Taking the traffic light system for quality control in sewing floor to the next level

1. Prashant Mithare
Beyond Traffic light …….
Towards Zero Defect
Prashant Mithare

2. What Traffic light do……..?

4. • Control the traffic …….. Yes
• Help vehicle to go in
order……Yes
• Minimize the gathering……Yes
• Do they identify defective
vehicles ????
NO !!!
What Traffic light do……..?

5. How traffic light system works in
Garment ……?
• Control the sewing line traffic ……..
NO
• Help garments to move in order……
NO
• Minimize the gathering……NO
• Do they identify defective Garments
????
Yes !!!

6. After that…………… ????

7. Out of the Box – Way Forward

8. NPD - Methodology
Set the Line Target
Develop CAP
Identify Poor
Performers
KPI to Line Chief
Convert to Zero
Defect Operator in 3
months
Identify Zero Defect
Operator
Set the KPI for all
Minimum 38%
operators as Zero
Defect Operators

9.  Operator Acknowledgement
 EachDefect noted must be acknowledged & signed by the operator
 Checking of operation should be done in next process
 QAChangeover
 The line QA to be reshuffled every 15th of the month.
 One line – 2 QAs in a month. One QA – one month in line
 Line Chief Involvement
 KPI to Line Chief to convert the Worst performer to Zero Defect
 RCA & CARA to be developed by Line Chief

10. Record the data
:-
Unit / Line
Operator
Process
Defect Details
Machine
NPD - Methodology

11. Poor Performers…..
The one who produce most
number of
defects throughout the month
rated as a poor performing
operator ………..
KPI - line chief – Convert to Zero
Defect – 3M

12. Analyze thedefects produced throughoutthemonth
Do theRoot Cause Analysis
Develop TNA
Impart SkillUpgradation Training
Monitor
Poor Performers….. Handling Process

13. Zero defect operator
Who is the zero defect operator….
The one who do not produce any
defect throughout the month
Attendance Mandatory = (
working days – 6 )…..
( no defect found in random
sampling)

14. KPI for entire team to have maximum
operators as Zero Defect Operators
Ultimate GOAL
Leapfrog towards Zero Defects 
Zero defect operator
Increase Numbers

15. On anaverageittakes 8min torepair oneDefective
If wereduce 100pc/ day= 800min= Apx$ 80
HUGEPotentialSaving
Ultimate GOAL
Leapfrog towards Zero Defects 

16. Ultimate Goal
Thank You