 80 2 2.5
15.04.21 0 0 1 H 1 80 2 2.5
16.04.21 1 1 0 TI 2 80 4 5
17.04.21 FRI M
18.04.21 0 2 1 1 E 0 1 80 5 6.25
19.04.21 0 0 1 0 80 1 1.25
20.04.21 0 0 1 1 80 2 2.5
21.04.21 2 0 1 80 3 3.75
22.04.21 0 1 1 80 2 2.5
23.04.21 1 0 0 80 1 1.25
24.04.21 FRI
25.04.21 1 2 80 3 3.75
26.04.21 0 1 1 0 80 2 2.5
27.04.21 0 0 1 0 80 1 1.25
28.04.21 1 1 2 0 80 4 5
29.04.21 0 0 1 1 0 80 2 2.5
30.04.21 0 2 1 0 80 3 3.75
 Operation Collar Joint Month April 21
Operator Fahim Farhan Sewing Input D
Operator ID 1857 Line 3

STANDARD OF TRAFFIC LIGHT SYSTEM

GREEN / OK YELLOW / Observation RED / Problem
Very poor Quality
Very poor attention
Stitching method OK Need to train Operator
Stitching wrong
Quality method OK Need to improve the Quality
method
Stop the Operator
Total
1st 2nd 3rd 4th 5th 6th 7th 8th Inspe Total DHU
DATE
HR HR HR HR HR HR HR HR c tion DHU %
Qty
01.04.21 0 1 0 2 0 0 1 2 70 6 8.6
02.04.21 0 0 3 0 0 2 1 0 70 6 8.6
03.04.21 FRI
04.04.21 0 2 0 0 1 0 1 0 70 4 5.7
05.04.21 1 0 0 2 1 0 1 0 70 5 7.1
06.04.21 0 0 3 0 0 0 1 0 50 4 8.0
07.04.21 0 4 0 0 0 1 0 0 70 5 7.1
08.04.21 1 0 0 4 0 0 0 0 70 5 7.1
09.04.21 0 0 2 1 0 2 0 0 70 5 7.1
10.04.21 FRI
11.04.21 0 0 0 0 1 0 3 1 70 5 7.1
LUNCH

12.04.21 0 0 1 0 0 3 1 0 70 5 7.1
TIME

13.04.21 0 0 0 0 0 0 0 0 0 0 0.0
14.04.21 0 2 0 0 3 0 0 0 70 5 7.1
15.04.21 0 0 4 0 0 0 0 1 70 5 7.1
16.04.21 1 1 0 0 0 0 3 0 70 5 7.1
17.04.21 FRI
18.04.21 0 2 1 1 0 0 0 0 70 4 5.7
19.04.21 0 3 0 0 1 0 0 0 70 4 5.7
20.04.21 0 0 2 0 0 2 0 0 70 4 5.7
21.04.21 1 2 0 0 0 0 0 1 56 4 7.1
22.04.21 0 0 0 0 2 0 1 0 70 3 4.3
23.04.21 1 0 0 2 0 0 0 0 70 3 4.3
24.04.21 FRI
25.04.21 0 0 0 0 0 0 0 0 0 0 0.0
26.04.21 0 0 1 0 0 1 0 0 70 2 2.9
27.04.21 0 0 0 0 1 0 0 0 70 1 1.4
28.04.21 0 1 0 0 0 0 0 0 70 1 1.4
29.04.21 0 0 0 0 0 0 0 0 70 0 0.0
30.04.21 0 0 56 0 0.0
 Cuff
Operation Month April-21
Joint
Maham
Operator Sewing Input D
udul
Operator ID 1854 Line 3
STANDARD OF TRAFFIC
LIGHT SYSTEM
GREEN / OK YELLOW / Observation RED / Problem
Very poor Quality
Need to train Operator
Stitching method OK Very poor attention
Need to improve the
Quality method OK Stitching wrong method
Quality
Stop the Operator
Total
2nd 3rd 4th 5th 7TH 8th Total
DATE 1st HR 6th HR Inspection DHU%
HR HR HR HR HR HR DHU
Qty
01.04.21 0 1 0 2 0 3 0 0 70 6 8.6
02.04.21 0 0 3 0 0 2 1 0 70 6 8.6
03.04.21 FRI
04.04.21 1 0 0 0 2 0 1 0 70 4 5.7
05.04.21 0 1 0 1 0 2 0 1 70 5 7.1
06.04.21 0 0 3 0 2 0 1 0 50 6 12.0
07.04.21 0 4 0 0 0 1 0 0 70 5 7.1
08.04.21 1 0 0 4 0 0 0 0 70 5 7.1
09.04.21 0 0 2 1 0 2 0 0 70 5 7.1
10.04.21 FRI
11.04.21 0 0 0 0 1 0 3 1 70 5 7.1
12.04.21 0 0 1 0 0 3 1 0 70 5 7.1
13.04.21 0 0 0 0 0 0 0 0 0 0.0
14.04.21 0 2 0 0 3 0 0 0 70 5 7.1
15.04.21 0 0 4 0 0 0 0 1 70 5 7.1
16.04.21 1 1 0 0 0 0 3 0 70 5 7.1
17.04.21 FRI
18.04.21 0 2 1 1 0 0 0 0 70 4 5.7
19.04.21 0 3 0 0 1 0 0 0 70 4 5.7
20.04.21 0 0 2 0 0 2 0 0 70 4 5.7
21.04.21 1 2 0 0 0 0 0 1 56 4 7.1
22.04.21 0 0 0 0 2 0 1 0 70 3 4.3
23.04.21 1 0 0 2 0 0 0 0 70 3 4.3
24.04.21 FRI
25.04.21 0 0 0 0 0 0 0 0 0 0 0.0
26.04.21 0 0 1 0 0 1 0 0 70 2 2.9
27.04.21 0
Operation 0 0 Sleeve
0 Joint
1 0Month 0 0 70April-211 1.4
28.04.21 0
Operator 1 0 Sujon
0 Parvej
0 0
Sewing 0
Input 0 70 D 0 0.0
29.04.21 0
Operator ID 0 0 01853 0 0 Line 0 0 70 3 0 0.0
30.04.21 0 0 0 0 STANDARD
1 0 TRAFFIC
OF 0 0 56 1 1.8
LIGHT SYSTEM
GREEN / OK YELLOW / Observation RED / Problem
Very poor Quality
Need to train Operator
Stitching method OK Very poor attention
Need to improve the
Quality method OK Stitching wrong method
Quality Stop the Operator
Total
1st 2nd 3rd 4th 5th 6th 7TH 8th Total
DATE Inspection DHU%
HR HR HR HR HR HR HR HR DHU
Qty
01.04.21 1 0 0 2 1 0 2 0 70 6 8.6
02.04.21 0 0 3 0 0 2 1 0 70 6 8.6
03.04.21 FRI 0.0
04.04.21 0 0 0 2 0 1 0 0 70 3 4.3
05.04.21
06.04.21 0 0 2 0 2 0 1 0 50 5 10.0
07.04.21 0 4 0 0 0 1 0 0 70 5 7.1
08.04.21 1 0 0 4 0 0 0 0 70 5 7.1
09.04.21 0 0 2 1 0 2 0 0 70 5 7.1
10.04.21 FRI
11.04.21 0 0 0 0 1 0 3 1 70 5 7.1
12.04.21 0 0 1 0 0 3 1 0 70 5 7.1
LUNCH

13.04.21 0 0 0 0 0 0 0 0 0 0.0
TIME

14.04.21 0 2 0 0 3 0 0 0 70 5 7.1
15.04.21 0 0 4 0 0 0 0 1 70 5 7.1
16.04.21 1 1 0 0 0 0 3 0 70 5 7.1
17.04.21 FRI
18.04.21 0 2 1 1 0 0 0 0 70 4 5.7
19.04.21 0 3 0 0 1 0 0 0 70 4 5.7
20.04.21 0 0 2 0 0 2 0 0 70 4 5.7
21.04.21 1 2 0 0 0 0 0 1 56 4 7.1
22.04.21 0 0 0 0 2 0 1 0 70 3 4.3
23.04.21 1 0 0 2 0 0 0 0 70 3 4.3
24.04.21 FRI
25.04.21 0 0 0 0 0 0 0 0 0 0 0.0
26.04.21 0 0 1 0 0 1 0 0 70 2 2.9
27.04.21 0 0 0 0 1 0 0 0 70 1 1.4
28.04.21 0 1 0 0 0 0 0 0 70 1 1.4
29.04.21 0 0 0 0 0 0 0 0 70 0 0.0
30.04.21 0 0 0 0 0 0 0 1 56 1 1.8
.
 Operation Side Seam Month April-20
Operator Rony Mia Sewing Input D
Operator ID 1859 Line 3
STANDARD OF TRAFFIC
LIGHT SYSTEM
GREEN / OK YELLOW / Observation RED / Problem
Very poor Quality
Need to train
Stitching method OK Very poor attention
Operator Need to
Quality method OK Stitching wrong method
improve the Quality
Stop the Operator
Total
1st 2nd 3rd 4th 5th 6th 7TH 8th Total
DATE Inspection DHU%
HR HR HR HR HR HR HR HR Qty DHU
01.04.21 0 0 1 0 2 1 0 2 70 6 8.6
02.04.21 0 0 3 0 0 2 1 0 70 6 8.6
03.04.21 FRI
04.04.21 0 0 0 0 0 0 0 0 70 0 0.0
05.04.21 1 0 2 0 0 0 0 0 70 3 4.3
06.04.21 0 0 2 0 2 0 0 0 50 4 8.0
07.04.21 0 4 0 0 0 1 0 0 70 5 7.1
08.04.21 1 0 0 4 0 0 0 0 70 5 7.1
09.04.21 0 0 2 1 0 2 0 0 70 5 7.1
10.04.21 FRI
11.04.21 0 0 0 0 1 0 3 1 70 5 7.1
12.04.21 0 0 1 0 0 3 1 0 70 5 7.1
LUNCH

13.04.21 0 0 0 0 0 0 0 0 0 0.0
TIME

14.04.21 0 2 0 0 3 0 0 0 70 5 7.1
15.04.21 0 0 4 0 0 0 0 1 70 5 7.1
16.04.21 1 1 0 0 0 0 3 0 70 5 7.1
17.04.21 FRI
18.04.21 0 2 1 1 0 0 0 0 70 4 5.7
19.04.21 0 3 0 0 1 0 0 0 70 4 5.7
20.04.21 0 0 2 0 0 2 0 0 70 4 5.7
21.04.21 1 2 0 0 0 0 0 1 56 4 7.1
22.04.21 0 0 0 0 2 0 1 0 70 3 4.3
23.04.21 1 0 0 2 0 0 0 0 70 3 4.3
24.04.21 FRI
25.04.21 0 0 0 0 0 0 0 0 0 0 0.0
26.04.21 0 0 1 0 0 1 0 0 70 2 2.9
27.04.21 0 0 0 0 1 0 0 0 70 1 1.4
28.04.21 0 1 0 0 0 0 0 0 70 1 1.4
29.04.21 0 0 0 0 0 0 0 0 70 0 0.0
30.04.21 0 0 0 0 0 0 0 0 56 0 0.0
 Operation Body Hem Month April-21
Operator Soniya Khatun Sewing Input D
Operator ID 1873 Line 3
STANDARD OF TRAFFIC
LIGHT SYSTEM
GREEN / OK YELLOW / Observation RED / Problem
Very poor Quality
Need to train
Stitching method OK Very poor attention
Operator Need to
Quality method OK Stitching wrong method
improve the Quality
Stop the Operator
Total
1st 2nd 3rd 4th 5th 6th 7TH 8th Total
DATE Inspection DHU%
HR HR HR HR HR HR HR HR DHU
Qty
01.04.21 0 0 1 0 3 1 0 0 70 5 7.1
02.04.21 0 0 3 0 0 2 1 0 70 6 8.6
03.04.21 FRI
04.04.21 0 0 1 0 2 1 0 0 70 4 5.7
05.04.21 0 1 0 2 0 2 0 0 70 5 7.1
06.04.21 0 0 3 0 2 0 1 0 50 6 12.0
07.04.21 0 4 0 0 0 1 0 0 70 5 7.1
08.04.21 1 0 0 4 0 0 0 0 70 5 7.1
09.04.21 0 0 2 1 0 2 0 0 70 5 7.1
10.04.21 FRI
11.04.21 0 0 0 0 1 0 3 1 70 5 7.1
12.04.21 0 0 1 0 0 3 1 0 70 5 7.1
LUNCH

13.04.21 0 0 0 0 0 0 0 0 0 0 0.0
TIME

14.04.21 0 2 0 0 3 0 0 0 70 5 7.1
15.04.21 0 0 4 0 0 0 0 1 70 5 7.1
16.04.21 1 1 0 0 0 0 3 0 70 5 7.1
17.04.21 FRI
18.04.21 0 2 1 1 0 0 0 0 70 4 5.7
19.04.21 0 3 0 0 1 0 0 0 70 4 5.7
20.04.21 0 0 2 0 0 2 0 0 70 4 5.7
21.04.21 1 2 0 0 0 0 0 1 56 4 7.1
22.04.21 0 0 0 0 2 0 1 0 70 3 4.3
23.04.21 1 0 0 2 0 0 0 0 70 3 4.3
24.04.21 FRI
25.04.21 0 0 0 0 0 0 0 0 0 0 0.0
26.04.21 0 0 1 0 0 1 0 0 70 2 2.9
27.04.21 0 0 0 0 1 0 0 0 70 1 1.4
28.04.21 0 1 0 0 0 0 0 0 70 1 1.4
29.04.21 0 0 0 0 0 0 0 0 70 0 0.0
30.04.21 0 0 0 0 0 0 0 0 56 0 0.0
 Operation Label Attached Month April-20
Operator Sumi Akter Sewing Input D
Operator ID 1846 Line 3
STANDARD OF TRAFFIC
LIGHT SYSTEM
GREEN / OK YELLOW / Observation RED / Problem
Very poor Quality Very poor
Need to train
Stitching method OK attention
Operator Need to
Quality method OK Stitching wrong method
improve the Quality Stop the Operator
Total
1st 2nd 3rd 4th 5th 6th 7TH 8th Total
DATE Inspectio DHU%
HR HR HR HR HR HR HR HR DHU
n Qty
01.04.21 0 0 0 2 0 0 2 70 4 5.7
02.04.21 0 0 3 0 0 2 1 0 70 6 8.6
03.04.21 FRI
04.04.21
05.04.21 0 0 2 0 3 0 1 0 70 6 8.6
06.04.21 0 0 0 0 2 0 1 0 50 3 6.0
07.04.21 0 4 0 0 0 1 0 0 70 5 7.1
08.04.21 1 0 0 4 0 0 0 0 70 5 7.1
09.04.21 0 0 2 1 0 2 0 0 70 5 7.1
10.04.21 FRI
11.04.21 0 0 0 0 1 0 3 1 70 5 7.1
12.04.21 0 0 1 0 0 3 1 0 70 5 7.1
LUNCH

13.04.21 0 0 0 0 0 0 0 0 0
TIME

14.04.21 0 2 0 0 3 0 0 0 70 5 7.1
15.04.21 0 0 4 0 0 0 0 1 70 5 7.1
16.04.21 1 1 0 0 0 0 3 0 70 5 7.1
17.04.21 FRI
18.04.21 0 2 1 1 0 0 0 0 70 4 5.7
19.04.21 0 3 0 0 1 0 0 0 70 4 5.7
20.04.21 0 0 2 0 0 2 0 0 70 4 5.7
21.04.21 1 2 0 0 0 0 0 1 56 4 7.1
22.04.21 0 0 0 0 2 0 1 0 70 3 4.3
23.04.21 1 0 0 2 0 0 0 0 70 3 4.3
24.04.21 FRI
25.04.21 0 0 0 0 0 0 0 0 0 0 0.0
26.04.21 0 0 1 0 0 1 0 0 70 2 2.9
27.04.21 0 0 0 0 1 0 0 0 70 1 1.4
28.04.21 0 1 0 0 0 0 0 0 70 1 1.4
29.04.21 0 0 0 0 0 0 0 0 70 0 0.0
30.04.21 0 0 0 0 0 0 0 0 56 0 0.0
.
 CHAPTER-04
Result & Discussion
Graphical representation of DHU% for operator Kadu Azad
Operator Kadu Azad was responsible for the operation of Placket Joint.

DHU% Of Oparetor Kadu Azad

14
12
10
8
6
DHU%

4
2
0

Axis Title
01.04.20
02.04.20

Fig: 4.1 DHU% for operator Kadu Azad

Above graph shows the DHU percentage of operator Kadu Azad in the sewing line 3 for one
month. It is clear from the graph that in the first week defect amount was high and highest was
6.25% at the fifth working day. Gradually it was decreased and at the last two day DHU
percentage was zero.
Graphical representation of DHU% for operator Fahim Farhan
Operator Fahim Farhan was responsible for the operation of Collar Joint.

DHU% Of Oparetor Fahim Farhan

14

12

10

8
DHU%

0
01.04.20
02.04.20

Axis Title

Fig: 4.2 DHU% for Operator Fahim Farhan

It has been seen from the above graph the DHU percentage was high in the first two days for
the operator Fahim Farhan. In the last week it was decreased more and obtained 0% at last
two days.
Graphical representation of DHU% for operator Mahmudul
Operator Zariful Islam was responsible for the operation of Collar Topsin.

DHU% Of Oparetor Zatriful Islam

14

12

10

8
DHU%

0
01.04.20
02.04.20

Axis Title

Fig: 4.3 DHU% for Operator Mahmudul

From the graph we can see the DHU percentage of operator Zariful Islam in the sewing line 3
for one month. It is clear from the graph that in the first week defect amount was high and
highest was 12% at the fifth working day. Gradually it was decreased in the last week and
acquire zero DHU percentage at last two days.
Graphical representation of DHU% for operator Sujon Parvej
Operator Sujon Parvej was responsible for the operation of Sleeve Joint.

DHU% OF OPARETOR SUJON PARVEJ

10
9
8.6 8.6

8
7.1 7.1 7.17.1 7.17.1 7.1 7.1 7.1
7
6
DHU%

6 5.7 5.7 5.7 5.7

5 4.3 4.3
4
2.9
3
2
1.4 1.4
1
0 00
01.04.20

0
02.04.20

Axis Title

Fig: 4.5 DHU% for Operator Sujon Parvej

It has been seen from the above graph the DHU percentage was high & highest 10% in the
first weak for the operator Sujon Parvej. In the last week it was decreased more and obtained
0% at last two days.
Graphical representation of DHU% for operator Rony Mia
Operator Rony Mia was responsible for the operation of Side Seam.

DHU% OF OPARETOR RONY MIA

10
9 8.6 8.6
8
7 7.1 7.1 7.17.1 7.17.1 7.1 7.1 7.1
6
6
DHU%

5 5.7 5.7 5.7 5.7

4
3 4.3 4.3
2
1 2.9
0
1.4 1.4

0 00
01.04.20
02.04.20

Axis Title

Fig: 4.6 DHU% for Operator Rony Mia

It is clear from the above graph the DHU percentage was high in the first week for the
operator Rony Mia and highest was 8.6% at 1st & 2nd April. In the last week it was decreased
more and obtained 0% at 25, 29 and 30th April.
Graphical representation of DHU% for operator Soniya Khatun
Operator Soniya khatun was responsible for the operation of Body Hem.

DHU% OF OPARETOR SONIYA KHATUN

10
9 8.6 8.6

8
7.1 7.1 7.17.1 7.17.1 7.1 7.1 7.1
7
6
DHU%

6 5.7 5.7 5.7 5.7

5 4.3 4.3
4
2.9
3
2
1.4 1.4
1
0 00
01.04.20

0
02.04.20

Axis Title

Fig: 4.7 DHU% for Operator Soniya khatun

From the graph we can see the DHU percentage of operator 3 in the sewing line 3 for one
month. It is clear from the graph that in the first week DHU amount was high and highest was
12% at the six working day. Gradually it was decreased and at the last two day DHUt
percentage was zero.
Graphical representation of DHU% for operator Sumi Akhter
Operator Sumi Akhter was responsible for the operation of Label Attached.

DHU% OF OPARETOR SUMI AKHTER

10

8.6 8.6
9
8
7.1 7.1 7.17.1 7.17.1 7.1 7.1 7.1
7
6
DHU%

6 5.7 5.7 5.7 5.7

5
4.3 4.3
4
2.9
3

2 1.4 1.4
1
0 00
01.04.20

0
02.04.20

Axis Title

Fig: 4.8 DHU% for Operator Sumi Akhter

It is clear from the above graph DHU percentage was high in the first week for the operator
Sumi Akhter and highest was 8.6% at 2nd & 5th April. In the last week it was decreased more
and obtained 0% at 25, 29 and 30th April.
CHAPTER-05
Conclusion
Conclusion:

Traffic light system is a system that can be implemented easily in any garment manufacturing
company and it will help to improve the quality status, reduced the cost, improve the lead time
and thus strengthen the supply chain performance without increasing the
resource. Poorly managed factory loses productivity up to 10% due to repair and reject. Hence
implementation of traffic light system will help to get more quality products from Operators
of this age.
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