Accessories &

Gears

Module 6:
MANUFACTURING CONCEPT
6.1. Quality Concept Best Practice

Updated by: Rina

Lukiandari
Date: November 2017
1 Repair Free Line

2 Right First Time

3 Traffic Light System

4 Self Inspection
REPAIR FREE LINE
World-wide Manufacturing Principles
SAFETY
1st Priority Machines/process/materials etc.

QUALITY
2nd Priority Beautiful product impressive customer.

SERVICES
3rd Priority Lead time, on time delivery.

EFFICIENCY
4th Priority More output with less manpower.
Quality Golden Rule

There are no minor or major defect in the line,

There are only defects which can be repaired or

replaced.

Minor or major defects only counts for AQL.

(JJB 2015)
What happens if the defective products go back to the line?

Only quality products count as output. Line become imbalanced

by doing repair in line. Output is lower and fluctuates from time to
time.

40

30
Seconds

R R
20

10

0
1 2 3 4 5

# of Operators
Why do We Need to do Repair Free Line

1 Easy to balance the line and gain higher productivity

2 All line members repair the product at the same time,

makes everyone knows the exact quality problem and
stops producing same defective products

3 Quality standard without compromise

How to do the repair free/performance line

Quality mindset training

Quality standard & SOP

sharing

Production line set up:

 “Repair Free” and “To
be Repaired” box at the To be repaired box Repair Free box
(next morning) (Right First Time)
end of line

Ground rules
•Line should be stopped if the defect rate reaches is >5% of the
hourly output.
•No defective product allowed to go back to normal line.
Repair all the defective •QC needs to communicate the defects back to line.
products by the team •Repair is done by whole team  understand what kind of
before new production defects have been made and how to avoid it.
•Defective review 2x per-day.
Repair Free/Performance Line Flow Chart

Quality Performance
Defects. (See Figure 1) Line Flow Chart

RFT %
Real
A- Grade
Box
Start
Production
QM & LM
Repair Defect Review Repair ing
Box 2 x Day Per iod

Defects
Report
New
Pr oduct /
Line Stop
End Line Inspection
Manual
F IGURE 1: QUALITY PERFORMANCE LINE F LOW C HART
RIGHT FIRST TIME
Definition & Calculation Method
Definition:
In making a product, it is better to perform an operation correctly the first time, rather than have to work on it
again in order to correct mistakes

Calculation:
End-line Reject
Quality issues found when the Product reaches final inspection at the end of the production line when the
product is completed.
Scope

• Prevent misunderstanding
• Prevent non adherence of process
• Prevent opportunities of error
Means causing
something not to How?
happen. • Study the work processes to increase understanding of how they
operate
• Understood the process requirements and identify how
requirements should be understood.

Deviation of any • Do we have double standard?

nature is not How?
acceptable. • Making personal commitment to not accept any error or deviation.

How?
Measure the • Measurement are everywhere.
performance against • Measuring allows us to find out what is happening.
the goal. • Measurement will help us to improve the way we meet our
performance.
ME Right-First-Time Template
TRAFFIC LIGHT SYSTEM
Introduction of Traffic Light System

Main issues that Objectives &

impact in-line Benefits
•Part of visual management which easy
quality for anyone at a glance to be able to
•Workmanship establish the quality issue.
•Dirty material/product •Formal/structured approach to in-line
•Machine settings/poor maintenance quality control.
•Defective materials •Problems are detected earlier with quick
response.

15
Traffic Light System Criteria

Quality standard is achieved

A minor fault is found and caution is

required

Quality standard is not achieved

16
Sequence of Movement Through Quality Levels
G
No
Action
Sample of Defect? taken
5
No
Yes
Minor >1 Minor No No Defect
defect?
Yes
defect? Y Sample of
5 ?

No Yes defect Yes

Sample of
5 ?

Yes
Action
taken

R
Immediate Actions

 When a fault is detected, the inline QC will alter the colored display cards to the relevant
status.

 .
The Line Supervisor will be informed whenever product falls outside the customers standard

 The fault will be entered on the defect record and must be signed by the line Supervisor.

 The Supervisor will take prompt action to correct the issue without delay.


A representative from the quality department will audit defective product prior to signing
clear for production.

18
18
Resource Required

Tight Control Requirement Ratio

Applicable to manufactures
that have poor end of line 1 QC for each 24 Sewers.
quality performance. Enables in-line QC’s to
carry out a minimum of 2
audits per-day per operator.
Can be adjusted, depends
on the sewing lines/groups
quality performance.

19
SELF-INSPECTION
3 DON’Ts

Don’t MAKE Don’t PASS Don’t ACCEPT

defect parts defect parts defect parts
Objectives


The inspection is carried our by the operator to ensure responsibility for their own
work & quality. Defects should be corrected immediately instead of being passed
down the production line.

 The main responsibility for quality inspection is done in-line by workers, because as
they handle a part they will subconsciously inspect it by sight and by touch.

 Operators are made to be more responsible for quality of their work..

 The cost of independent QC can be reduced and the role is minimized.

THANK
YOU
 Revision
Document Modification Record
Revision Date Versions Revision Content Revised by

2014-1-12 V 1.0 New build Bono

2017-12 V 2.0 New format Rina