1.1.1_RQC Pre-Production Section

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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


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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“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.


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.


“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.


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


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.


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




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


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


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 (√)


Move to the next table

NONONONO WITH DEFECTWITH DEFECTWITH DEFECTWITH DEFECT


Move to the next table

ROVING QC PROCEDURE

IN SPREADING (B)

Inform the Spreader to lay nextmarker

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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


(√)

Move onto the next operator

NO NO NO NO DEFECTDEFECTDEFECTDEFECT


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.



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


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)


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


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



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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MOULDING



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.



Moulding Supervisor ask the Operatorto stop & mould another bundle.


(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





Moulding Supervisor calls theRQC and inform the result

Raise the Green cone & move onto the next Cutter


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.


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)




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



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.


Raise the Red cone and move onto the next operator


(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



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


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.




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


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HEATSEAL(RHINESTONES,

RUBBERISED MOTIF, & DIAMONTES)





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



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




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.




(by QA Manager)

Heatseal Supervisor instructthe operator to stop & do

another bundle

Heatseal Supervisor calls theRQC and inform the result


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




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.



Heatseal Supervisor will ask the Operator to heat press another bundle, check the finished piece, then call the

RQC to check the new works.


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SHOULDERSTRAP CUTTING/SEWING





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


Return the sewn/cut straps back into the

bundle

In the ODSODSODSODS, colorthe appropriate cell in Green


(√)

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




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.




(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 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



Raise the Green cone & move onto the next Cutter/Sewer


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.



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





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



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


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.


Raise the Red cone and move onto the next Operator

NO NO NO NO DEFECTDEFECTDEFECTDEFECT MINORMINORMINORMINOR



RAW MATERIAL FAULTRAW MATERIAL FAULTRAW MATERIAL FAULTRAW MATERIAL FAULT


(by QA Manager)

Label Supervisor instructthe operator to stop & arrange

to 100% check all WIP

Label Supervisor calls theRQC and inform the result



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



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.


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.


©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


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

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


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

1.1.1_RQC Pre-Production Section

Documents

Transcript of 1.1.1_RQC Pre-Production Section