Development Pre-production Production Post-production Distribution.
1.1.1_RQC Pre-Production Section
Transcript of 1.1.1_RQC Pre-Production Section
©Triumph
Roving Quality Control System
(Pre-Production Section)
JANUARY 2010
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PREPREPREPRE----PRODUCTION ROVING QC ROLLPRODUCTION ROVING QC ROLLPRODUCTION ROVING QC ROLLPRODUCTION ROVING QC ROLL----OUT IMPLEMENTATIONOUT IMPLEMENTATIONOUT IMPLEMENTATIONOUT IMPLEMENTATION
Wk 1 Wk 2 Wk 3 Wk 4 Wk 5 Wk 6 Wk7 Wk 8 Wk 9 Wk 10 Wk 11 Wk 12
Spreading
Moulding
Cutting
Bow Lace
TRAINING WEEKTRAINING WEEKTRAINING WEEKTRAINING WEEK
1st Day: Orientation of Supervisors (PPSV, QSV, RQC)
2nd Day: Introduction to Pre-Production Operators
Observation/Practice/Familiarisation of RQC
MONTHLY EVALUATIONMONTHLY EVALUATIONMONTHLY EVALUATIONMONTHLY EVALUATION
Consolidation of Rejects recorded in the Roving QC Weekly Analysis
ACTUAL IMPLEMENTATION & CONTINUOUS MONITORINGACTUAL IMPLEMENTATION & CONTINUOUS MONITORINGACTUAL IMPLEMENTATION & CONTINUOUS MONITORINGACTUAL IMPLEMENTATION & CONTINUOUS MONITORING
Triumph Roving QC Weekly Analysis
Roving QC Weekly Summary Report
No W
ork
No W
ork
No W
ork
No W
ork
JANUARYJANUARYJANUARYJANUARY FEBRUARYFEBRUARYFEBRUARYFEBRUARY MARCHMARCHMARCHMARCHAREAAREAAREAAREA
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What tools are needed by the Roving QC?
Roving QC Daily SheetGreen & Red
highlighters
Roving QC Daily
Sheet
Clipboard
Pencil
Approved Pattern,
Standards, &
Specifications
A good eye !!!!!!!!
CUTTING INSTRUCTION SHEET
CUTTING INSTRUCTION SHEET
MOULDING SPECIRICATION
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What do we need at the Pre-Production ?
OPERATORDAILYSHEET
OPERATORDAILYSHEET
Green cone Red cone
Operators Daily Sheet
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How will the Roving QC be implemented in the Pre-Production Section?
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TRIUMPH ROVING QUALITY CONTROL - WORK INSTRUCTION
(PRE-PRODUCTION)
Equipment: Pencil
Highlighters – Green & Red
Report: <OPERATOR DAILY SHEET>
<ROVING QC DAILY SHEET>
Frequency: As Required
Related Parties: Roving QC, Pre-Production Supervisor, Pre-Production Section
Chief, Pre-Production Assistant, Quality Control Supervisor,
Production Manager
METHOD:
1. At the start of each day, the Roving QC refers to the QC Supervisor to determine
what defects are frequently encountered and in need of close attention.
2. The Roving QC should visit operators as stated for every areas concerned.
3. On the <OPERATOR DAILY SHEET>, the RQC enters “Month”, “Area”, and
“Operator”. On the <ROVING QC DAILY SHEET>, the RQC enters “Date”,
“Day”, “Area”, and “Quality Supervisor”
4. Roving QC randomly selects samples (number of samples as stated for every
Areas concerned) and checks the work against the Required Specification &
Quality Standards for each area. According to the classification of faults found
(MINOR or MAJOR), Roving QC follows Steps 5, 6, or 7.
5. If NO FAULT is found:
5.1 Roving QC returns the inspected samples to the operator to continue with the
operation.
5.2 Roving QC fills in the appropriate space on the <OPERATOR DAILY
SHEET> with Green highlighter.
5.3 Roving QC fills in each column on the <ROVING QC DAILY SHEET>:
“Operation” (abbreviation or code), “Operator”, “Quantity Inspected”,
“Result” (check mark)
5.4 Roving QC raises the green cone at the work station and moves on to the next
operator.
6. If MINOR FAULTS are found: (a minor fault can be defined as a fault that if not
given due monitoring, may later on becomes MAJOR fault).
6.1 Roving QC returns the defective pieces to the Operator.
6.1.1 For Spreading – Roving QC indicates the defect found in the marker to
serve as warning for the Cutting – Quality Supervisor, Operator, Pre-
Production
6.2 Roving QC fills in the appropriate space on the <OPERATOR DAILY
SHEET> with Green highlighter. Enters relevant defect code and quantity
(e.g., 2/MD) and signs it off. Pre-Production Supervisor also signs off.
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1.1 Roving QC fills in each column on the <ROVING QC DAILY SHEET>:
“Operation” – abbreviation or code, “Style Number”, “Operator”, “Quantity
Inspected”, “Result” – X, “Defect Qty/Code”, and “Remarks”.
1.2 Roving QC raises the Green cone at the work station and moves on to the
next Operator.
2. If MAJOR FAULTS are found: (a major fault can be defined as a fault that will
definitely result in rejection by the customer and likely return).
2.1 Roving QC instantly informs the Pre-Production Supervisor to come to the
operation to determine how to handle the defects and request the operator not
to proceed with the operation unless the problem is resolved.
2.2 Roving QC fills in the appropriate space on the <OPERATOR DAILY
SHEET> with Red highlighter and enters the relevant defect code and
quantity (e.g., 2/MD) and signs it off. Pre-Production Supervisor and Quality
Supervisor also signs off.
2.3 Roving QC fills in each column on the <ROVING QC DAILY SHEET>:
“Operation” – abbreviation or code, “Style”, “Operator”, “Quantity
Inspected”, “Result” – X, “Defect Qty/Code”, and “Remarks”.
2.4 Roving QC raises the Red cone at the work station and moves on to the next
operator.
2.5 After the operator had finished checking and repairing, Pre-Production
Supervisor calls on the Roving QC back to the operator.
2.6 Roving QC should follow Step 4.
2.7 If no fault is found, follow Step 5. If minor faults are found, follow Step 6. If
major faults are still found, proceed as follows:
2.8 Roving QC requests the Pre-Production Supervisor to STOP the operator.
This time Pre-Production Supervisor should inform the Pre-Production
Section Chief. Both Pre-Production Supervisor and Pre-Production Section
Chief will decide how to handle and solve the problem.
2.9 Roving QC fills in the appropriate space on the <OPERATOR DAILY
SHEET> with Red highlighter and enters the relevant defect code and
quantity (e.g., 4/MD) and signs it off.
2.10 Pre-Production Supervisor and Pre-Production Section Chief sign off on
the <OPERATOR DAILY SHEET>.
2.11 Roving QC fills in the column “Follow-Up” on the <ROVING QC
DAILY SHEET>, enter the relevant defect code and quantity
2.12 Roving QC keeps the Red cone at the work station and moves on to the
next operator.
2.13 Roving QC must ensure to check the Operator again after 2 consecutive
“Reds”.
2.14 Operator will only be allowed to continue with the operation if the Red
cone is immediately replaced by Green cone.
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No. of Samples to be Inspected1) SPREADING
Roving QC Cutting should check ALL finished laid markers/fabric for the day, plus (+) 15 markers (during process of spreading).
2) LAMINATION
Roving QC checks 10% of every commission (on roll form) & 7pieces/bundle (on panel form).
3) CUTTING – BANDKNIFE/DYE-CUT
Roving QC should check all parts in a lay (top, middle, and bottom) regardless of size. Check should be made at least twice a day per operator/shift.
4) CUTTING – BOW LACE
Roving QC should check all parts in a lay (top, middle, and bottom) regardless of size. Check should be made at least twice a day per operator/shift.
5) CUTTING – MOULDED CUPS
Roving QC should check one operator twice per day/shift, 7pcs per bundle (top, middle, & bottom)
6) MOULDING
7pcs/bundle (top-middle-bottom), at least twice a day per operator/shift.
7) FUSING/BONDING
Minimum 10% of every commission, covering all sizes.
8) HEATSEAL
7pcs/bundle, at least twice a day per operator/shift.
9) LABEL PRINTING
Roving QC checks 10% per bundle or box at least twice a day per operator/shift.
10) LABEL PRINTING ON EYE TAPE
RQC checks 10% per bundle at least twice a day per operator/shift.
11) SHOULDER STRAP SEWING
Roving QC should check 7pairs per bundle at least twice a day per operator/shift.
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What are the Classification of Defects?
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A SF1 No. of Layers not According to Spec. A MD1 Unbalanced Drawing
A SF2 Missing Separator for Different Shades A MD2 Colour Change After Moulding
A SF3 Wrong Spreading Method A MD3 Loose Diameter/Cup Deepness/ShrinkageA SF4 Wrong Placement of Marker A MD4 Wrinkles/Puckered/Creased
A SF5 Faulty Blocking A MD5 Stain/Foreign Material/Contamination
A SF6 Incomplete Size/Size not in Set A MD6 Wrong Cutting Line
A SF7 Material Not Flat/Uneven A MD7 Wrong Kegel Used
A SF8 Wrong Material A MD8 Mould Mark (Ring Mark)
A MD9 Distorted/Displaced Bustpoint
A MD10 Too High Temperature (Fabric Became Brittle)
A CT1 Nicks too deep B MDPA1 Missing No. of LayersB CT2 Uneven Cutting Edge A MDPA2 Wrong Size
A CT3 Out of Cutting Allowance
B CT4 Fused Cutting Edge BD - BONDING FAULTSA CT5 Cutwork not According to Pattern A BD1 Delamination
A CT6 Wrong Dye-Cut Used A BD2 Bubbles/Wrinkles
B CT7 Missing Nick/Missing UV Mark A BD3 Incorrect Face Side
A CT8 Wrong Cutting Line A BD4 Colour change after bonding
A CT9 Wrong Size A BD5 Non-symmetrical (if in pairs)
A CT10 Folded Fabric
HS - HEATSEAL FAULTS
A HS1 Delamination/Peeling Off
A BF1 Width Variation & Repeat Length A HS2 Incorrect Placement
A BF2 Wrong Placement of Pattern/One-Way Lay A HS3 Incorrect for Colour
B BF3 Missing Ultraviolet Pen for Nicks/ A HS4 Damage on motif Missing Number of Layers A HS5 Discolouration after heat pressing
B BF4 Uneven Pinning of Materials B HS6 Misplacement of 1-2mm (motif)
B BF5 Layers too high/
Excessive Bundles (too many) SHOULDER STRAP FAULTS -
A BF6 Incorrect Material A SS1 Wrong Width/LengthA BF7 Folded Lace A SS2 Wrong Direction (for patterned straps)
A SS3 Incorrect Material Used (Size & Colour)
A SS4 Elongation (Too Much/Too Little)A RM1 Shade Variation B SS5 Uneven Cut Edge
A RM2 Scattered Blue/Black Dots, Stain, B SS6 Missing Nick/Missing UV Mark
Glue Spot A SS7 Stitch Density Too Tight/Loose
A RM3 Width Variation/Short Width/ A SS8 Sharp Edge After Sewing
Shrinkage/Repeat Length A SS9 Too Wavy/CurvedA RM4 Hole/Joining/Run Line/Crease Mark/ A SS10 Cracking Stitch
Warp Line/Weft Line/Folded Mark/ A SS11 Incorrect Stitch Used
Snags/Fluffs/Moiree or Water Marks A SS12 Style/Colour Mix-Up
A SS13 Incorrect Bundle Quantity
LM - LAMINATION FAULTS
A LM1 Delamination LB - LABEL PRINTING FAULTA LM2 Wrong Material Used A LB1 Unclear Print (Unreadable)
A LM3 Bubbles/Wrinkles A LB2 Smudged Print/Stain/Ink
A LM4 Incorrect Face Side A LB3 Incorrect Details
A LM5 Foreign Material Inside the Laminated Fabric A LB4 Missing Letters/Details
A LM6 Handfeel Too Hard/Harsh A LB5 Incorrect Materials UsedA LM7 Uneven Edges A LB6 Print is Peeling-Off
A LB7 Incorrect Placement
A LB8 Mix-Up - style/size/colour
B LB9 Slight stain/smudge
MD - MOULDING FAULTS
Fault Type: A - Major; B - Minor
CLASSIFICATION OF DEFECTS - PRE-PRODUCTION
RM - RAW MATERIAL FAULTS
SF - SPREADING FAULTS
BK - BANDKNIFE FAULTS/DYE-CUT
BF - BOWLACE FAULTS
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How will the RQC Pre-Production System Work?
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EquipmentEquipmentEquipmentEquipment: Pencil, Highlighter (Green& Red)
Frequency:Frequency:Frequency:Frequency: As Required
<Operator Daily Sheet>Operator Daily Sheet>Operator Daily Sheet>Operator Daily Sheet> - Enter ‘Month’, ‘Area’,‘Operator’
<Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet>- Enter‘Date’, ‘Area’, ‘RQC’, QC Supervisor
Check markers during processCheck markers during processCheck markers during processCheck markers during processof spreadingof spreadingof spreadingof spreading
DEFECT
Inform the spreader to continue
In the Operator Daily Sheet,Operator Daily Sheet,Operator Daily Sheet,Operator Daily Sheet, colorthe appropriate cell in Green
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill theresult in relevant column (√)
Raise the Green cone
Move onto the next table
Inform the Pre-Prod Supervisorof the defect found
In the Operator Daily SheetOperator Daily SheetOperator Daily SheetOperator Daily Sheet, color the appropriate cell in Red & indicatethe nature of defect (e.g. SF3). Pre-Prod Supervisor & RQC signs off.
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill the result in relevant column (x)
Raise the Red cone
Move onto the next table
Pre-Prod Supervisor checks thelay-out & instruct the spreader to
re-layout
Pre-Prod Supervisor re-checks there-laid out fabric/ace and ask
the RQC to check again
Instantly inform the Pre-Prod Supervisor of the defect found
In the Operator Daily SheetOperator Daily SheetOperator Daily SheetOperator Daily Sheet, color the appropriate cell in Red & indicatethe nature of defect (e.g. RM3). Pre-Prod Supervisor & RQC signs off.
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill the result in relevant column (x)
Raise the Red cone & move on to the next table
Pre-Prod Supervisor checks theDefects found & inform ProductionSection Chief & QC Supervisor
Defect within Tolerance (by QA Manager)
Pre-Prod Supervisor instructs thespreader not to continue, re-roll the
fabric & lay another marker
Pre-Prod Supervisor calls the RQCand inform the result
In the Operator Daily SheetOperator Daily SheetOperator Daily SheetOperator Daily Sheet, colorthe appropriate cell in Green
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill theresult in relevant column(√)& indicate “return fabric”
Pre-Prod Supervisor calls theRQC and inform the result
Inform the spreader to continue
RQC indicates in the marker defectfound to alert RQC in Cutting
In the Operator Daily SheetOperator Daily SheetOperator Daily SheetOperator Daily Sheet, colorthe appropriate cell in Green
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill theresult in relevant column (√)
Raise the Green cone
Move onto the next table
NO DEFECTNO DEFECTNO DEFECTNO DEFECT MAJOR FAULTMAJOR FAULTMAJOR FAULTMAJOR FAULT RAW MATERIAL FAULTRAW MATERIAL FAULTRAW MATERIAL FAULTRAW MATERIAL FAULT
NONONONO YESYESYESYES
ROVING QC PROCEDUREIN SPREADING (A)
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Checks ALL finished Checks ALL finished Checks ALL finished Checks ALL finished laid markers/fabriclaid markers/fabriclaid markers/fabriclaid markers/fabric
DEFECT
In the OperatorOperatorOperatorOperatorDaily SheetDaily SheetDaily SheetDaily Sheet, colorthe appropriate cell in Green
In Roving QC DailyRoving QC DailyRoving QC DailyRoving QC DailySheetSheetSheetSheet, fill the resultin relevant column
(√)
NO DEFECTNO DEFECTNO DEFECTNO DEFECT
Instantly inform the CuttingSupervisor of the defect found
In the Operator Daily SheetOperator Daily SheetOperator Daily SheetOperator Daily Sheet, color theappropriate cell in Red and indicate the nature of defect (e.g. RM1). Pre-Prod
Supervisor & RQC signs off.
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill theresult in relevant column (x)
Raise the Red cone and move onto the next table
Cutting Supervisor checks the defects foundand inform Cutting Section Chief & QC Supervisor
Defect WithinTolerance (By QA
Manager)
Cutting Supervisor calls the RQC & inform the result
RQC indicates in the markerdefect found to warn RQC in cutting
In the Operator Daily SheetOperator Daily SheetOperator Daily SheetOperator Daily Sheet color theappropriate cell in Green
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet fill theresult in relevant column (√)
Cutting Supervisor instructthe spreader to stop,
re-roll the fabric & lay another marker.
Cutting Supervisor calls theRQC and inform the result
In the Operators Daily SheetOperators Daily SheetOperators Daily SheetOperators Daily Sheet,color the appropriate cell in Green
In the Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fillthe result in relevant column &
indicate “return fabric”
Inform the Cutting Supervisor of the defect found
In the Operator Daily SheetOperator Daily SheetOperator Daily SheetOperator Daily Sheet, colorthe appropriate cell in Red &
indicate the nature of defect (e.g.SF3). Cutting Supervisor & RQC
signs off.
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill theresult in relevant column (x)
Raise the Red cone
Move on to the next table
Cutting Supervisor checks thelayout & instruct the spreader
to re-layout
Cutting Supervisor re-checks the re-laid out & ask the RQC
to check again
Raise the Green cone
Inform the spreader to proceed with blocking
Inform the Cutting Supervisorof the defect found
Cutting Sup instructs the spreader to remove the affected part (size/pattern), re-lay another fabric for the particular size affected
In the Operator Daily SheetOperator Daily SheetOperator Daily SheetOperator Daily Sheet, indicate the defect code, colorthe appropriate cell in Red. Pre-Prod Sup & RQC signs off.
In the Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill the result in relevant column (x)
RAW MATERIAL FAULTRAW MATERIAL FAULTRAW MATERIAL FAULTRAW MATERIAL FAULT MAJOR FAULTMAJOR FAULTMAJOR FAULTMAJOR FAULT
YESYESYESYES NONONONO
DEFECT
Raise the Red cone
Move onto the next table
Pre-Prod Supervisor checks the re-laid fabric & ask theRQC to check again
In the Operator Daily Sheet,Operator Daily Sheet,Operator Daily Sheet,Operator Daily Sheet, color theappropriate cell in Green
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill the resultin relevant column (√)
Raise the Green cone
Move to the next table
NONONONO WITH DEFECTWITH DEFECTWITH DEFECTWITH DEFECT
Raise the Green cone
Move to the next table
ROVING QC PROCEDURE
IN SPREADING (B)
Inform the Spreader to lay nextmarker
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EquipmentEquipmentEquipmentEquipment: Pencil, Highlighter (Green& Red)
Frequency:Frequency:Frequency:Frequency: As Required
<Operator Daily Sheet>Operator Daily Sheet>Operator Daily Sheet>Operator Daily Sheet> - Enter ‘Month’, ‘Area’,‘Operator’
<Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet>- Enter‘Date’, ‘Area’, ‘RQC’, QC Supervisor
Review approved/correct pattern, cutting specification, & any other points agreed in PP Meeting
ALL PARTS/ALL SIZES ALL PARTS/ALL SIZES ALL PARTS/ALL SIZES ALL PARTS/ALL SIZES FOR NEW STYLES MUST FOR NEW STYLES MUST FOR NEW STYLES MUST FOR NEW STYLES MUST
BE CHECKEDBE CHECKEDBE CHECKEDBE CHECKED
Check cut panels for measurement & balance. Check top, middle, & bottom ply against the approved pattern.
DEFECT
In the ODSODSODSODS, colorthe appropriate cell in Green
In Roving QC DailyRoving QC DailyRoving QC DailyRoving QC DailySheetSheetSheetSheet, fill the resultin relevant column
(√)
Move onto the next operator
NO NO NO NO DEFECTDEFECTDEFECTDEFECT
Raise the Green cone
Return the defective pieces back tothe Operator for repair
MINORMINORMINORMINOR
In the ODSODSODSODS, enter the relevantdefect code (e.g.CT2/1). Color the appropriate cell in Green and sign
it off
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fillthe result in relevant column (x)
Return the cut panelsback into the bundle
RQC instantly inform & return the defective pieces
to Cutting Supervisor
Cutting Supervisor shoulddetermine how to handlethe defect & ask theOperator to check the
whole bundle
In the ODSODSODSODS, color the appropriate cell inRed and indicate the nature of defect (e.g. CT1/1). Cutting Supervisor & RQC
signs off.
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill the result in relevant column (x)
Raise the Red cone and move onto the next table
If the defect can be repaired, CuttingSupervisor will call the RQC back as soonas the Operator is finished with the repair.
If the defect cannot be repaired, Cutting Supwill ask the Operator to cut another lay, check the cut pieces, then call the RQC to
check the new cutworks.
At the start of each day, refer to the QC Supervisor for styles/cutworks in need of special attention
RAW MATERIAL FAULTRAW MATERIAL FAULTRAW MATERIAL FAULTRAW MATERIAL FAULT MAJOR FAULTMAJOR FAULTMAJOR FAULTMAJOR FAULT
RQC instantly inform & return the defective pieces to Cutting Supervisor
Cutting Supervisor should determine howto handle the defect & ask the Operator
to check the whole bundle
In the ODSODSODSODS, color the appropriate cell in Red and indicate the nature of defect
(e.g. RM4/1). Cutting Supervisor & RQC signs off.
In RQCRQCRQCRQC----Daily SheetDaily SheetDaily SheetDaily Sheet, fill the result in relevant column (x)
Raise the Red cone and move onto the next table
Defect WithinTolerance
(by QA Manager)
NONONONO
Cutting Sup instructs the Cutter not to continue & cut another lay
Cutting Supervisor calls theRQC and inform the result
In the ODSODSODSODS, color the appropriate cell in Green
In the Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fillthe result in relevant column &
indicate “return fabric”
Cutting Supervisor calls the RQC & inform the result
Inform the Cutter to continue
RQC indicates in the panels defectfound to alert RQC in Sewing
In the ODSODSODSODS, color the appropriate cell in Green
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill theresult in relevant column (√)
YESYESYESYES
Raise the Green cone & move onto the next Cutter
ROVING QC PROCEDURE IN FABRIC, DIE-CUT, & BOWLACE CUTTING
Cutting Supervisor re-checks the new cutwork & ask the RQC
to check again
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EquipmentEquipmentEquipmentEquipment: Pencil, Highlighter (Green& Red)
Frequency:Frequency:Frequency:Frequency: As Required
MOULDING
<Operator Daily Sheet>Operator Daily Sheet>Operator Daily Sheet>Operator Daily Sheet> - Enter ‘Month’, ‘Area’,‘Operator’
<Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet>- Enter‘Date’, ‘Area’, ‘RQC’, QC Supervisor
At the start of each day, refer to the QC Supervisor for cups in need of special attention
Review approved/correct plastic shot, moulding specification, approved standard, or any other points agreed in PP Meeting
Check top, middle, & bottom of the bundle against the approved plastic shot/standardALL SIZES FOR NEW ALL SIZES FOR NEW ALL SIZES FOR NEW ALL SIZES FOR NEW STYLE and COLOUR MUST STYLE and COLOUR MUST STYLE and COLOUR MUST STYLE and COLOUR MUST
BE CHECKEDBE CHECKEDBE CHECKEDBE CHECKED
DEFECT
Return the moulded cupsback into the bundle
NO NO NO NO DEFECTDEFECTDEFECTDEFECT
In the ODSODSODSODS, color the appropriatecell in Green
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill the result in relevant column (√)
RAW MATERIAL DEFECTRAW MATERIAL DEFECTRAW MATERIAL DEFECTRAW MATERIAL DEFECT
RQC instantly inform & return the defective pieces to Moulding Supervisor
Moulding Supervisor should determine how to handle the defect & ask the Operator to check
the whole bundle & sort the defect out.
In the ODSODSODSODS, color the appropriate cell in Redand indicate the nature of defect (e.g. MD2/5).
Moulding Supervisor & RQC signs off.
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill the result in relevant column (x)
Raise the Red cone and move onto the next table
Moulding Supervisor ask the Operatorto stop & mould another bundle.
Defect WithinTolerance
(by QA Manager)
Moulding Supervisor calls theRQC and inform the result
In the Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill the result in relevant column & indicate “replaced cups””
Inform the Moulder to continue
RQC indicates in the panels defectfound to alert QC in succeeding check
In the ODSODSODSODS, color the appropriate cell in Green
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill theresult in relevant column (√)
NONONONO YESYESYESYES
Move onto the next operator
Moulding Supervisor calls theRQC and inform the result
Raise the Green cone & move onto the next Cutter
In the ODSODSODSODS, color the appropriate cell in Green
Moulding Supervisor re-checks the new work & ask the RQC
to check again
RQC instantly inform & return the defective piecesto Moulding Supervisor
Moulding Supervisor should determine how to handle the defect & ask the Operator to check the
whole bundle & sort out.
In the ODSODSODSODS, color the appropriate cell in Red and indicate the natureof defect (e.g. MD1/1). MouldingSupervisor & RQC signs off.
In RQCRQCRQCRQC----Daily SheetDaily SheetDaily SheetDaily Sheet, fill the result in relevant column (x)
Raise the Red cone and moveon to the next operator
Moulding Supervisor willask the Operator to mould another bundle, check the finished piece, then call the RQC to check
the new works.
MAJORMAJORMAJORMAJOR
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Equipment: Pencil, Highlighter (Green& Red)
Frequency: As Required
<Operator Daily Sheet>Operator Daily Sheet>Operator Daily Sheet>Operator Daily Sheet> - Enter ‘Month’, ‘Area’,‘Operator’
<Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet>- Enter‘Date’, ‘Area’, ‘RQC’, QC Supervisor
At the start of each day, refer to the QC Supervisor for laminated works in need of special attention
Review approved standard, lamination/bonding specification, and any other points agreed in PP Meeting
Check 7pcs/bundle or 10%/roll of laminated fabric
LAMINATION/BONDING
DEFECTNO NO NO NO
DEFECTDEFECTDEFECTDEFECT RAW MATERIAL DEFECTRAW MATERIAL DEFECTRAW MATERIAL DEFECTRAW MATERIAL DEFECT
Return the laminatedpanels back into the bundle
In the ODSODSODSODS, color the appropriatecell in Green
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill the result in relevant column (√)
RQC instantly inform & return the defective pieces to Lamination Supervisor
Lamination Supervisor should determine how to handle the defect & ask the Operator to check
the whole bundle & sort the defect out.
In the ODSODSODSODS, color the appropriate cell in Redand indicate the nature of defect (e.g. LM1/1 ).
Lamination Supervisor & RQC signs off.
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill the result in relevant column (x)
Raise the Red cone and move onto the next operator
Defect WithinTolerance
(by QA Manager)
Lam/Bond Supervisor ask the Operator To stop & process another bundle/roll
In the Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill the result in relevant column & indicate “replaced panel”
Lamination Supervisor calls theRQC and inform the result
Inform the operator to continue
RQC indicates in the panels defectfound to alert QC in succeeding check
In the ODSODSODSODS, color the appropriate cell in Green
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill theresult in relevant column (√)
NO NO NO NO YESYESYESYES
PLEASE REFER TO THE RAWPLEASE REFER TO THE RAWPLEASE REFER TO THE RAWPLEASE REFER TO THE RAWMATERIAL GLOBAL QUALITYMATERIAL GLOBAL QUALITYMATERIAL GLOBAL QUALITYMATERIAL GLOBAL QUALITY
MANUAL (JAN ’10) FOR TESTING MANUAL (JAN ’10) FOR TESTING MANUAL (JAN ’10) FOR TESTING MANUAL (JAN ’10) FOR TESTING REQUIREMENT BEFORE START REQUIREMENT BEFORE START REQUIREMENT BEFORE START REQUIREMENT BEFORE START
OF BULK PRODUCTIONOF BULK PRODUCTIONOF BULK PRODUCTIONOF BULK PRODUCTION
Move onto the next operator
Raise the Green cone & move onto the next Operator
RQC instantly inform & returnthe defective pieces to Lami-nation/Bonding Supervisor
Lam/Bonding Sup should determinehow to handle the defect & ask the Operator to check the whole bundle
In the ODSODSODSODS, color the appropriate cell in Red and indicate the natureof defect (e.g. LM1/1). Lam/Bonding
Supervisor & RQC signs off.
MAJORMAJORMAJORMAJOR
In RQCRQCRQCRQC----Daily SheetDaily SheetDaily SheetDaily Sheet, fill the result in relevant column (x)
Raise the Red cone and move onto the next operator
Heatseal Supervisor will ask the Operator to heat press another bundle, check the finished piece, then call the
RQC to check the new works.
Lam/Bond Supervisor calls theRQC and inform the result
Lam/Bond Supervisor re-checks the new work & ask the RQC
to check the new works
In the ODSODSODSODS, color the appropriate cell in Green
©Triumph
HEATSEAL(RHINESTONES,
RUBBERISED MOTIF, & DIAMONTES)
Equipment: Pencil, Highlighter (Green& Red)
Frequency: As Required
<Operator Daily Sheet>Operator Daily Sheet>Operator Daily Sheet>Operator Daily Sheet> - Enter ‘Month’, ‘Area’,‘Operator’
<Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet>- Enter‘Date’, ‘Area’, ‘RQC’, QC Supervisor
Review approved sample, heatseal parameters on A/D, correct placement, and any other points agreed in PP Meeting
Check 7pcs/bundle or 10% per commission
DEFECT
Return the piecesback into the bundle
In the ODSODSODSODS, color the appropriatecell in Green
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill the result in relevant column (√)
MINORMINORMINORMINORNO NO NO NO
DEFECTDEFECTDEFECTDEFECT
Return the defective pieces back tothe Operator for his/her info
In the ODSODSODSODS, enter the relevantdefect code (e.g.HS5/1). Color the appropriate cell in Green and sign
it off
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fillthe result in relevant column (x)
Raise the Green cone
Move onto the next operator
RAW MATERIAL FAULT RAW MATERIAL FAULT RAW MATERIAL FAULT RAW MATERIAL FAULT
RQC instantly inform & return the defective pieces to Heatseal Supervisor
Heatseal Supervisor should determine how to handlethe defect & ask the Operator to check the whole bundle
In the ODSODSODSODS, color the appropriate cell in Red and indicate the nature of defect (e.g. HS1/1).
Heatseal Supervisor & RQC signs off.
In RQCRQCRQCRQC----Daily SheetDaily SheetDaily SheetDaily Sheet, fill the result in relevant column (x)
Raise the Red cone and move onto the next operator
Defect WithinTolerance
(by QA Manager)
Heatseal Supervisor instructthe operator to stop & do
another bundle
Heatseal Supervisor calls theRQC and inform the result
In the ODSODSODSODS, color the appropriate cell in Green
In the Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fillthe result in relevant column &indicate “replaced panels”
Heatseal Supervisor calls the RQC & inform the result
Inform the Operator to continue
RQC indicates in the panels defectfound to alert RQC in Sewing
In the ODSODSODSODS, color the appropriate cell in Green
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill theresult in relevant column (√)
NONONONO YESYESYESYES
Heatseal Supervisor re-checks the new work & ask the RQC
to check again
Raise the Green cone & move onto the next Cutter/Sewer
RQC instantly inform & return the defective piecesto Heatseal Supervisor
Heatseal Supervisor should determinehow to handle the defect & ask the Operator to check the whole bundle
In the ODSODSODSODS, color the appropriate cell in Red and indicate the natureof defect (e.g. HS1/1). HeatsealSupervisor & RQC signs off.
In RQCRQCRQCRQC----Daily SheetDaily SheetDaily SheetDaily Sheet, fill the result in relevant column (x)
Raise the Red cone and move onto the next operator
Heatseal Supervisor will ask the Operator to heat press another bundle, check the finished piece, then call the
RQC to check the new works.
MAJORMAJORMAJORMAJOR
©Triumph
SHOULDERSTRAP CUTTING/SEWING
Equipment: Pencil, Highlighter (Green& Red)
Frequency: As Required
<Operator Daily Sheet>Operator Daily Sheet>Operator Daily Sheet>Operator Daily Sheet> - Enter ‘Month’, ‘Area’,‘Operator’
<Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet>- Enter‘Date’, ‘Area’, ‘RQC’, QC Supervisor
At the start of each day, refer to the QC Supervisor for styles/straps in need of special attention
Review approved sample, A/D specification - length, material number, & width plus any other points agreed in PP Meeting
Check cut/sewn straps for measurement, appearance, balance, &elongation. Check 7pairs per bundle
DEFECT
NO NO NO NO DEFECTDEFECTDEFECTDEFECT MINORMINORMINORMINOR
RAW MATERIAL FAULTRAW MATERIAL FAULTRAW MATERIAL FAULTRAW MATERIAL FAULT MAJOR FAULTMAJOR FAULTMAJOR FAULTMAJOR FAULT
Return the sewn/cut straps back into the
bundle
In the ODSODSODSODS, colorthe appropriate cell in Green
In Roving QC DailyRoving QC DailyRoving QC DailyRoving QC DailySheetSheetSheetSheet, fill the resultin relevant column
(√)
Return the defective pieces back tothe Operator for repair
In the ODSODSODSODS, enter the relevantdefect code (e.g.SS6/1). Color the appropriate cell in Green and sign
it off
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fillthe result in relevant column (x)
Raise the Green cone
Move onto the next operator
RQC instantly inform & return the defective pieces to S/S Supervisor
S/S Supervisor should determine howto handle the defect & ask the Operatorto check the whole bundle & sort out
In the ODSODSODSODS, color the appropriate cell in Red and indicate the nature of defect (e.g. RM3/1). S/S Supervisor & RQC
signs off.
In RQCRQCRQCRQC----Daily SheetDaily SheetDaily SheetDaily Sheet, fill the result in relevant column (x)
Raise the Red cone and move onto the next table
Defect WithinTolerance
(by QA Manager)
S/S Supervisor instructthe operator to stop & arrange for 100% check on all WIP
S/S Supervisor calls theRQC and inform the result
In the ODSODSODSODS, color the appropriate cell in Green
In the Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fillthe result in relevant column &indicate “return elastic/straps”
S/S Supervisor calls the RQC & inform the result
Inform the Cutter/Sewer to continue
RQC indicates in the straps defectfound to alert RQC in Sewing
In the ODSODSODSODS, color the appropriate cell in Green
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill theresult in relevant column (√)
Raise the Green cone & move onto the next Cutter/Sewer
NONONONO YESYESYESYES
RQC instantly inform & return the defective pieces
to S/S Supervisor
S/S Supervisor should determine how tohandle the defect & ask the Operator to
check the whole bundle & repair
In the ODSODSODSODS, color the appropriate cell inRed and indicate the nature of defect (e.g. M1/1). S/S Supervisor & RQC
signs off.
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill the result in relevant column (x)
Raise the Red cone and move onto the next table
If the defect can be repaired, S/SSupervisor will call the RQC back assoon as the Operator finished the
repair.
If the defect cannot be repaired, S/S Supervisor will ask the Operator to Cut/sew another lay, check the cut/sewn
pieces, then call the RQC tocheck the new cutworks.
©Triumph
LABEL PRINTING/LABEL PRINTED DIRECTLY ON
THE GARMENT
Equipment: Pencil, Highlighter (Green& Red)
Frequency: As Required
<Operator Daily Sheet>Operator Daily Sheet>Operator Daily Sheet>Operator Daily Sheet> - Enter ‘Month’, ‘Area’,‘Operator’
<Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet>- Enter‘Date’, ‘Area’, ‘RQC’, QC Supervisor
At the start of each day, refer to the QC Supervisor for labels in need of special attention
Review required information to be printed on labels from the approved document provided for printing
Check 10% per commission covering all sizes
Return the piecesback into the bundle
In the ODSODSODSODS, color the appropriate cell in Green
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill the result in relevant column (√)
Return the defective pieces back tothe Operator for his/her info
In the ODSODSODSODS, enter the relevantdefect code (e.g.LBL9/1). Color the appropriate cell in Green and sign
it off
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fillthe result in relevant column (x)
DEFECT
RQC instantly inform & return the defective pieces to Label Supervisor
Label Supervisor should determine howto handle the defect & ask the Operatorto check the whole bundle & sort out
In the ODSODSODSODS, color the appropriate cell in Red and indicate the nature of defect (e.g. RM4/1). Label Supervisor & RQC
signs off.
In RQCRQCRQCRQC----Daily SheetDaily SheetDaily SheetDaily Sheet, fill the result in relevant column (x)
Raise the Red cone and move onto the next Operator
NO NO NO NO DEFECTDEFECTDEFECTDEFECT MINORMINORMINORMINOR
Raise the Green cone
Move onto the next operator
RAW MATERIAL FAULTRAW MATERIAL FAULTRAW MATERIAL FAULTRAW MATERIAL FAULT
Defect WithinTolerance
(by QA Manager)
Label Supervisor instructthe operator to stop & arrange
to 100% check all WIP
Label Supervisor calls theRQC and inform the result
In the ODSODSODSODS, color the appropriate cell in Green
In the Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fillthe result in relevant column &
indicate “return labels”
Raise the Green cone & move onto the next Operator
Label Supervisor calls the RQC & inform the result
Inform the Operator to continue
RQC indicates in the labels defectfound to alert RQC in Sewing
In the ODSODSODSODS, color the appropriate cell in Green
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill theresult in relevant column (√)
MAJOR FAULTMAJOR FAULTMAJOR FAULTMAJOR FAULT
RQC instantly inform & return the defective labels
to Label Supervisor
Label Supervisor shoulddetermine how to handle the defect & ask the Operator to check the
whole bundle & sort out defective qty
In the ODSODSODSODS, color the appropriate cell inRed and indicate the nature of defect (e.g. LB1/1). Label Supervisor & RQC
signs off.
In Roving QC Daily SheetRoving QC Daily SheetRoving QC Daily SheetRoving QC Daily Sheet, fill the result in relevant column (x)
Raise the Red cone and move onto the next Operator
Label Supervisor will ask the Operator to print another batch, check the newly printed pieces, then call the RQC to
check the new labels.
NONONONO YESYESYESYES
©Triumph
What forms to be used?
©Triumph
ROVING QC DAILY SHEET - Pre-ProductionTRIUMPH ROVING QC SYSTEM
ROVING QC NAME:
DATE: DAY: QC SUPERVISOR:
AREA: Entered By QC Clerk:
(For Office Use Only)
DEFECT CODE:
SF = SPREADING FAULTS MD = MOULDING FAULTS HS = HEATSEAL FAULTS RM = RAW MATERIAL FAULTS
SF1 No. of layers not according to spec MD1 Unbalanced drawing HS1 Delamination/Peeling off RM1 Shade variation
SF2 Missing separator for different shade material MD2 Colour change after moulding HS2 Incorrect placement RM2 Scattered blue/Black dots/Stain/Glue spot
SF3 Wrong spreading method MD3 Loose diameter/Cup deepness/Shrinkage HS3 Incorrect colour RM3 Width variation/Short width/Shrinkage/Repeat
SF4 Wrong placement of marker MD4 Wrinkles/Puckered/Creased HS4 Damage on motif length
SF5 Faulty blocking MD5 Stain/Foreign material HS5 Discolouration after heat pressing RM4 Hole/Joining/Run line/Crease mark/Warp line/
SF6 Incomplete Size/Size not in Set MD6 Wrong cutting line HS6 Misplacement of between 1-2mm Weft line/Folded mark/Snags/Fluffs/
SF7 Material Not Flat/Uneven MD7 Wrong kegel used Moiree or water mark
SF8 Wrong Material MD8 Kegel mark (Ring mark)/Mould Mark SS = SHOULDERSTRAP FAULTS
MD9 Distorted/Displaced Bustpoint SS1 Wrong width or length
BF = BOWLACE FAULTS MD10 Too High Temperature (Fabric Became Brittle) SS2 Wrong direction (for patterned straps)
BF1 Width variation & repeat length MDPA1 Missing number of layers SS3 Incorrect material used (size & colour)
BF2 Wrong placement of pattern MDPA2 Wrong size SS4 Elongation (loose/tight)
BF3 Missing ultraviolet pen for nicks/Missing no. of layers SS5 Uneven cut edge
BF4 Uneven pinning of materials LM = LAMINATION FAULTS SS6 Missing nick or UV mark
BF5 Layers too high/Excessive bundles (too much) LM1 Delamination SS7 Stitch density too tight/too loose
BF6 Incorrect material LM2 Wrong material used SS8 Sharp edge after stitching
BF7 Folded lace LM3 Bubbles/Wrinkles SS9 Too wavy/curved
LM4 Incorrect face side SS10 Cracking stitch
BK = BANDKNIFE/DIE-CUT FAULTS LM5 Foreign material inside SS11 Incorrect stitch used
CT1 Nicks too deep LM6 Handfeel too harsh/hard SS12 Style/colour mix-up
CT2 Uneven cutting edge LM7 Uneven edges SS13 Incorrect bundle quantity
CT3 Out of cutting allowance
CT4 Fused cutting edge BD = BONDING FAULTS LB = LABEL PRINTING FAULTS
CT5 Cutwork not according to pattern BD1 Delamination LB1 Unclear print (unreadable)
CT6 Wrong die-cut used BD2 Bubbles/Wrinkles LB2 Smudged print/stain/ink
CT7 Missing nick/Missing UV mark BD3 Incorrect face side LB3 Incorrect print details
CT8 Wrong cutting line BD4 Colour change after bonding LB4 Missing letter/number/detail
CT9 Wrong size BD5 Non-symmetrical (if in pairs) LB5 Incorrect material used
CT10 Folded fabric LB6 Print peeling-off
LB7 Incorrect placement
LB8 Mix-up - style/size/colour
LB9 Slight stain/smudge
Material Follow-up RemarksOperator's NameLayers
Inspected
Result
(√ or X)
Qty of Layer with
Defect/RejectedStyle Commission # Colour Cup
©Triumph
OPERATOR'S DAILY SHEET - Pre-ProductionTRIUMPH ROVING QC SYSTEM OPERATOR DAILY SHEET (to be kept at the operator's workstation at all times)
Month: Area: Operator:
Date
Time
Roving QC
Pre-Prod Supervisor
Prod Section Chief
QC Supervisor
Remarks:
Roving QC
Pre-Prod Supervisor
Prod Section Chief
QC Supervisor
Remarks:
Roving QC
Pre-Prod Supervisor
Prod Section Chief
QC Supervisor
Remarks:
If operator is on leave, mark "L" in the cell.
Green = all pass Red = 1 major fault
If Green and no rejections, no signature needed; If Green and some rejection, RQC signs; If Red, RQC, PP Sup, & PS Chief signs; If Red again, immediately PS Chief & QC Supervisor signs.
DEFECT CODE:
SF = SPREADING FAULTS MD = MOULDING FAULTS HS = HEATSEAL FAULTS RM = RAW MATERIAL FAULTS
SF1 No. of layers not according to spec MD1 Unbalanced drawing HS1 Delamination/Peeling off RM1 Shade variation
SF2 Missing separator for different shade material MD2 Colour change after moulding HS2 Incorrect placement RM2 Scattered blue/Black dots/Stain/
SF3 Wrong spreading method MD3 Loose diameter/Cup deepness/Shrinkage HS3 Incorrect colour Glue spot
SF4 Wrong placement of marker MD4 Wrinkles/Puckered/Creased HS4 Damage on motif RM3 Width variation/Short width/
SF5 Faulty blocking MD5 Stain/Foreign material HS5 Discolouration after heat pressing Shrinkage/Repeat length
SF6 Incomplete Size/Size not in Set MD6 Wrong cutting line HS6 Misplacement of between 1-2mm RM4 Hole/Joining/Run line/Crease
SF7 Material Not Flat/Uneven MD7 Wrong kegel used mark/Warp line/Weft line/Folded
SF8 Wrong Material MD8 Kegel mark (Ring mark)/Mould Mark SS = SHOULDERSTRAP FAULTS mark/Snags/Fluffs/Moiree
MD9 Distorted/Displaced Bustpoint SS1 Wrong width or length or water mark
BF = BOWLACE FAULTS MD10 Too High Temperature (Fabric Became Brittle) SS2 Wrong direction (for patterned straps)
BF1 Width variation & repeat length MDPA1 Missing number of layers SS3 Incorrect material used (size & colour)
BF2 Wrong placement of pattern MDPA2 Wrong size SS4 Elongation (loose/tight)
BF3 Missing ultraviolet pen for nicks/Missing no. of layers SS5 Uneven cut edge
BF4 Uneven pinning of materials SS6 Missing nick or UV mark
BF5 Layers too high/Excessive bundles (too much) LM = LAMINATION FAULTS SS7 Stitch density too tight/too loose
BF6 Incorrect material LM1 Delamination SS8 Sharp edge after stitching
BF7 Folded lace LM2 Wrong material used SS9 Too wavy/curved
LM3 Bubbles/Wrinkles SS10 Cracking stitch
BK = BANDKNIFE/DIE-CUT FAULTS LM4 Incorrect face side SS11 Incorrect stitch used
CT1 Nicks too deep LM5 Foreign material inside SS12 Style/colour mix-up
CT2 Uneven cutting edge LM6 Handfeel too harsh/hard SS13 Incorrect bundle quantity
CT3 Out of cutting allowance LM7 Uneven edges
CT4 Fused cutting edge LB = LABEL PRINTING FAULTS
CT5 Cutwork not according to pattern BD = BONDING FAULTS LB1 Unclear print (unreadable)
CT6 Wrong die-cut used BD1 Delamination LB2 Smudged print/stain/ink
CT7 Missing nick/Missing UV mark BD2 Bubbles/Wrinkles LB3 Incorrect print details
CT8 Wrong cutting line BD3 Incorrect face side LB4 Missing letter/number/detail
CT9 Wrong size BD4 Colour change after bonding LB5 Incorrect material used
CT10 Folded fabric BD5 Non-symmetrical (if in pairs) LB6 Print peeling-off
LB7 Incorrect placement
LB8 Mix-up - style/size/colour
LB9 Slight stain/smudge
Morning
Afternoon
Night
Remarks:
01 02 03 04 05 06 07 08 13 14 1509 10 11 12
©Triumph
Forms to be used for Evaluation?
©Triumph
DAILY CHECKING SUMMARY (EXCEPTIONS) - PRE-PRODUCTION Week Commencing :
TRIUMPH ROVING QC SYSTEM
Unit:
SF1 SF2 SF3 SF4 SF5 SF6 SF7 SF8 CT1 CT2 CT3 CT4 CT5 CT6 CT7 CT8 CT9 CT10 BF1 BF2 BF3 BF4 BF5 BF6 BF7 MD1 MD2 MD3 MD4 MD5 MD6 MD7 MD8 MD9 MD10MDPA1 MDPA2 BD1 BD2 BD3 BD4 BD5 LM1 LM2 LM3 LM4 LM5 LM6 LM7
SF
11-222/JPN-
01/2-234
#1
Dan/Ronie 2 1
33-444TWN-
05/6-789 #2 Joe/Max 3 1
H55-666 SIN-
10/1-222
#3
Rick/Alex 5 1 1
#4
Ming/Ken 4 1
#5
Nick/Willy 6 120 5 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
MD
19-777
PRC11/333 P. Cruz 40 20 20
40 20 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 20 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
CT
H88-999
PRN12/444 D. Reyes 20 20 20
16-222
MAL13/555 L. Inigo 20 2 2
17-333
THL14/666 M. Bautista 20 4 4
60 26 0 0 0 0 0 0 0 0 0 0 6 0 0 0 0 0 20 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
51 0 0 0 0 0 0 0 1 0 0 6 0 0 0 0 0 20 0 0 0 0 0 0 0 0 0 20 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
NOTE: AM PM
Spreading 12 12 6
Cutting 13 14 15
Bowlace 7 5 6
Moulding 14 13 15
Bonding 4 5 2
Lamination 7 7 3
Heatseal 4 4 2
Shouderstrap 13 14 14
Label 4 3 2
NOTES REGARDING THIS SHEET: DEFECT CODE:
Once the data is entered, the auto filter can be actioned SF = SPREADING FAULTS BK = BANDKNIFE FAULTS MD = MOULDING FAULTS
to allow detail of each area to be viewed individually SF1 No. of layers not according to spec CT1 Nicks too deep MD1 Unbalanced drawing
SF2 Missing separator for different shade material CT2 Uneven cutting edge MD2 Colour change after moulding
MONDAY SF3 Wrong spreading method CT3 Out of cutting allowance MD3 Loose diameter/Cup deepness/Shrinkage
"Data"/"Sort"/"Column A" function can be used to SF4 Wrong placement of marker CT4 Fused cutting edge MD4 Wrinkles/Puckered/Creased
sort the data into numerical production line order SF5 Faulty blocking CT5 Cutwork not according to pattern MD5 Stain/Foreign material/ContaminationSF6 Incomplete Size/Size not in Set CT6 Wrong die-cut used MD6 Wrong cutting line
Once sorted, a blank row can then be inserted SF7 Material Not Flat/Uneven CT7 Missing nick/Missing UV mark MD7 Wrong kegel used
after the last row for each production line and the SF8 Wrong Material CT8 Wrong cutting line MD8 Mould mark (Ring mark)
auto sum function added to columns D to Q to see CT9 Wrong size MD9 Distorted/Displaced bustpoint
the totals by line. CT10 Folded fabric MD10 Too high temperature (Fabric Became Brittle)
RM = RAW MATERIAL FAULTS MDPA1 Missing number of layersRM1 Shade variation BF = BOWLACE FAULTS MDPA2 Wrong sizeRM2 Scattered blue/black dots/Stain/Glue spot BF1 Width variation & repeat lengthRM3 Width variation/Short width/Shrinkage/Repeat BF2 Wrong placement of pattern (one-way lay) BD = BONDING FAULTS
length BF3 Missing ultraviolet pen for nicks/Missing no. of layers BD1 Delamination
RM4 Hole/Joining/Run line/Crease mark/Warp line/ BF4 Uneven pinning of materials BD2 Bubbles/Wrinkles
Weft line/Folded mark/Fluffs/Moiree BF5 Layers too high/Bundles too much BD3 Incorrect face side
BF6 Incorrect material BD4 Colour change after bonding
BF7 Folded lace BD5 Non-symmetrical (if in pairs)
S/S
LB
BD
BF/DC
LM
HS
Total number of rounds taken by RQC:
TOTAL FAILED/REASONS
Total
Failed
Total
Checked
Spreading Faults Bandknife/Die-Cut Faults Bowlace Faults
TOTAL NO. OF OPERATORS/AREA
TRIUMPH FACTORY
Operator's
Name
Style/Comm
NumberArea
Moulding Faults Bonding Faults Lamination Faults
©Triumph
TRIUMPH ROVING QC SYSTEM
AREA
Total
Checked
Per Area
AreaRaw
Materials
Areas
Fault
Raw
Materials
Fault
SF1 SF2 SF3 SF4 SF5 SF6 SF7 SF8 RM1 RM2 RM3 RM4
Spreading 0 0 0 0 1 0 0 0 0 1 1 7 62 1 10 1.6% 16.1%
CT1 CT2 CT3 CT4 CT5 CT6 CT7 CT8 CT9 CT10 RM1 RM2 RM3 RM4
Bandknife/Dye Cut 0 0 15 0 22 0 0 0 0 0 0 0 0 0 130 37 0 28.5% 0.0%
BF1 BF2 BF3 BF4 BF5 BF6 BF7 RM1 RM2 RM3 RM4
Bowlace 0 0 0 0 0 0 0 0 0 0 #DIV/0! #DIV/0!
MD1 MD2 MD3 MD4 MD5 MD6 MD7 MD8 MD9 MD10 MD11 MDPA1 MDPA2 RM1 RM2 RM3 RM4
Moulding 0 20 0 0 0 0 0 0 0 5 0 0 0 0 50 25 0 50.0% 0.0%
LM1 LM2 LM3 LM4 LM5 LM6 LM7 RM1 RM2 RM3 RM4
Lamination #DIV/0! #DIV/0!
BD1 BD2 BD3 BD4 BD5 RM1 RM2 RM3 RM4
Bonding #DIV/0! #DIV/0!
HS1 HS2 HS3 HS4 HS5 HS6 RM1 RM2 RM3 RM4
Heatseal #DIV/0! #DIV/0!
SS1 SS2 SS3 SS4 SS5 SS6 SS7 SS8 SS9 SS10 SS11 SS12 SS13 RM1 RM2 RM3 RM4
Shoulderstrap #DIV/0! #DIV/0!
LB1 LB2 LB3 LB4 LB5 LB6 LB7 LB8 LB9 RM1 RM2 RM3 RM4
Label Printing #DIV/0! #DIV/0!
242 63 10 26.0% 4.1%
DEFECT CODE:SF = SPREADING FAULTS MD = MOULDING FAULTS HS = HEATSEAL FAULTS LB = LABEL PRINTING FAULTS
SF1 No. of layers not according to spec MD1 Unbalanced drawing HS1 Delamination/Peeling off LB1 Unclear print (unreadable)
SF2 Missing separator for different shade material MD2 Colour change after moulding HS2 Incorrect placement LB2 Smudged print/stain/ink
SF3 Wrong spreading method MD3 Loose diameter/Cup deepness/Shrinkage HS3 Incorrect colour LB3 Incorrect print details
SF4 Wrong placement of marker MD4 Wrinkles/Puckered/Creased HS4 Damage on motif LB4 Missing letter/number/detail
SF5 Faulty blocking MD5 Stain/Foreign material HS5 Discolouration after heat pressing LB5 Incorrect material used
SF6 Incomplete Size/Size not in Set MD6 Wrong cutting line HS6 Misplacement of between 1-2mm LB6 Print peeling-off
SF7 Material Not Flat/Uneven MD7 Wrong kegel used LB7 Incorrect placement
SF8 Wrong Material MD8 Kegel mark (Ring mark)/Mould Mark SS = SHOULDERSTRAP FAULTS LB8 Mix-up - style/size/colour
MD9 Distorted/Displaced Bustpoint SS1 Wrong width or length LB9 Slight stain/smudge
BF = BOWLACE FAULTS MD10 Too High Temperature (Fabric Became Brittle) SS2 Wrong direction (for patterned straps)
BF1 Width variation & repeat length MDPA1 Missing number of layers SS3 Incorrect material used (size & colour) RM = RAW MATERIAL FAULTS
BF2 Wrong placement of pattern MDPA2 Wrong size SS4 Elongation (loose/tight) RM1 Shade variation
BF3 Missing ultraviolet pen for nicks/Missing no. of layers SS5 Uneven cut edge RM2 Scattered blue/Black dots/Stain/Glue spot
BF4 Uneven pinning of materials LM = LAMINATION FAULTS SS6 Missing nick or UV mark RM3 Width variation/Short width/Shrinkage/Repeat
BF5 Layers too high/Excessive bundles (too much) LM1 Delamination SS7 Stitch density too tight/too loose length
BF6 Incorrect material LM2 Wrong material used SS8 Sharp edge after stitching RM4 Hole/Joining/Run line/Crease mark/Warp line/
BF7 Folded lace LM3 Bubbles/Wrinkles SS9 Too wavy/curved Weft line/Folded mark/Snags/Fluffs/
LM4 Incorrect face side SS10 Cracking stitch Moiree or water mark
BK = BANDKNIFE/DIE-CUT FAULTS LM5 Foreign material inside SS11 Incorrect stitch used
CT1 Nicks too deep LM6 Handfeel too harsh/hard SS12 Style/colour mix-up
CT2 Uneven cutting edge LM7 Uneven edges SS13 Incorrect bundle quantity
CT3 Out of cutting allowance
CT4 Fused cutting edge BD = BONDING FAULTS
CT5 Cutwork not according to pattern BD1 Delamination
CT6 Wrong die-cut used BD2 Bubbles/Wrinkles
CT7 Missing nick/Missing UV mark BD3 Incorrect face side
CT8 Wrong cutting line BD4 Colour change after bonding
CT9 Wrong size BD5 Non-symmetrical (if in pairs)
CT10 Folded fabric
Percentage (%)
WEEKLY SUMMARY OF DEFECTS FOUND
TOTAL FAULTS FOUND IN PRE-PRODUCTION
73
FAIL REASON
Total Failed Reason
©Triumph
Thank you..
Any Questions ?