A PROJECT ON

TRAFFIC LIGHT SYTEM REPORT

INTRODUCTION

Rework is a vital issue for poor quality product and low production rate. Stitching
operations (with respect to cutting and finishing) needs high skill as well as quality
work, because of difficulty associated with repairing of products sewed with wrong
specifications. We have to give more attention to stitching than to cutting and
finishing. Here, how a traffic light system in sewing floor can be used to detect
defects at source level is described.

OBJECTIVE

Traffic light system is the most effective inspection tool to reduce defect generation
at source.

This is a random inspection system. Traffic light system is more effective in

controlling shop floor quality than other quality tools because of its visual
communication. At the same time it measure operators performance level in
quality. No operators like to be presented themselves as lower quality makers. They
concentrate on quality aspect during stitching garments.

Inline checking system will alert operators in concentrating their job. If less number
of defective seam is made, less the time will be lost in repairing it. It also helps in
other way. May be at the start of the style an operator do not understand the
specification, an interaction with quality inspector will make an operator clear
about the quality requirement. Traffic Light System is designed to flag the problem
at source and allow immediate corrective action rather than all potentially
defective product to continue to be manufactured.

METHODOLOGY

Traffic Light System is a visual control for highlighting quality issues in sewing line.

Traffic light quality system works in a similar fashion the transportation traffic light
system works . Three different colour cards are placed in each operators place.
Green indicates that Quality meets the customers Standard. Yellow indicates that a
minor fault has been found and caution is required. Red indicates that the Quality
Standard does not meet the customers standard requirement.

One Inline Quality Checker is to be allocated for every line of particular style or
cover 25 Workstations. She/he has to check the semi finished garment pieces from
current bundle once in two hours. Pieces will be taken randomly and check all the
quality parameters required for that operation. Stitches per inch, seam width,
sewing allowance, correct trims and their placement and measurement etc are to be
verified by the Inline Quality checker. While inspecting, depending upon the quality
level, colour flags are placed on their machine.

The red card is given for those, who are identified by the line supervisor have produced
2 or more defective item out of five pieces inspected. The yellow card is given to those
who are identified by the line supervisor have produced 1 defective items out of five
inspected. The green card is given if no reworks are found. This can motivate the
worker to produce good quality products. It is also an indication of how and which
operator is going wrong to the production in charge and quality supervisor.
They can monitor from any corner of the floor easily. 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. The extra care may be in a way that he or she
should be trained for that operation or if there have any problem, could be solved.

The format shown below is used for a single operator or workstation. A single sheet
will keep record for 15 days for an operator. Inline Quality checker, on the first day
have to fill details such as Operator name, Line number and name of the Month.
Each row contains space to cover hourly inspections in a shift. The space is filled
with respective colour pen. At the end of the day quality auditor /supervisor has to
sign in the report.

Operators name:___________ Operator:__________ Line:___ style:_______

Floor:___________ Month:___________

(instruction: each operation to be inspected every second hour,

standard sample size 5 pieces)

Mark Green G if no defect found; Mark Yellow Y if one defect found; Mark
Red R if found two or more defect ( also write defect quantity if found R)

Date
I

II

III

IV

QA
sign

QC
sign

Later on realizing that this format was very hectic to maintain as it contained information
about only one operation. As 25 operations were to be audited, the conclusion of the audit
was difficult to be analyzed. So we decided to design a format which would be easy handle
and have transparent information for the viewer.
 Shift Quantity Percentag
e
OPERATION OPERATOR 1 2 3 4 G Y R G% Y% R%
NAME
1.B/H
PLACKET
FOLD
2. BUTTON
PLACKET
FOLD
3. POCKET
PRESSING
4. POCKET
ATTACH
5.POCKET
ATTACH
6.SLEEVE
DIAMOND
FINISH
7. SLEEVE
DIAMOND
FINISH
8. COLLAR
BAND
PRESSING
9. COLLAR
READY
PRESSING
10. COLLAR
ATTTACH
11. COLLAR
FINISH
12. COLLAR
FINISH
13. SLEEVE
ATTACH
14. SLEEVE
ATTACH
15.A/H T/S
16. A/H T/S
17. INLINE
CHECKING
18. SIDE
SEAM
19. SIDE
SEAM
20.
BOTTOM
FOLD
21
BOTTOM
FOLD
22. CUFF
ATTACH
23. CUFF
ATTACH
24.W/C
LABEL
25. FINAL
CHECKING
TOTAL
Line 11 Style Shift Quantity Percentage
9/8/2016 1797
OPERATIO OPERATO 1 2 3 4 G Y R G% Y% R%
N R
NAME
1.B/H Renu G G 10 100%
PLACKET
FOLD
2. BUTTON Simran R-4 G 6 4 60% 40%
PLACKET
FOLD
3. POCKET Rahul G G 10 10%
PRESSING
4. POCKET Kiran R-2 R-3 5 5 50% 50%
ATTACH
5.POCKET Preeti Y Y 8 2 80% 20%
ATTACH
6.SLEEVE Manju Y G 9 1 90% 10%
DIAMOND
FINISH
7. SLEEVE Shakuntal G R-3 7 3 70% 30%
a
DIAMOND
FINISH
8. COLLAR Suraj G G 10 100%
BAND
PRESSING
9. COLLAR Niraj G G 10 100%
READY
PRESSING
10. Mohan G R-3 7 3 70% 30%
COLLAR
ATTTACH
11. Anima G R-2 8 2 80% 20%
COLLAR
FINISH
12. Hansa G Y 9 1 90% 10%
COLLAR
FINISH
13. Shriraj G G 10 100%
SLEEVE
ATTACH
14. brejrashi G G 10 100%
SLEEVE
ATTACH
15.A/H T/S Preeti G G 10 100%
16. A/H Neema G Y 9 1 90% 10%
T/S
17. INLINE Mamta Y R-4 5 1 4 50% 10% 40%
CHECKING
18. SIDE Sarita G Y 9 1 90% 10%
SEAM
19. SIDE Reema R-2 G 8 2 80% 20%
SEAM
20. Chandini Y G 9 1 90% 10%
BOTTOM
FOLD
21 Anil G G 10 100%
BOTTOM
FOLD
22. CUFF Upma Y Y 8 2 80% 20%
ATTACH
23. CUFF Babita G G 10 100%
ATTACH
24.W/C Shabana G G 10 100%
LABEL
25. FINAL Vijay G Y 9 1 90% 10%
CHECKING
TOTA 201 11 23 85.5% 4.7% 10%
L
Line 11 Style Shift Quantity Percentage
10/8 1797
OPERATIO OPERATO 1 2 3 4 G Y R G% Y% R%
N R
NAME
1.B/H Reenu G G G 15 100%
PLACKET
FOLD
2. BUTTON Simran G G G 15 100%
PLACKET
FOLD
3. POCKET Rahul G G G 15 100%
PRESSING
4. POCKET Preeti G G Nil 10 100%
ATTACH
5.POCKET Kiran G G Nil 10 100%
ATTACH
6.SLEEVE Manju R-2 G G 13 2 86.6 13.4%
%
DIAMOND
FINISH
7. SLEEVE Shakuntal G G G 15 100%
a
DIAMOND
FINISH
8. COLLAR Suraj G G G 15 100%
BAND
PRESSING
9. COLLAR rajkumari G G G 15 100%
READY
PRESSING
10. Mohan G G G 15 100
COLLAR
ATTTACH
11. Anima R-2 G G 13 2 86.6 13.4%
COLLAR %
FINISH
12. Hansa G G G 15 100%
COLLAR
FINISH
13. Raj G G G 15 100%
SLEEVE
ATTACH
14. Shreeraj G G G 15 100%
SLEEVE
ATTACH
15.A/H T/S Reema G G G 15 100%
16. A/H Preeti G G G 15 100%
T/S
17. INLINE Mamta Y G G 14 1 93.3 6.7%
%
CHECKING
18. SIDE Sabhya Y G G 14 1 93.3 6.7%
%
SEAM
19. SIDE Asha G G G 15 100%
SEAM
20. Anil G G G 15 100%
BOTTOM
FOLD
21 Chandini G G G 15 100%
BOTTOM
FOLD
22. CUFF Mukesh G G G 15 100%
ATTACH
23. CUFF Nitesh Y G G 14 1 93.3 6.7%
%
ATTACH
24.W/C Sabana G G G 15 100%
LABEL
25. FINAL Shailendr R-3 G G 12 3 80% 20%
a
CHECKING
TOTA 355 3 7 97.2 0.8% 2%
L %
Line-11 Style-1797 Shift Quantity Percentage
11/8
OPERATIO OPERATOR 1 2 3 4 G Y R G% Y% R%
N
NAME
1.B/H Reenu G G 10 100%
PLACKET
FOLD
2. BUTTON Simran Y G 9 1 90% 10%
PLACKET
FOLD
3. POCKET
PRESSING
4. POCKET
ATTACH
5.POCKET
ATTACH
6.SLEEVE Shakuntala G G 10 100%
DIAMOND
FINISH
7. SLEEVE Manju Y G 9 1 90% 10%
DIAMOND
FINISH
8. COLLAR
BAND
PRESSING
9. COLLAR
READY
PRESSING
10. Mohan G G 10 100%
COLLAR
ATTTACH
11. Hansa Y Y 8 2 80% 20%
COLLAR
FINISH
12. Anima G G 10 100%
COLLAR
FINISH
13.
SLEEVE
ATTACH
14.
SLEEVE
ATTACH
15.A/H T/S Reema Y G 9 1 90% 10%
16. A/H Preeti G G 10 100%
T/S
17. INLINE Mamta R-3 R-2 5 5 50% 50%
CHECKING
18. SIDE
SEAM
19. SIDE
SEAM
20. Anil G G 10 100%
BOTTOM
FOLD
21 Chandini G G 10 100%
BOTTOM
FOLD
22. CUFF Babita G G 10 100%
ATTACH
23. CUFF Laxami R-2 G 8 2 80% 20%
ATTACH
24.W/C
LABEL
25. FINAL Vijay G G 10 100%
CHECKING
TOTA 138 5 7 92% 3.3% 4.6%
L
Line-11 Style-1797 Shift Quantity Percentage
12/8
OPERATIO OPERATOR 1 2 3 4 G Y R G% Y% R%
N
NAME
1.B/H Dharmend G G G G 20 100%
ar
PLACKET
FOLD
2. BUTTON Simran NIL G G R-5 10 5 66.6 33.3%
%
PLACKET
FOLD
3. POCKET Rahul R-3 R-2 Y Y 13 2 5 65% 10% 25%
PRESSING
4. POCKET Priti G G Y R-2 17 1 2 85% 5% 10%
ATTACH
5.POCKET Kiran G G Y R-2 17 1 2 85% 5% 10%
ATTACH
6.SLEEVE Mukesh G Y G R-2 17 1 2 85% 5% 10%
DIAMOND
FINISH
7. SLEEVE Sapna Y Y Y R-2 15 3 2 75% 15% 10%
DIAMOND
FINISH
8. COLLAR Suraj G G G G 20 100%
BAND
PRESSING
9. COLLAR Niraj G G G G 20 100%
READY
PRESSING
10. Mohan G G G Y 19 1 95% 5%
COLLAR
ATTTACH
11. Hansa G G G Y 19 1 95% 5%
COLLAR
FINISH
12. Anima G G G G 20 100%
COLLAR
FINISH
13. Ssriraj G G G G 20 100%
SLEEVE
ATTACH
14. Birajraj G G G G 20 100%
SLEEVE
ATTACH
15.A/H T/S Priti G G G G 20 100%
16. A/H Nima NIL G G G 15 100%
T/S
17. INLINE Pradeep G G G G 20 100%
CHECKING
18. SIDE Savita G G G G 20 100%
SEAM
19. SIDE Rani G G Y G 19 1 95% 5%
SEAM
20. Anil G G G Y 19 1 95% 5%
BOTTOM
FOLD
21 Chandni G G G G 20 100%
BOTTOM
FOLD
22. CUFF Mukesh G G Y G 19 1 95% 5%
PRESS
23. CUFF Laxmi G G G G 20 100%
FINISH
24.W/C Pooja Y G G G 19 1 95% 5%
LABEL
25. FINAL Vijay G G G G 20 100%
CHECKING
TOTA 458 14 18 93.4 3% 3.6%
L %
LINE-11 STYLE- Shift Quantity Percentage
1797
13/8
OPERATIO OPERATOR 1 2 3 4 G Y R G% Y% R%
N
NAME
1.B/H Dharmend G G G G 20 100%
ar
PLACKET
FOLD
2. BUTTON Simran G R-2 G G 18 2 90% 10%
PLACKET
FOLD
3. POCKET Rahul R-2 Y G G 17 1 2 85% 5% 10%
PRESSING
4. POCKET Priti Y G G G 19 1 95% 5%
ATTACH
5.POCKET Kiran Y G G G 19 1 95% 5%
ATTACH
6.SLEEVE Mukesh G Y R-2 G 17 1 2 85% 5% 10%
DIAMOND
FINISH
7. SLEEVE Sapna G G G G 20 100%
DIAMOND
FINISH
8. COLLAR Suraj G G G G 20 100%
BAND
PRESSING
9. COLLAR Niraj G G G G 20 100%
READY
PRESSING
10. Mohan G G G G 20 100%
COLLAR
ATTTACH
11. Hansa G G G G 20 100%
COLLAR
FINISH
12. Anima G G G G 20 100%
COLLAR
FINISH
13. Sriraaj G G G G 20 100%
SLEEVE
ATTACH
14. Brijraj G G G G 20 100%
SLEEVE
ATTACH
15.A/H T/S Priti G R-2 R-2 R-2 14 6 70% 30%
16. A/H Neema G Y Y G 18 2 90% 10%
T/S
17. INLINE Pradeep G G Y G 19 1 95% 5%
CHECKING
18. SIDE Savita G G G G 20 100%
SEAM
19. SIDE Rani G G G G 20 100%
SEAM
20. Anil G G G G 20 100%
BOTTOM
FOLD
21 Chandni G Y G G 19 1 95% 5%
BOTTOM
FOLD
22. CUFF Mukesh G G G G 20 100%
ATTACH
23. CUFF Laxmi G G G G 20 100%
ATTACH
24.W/C Pooja G G Y Y 18 2 90% 10%
LABEL
25. FINAL Vijay NIL NIL G G 10 100%
CHECKING
TOTA 468 10 12 95.5 2% 2.4%
L %
LINE 9 STYLE 1797 Shif Quantity Percentage
t
9/8/2016
OPERATIO OPERATOR 1 2 3 4 G Y R G% Y% R%
N NAME
1.B/H SAADHNA R-4 G 6 4 60% 40%
PLACKET
FOLD
2. BUTTON SHASHI R-3 G 7 3 70% 30%
PLACKET
FOLD
3. POCKET ABHIJEET G G 10 100%
PRESSING
4. POCKET PRATIMA G Y 9 1 90% 10%
ATTACH
5.POCKET KAVITA R-3 G 7 3 70% 30%
ATTACH
6.SLEEVE RENU R-3 G 7 3 70% 30%
DIAMOND
FINISH
7. SLEEVE POONAM Y G 9 1 90% 10%
DIAMOND
FINISH
8. COLLAR UDAY G G 10 100%
BAND
PRESSING
9. COLLAR SADHNA G G 10 100%
READY
PRESSING
10. SEEMA G G 10 100%
COLLAR
ATTTACH
11. PASHURAM G R-2 8 2 80% 20%
COLLAR
FINISH
12. NAUSHAD G G 10 100%
COLLAR
FINISH
13. SADHNA G G 10 100%
SLEEVE
ATTACH
14. PAPPU G G 10 100%
SLEEVE
ATTACH
15.A/H T/S LAXMI G G 10 100%
16. A/H SIKSHA Y G 9 1 90% 10%
T/S
17. INLINE MANOJ Y G 9 1 90% 10%
CHECKING
18. SIDE JAVITRI G G 10 100%
SEAM
19. SIDE SUSHMA G G 10 100%
SEAM
20. SARLA R-3 Y 6 1 3 60% 10% 30%
BOTTOM
FOLD
21 SUMITRA Y G 9 1 90% 10%
BOTTOM
FOLD
22. CUFF DOLLY/NAUSAD R-3 G 7 3 70% 30%
ATTACH
23. CUFF SATTO R-3 G 7 3 70% 30%
ATTACH
24.W/C KUSUM G G 10 100%
LABEL
25. FINAL CHANDRAPRAKA G Y 9 1 90% 10%
SH
CHECKING
TOTAL 219 7 24 87.6 2.8% 9.6%
%
10/8 Style-1797 Shif Quantity Percentage
t
line -9
OPERATION OPERATOR 1 2 3 4 G Y R G% Y% R%
NAME
1.B/H SADHNA Y G G 14 1 93.3 6.7%
%
PLACKET
FOLD
2. BUTTON SHASHI Y G G 14 1 93.3 6.7%
%
PLACKET
FOLD
3. POCKET PRADEEP G G G 15 100%
PRESSING
4. POCKET PRATIMA G Y G 14 1 93.3 6.7%
%
ATTACH
5.POCKET KAVITA G G G 15 100%
ATTACH
6.SLEEVE POONAM Y G G 14 1 93.3 6.7%
%
DIAMOND
FINISH
7. SLEEVE RENU G Y G 14 1 93.3 6.7%
%
DIAMOND
FINISH
8. COLLAR UDAY G G G 15 100%
BAND
PRESSING
9. COLLAR SADHNA G G G 15 100%
READY
PRESSING
10. COLLAR SEEMA G R-3 Y 11 1 3 73.3 6.6% 20%
%
ATTTACH
11. COLLAR PASHURAM R-2 Y G 12 1 2 80% 6.6% 13.3%
FINISH
12. COLLAR SEHZAD R-2 Y G 12 1 2 80% 6.6% 13.3%
FINISH
13. SLEEVE SADHNA G G G 15 100%
ATTACH
14. SLEEVE PAPPU G G G 15 100%
ATTACH
15.A/H T/S SEEKSHA R-2 R-2 Y 10 1 4 66.6 6.6% 26.6%
%
16. A/H T/S LAXMI G Y Y 13 2 86.6 13.3
% %
17. INLINE MANOJ R-2 R-2 Y 10 1 4 66.6 6.6% 26.6%
%
CHECKING
18. SIDE GUDDI G G G 15 100%
SEAM
19. SIDE VIJAY G G G 15 100%
SEAM
20. BOTTOM SARLA R-3 R-2 Y 9 1 5 60% 6.6% 33.3%
FOLD
21 BOTTOM SUMITRA G Y G 14 1 93.3 6.6%
 %
FOLD
22. CUFF NAUSAD G G G 15 100%
ATTACH
23. CUFF SATTO G G G 15 100%
ATTACH
24.W/C KUSUM Y Y Y 12 3 80% 20%
LABEL
25. FINAL CHANDRAPRAT Y R-2 Y 11 2 2 73.3 13.3 13.3%
AP % %
CHECKING
TOTAL 334 19 22 89% 5% 6%
Line -9 Style Shift Quantity Percentage
1797
11/8
OPERATION OPERATOR 1 2 3 4 G Y R G% Y% R%
NAME
1.B/H Sadhna Y Y 8 2 80% 20%
PLACKET
FOLD
2. BUTTON Shashi G G 10 100%
PLACKET
FOLD
3. POCKET
PRESSING
4. POCKET
ATTACH
5.POCKET
ATTACH
6.SLEEVE Poonam Y G 9 1 90% 10%
DIAMOND
FINISH
7. SLEEVE Renu Y G 9 1 90% 10%
DIAMOND
FINISH
8. COLLAR
BAND
PRESSING
9. COLLAR
READY
PRESSING
10. Seema Y G 9 1 90% 10%
COLLAR
ATTTACH
11. Gautam Y Y 8 2 80% 20%
COLLAR
FINISH
12. Shahzad G Y 9 1 90% 10%
COLLAR
FINISH
13. SLEEVE
ATTACH
14. SLEEVE
ATTACH
15.A/H T/S Siksha Y G 9 1 90% 10%
16. A/H T/S Laxmi Y G 9 1 90% 10%
17. INLINE Manoj G G 10 100%
CHECKING
18. SIDE
SEAM
19. SIDE
SEAM
20. Sarla G G 10 100%
BOTTOM
FOLD
21 BOTTOM Sumitra G G 10 100%
FOLD
22. CUFF Satto Y G 9 1 90% 10%
ATTACH
23. CUFF Naushad G R-2 8 2 80% 20%
ATTACH
24.W/C
LABEL
25. FINAL Chdraprata G Y 9 1 90% 10%
p
CHECKING
TOTA 236 12 2 94% 5% 1%
L
Line -9 Style Shift Quantity Percentage
12/8 1797
OPERATION OPERATO 1 2 3 4 G Y R G% Y% R%
R
NAME
1.B/H Sadhna R-2 G G G 18 2 90% 10%
PLACKET
FOLD
2. BUTTON Shashi G G G G 20 100%
PLACKET
FOLD
3. POCKET Pradep G G G G 20 100%
PRESSING
4. POCKET Kavita R-2 Y G Y 16 2 2 80% 10% 10%
ATTACH
5.POCKET Reema R-2 Y G Y 16 2 2 80% 10% 10%
ATTACH
6.SLEEVE Poonam R-2 G G G 18 2 90% 10%
DIAMOND
FINISH
7. SLEEVE Renu Y G G G 19 1 95% 5%
DIAMOND
FINISH
8. COLLAR Uday G G G G 20 100%
BAND
PRESSING
9. COLLAR Sadhna G G G G 20 100%
READY
PRESSING
10. Seema G G G G 20 100%
COLLAR
ATTTACH
11. Shehzad R-2 G G G 18 2 90% 10%
COLLAR
FINISH
12. Gautam Y G G G 19 1 95% 5%
COLLAR
FINISH
13. SLEEVE Pappu G G G G 20 100%
ATTACH
14. SLEEVE Sadhna G Y G G 19 1 95% 5%
ATTACH
15.A/H T/S Laxmi G Y G G 19 1 95% 5%
16. A/H T/S Siksha Y Y G G 18 2 90% 10%
17. INLINE Manoj NIL NIL NIL NIL
CHECKING
18. SIDE Guddi G G G G 20 100%
SEAM
19. SIDE Vijay G Y G G 19 1 95% 5%
SEAM
20. Sarla Y G G G 19 1 95% 5%
BOTTOM
FOLD
21 BOTTOM Sumitra Y G G G 19 1 95% 5%
FOLD
22. CUFF Satto Y G G G 19 1 95% 5%
ATTACH
23. CUFF Naushad Y G G G 19 1 95% 5%
ATTACH
24.W/C Kanchan G G G G 20 100%
LABEL
25. FINAL Punchan R-2 Y G G 17 1 2 85% 5% 10%
CHECKING
TOTA 452 16 12 94.1% 3.3% 2.5%
L
LINE-9 STYLE- Shift Quantity Percentage
13/8 1797
OPERATION OPERATO 1 2 3 4 G Y R G% Y% R%
R
NAME
1.B/H SADHNA G Y G G 19 1 95% 5%
PLACKET
FOLD
2. BUTTON SHASHI G G G Y 19 1 95% 5%
PLACKET
FOLD
3. POCKET PRADEEP G G G G 20 100%
PRESSING
4. POCKET KAVITA Y Y G G 18 2 90% 10%
ATTACH
5.POCKET RIMA Y Y G G 18 2 90% 10%
ATTACH
6.SLEEVE POONAM G G Y G 19 1 95% 5%
DIAMOND
FINISH
7. SLEEVE RENU G G G G 20 100%
DIAMOND
FINISH
8. COLLAR UDAY G G G G 20 100%
BAND
PRESSING
9. COLLAR SADHNA G G G G 20 100%
READY
PRESSING
10. SEEMA G G G G 20 100%
COLLAR
ATTTACH
11. SEHZAD Y Y Y G 17 3 85% 15%
COLLAR
FINISH
12. GAUTAM Y G G Y 18 2 90% 20%
COLLAR
FINISH
13. SLEEVE PAPPU G G G G 20 100%
ATTACH
14. SLEEVE SADHNA G G Y G 19 1 95% 5%
ATTACH
15.A/H T/S LAXMI G G G G 20 100%
16. A/H T/S SEEKSHA G Y G G 19 1 95% 5%
17. INLINE MANOJ NIL NIL G R-3 7 3 70% 30%
CHECKING
18. SIDE GUDDY G G Y Y 18 2 90% 10%
SEAM
19. SIDE VIJAY G G G G 20 100%
SEAM
20. SARLA G G G G 20 100%
BOTTOM
FOLD
21 BOTTOM SUMITRA G G Y G 19 1 95% 5%
FOLD
22. CUFF NAUSHAD Y G G G 19 1 95% 5%
ATTACH
23. CUFF SATTIO Y G G G 19 1 95% 5%
ATTACH
24.W/C KANCHAN G G Y G 19 1 95% 5%
LABEL
25. FINAL PANCHAM Y R-2 G G 17 1 2 85% 5% 10%
CHECKING
TOTA 464 21 5 94.6% 4.3% 1%
L
Findings

Below are two graphical representation which shows the reduction in final
checking DHU after the implementation of traffic light system.

DHU by date after applying TLS system.

Line no. 9 style 1797

70
60
50
40
defect
30
20
10
0
633 511 531 340 413

Date No. of pieces checked Defect Percentage

9/8/2016 633 61 9.6%
10/8/2016 511 60 11.74%
11/8/2016 531 57 10.7%
12/8/2016 340 32 9.4%
13/8/2016 413 27 6.5%

DHU by date after applying TLS system

Line no. 11 style-1797

160
140
120
100
80 defe
ct
60
40
20
0
413 572 607 550 558

Date No.of pieces checked Defect Percentage

9/8/2016 413 101 24.5%
10/8/2016 572 143 25%
11/8/2016 607 93 15.3%
12/8/2016 550 86 15.6%
13/8/2016 558 75 13.4%
Conclusion

Traffic light system is a system that can be implemented easily in any garment
manufacturing company and it will help to improve the quality status, reduced the
cost, improve the lead time and thus strengthen the supply chain performance
without increasing the resource. Hence implementation of traffic light system will
help to get more quality products from Operators of this age.