SOP Traffic Light System

Performed By: - Quality Controller.

Responsible Department - Quality Department.
Purpose:

- To inspect the sewing operations (quality).

- To check for any machine malfunctioning.
- To track operators skill set.

Scope:

- To be done in the sewing lines by the quality controller, where three cards with three specific shades,
all with different standards are given to the operators on the basis of their performance. The
performance check is done at least twice a day, mainly morning and afternoon in order to minimize
defects simultaneously in the process.

Equipment:

- Traffic light system format.

- Green, Yellow, Red cards

Procedure:

1. While starting a new layout, one format is allocated for each and every operator in a line by the QC
and production unit, line number, style number, job number, PO number, month and year of
production, buyers name, name of operation, operators name and card number must be noted in the
prescribed format.
2. One format should be issued for one particular operator. And the format needs to be replaced with a
new one if the style of the garment in the line changes.
3. At least twice every day (morning and afternoon), the line QC must visit each and every operator in
the line and 7 pieces should be picked randomly to check the quality of the output according to the
buyers requirement.
4. If the QC finds that all the selected pieces have been produced according to the required standards,
then he rewards a green card to the operator to proceed further.
5. In case if the one defective piece, then the operator should be given with a yellow card keeping
record in the given format about the defect and quantity of the defect accordingly.
a. The QC must visit that particular operator at least four times during the whole day.
b. While the next visit, if the QC finds no defect, then the operator should be rewarded a green
card.
c. But if the QC finds the same defect again, then the operator should be given a red card. And
the following procedure no. 5 (a-e) should be followed.
d. The operator should be given a yellow card if one defect is found from the operator, after the
visit when he was given a green card and so the process continues.
6. In case if the two or more defective piece, then the operator should be given with a red card and the
machine should be stopped immediately, keeping record in the given format about the defect and
quantity of the defect accordingly..

a. The QC must visit that particular operator several times during the whole day.
 b. The QC notifies the maintenance and production department. Analysis of the process is done
on spot by the authorized personnel of the respective departments. They are expected to find
the problem related to the machine or operator and solve it accordingly within 10 minutes and
hence, the machine starts working again. All of them must be there and check few pieces until
the machine works properly.
c. In the next visit, if the QC finds the same problem once again then the previous process
follows.
d. But in case if the QC does not find any defect, then also the operator will retain the red card
as warning.
e. In the next two visits also if the QC finds no defect then the operator will be given a yellow
card, followed by a green card eventually.
7. The Line Quality Controller should sign the report after summarizing total checked quantity, total
defect quantity, and should calculate defect percentage and should note down the data in the given
format accordingly.
8. Actions taken for Red card by the personnels are noted down on the reverse side of the Daily In-
line Audit Report(7/0-Audit)