1.1.1 - RQC Pre-Production Section

Roving Quality Control System
(Pre-Production Section)
JANUARY 2010
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PREPRE-PRODUCTION ROVING QC ROLLROLL-OUT IMPLEMENTATION
JANUARY
AREA
Wk 1
Wk 2
Wk 3
FEBRUARY
Wk 4
Wk 5
Wk 6
Wk 8
Wk 9
No Work
Spreading
Wk7
MARCH
Moulding
Cutting
Bow Lace
TRAINING WEEK
1st Day: Orientation of Supervisors (PPSV, QSV, RQC)
2nd Day: Introduction to Pre-Production Operators
Observation/Practice/Familiarisation of RQC
MONTHLY EVALUATION
Consolidation of Rejects recorded in the Roving QC Weekly Analysis
ACTUAL IMPLEMENTATION & CONTINUOUS MONITORING

Triumph Roving QC Weekly Analysis
Roving QC Weekly Summary Report
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Wk 10
Wk 11
Wk 12
What tools are needed by the Roving

QC?
Green & Red
highlighters
Approved Pattern,
Standards, &
Specifications
Clipboard
Roving QC Daily Sheet
Roving QC Daily
Sheet
MOULDING SPECIRICATION
CUTTING INSTRUCTION
SHEET
CUTTING INSTRUCTION
SHEET
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Pencil
A good eye !!!!!!!!
What do we need at the Pre-Production ?
Red cone
Green cone
Operators Daily Sheet
OPERATORDAILY SHEET
OPERATORDAILY SHEET
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How will the Roving QC be

implemented in the PreProduction 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, PreProduction
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 Inspected

1)
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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CLASSIFICATION OF DEFECTS - PRE-PRODUCTION

Fault Type: A - Major; B - Minor
SF - SPREADING FAULTS
A
A
A
A
A
A
A
A
SF1
SF2
SF3
SF4
SF5
SF6
SF7
SF8
No. of Layers not According to Spec.

Missing Separator for Different Shades
Wrong Spreading Method
Wrong Placement of Marker
Faulty Blocking
Incomplete Size/Size not in Set
Material Not Flat/Uneven
Wrong Material
BK - BANDKNIFE FAULTS/DYE-CUT
A
B
A
B
A
A
B
A
A
A
CT1
CT2
CT3
CT4
CT5
CT6
CT7
CT8
CT9
CT10
Nicks too deep

Uneven Cutting Edge
Out of Cutting Allowance
Fused Cutting Edge
Cutwork not According to Pattern
Wrong Dye-Cut Used
Missing Nick/Missing UV Mark
Wrong Cutting Line
Wrong Size
Folded Fabric
MD - MOULDING FAULTS
A
A
A
A
A
A
A
A
A
A
B
A
MD1
MD2
MD3
MD4
MD5
MD6
MD7
MD8
MD9
MD10
MDPA1
MDPA2
Unbalanced Drawing
Colour Change After Moulding
Loose Diameter/Cup Deepness/Shrinkage
Wrinkles/Puckered/Creased
Stain/Foreign Material/Contamination
Wrong Cutting Line
Wrong Kegel Used
Mould Mark (Ring Mark)
Distorted/Displaced Bustpoint
Too High Temperature (Fabric Became Brittle)
Missing No. of Layers
Wrong Size
BD - BONDING FAULTS
A
A
A
A
A
BD1
BD2
BD3
BD4
BD5
Delamination
Bubbles/Wrinkles
Incorrect Face Side
Colour change after bonding
Non-symmetrical (if in pairs)
HS - HEATSEAL FAULTS
BF - BOWLACE FAULTS
A
A
B
BF1
BF2
BF3
B
B
BF4
BF5
A
A
BF6
BF7
Width Variation & Repeat Length

Wrong Placement of Pattern/One-Way Lay
Missing Ultraviolet Pen for Nicks/
Missing Number of Layers
Uneven Pinning of Materials
Layers too high/
Excessive Bundles (too many)
Incorrect Material
Folded Lace
RM - RAW MATERIAL FAULTS

A
A
RM1
RM2
RM3
RM4
Shade Variation
Scattered Blue/Black Dots, Stain,
Glue Spot
Width Variation/Short Width/
Shrinkage/Repeat Length
Hole/Joining/Run Line/Crease Mark/
Warp Line/Weft Line/Folded Mark/
Snags/Fluffs/Moiree or Water Marks
A
A
A
A
A
B
HS1
HS2
HS3
HS4
HS5
HS6
Delamination/Peeling Off
Incorrect Placement
Incorrect for Colour
Damage on motif
Discolouration after heat pressing
Misplacement of 1-2mm (motif)
SHOULDER STRAP FAULTS A

A
A
A
B
B
A
A
A
A
A
A
A
SS1
SS2
SS3
SS4
SS5
SS6
SS7
SS8
SS9
SS10
SS11
SS12
SS13
Wrong Width/Length
Wrong Direction (for patterned straps)
Incorrect Material Used (Size & Colour)
Elongation (Too Much/Too Little)
Uneven Cut Edge
Missing Nick/Missing UV Mark
Stitch Density Too Tight/Loose
Sharp Edge After Sewing
Too Wavy/Curved
Cracking Stitch
Incorrect Stitch Used
Style/Colour Mix-Up
Incorrect Bundle Quantity
LM - LAMINATION FAULTS
A
A
A
A
A
A
A
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LM1
LM2
LM3
LM4
LM5
LM6
LM7
Delamination
Wrong Material Used
Bubbles/Wrinkles
Incorrect Face Side
Foreign Material Inside the Laminated Fabric
Handfeel Too Hard/Harsh
Uneven Edges
LB - LABEL PRINTING FAULT

A
A
A
A
A
A
A
A
B
LB1
LB2
LB3
LB4
LB5
LB6
LB7
LB8
LB9
Unclear Print (Unreadable)

Smudged Print/Stain/Ink
Incorrect Details
Missing Letters/Details
Incorrect Materials Used
Print is Peeling-Off
Incorrect Placement
Mix-Up - style/size/colour
Slight stain/smudge
How will the RQC Pre-Production

System Work?
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<Operator
Operator Daily Sheet> - Enter Month, Area,
Operator
<Roving
Roving QC Daily Sheet>Sheet Enter
Date, Area, RQC, QC Supervisor
Equipment:
Equipment Pencil, Highlighter (Green
& Red)
Frequency: As Required
Check markers during process

of spreading
NO DEFECT
Inform the spreader to continue

In the Operator Daily Sheet, color
the appropriate cell in Green
In Roving QC Daily Sheet,
Sheet fill the
result in relevant column ()
Raise the Green cone
Move onto the next table
DEFECT
MAJOR FAULT
RAW MATERIAL FAULT
Inform the Pre-Prod Supervisor

of the defect found
Instantly inform the Pre-Prod

Supervisor of the defect found
In the Operator Daily Sheet,
Sheet color
the appropriate cell in Red & indicate
the nature of defect (e.g. RM3). PreProd Supervisor & RQC signs off.

Sheet color
the appropriate cell in Red & indicate
the nature of defect (e.g. SF3). PreProd Supervisor & RQC signs off.

Sheet fill the
result in relevant column (x)

Sheet fill the
Raise the Red cone & move on

to the next table
Raise the Red cone
Pre-Prod Supervisor checks the

Defects found & inform Production
Section Chief & QC Supervisor

Pre-Prod Supervisor checks the
lay-out & instruct the spreader to
re-layout
Pre-Prod Supervisor re-checks the
re-laid out fabric/ace and ask
the RQC to check again
Pre-Prod Supervisor instructs the

spreader not to continue, re-roll the
fabric & lay another marker
NO
YES
Defect within
Tolerance (by
QA Manager)
Inform the spreader to continue
Pre-Prod Supervisor calls the RQC

and inform the result
RQC indicates in the marker defect

found to alert RQC in Cutting

Sheet color

Sheet color

Sheet fill the
result in relevant column()
& indicate return fabric
ROVING QC PROCEDURE
IN SPREADING (A)

Sheet fill the

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Pre-Prod Supervisor calls the

RQC and inform the result
Checks ALL finished

laid markers/fabric
NO DEFECT
DEFECT
RAW MATERIAL FAULT
MAJOR FAULT
Instantly inform the Cutting

Supervisor of the defect found
In the Operator
Daily Sheet,
Sheet color
the appropriate
cell in Green
Inform the Cutting Supervisor

of the defect found
Sheet color
the appropriate cell in Red &
indicate the nature of defect (e.g.
SF3). Cutting Supervisor & RQC
signs off.

Sheet color the
appropriate cell in Red and indicate the
nature of defect (e.g. RM1). Pre-Prod
Supervisor & RQC signs off.
In Roving QC Daily
Sheet, fill the result
Sheet
in relevant column
()

Sheet fill the

Sheet fill the
Raise the Red cone and move on

to the next table
Raise the Red cone
Cutting Supervisor checks the defects found

and inform Cutting Section Chief & QC Supervisor
Move to the next table
YES
Cutting Supervisor calls the

RQC & inform the result
Defect Within
Tolerance (By QA
Manager)
RQC indicates in the marker

defect found to warn RQC in cutting
Cutting Supervisor instruct

the spreader to stop,
re-roll the fabric & lay another
marker.
In the Operator Daily Sheet color the

appropriate cell in Green
ROVING QC
PROCEDURE
IN SPREADING (B)
NO
Move on to the next table

Cutting Supervisor checks the
layout & instruct the spreader
to re-layout
Cutting Supervisor re-checks
the re-laid out & ask the RQC
to check again
In the Operators Daily Sheet,

Sheet
color the appropriate cell in Green
In Roving QC Daily Sheet fill the

In the Roving QC Daily Sheet,

Sheet fill
the result in relevant column &
indicate return fabric
Inform the spreader to proceed with blocking

Inform the Spreader to lay next
marker
In the Operator Daily Sheet, color the
Sheet fill the result
in relevant column ()
Move to the next table
NO
DEFECT
WITH DEFECT
Inform the Cutting Supervisor

of the defect found
Cutting Sup instructs the spreader to remove the affected part (size/
pattern), re-lay another fabric for the particular size affected
Sheet indicate the defect code, color
the appropriate cell in Red. Pre-Prod Sup & RQC signs off.
Sheet fill the result in relevant column (x)
Raise the Red cone
Pre-Prod Supervisor checks the re-laid fabric & ask the
RQC to check again
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<Operator
Operator
<Roving
Equipment:
& Red)
At the start of each day, refer to the QC Supervisor for styles/cutworks in need of special attention
Review approved/correct pattern, cutting specification,
& any other points agreed in PP Meeting
ALL PARTS/ALL SIZES
FOR NEW STYLES MUST
BE CHECKED
Check cut panels for measurement & balance. Check top, middle, & bottom ply
against the approved pattern.
DEFECT
NO
DEFECT
RAW MATERIAL FAULT
MINOR
Return the cut panels

back into the bundle
RQC instantly inform & return the

defective pieces to Cutting Supervisor
Return the defective pieces back to

the Operator for repair
In the ODS,
ODS color
the appropriate
cell in Green
In Roving QC Daily
Sheet
in relevant column
()
RQC instantly inform &

return the defective pieces
to Cutting Supervisor
Cutting Supervisor should determine how

to handle the defect & ask the Operator
to check the whole bundle
In the ODS,
ODS enter the relevant
defect code (e.g.CT2/1). Color the
appropriate cell in Green and sign
it off
Cutting Supervisor should

determine how to handle
the defect & ask the
Operator to check the
whole bundle
In the ODS,
ODS color the appropriate cell in
Red and indicate the nature of defect
(e.g. RM4/1). Cutting Supervisor & RQC
signs off.

Sheet fill
the result in relevant column (x)
In RQCRQC-Daily Sheet,
Sheet fill the
In the ODS,
(e.g. CT1/1). Cutting Supervisor & RQC
signs off.

to the next table
Move onto the next operator

Sheet fill the
NO
Cutting Sup instructs the Cutter
not to continue & cut another lay
ROVING QC PROCEDURE IN
FABRIC, DIE-CUT, &
BOWLACE CUTTING
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MAJOR FAULT
Defect Within
Tolerance
(by QA Manager)
YES
Inform the Cutter to continue
Cutting Supervisor re-checks

the new cutwork & ask the RQC
to check again
RQC indicates in the panels defect

found to alert RQC in Sewing
In the ODS,
ODS color the appropriate
cell in Green
In the ODS,
cell in Green

Sheet fill
indicate return fabric

Sheet fill the
Raise the Green cone & move onto the next Cutter

to the next table
If the defect can be repaired, Cutting
Supervisor will call the RQC back as soon
as the Operator is finished with the repair.
If the defect cannot be repaired, Cutting Sup
will ask the Operator to cut another lay,
check the cut pieces, then call the RQC to
check the new cutworks.
<Operator
Operator
<Roving
Equipment:
& Red)
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
ALL SIZES FOR NEW
STYLE and COLOUR MUST
BE CHECKED
Check top, middle, & bottom of the bundle against the approved plastic shot/standard
DEFECT
MAJOR
RAW MATERIAL DEFECT
NO
DEFECT

to Moulding Supervisor

defective pieces to Moulding Supervisor
Return the moulded cups

Moulding Supervisor should determine how to

handle the defect & ask the Operator to check
the whole bundle & sort the defect out.
In the ODS,
cell in Green
Moulding Supervisor should

determine how to handle the defect
& ask the Operator to check the
whole bundle & sort out.
In the ODS,
ODS color the appropriate cell in Red
and indicate the nature of defect (e.g. MD2/5).
Moulding Supervisor & RQC signs off.

Sheet fill
the result in relevant column ()
In the ODS,
cell in Red and indicate the nature
of defect (e.g. MD1/1). Moulding

Sheet fill the
Sheet fill the

to the next table
Raise the Red cone and move

on to the next operator
Moulding Supervisor ask the Operator
to stop & mould another bundle.
NO
Moulding Supervisor calls the

YES
Moulding Supervisor calls the

Inform the Moulder to continue
Moulding Supervisor re-checks

the new work & ask the RQC
to check again

found to alert QC in succeeding check
In the ODS,
cell in Green
MOULDING
Defect Within
Tolerance
(by QA Manager)
In the ODS,
cell in Green

Sheet fill the result in
relevant column & indicate replaced cups

Sheet fill the
Raise the Green cone & move onto the next Cutter
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Moulding Supervisor will

ask the Operator to mould
another bundle, check
the finished piece, then
call the RQC to check
the new works.
<Operator
Operator
<Roving
Equipment: Pencil, Highlighter

(Green& Red)
At the start of each day, refer to the QC Supervisor for laminated works in need of special attention
PLEASE REFER TO THE RAW
MATERIAL GLOBAL QUALITY
MANUAL (JAN 10) FOR TESTING
REQUIREMENT BEFORE START
OF BULK PRODUCTION
Review approved standard, lamination/bonding specification,

and any other points agreed in PP Meeting
Check 7pcs/bundle or 10%/roll of laminated fabric
DEFECT
NO
DEFECT
RAW MATERIAL DEFECT
Return the laminated

panels back into the bundle

defective pieces to Lamination Supervisor
RQC instantly inform & return

the defective pieces to Lamination/Bonding Supervisor
Lamination Supervisor should determine how to

handle the defect & ask the Operator to check
the whole bundle & sort the defect out.
In the ODS,
cell in Green
Sheet fill
MAJOR
In the ODS,
and indicate the nature of defect (e.g. LM1/1 ).
Lamination Supervisor & RQC signs off.
Lam/Bonding Sup should determine

how to handle the defect & ask the
Operator to check the whole bundle
In the ODS,
of defect (e.g. LM1/1). Lam/Bonding

Sheet fill the
to the next operator
Sheet fill the
Lam/Bond Supervisor ask the Operator

To stop & process another bundle/roll
Lam/Bond Supervisor calls the
Lam/Bond Supervisor re-checks
to check the new works
LAMINATION/
BONDING
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In the ODS,
cell in Green
Sheet fill the result in
relevant column & indicate replaced panel
NO
Defect Within
Tolerance
(by QA Manager)
YES
Lamination Supervisor calls the
Inform the operator to continue
found to alert QC in succeeding check
In the ODS,
cell in Green
Sheet fill the
Raise the Green cone & move onto the next Operator
Heatseal Supervisor will ask the

Operator to heat press another bundle,
check the finished piece, then call the
RQC to check the new works.
<Operator
Operator
<Roving

(Green& Red)
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
RAW MATERIAL FAULT
NO
DEFECT
MINOR
Return the pieces


the Operator for his/her info
In the ODS,
cell in Green
In the ODS,
defect code (e.g.HS5/1). Color the
it off

Sheet fill

defective pieces to Heatseal Supervisor
Heatseal Supervisor should determine how to handle
the defect & ask the Operator to check the whole bundle
In the ODS,
and indicate the nature of defect (e.g. HS1/1).
Heatseal Supervisor & RQC signs off.

Sheet fill

Heatseal Supervisor instruct

the operator to stop & do
another bundle
Heatseal Supervisor calls the
HEATSEAL
(RHINESTONES,
RUBBERISED
MOTIF, & DIAMONTES)
Heatseal Supervisor re-checks

to check again
In the ODS,
cell in Green
NO
Defect Within
Tolerance
(by QA Manager)
YES
Sheet fill the
Heatseal Supervisor calls the

Inform the Operator to continue
Heatseal Supervisor will ask the

Operator to heat press another bundle,
check the finished piece, then call the
RQC to check the new works.

In the ODS,
cell in Green
Sheet fill the

Sheet fill
indicate replaced panels
Raise the Green cone & move onto the next Cutter/Sewer
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Heatseal Supervisor should determine

how to handle the defect & ask the
Operator to check the whole bundle
In the ODS,
of defect (e.g. HS1/1). Heatseal
Sheet fill the
MAJOR
to Heatseal Supervisor
<Operator
Operator
<Roving

(Green& Red)
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
RAW MATERIAL FAULT
NO
DEFECT
MINOR
Return the sewn/cut

straps back into the
bundle

defective pieces to S/S Supervisor

the Operator for repair
In the ODS,
ODS color
the appropriate
cell in Green
In Roving QC Daily
Sheet
in relevant column
()

Sheet fill the
to the next table

to the next table
S/S Supervisor instruct

the operator to stop & arrange
for 100% check on all WIP
S/S Supervisor calls the
In the ODS,
cell in Green
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In the ODS,
(e.g. M1/1). S/S Supervisor & RQC
signs off.
Sheet fill the
SHOULDERSTRAP
CUTTING/SEWING
S/S Supervisor should determine how to

handle the defect & ask the Operator to
check the whole bundle & repair
In the ODS,
(e.g. RM3/1). S/S Supervisor & RQC
signs off.

Sheet fill

to S/S Supervisor
S/S Supervisor should determine how

to check the whole bundle & sort out
In the ODS,
defect code (e.g.SS6/1). Color the
it off

Sheet fill
indicate return elastic/straps
NO
Defect Within
Tolerance
(by QA Manager)
MAJOR FAULT
YES
S/S Supervisor calls the
Inform the Cutter/Sewer to continue
RQC indicates in the straps defect
In the ODS,
cell in Green
Sheet fill the
Raise the Green cone & move onto the next Cutter/Sewer
If the defect can be repaired, S/S

Supervisor will call the RQC back as
soon 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 to
check the new cutworks.
<Operator
Operator
<Roving

(Green& Red)
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
DEFECT
NO
DEFECT
MINOR
Return the pieces

In the ODS,
ODS color the

Sheet fill
RAW MATERIAL FAULT

the Operator for his/her info

defective pieces to Label Supervisor
In the ODS,
defect code (e.g.LBL9/1). Color the
it off

return the defective labels
to Label Supervisor
Label Supervisor should determine how

to check the whole bundle & sort out

Sheet fill
In the ODS,
(e.g. RM4/1). Label Supervisor & RQC
signs off.
MAJOR FAULT
Sheet fill the
Label Supervisor should

determine how to handle the defect
& ask the Operator to check the
whole bundle & sort out defective qty
In the ODS,
(e.g. LB1/1). Label Supervisor & RQC
signs off.
Sheet fill the

to the next Operator

to the next Operator
Label Supervisor instruct
the operator to stop & arrange
to 100% check all WIP
Label Supervisor calls the
In the ODS,
cell in Green
LABEL PRINTING/LABEL
PRINTED DIRECTLY ON
THE GARMENT
Triumph

Sheet fill
indicate return labels
NO
Defect Within
Tolerance
(by QA Manager)
YES
Label Supervisor calls the
Inform the Operator to continue
RQC indicates in the labels defect
In the ODS,
cell in Green
Sheet fill the
Raise the Green cone & 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.
What forms to be used?
Triumph
ROVING QC DAILY SHEET - Pre-Production

TRIUMPH ROVING QC SYSTEM
ROVING QC NAME:
DATE:
AREA:
Style
Commission #
Colour
DAY:
Cup
Material
QC SUPERVISOR:
Entered By QC Clerk:
(For Office Use Only)
Operator's Name
Layers
Inspected
Result
( or X)
Qty of Layer with

Defect/Rejected
Follow-up
Remarks
DEFECT CODE:
SF = SPREADING FAULTS
SF1
SF2
SF3
SF4
SF5
SF6
SF7
SF8
No. of layers not according to spec

Missing separator for different shade material
Wrong spreading method
Wrong placement of marker
Faulty blocking
Wrong Material
BF = BOWLACE FAULTS
BF1
BF2
BF3
BF4
BF5
BF6
BF7
Width variation & repeat length

Wrong placement of pattern
Missing ultraviolet pen for nicks/Missing no. of layers
Uneven pinning of materials
Layers too high/Excessive bundles (too much)
Incorrect material
Folded lace
BK = BANDKNIFE/DIE-CUT FAULTS
CT1
CT2
CT3
CT4
CT5
CT6
CT7
CT8
CT9
CT10
Nicks too deep

Uneven cutting edge
Out of cutting allowance
Fused cutting edge
Cutwork not according to pattern
Wrong die-cut used
Missing nick/Missing UV mark
Wrong cutting line
Wrong size
Folded fabric
Triumph
MD = MOULDING FAULTS
MD1
MD2
MD3
MD4
MD5
MD6
MD7
MD8
MD9
MD10
MDPA1
MDPA2
LM = LAMINATION FAULTS
LM1
LM2
LM3
LM4
LM5
LM6
LM7
HS = HEATSEAL FAULTS
Unbalanced drawing
HS1
Colour change after moulding
HS2
Loose diameter/Cup deepness/Shrinkage
HS3
HS4
Stain/Foreign material
HS5
Wrong cutting line
HS6
Wrong kegel used
Kegel mark (Ring mark)/Mould Mark
SS = SHOULDERSTRAP FAULTS
SS1
SS2
Missing number of layers
SS3
Wrong size
SS4
SS5
SS6
Delamination
SS7
Wrong material used
SS8
Bubbles/Wrinkles
SS9
Incorrect face side
SS10
Foreign material inside
SS11
Handfeel too harsh/hard
SS12
Uneven edges
SS13
BD = BONDING FAULTS
BD1
BD2
BD3
BD4
BD5
Delamination
Bubbles/Wrinkles
Incorrect face side
LB = LABEL PRINTING FAULTS

LB1
LB2
LB3
LB4
LB5
LB6
LB7
LB8
LB9
RM = RAW MATERIAL FAULTS

Delamination/Peeling off
RM1
Shade variation
Incorrect placement
RM2
Scattered blue/Black dots/Stain/Glue spot
Incorrect colour
RM3
Width variation/Short width/Shrinkage/Repeat
Damage on motif
length
RM4
Hole/Joining/Run line/Crease mark/Warp line/
Misplacement of between 1-2mm
Weft line/Folded mark/Snags/Fluffs/
Moiree or water mark
Wrong width or length
Wrong direction (for patterned straps)
Incorrect material used (size & colour)
Elongation (loose/tight)
Uneven cut edge
Missing nick or UV mark
Stitch density too tight/too loose
Sharp edge after stitching
Too wavy/curved
Cracking stitch
Incorrect stitch used
Style/colour mix-up
Incorrect bundle quantity
Unclear print (unreadable)

Smudged print/stain/ink
Incorrect print details
Missing letter/number/detail
Incorrect material used
Print peeling-off
Incorrect placement
Mix-up - style/size/colour
Slight stain/smudge
OPERATOR'S DAILY SHEET - Pre-Production

Month:
Date
01
Time
OPERATOR DAILY SHEET (to be kept at the operator's workstation at all times)
Operator:
Area:
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Morning
Roving QC
Pre-Prod Supervisor
Prod Section Chief
QC Supervisor
Remarks:
Afternoon
Roving QC
Pre-Prod Supervisor
Prod Section Chief
QC Supervisor
Remarks:
Night
Roving QC
Pre-Prod Supervisor
Prod Section Chief
QC Supervisor
Remarks:
If operator is on leave, mark "L" in the cell.
Remarks:
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:
MD1
Unbalanced drawing
HS1
RM1
Shade variation
MD2
HS2
Incorrect placement
RM2
Scattered blue/Black dots/Stain/
SF3
MD3
HS3
Incorrect colour
SF4
MD4
HS4
Damage on motif
SF5
Faulty blocking
MD5
HS5
HS6
SF6
MD6
Wrong cutting line
SF7
MD7
Wrong kegel used
SF8
Wrong Material
MD8
SS1
MD10
SS2
BF1
MDPA1
SS3
MDPA2
Wrong size
MD9
BF = BOWLACE FAULTS
BF2
SS4
SS5
Uneven cut edge
SS6
SS7
BF6
Incorrect material
LM1
Delamination
SS8
BF7
Folded lace
LM2
Wrong material used
SS9
Too wavy/curved
LM4
Incorrect face side
SS11
CT1
Nicks too deep
LM5
SS12
Style/colour mix-up
SS13
LM3
Bubbles/Wrinkles
Uneven cutting edge
LM6
CT3
LM7
Uneven edges
CT4
Fused cutting edge
CT2
CT5
SS10
Cracking stitch

BD = BONDING FAULTS
LB1
CT6
Wrong die-cut used
BD1
Delamination
LB2
CT7
BD2
Bubbles/Wrinkles
LB3
CT8
Wrong cutting line
BD3
Incorrect face side
Width variation/Short width/

Shrinkage/Repeat length
RM4
Hole/Joining/Run line/Crease
mark/Warp line/Weft line/Folded
BF3
Glue spot
RM3
mark/Snags/Fluffs/Moiree
BF4
BF5
Triumph
SF1
SF2
LB4
CT9
Wrong size
BD4
LB5
CT10
Folded fabric
BD5
LB6
Print peeling-off
LB7
Incorrect placement
LB8
LB9
Slight stain/smudge
or water mark
Forms to be used for Evaluation?
Triumph
DAILY CHECKING SUMMARY (EXCEPTIONS) - PRE-PRODUCTION
Week Commencing :

Unit:
TRIUMPH FACTORY
Area
SF
MD
CT
Style/Comm Operator's
Total
Number
Checked
Name
11-222/JPN#1
01/2-234
Dan/Ronie
33-444TWN05/6-789
#2 Joe/Max
H55-666 SIN#3
10/1-222
Rick/Alex
#4
Ming/Ken
#5
Nick/Willy
19-777
PRC11/333
H88-999
PRN12/444
16-222
MAL13/555
17-333
THL14/666
Spreading Faults
Bandknife/Die-Cut Faults
SF1 SF2 SF3 SF4 SF5 SF6 SF7 SF8 CT1 CT2 CT3 CT4 CT5 CT6 CT7 CT8 CT9 CT10 BF1
Total
Failed
Bowlace Faults
BF3 BF4 BF5 BF6
BF2
Moulding Faults
MD1 MD2 MD3 MD4 MD5 MD6 MD7 MD8 MD9 MD10MDPA1
BF7
MDPA2
Bonding Faults
Lamination Faults
BD1 BD2 BD3 BD4 BD5 LM1 LM2 LM3 LM4 LM5 LM6 LM7
6
20
1
5
P. Cruz
40
20
40
20
D. Reyes
20
20
L. Inigo
20
M. Bautista
20
60
4
26
4
6
20
0
20
20
20
2
BF/DC
BD
LM
HS
S/S
LB
0
TOTAL FAILED/REASONS
NOTE:
AM
PM
12
13
7
14
4
7
4
13
4
12
14
5
13
5
7
4
14
3
51
20
20
TOTAL NO. OF OPERATORS/AREA
Total number of rounds taken by RQC:
Spreading
Cutting
Bowlace
Moulding
Bonding
Lamination
Heatseal
Shouderstrap
Label
NOTES REGARDING THIS SHEET:

Once the data is entered, the auto filter can be actioned
to allow detail of each area to be viewed individually
MONDAY
"Data"/"Sort"/"Column A" function can be used to
sort the data into numerical production line order
Once sorted, a blank row can then be inserted
after the last row for each production line and the
auto sum function added to columns D to Q to see
the totals by line.
6
15
6
15
2
3
2
14
2
DEFECT CODE:
SF1
SF2
SF3
SF4
SF5
Faulty blocking
SF6
SF7
SF8
Wrong Material

RM1
Shade variation
RM2
Scattered blue/black dots/Stain/Glue spot
RM3
length
RM4
Weft line/Folded mark/Fluffs/Moiree
Triumph
BK = BANDKNIFE FAULTS
CT1
Nicks too deep
CT2
Uneven cutting edge
CT3
CT4
Fused cutting edge
CT5
CT6
Wrong die-cut used
CT7
CT8
Wrong cutting line
CT9
Wrong size
CT10
Folded fabric
BF = BOWLACE FAULTS
BF1
BF2
Wrong placement of pattern (one-way lay)
BF3
BF4
BF5
Layers too high/Bundles too much
BF6
Incorrect material
BF7
Folded lace
MD1
Unbalanced drawing
MD2
MD3
MD4
MD5
Stain/Foreign material/Contamination
MD6
Wrong cutting line
MD7
Wrong kegel used
MD8
Mould mark (Ring mark)
MD9
Distorted/Displaced bustpoint
MD10
Too high temperature (Fabric Became Brittle)
MDPA1
MDPA2
Wrong size
BD = BONDING FAULTS
BD1
Delamination
BD2
Bubbles/Wrinkles
BD3
Incorrect face side
BD4
BD5
WEEKLY SUMMARY OF DEFECTS FOUND

Total Failed Reason

FAIL REASON
AREA
Spreading
Bandknife/Dye Cut
Bowlace
Moulding
SF1
SF2
SF3
SF4
SF5
SF6
SF7
SF8
RM1
RM2
RM3
RM4
CT1
CT2
CT3
CT4
CT5
CT6
CT7
CT8
CT9
CT10
RM1
RM2
RM3
RM4
15
22
BF1
BF2
BF3
BF4
BF5
BF6
BF7
RM1
RM2
RM3
RM4
MD6
MD7
MD8
MD9
MD1
MD2
MD3
MD4
MD5
20
LM1
LM2
LM3
LM4
LM5
LM6
LM7
RM1
0
MD10 MD11 MDPA1 MDPA2
RM2
RM3
RM4
RM1
RM2
RM3
RM4
Area
Raw
Materials
Areas
Fault
Raw
Materials
Fault
62
10
1.6%
16.1%
130
37
28.5%
0.0%
#DIV/0!
#DIV/0!
50
25
50.0%
0.0%
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
26.0%
4.1%
Lamination
BD1
BD2
BD3
BD4
BD5
RM1
RM2
RM3
RM4
Bonding
HS1
HS2
HS3
HS4
HS5
HS6
RM1
RM2
RM3
RM4
Heatseal
SS1
SS2
SS3
SS4
SS5
SS6
SS7
SS8
SS9
SS10
SS11
SS12
SS13
RM1
RM2
RM3
RM4
Shoulderstrap
LB1
LB2
LB3
LB4
LB5
LB6
LB7
LB8
Percentage (%)
Total
Checked
Per Area
LB9
RM1
RM2
RM3
RM4
Label Printing
TOTAL FAULTS FOUND IN PRE-PRODUCTION
242
63
10
73
DEFECT CODE:
SF1
SF2
SF3
SF4
SF5
SF6
SF7
SF8

Faulty blocking
Wrong Material
BF1
BF2
BF3
BF4
BF5
BF6
BF7

Incorrect material
Folded lace
BF = BOWLACE FAULTS
CT1
CT2
CT3
CT4
CT5
CT6
CT7
CT8
CT9
CT10
Triumph
Nicks too deep

Uneven cutting edge
Fused cutting edge
Wrong die-cut used
Wrong cutting line
Wrong size
Folded fabric
MD1
Unbalanced drawing
MD2
MD3
MD4
MD5
MD6
Wrong cutting line
MD7
Wrong kegel used
MD8
MD9
MD10
MDPA1 Missing number of layers
MDPA2 Wrong size
LM1
Delamination
LM2
Wrong material used
LM3
Bubbles/Wrinkles
LM4
Incorrect face side
LM5
LM6
LM7
Uneven edges
BD = BONDING FAULTS
BD1
Delamination
BD2
Bubbles/Wrinkles
BD3
Incorrect face side
BD4
BD5
HS1
HS2
Incorrect placement
HS3
Incorrect colour
HS4
Damage on motif
HS5
HS6
SS1
SS2
SS3
SS4
SS5
Uneven cut edge
SS6
SS7
SS8
SS9
Too wavy/curved
SS10
Cracking stitch
SS11
SS12
Style/colour mix-up
SS13

LB1
LB2
LB3
LB4
LB5
LB6
Print peeling-off
LB7
Incorrect placement
LB8
LB9
Slight stain/smudge
RM1
Shade variation
RM2
Scattered blue/Black dots/Stain/Glue spot
RM3
length
RM4
Weft line/Folded mark/Snags/Fluffs/
Moiree or water mark
Thank you..
Any Questions ?
Triumph

1.1.1 - RQC Pre-Production Section

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1.1.1 - RQC Pre-Production Section

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Roving Quality Control System

PREPRE-PRODUCTION ROVING QC ROLLROLL-OUT IMPLEMENTATION

ACTUAL IMPLEMENTATION & CONTINUOUS MONITORING

What tools are needed by the Roving

A good eye !!!!!!!!

What do we need at the Pre-Production ?

How will the Roving QC be

TRIUMPH ROVING QUALITY CONTROL - WORK INSTRUCTION

<OPERATOR DAILY SHEET>

Roving QC, Pre-Production Supervisor, Pre-Production Section

1.1 Roving QC fills in each column on the <ROVING QC DAILY SHEET>:

No. of Samples to be Inspected

What are the Classification of

CLASSIFICATION OF DEFECTS - PRE-PRODUCTION

No. of Layers not According to Spec.

Nicks too deep

Width Variation & Repeat Length

RM - RAW MATERIAL FAULTS

SHOULDER STRAP FAULTS A

LB - LABEL PRINTING FAULT

Unclear Print (Unreadable)

How will the RQC Pre-Production

Check markers during process

Inform the spreader to continue

RAW MATERIAL FAULT

Inform the Pre-Prod Supervisor

Instantly inform the Pre-Prod

In the Operator Daily Sheet,

In Roving QC Daily Sheet,

In Roving QC Daily Sheet,

Raise the Red cone & move on

Raise the Red cone

Pre-Prod Supervisor checks the

Move onto the next table

Pre-Prod Supervisor instructs the

Inform the spreader to continue

Pre-Prod Supervisor calls the RQC

RQC indicates in the marker defect

In the Operator Daily Sheet,

In the Operator Daily Sheet,

In Roving QC Daily Sheet,

In Roving QC Daily Sheet,

Raise the Green cone

Pre-Prod Supervisor calls the

Checks ALL finished

Instantly inform the Cutting

Inform the Cutting Supervisor

In the Operator Daily Sheet,

In Roving QC Daily Sheet,

In Roving QC Daily Sheet,

Raise the Red cone and move on

Raise the Green cone

Raise the Red cone

Cutting Supervisor checks the defects found

Move to the next table

Cutting Supervisor calls the

RQC indicates in the marker

Cutting Supervisor instruct

In the Operator Daily Sheet color the

Move on to the next table

In the Operators Daily Sheet,

In Roving QC Daily Sheet fill the