project II

implementation
of in-line traffic light system
of inspection

Title: In-Line Traffic Light System of Inspection

Objective: To build in quality at the point of operation through Traffic light system in order to reduce
defects leading to reworking\ alterations and to improve factory efficiency.
Background:The project is specifically aimed at improving first time quality of the product by bringing
precision and consistency in execution of operations, by making operators cognizant with their
performance level and accuracy at specified intervals. This will lead to rise in efficiency of
operators, resulting in growth in output of the factory; as well as reduction in number of defected
pieces at the end of sewing lines, subsequently saving the time and the cost incurred by the
company on their reworking and alteration.
Need for the project: REDUCING ALTERATION RATE - Higher alteration rate stands as a severe bottleneck
in achieving an uninterrupted production flow, and adding up unnecessary production
cost and time.
INCREASING OPERATOR EFFICIENCY - Operator efficiency is a very crucial factor
in determining the attainment of specified target in production lines. Higher efficiency is
directly proportional to better productivity.
QUALITY IMPROVEMENT- Quality is the one of the most important aspects which
influences the salability of the product. Consumer satisfaction is highly based on the
quality being offered. Thus it is very essential to have an avant-garde approach towards
quality.
DESCRIPTION
The traffic signal system is based on three lights green, yellow and red. The lights are used to
symbolize the quality status at the operation and make supervisor aware of where problems are
occurring and give the in line controllers an idea where they have to spend more time.
Green:
Yellow:
Red:

Good
Isolated defects found
Recurring defects or major defects found

In line QC has to check a minimum of 10 pieces in each visit of the work station. The In line
controller will monitor the inspection and record it. The marking of lights are done as follows:
If 9-10 checked pieces are found correct

If 8 pieces are found correct

If 7 or <7 pieces are found correct

METHODOLOGY:PART I
Step 1: Studying of the productivity of the line with respect to the running style on a single day.
Step 2: Separation of defect-free and pieces with defects during end line auditing\ inspection.
Step 3: Classification and recognition of defects on the basis of intensity of occurrence.
Step 4: Calculation of total production and no. of pieces send back for rework\ alteration.
Step 5: Continuation of the process for a week (5 working days).
Step 6: Determination of average production and average percentage alteration.
PART II
Step 1: Putting of formats of Traffic Light System on critical operations (defined on the basis of
maximum no. of associated defects)
Step 2: Checking of pieces and filling of formats with prescribed colors by In-line QC on hourly
basis for the whole day.
Step 3: Calculation of total production and no. of finished pieces send for rework\ alteration in
terms of percentage at the end of the day.
Step 4: Continuation of the process for 3 weeks
Step 5: Determination of average production and average percentage alteration per week.
Step 6: Comparison of the difference of average productivity and percentage alteration pre and
post implantation of Traffic Light System.

IMPLEMENTATION
In accordance with our project, the In-Line Traffic Light System of Inspection got implemented
in Line No. 1 loaded with:
Style no. 312450
Buyer- STARDIVARIUS
Description- Dress
Order Quantity- 60000

*Prior to implementation of Traffic Light System of Inspection

DATE
7-07-2014
8-07-2014
9-07-2014
10-07-2014
11-07-2014
12-07-2014
TOTAL

Average production

OUTPUT
(LINE NO. 1)
1120
1122
1120
1118
1131
1145
6756

= 6756\6
= 1126

Average alteration = 140\6

= 23.33%

DEFECTED
PIECES
235
253
301
256
271
255
1571

ALTERATION %
21
23
27
23
24
22
140

*Post implementation (1st week) of Traffic Light System of Inspection

DATE
14-07-2014
15-07-2014
16-07-2014
17-07-2014
18-07-2014
19-07-2014
TOTAL

Average Production

OUTPUT
(LINE NO. 1)
1135
1142
1130
1132
1137
1128
6804

DEFECTED
PIECES
245
257
250
222
259
212
1445

ALTERATION %
22
22
22
20
23
19
128

= 6804\6
= 1134

Average alteration

= 128\6
= 21.33%

*Post implementation (2nd week) of Traffic Light System of Inspection

DATE
21-07-2012
22-07-2012
23-07-2012
24-07-2012
25-07-2012
26-07-2012
Total

Average production

OUTPUT
(LINE NO. 1)
1150
1155
1160
1158
1148
1152
6923

= 6923\6
= 1154

Average alteration

= 121\6
= 20.2%

DEFECTED
PIECES
250
230
257
219
217
220
1393

ALTERATION %
21
20
22
19
19
20
121

*Post implementation (3rd week) of Traffic Light System of Inspection

DATE

OUTPUT
(LINE NO. 1)

DEFECTED
PIECES

ALTERATION %

28-07-2012
29-07-2012
30-07-2012
31-07-2012
01-08-2012
02-08-2012
TOTAL

1170

180

15

1175

149

13

1180

152

13

1168

173

15

1172

186

16

1178

149

13

7043

989

84

Average production

= 7043\6
= 1174

Average alteration

= 84\6
= 14%

*Post implementation (4th week) of Traffic Light System of Inspection

DATE

OUTPUT
(LINE NO. 1)

DEFECTED
PIECES

04-08-2012
05-08-2012
06-08-2012
07-08-2012
08-08-2012
09-08-2012
TOTAL

1205

131

11

1213

118

10

1205

132

11

1228

129

11

1218

129

11

1240

126

10

7309

765

64

Average production

= 7309\6
= 1218

Average alteration

= 64\6

ALTERATION %

= 10%

ANALYSIS: -

Average production post implementation

1250
1200
1150
1100
1050

INFERENCES: -

Average alteration % post implementation

25
20
15
10
5
0

% Production rise post implementation

4.5
4
3.5
3
2.5
2
1.5
1
0.5
0

% Alteration reduction post implementation

14
12
10
8
6
4
2
0

COST- BENEFIT ANALYSIS

MAJOR DEFECTS ZONE

(OPERATION)
Bind neck all around

NORMAL SAM

Join piping @ armhole

Binding @ zipper
Attach zipper
Tack zipper @ (bottom &
top)

COST

0.61

ALTERATION SAM
(AVERAGE)
3

0.31
0.47
0.81
1.12

2
2.5
4
5

Rs 2
Rs 2.5
Rs 4
Rs 5

*Operational cost per minute = Rs 1.0/-

Average alteration cost = (3+2+2.5+4+5)\6

= Rs 3.30

Rs 3

PRE- IMPLEMENTATION
Alteration cost = No. altered piece\week * Average alteration cost
= 1575*Rs3.3
= Rs5197.5
POST IMPLEMENTATION
Alteration Profit
No. of altered
piece\week

Total
alteration cost

Alteration
Benefit

1ST Week

1445

4678.3

519.2

2ND Week

1393

4596.9

600.6

3RD Week

989

3263.7

1933.8

4TH Week

765

2524.5

2673

Total Profit

Rs. 5726.6

Production Profit
Rise in
Production
1st Week

Operational Cost per

Piece

Production
Benefit

46

9.2

423.2

2nd Week

167

9.2

1536.4

3rd Week

287

9.2

2640.4

4th Week

553

9.2

5087.6

Total Benefit

9687.6

*Cost of employing In-line QC = Rs350 per day

For a period 4 weeks, it is (Rs350*24) = Rs8400
Gross Profit= Alteration Benefit+ Production Benefit-Cost of Employing
QC

Gross Profit = (Rs 5726 + Rs 9687 Rs 8400)

= Rs. 7013
LIMITATIONS

It is costly as we install it.

Not easy for workers to understand.
Requires a systematic and regular attention for updating the format.
May create extra pressure on operators which could create adverse impact in the long run.

SCOPE

The formats can be put on each and every operation for complete minimization of
alteration.
There can be a separate format for line supervisor as well; so that they also become
careful about the defected operations.