SOP/SEW/QA/006/2013

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Issue -01

Procedure
For
Traffic Light Quality System

Issue Date
Dept/ Sec/Unit

Sewing Q.A Department

Designation
Reviewed &
Approved By
Written By

General Manager
SOP-Responsible

Signature

Table of Contents
Page
1.0 Objective

2.0 Scope

3.0 Definition of Traffic Light Quality System

4.0 Procedure

4.1 Application

4.2 Defect, Color Code & Frequency of Q.C Visit

4.3 In Line Process Visit of Q.C, Color Code Flag Raising & Process Rectification

4.4 Data Accusation

4.5 Data Authentication & Verification

4.6 Data Interferences

4.7 Data Software Entry

4.8 Performance Data

5.0 Personal Qualification / Requirement

6.0 Control of Non Conforming Process

7.0 Control of Document

8.0 Control Record

9.0 Corrective Action & Preventive Action

10.0 Internal Audit

11.0 Training

12.0 Conclusion

13.0 Attachments

14.0 References

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1.0 OBJECTIVE
TEXEUROP (BD) LTD is rising with its continuous Quality improvement journey, to grow and
excel the organization as its mission. Our cooperative working environment involves all
departments and all personnel have to work together in a team as a quality rally inside the
entire company. This Traffic Light System procedure adopted as a tool of lean quality system,
to produce highest quality apparels & achieve shorter lead time with lowest cost. As a proven
quality control tool, it would increase the production capacity & strength the supply chain.
Besides TEXEUROP (BD) LTD gives value of our stakeholders branding in USA & European
retails chains, to present highly controlled quality apparels for end customers.
2.0 SCOPE
The scope of this Traffic Light System emphasizes the sewing quality assurance, through in
line individual process inspections. This inline process inspection shall be conducted as per
controlled machine lay out plan and customers requirement. This inspection requires to verify
the assembled accuracy apparel cut panels as per the style specification. This procedure also
covers the rectification of the sewing process & also requires a re-inspection with a frequency.
3.0 DEFINATION OF TRAFFIC LIGHT QUALITY SYSTEM
Traffic light quality system works in a similar fashion the transportation traffic light system
works. Like the transportation system it includes three quality signal cards: green, yellow and
red. In the production line each worker is characterized by a card and the card is being
hanged above his/her head. Green is for good quality, yellow is for warning condition and red
stands for stopping the production due to quality fault. Seven piece quality checking system
has been implemented and the quality controllers were instructed to check the quality status
every two hours interval and collect data of each worker on a regular basis.
4.0 PROCEDURE
4.1 APPLICATION
Traffic Light Quality System is a visual control for highlighting quality issues in
sewing line. When a worker produces quality product with zero defect, he or she is
characterized by a green card. A worker who does a single fault out of the checked
seven pieces, he or she is warned by a yellow card that indicates that he or she should
be more careful about quality for the next time. 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.

No defects/ Zero defect per 7 pcs inspected

1 defect per 7 pcs inspected
2 or more defects per 7 pcs inspected

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4.2 DEFECT,COLOR CODE & FREQUENCY OF Q.C VISIT
Below table is showing the stages of
Defect
Found
None

One

Color code

Frequency of
Q.C Visit

apparel Sewing Quality Assurance

Signature

Action Required

Green

Once Per
Hour

Q.C

None

Yellow

Twice Per
Hour

Q.C

Inform Operator Supervisor, Line Chief Production

Manager to make necessary correction of the
process.
1. Show the correction method to the operator.
2. Involve the mechanic to solve sewing machine
Problem.

Two or
More

Three times
per Hour

Red

Q.C

3.If Operator cannot reach the quality level of the

Process, sewing operator change is required.
4.If sewing machine trouble cannot be solved ,
need to be replace the machine.
5. If machine cannot be replaced stop the
Machine operation.

4.3 IN LINE PROCESS VISIT OF Q.C,COLOR CODE FLAG RAISING & PROCESS
RECTIFICATION
Below table is showing the frequency of Q.C Visit at the defective sewing in line process:
Color of
Flag

Time

2nd
Check

0 Fault

Green

1/hr

1 Fault

Yellow

1 Fault

Yellow

1st
Check

1 Fault

2 or
More
Red
2 or
More
Red

Color of
Flag

Time

None

Green

1/hr

2/hr

None

Green

1/hr

2/hr

1Fault

Red

2/hr

Yellow

2/hr

1Fault

Red

2/hr

Red

2/hr

None

Yellow

2/hr

Red

2/hr

1 or
more

Red
&Stop

3rd
Check

Color of
Flag

Time

4th
Check

Color Of
Flag

None

Yellow

2/hr

None

Green

Red &
Stop

If 2
Red
stop/
Infor
m QA
Mana
ger
&
Line
Chief

1 Fault

Time

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4.4 DATA ACCUSATION
The Concerned Quality Controller shall generate Operator Quality Performance
Report ( Form No F|QA|SEW|41 ) as per Attachment-1 . Which state as part A&
Part B .
The following informations shall be filled with the data form as per under mentioned
required informations:
(a) Operator Name , ID No , Unit no , Line no
(b) If Style change the marking round circle area shall be blank
(c) If machine problem the marking round circles area shall be blue color.
Below sample is self explanatory as stated:

A generated report of Operator Quality Performance Report ( Form No F|QA|SEW|41 )

4.5 DATA AUTHENTICATION & VERIFICATION

Operator Quality Performance Report (Form No F|QA|SEW|41) Shall be
authenticated & must be verified by the Line Chief , Asst. quality Manager , Production
Manager & Manager Q.A , as per the report requirement .
4.6 DATA INTERFERENCES
The data interferences shall be together between Operator Quality Performance
Report (Form No F|QA|SEW|41) & Quality Control In Line /Process wise
Inspection Report ( Form No F|QA|SEW|17) as per the 7 pcs Inspection criteria .
4.7 DATA SOFTWARE ENTRY
To analyze the whole line defective level the data shall be analyzed after software entry
on daily basis.

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4.8 PERFORMANCE DATA

For annual performance evaluation the monthly generated
Operator Quality
Performance Report (Form No F|QA|SEW|41) shall be deposited to Human
Resource to attach with personal file.
5.0 PERSONNEL QUALIFICATION / REQUIREMENT
Recruitment for competent personnel, defined at recruitment policy of the organization.

6.0 CONTROL OF NON CONFORMING PRODUCTS

To monitor all types of non-conformance of sewing processes, its advised to report to Manger
Production & Quality Assurance Manager for corrective & Preventive action . The product /
with any kind of non Conformances must be investigated. Appropriate and timely corrective
action must be taken according to the nature of the non-conformance. Non conformance of
sewing process shall be documented as per defect codes (Annexture-1).
7.0 CONTROL OF DOCUMENT
All stages document of Traffic Light Quality System inspection must be controlled with
individual identification stated information like Month , Operator name , Id No , Unit , Line no
, Date , Style reference number , Operation Name /Code , Time & Color Mark , Daily Mark
Nos summary.
8.0 CONTROL OF RECORD
All records shall be controlled as per the standard requirement .Which must be stored for a
minimum (03) years. Although the test reports shall be generated in a computer software and
stored also.
Description of non-conformity, result of root cause analysis, list of possible corrective &
Preventive actions, implementation monitoring and validation records, shall be kept by the
Manager QA.
[
(a)
(b)
(c)

9.0 CORRECTIVE ACTION & PREVENTIVE ACTION

Any non conformance product is the factor of time loss & cost involvement. If any
inconsistency found with any stages of cutting , first to find out the root cause if its a person
even .There after analyze the cause of non-conformance & make the action plan.
If its a floor visit suggestion from any customer regarding the non-conformance the
organization shall documented it as a record & must have the defined action plan also .
10.0

INTERNAL AUDIT

Internal audit shall be conducted periodically to ensure the followings:

To ensure that, the procedures in quality manual related to quality systems, related
testing activities, are being followed.
To ensure all deficiencies in the quality system and activities are documented
through its corrective action process.

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This internal audit to analyze sewing process quality systems, policies, procedure,
work instructions, analytical records and reports.

This internal audit shall be conducted with trained and knowledgeable official of the
organization.
11. 0 TRAINING
A regular quality training program shall be conducted to improve the sewing operators
performance to achieve the objective of this procedure . Implementation of the traffic light
system for the improvement of quality level & overcome the deficiencies of the sewing
process.
12.0CONCLUTION
Traffic light system is a system that is easy to implement & enable the quality triggers to
improve the quality status, reduced the cost, improve the lead time & strength the supply
chain performance .
13.0 ATTACHMENTS
(i)
(ii)
(iii)

F|QA| SEW|17- Quality Control In Line / Process wise Inspection Report

F|QA| SEW|41- Operator Quality Performance Report
Sewing Defect Codes (Annexture-1).

14.0 REFERENCES
(i)

Enhancing lean supply chain through traffic light quality management system,
Management Science letters 3 (2013) 867-878 .
End of the Document