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Guidelines
Version 1.0 15 July 2014
Title:
NB QMS Guidelines
Version:
15 July 2014
Filename:
Distribution:
Contents
1.
Introduction
1.1. Background
1.2. Purpose
1.3. QMS Organization Structure
1.4. Recruitment and Training QMS personnel
2.
QMS Guidelines
2.1 Incoming Materials Warehouse and Inspection
2.2 Implementation On the Line
2.3 Finish Goods Warehouse
1. Introduction
1.1 Background
The New Balance Quality Management System (QMS) detailed in these
Guidelines are recommended actions for monitoring and controlling quality from Incoming Materials
through the production process to the Finished Goods Warehouse and Shipping Inspections.
These Guidelines will be focused on achieving New Balance quality policies
and objectives to ensure we are meeting our customers wants and
needs and will be expressed as the organizational structure, policies,
procedures, processes and resources needed to implement effective
quality management.
1.2 Purpose
The purpose of the NB QMS Guidelines is to provide our T1 factories a clear, but flexible set of
requirements to control footwear product quality end-to-end and provide the basis for periodic
audit by NB, as well as to create mutual trust and greater synergy with our factory partners.
1. Introduction
1.3 QMS Organization Structure
NB T1 factories must prepare a QMS organization chart in the format shown below.
QMS Manager
QMS Procedure
QMS Supervisor
RQC
EOLQC
QMS Supervisor
RQC
EOLQC
QMS Supervisor
RQC
EOLQC
1. Introduction
1.4 Recruitment & Training QMS Personnel
For the recruiting and training of QMS Personnel such as EOL Inspectors,
Roving QC Inspectors & SI Inspectors from both inside and outside the factory
(see attachment).
2.1
Incoming Materials
Warehouse & Inspection
Reject
Area
Release Area
Preparation
Area
Inspection Areas
Incoming
Materials
Release Area
Excess
Material
A = Leather Inspection
B = Synthetic Inspection
C = Accessories Inspection
As shown in the drawing, background color of area location ID signs should be same color as borders.
The lettering color on the area ID signs should be in contrast to the background color.
9
Pass
Y
Place material in
Inspection area
Attach Tracking
Sticker and fill out
material information
Attach Red
Rejected sticker and
move to rejected area
Physical test
Pass
Claim to T2 supplier
Y
Visual inspection
Attach Green
Released sticker and
move to release area
PO. No.
Date Received
Roll No/Lot/Batch
Expire Date
Quantity
Production Month
to be checked prior release
PASS FAIL
FIFO
12
Diameter 30 mm
10 11
6
12
13
13
Storage row location signs: are placed at the top of the entrance to each row.
Storage Shelf Bins/Sections:
Each storage Row should be numbered 1,2,3,4, etc.
Each shelve bins/section location should be identified by a letter e.g., A, B, C, D,
At the entrance to each Row there should be a material location board
which shows the row and bin/section location number and letter;
For example 2F = Row number 2, Bin/Section F.
With this system materials can be easily located.
REJECTED
RELEASED
Yes:
The sticker size is
95mm x 35mm
April 2014
21
22
Level Of Inspection
Inspection Method
AQC Score
Sample Number
Accepted / Released
n
Incoming Lot
2,5
AC
AC
AC
Re
Re
Re
0
1
0
1
0
1
0
0
1
0
0
1
0
1
0
1
0
1
1
0
1
0
1
0
2
1
2
1
0
1
0
2
1
2
2
3
1
2
1
2
2
2
3
4
4
5
6
3
3
3
4
6
6
0- 8
.9 - 15
16 - 25
26 - 50
51 - 90
13
91 - 150
20
151 - 200
32
2001 - 500
50
5001 - 1200
80
1201 - 3000
126
3001 - 10.000
200
4
6
11
15
10.001 - 36.000
315
7
8
14
15
21
22
36.001 - 70.000
600
70.001 - 120.000
1000
12.001 - 170.000
1250
170.001 - 250.000
( over 250.000 include material )
2000
7
9
7
8
10
11
10
14
10
21
11
22
21
22
14
15
21
22
21
22
21
21
22
22
21
22
21
22
21
22
21
22
NOTE :
1 . In program of materials inspection of parts of to be check visually as according to " visual Form Inspection of Incamoing material " : Hardness, Thickness ,Color
Appearance.Level inspection from material arrival differe can be altered by pursuant to former inspection wxperience.Classification assessment from supplier or
over all of material type will give an indocation to handle the inspection random by more flexible .
2. Material which Rejected have to re-inspect by increase up 1 level,if level 1 have been used ,do by 100% inspection.if material 2 time do by 100% inspection.
3. We have 3 level defect ( AQL 1 for Tight Inspection / AQL 2,5 for Normal Inspection / AQL 4 for minor Inspection.
c. In Sheets
Outer Carton boxes, Inner boxes
Note: If material FAILs visual inspection it does not need to be sent to the lab for physical testing.
26
Examples of tools Incoming Inspection QCs must have on hand for proper inspection of Leather:
1. Measuring devices
2. Material swatch
books
27
BACKING HAIRY
LOOSE GRAIN
GROWTH MARKS
BRAND MARKS
TICK MARKS
Physical/Lab - Testing
- All Incoming materials must pass physical lab tests before being Release.
- Test frequency for each type and batch of material is established by the NB Lab Manager.
- Physical testing for production materials must be conducted according to NB standards.
- Specimens should be taken only by authorized QMS QC personnel.
29
MATERIAL NAME
LEATHER
OUTSOLE/MIDSOLE
INLAYSOLE
2
TEXTILE,PVC, SYNTHETIC
RECEIVED
QUANTITY
- 20.000 sf
1 Piece
20.001
- 40.000 sf
2 Piece
40.001
- 60.000 sf
3 Piece
60.001
- .
4 Piece
- 5.000 prs
1 Pairs
5.001
- 10.000 prs
2 Pairs
10.001
- 20.000 prs
3 Pairs
20.001
- .
4 Pairs
- 50 Rolls
1 Roll / Type
51
- 100 Rolls
2 Roll / type
101
- 150 Rolls
3 Roll / Type
151
- .
4 roll ? Type
ACCESSORIES
Material type " A "
1 Specimen for once physical Test
0
- 25 Cartons
26
- 50 cartons
51
- ..
- 100 Rolls
101
- 200 Rolls
201
- .
- 10.000 pcs
1.0001
- 20.000 pcs
20.001
- ....
Lace,Tongue,Label,Hang Tag,Size
REMARK
2.2
Implementation On the Line
(Quality Control in Production)
Generally:
1 QC Inspector at the end of each upper stitching line;
1 or 2 EOL QC at the end of each production line; and,
1 RQC to cover no more than two production lines
32
End-of-Line QC
(EOL QC)
EOL QC
EOL QCs must have sufficient work space and good lighting to conduct proper inspection of the product.
Two (2) Defect Carts on wheels should be available for the EOL QC to place defective shoes
The Defect Carts should have 3-4 shelves labelled Dirty - Assembly - Stitching & Cutting.
When 1 Cart is full the EOL QC turns the shoes over to the production line supervisor and then takes
the 2nd Cart back to the work station. The Line supervisor takes the Defect Cart to each applicable location
and returns the shoes to the appropriate operators to be repaired. The operators repair the defects
(when possible) and place the shoes back on the line.
Good lighting
The EOL QC also needs proper lighting to be able to see and identify defects clearly
Defects Cart
37
The EOL QC must consistently identify defect locations on product using defect arrow stickers and
must record each defect on a Daily Quality Report .
38
NOTE:
EOL QCs must be empowered to make decision to B-Grade shoes and stop the line
39
Repairs at EOL QC
No repair is allowed by EOL QCs.
All shoes are passes through the Metal Detector after the EOL QC check.
a. If the MD alarm sounds or flashes as the shoes pass through the shoes are isolated
b. The RQC and Line Supervisor will use handheld MD to determine if metal is detected in L or R shoe
c. If metal detected, shoe is cut to locate metal object and report
STEP 1
CENTER
LEFT
RIGHT
ALERT
STEP 2
CENTER
Put the Ferrous testtick on top of a 50
mm High box
in the center ans
pass through the
conveyor belt
STEP 3
MIDDLE
Put Non Ferrous testtick in the center and
pass through the
conveyor belt
Non Ferrous
ball test-tick
diameter 2 mm
STITCHING QC
Check tongue
Logo wrinkles
Inconsistent alignment of
webbing
Stitching open
Upper wrinkles
Misalignment
Misaligned or excess
Reinforcement
ROVING QC
(RQC)
RQC
Checklist
RQCs Duties
Ensure that a correct SOP is clearly displayed (in color) at each operator work station
3
SOP Check Points:
1. Clearly explains the SOP for the specific process in production
2. SOP shows critical areas to check.
3. SOP has correct reference number
49
Roving QC (RQC)
Example RQC Checklist
RQCs must carry their work instruction and Daily Checklist with them on a clip board.
NOTE: RQCs are monitoring production lines to control quality consistency. They should be
well trained in production processes and NB quality standards and demonstrate good
self-confidence and decision making ability.
50
51
- Every 8 hours the cutting board should be flipped over to ensure optimal use of cutting surface
52
x
Note : Component Quality and
Quantities must be controlled
53
Damaged components
55
Cutting Die
Pattern
Width stitching 5 -6 mm
Left and Right
components height must
be flat
L Component
R Component
Component must be flat
Not overlap
c
ab
size code
Needles are
controlled by
Supervisor
59
Attaching Process
The function is to attach
the upper and bottom
unit following the parking
and buffing process
Poor Alignment
Loose/open Strobel
Bonding
Wrinkled Midsole
Over cementing
Variation in
Heel Heights
Application Brushes are color coded and should follow the same color as the bowl cover i.e., a BLUE bowl
cover requires that the Operator also be using a BLUE colored brush. The change times should be clearly
posted at the workstation
66
Lasts should be cleaned and stored properly by sixe after each use
67
All PCS should have signed hangtag attached showing last date reviewed
All PCS should be kept in Zip-lock plastic bags to keep them clean
If a PCS needs to be replaced, a half pair is taken from production and must be signed by both
the factory QMS Manager & the NB QA
68
69
5. To standardize the F/G process flow for easy monitoring and control.
70
71
72
73
For all other POs = Lines may be any color except RED, BLUE, or GREEN
This factory is
74
75
+ - 1 meter
76
6 cartons high
7 cartons high
77
END