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Logistic & Shipment

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clothing manufacturer

clothing manufacturers

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garments manufacturer

garments manufacturers

garments factory

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Logistic & Shipment

cloth manufacturer

clothes manufacturer

clothing manufacturer

clothing manufacturer

clothing manufacturers

apparel manufacturers

garments manufacturer

garments manufacturers

garments factory

fashion clothing manufacturer

fashion clothing manufacturers

Logistic & Shipment

cloth manufacturer

clothes manufacturer

clothing manufacturer

clothing manufacturer

clothing manufacturers

apparel manufacturers

garments manufacturer

garments manufacturers

garments factory

fashion clothing manufacturer

fashion clothing manufacturers

Logistic & Shipment

cloth manufacturer

clothes manufacturer

clothing manufacturer
clothing manufacturer
clothing manufacturers
apparel manufacturers
garments manufacturer
garments manufacturers
garments factory
fashion clothing manufacturer
fashion clothing manufacturers
Logistic & Shipment
cloth manufacturer
clothes manufacturer

clothing manufacturer

clothing manufacturers

apparel manufacturers

garments manufacturer

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garments factory

fashion clothing manufacturer

apparel manufacturer

Traffic Light System for Quality Inspection in Garment Manufacturing

Traffic Light System for Quality Inspection in Garment Manufacturing


Like other quality inspection tools, traffic light inspection system is widely used in garment quality inspection. This system is used to stop producing defect 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 operator’s performance level in quality. No operators like be presented themselves as lower quality makers. They concentrate on quality aspect during stitching garments.

The format used for displaying as well as recoding audit report. The format is very simple to use and to understand. The format is printed on a slightly thick A4 sheet and hanged on the sewing machine. In this system quality auditor visit operator’s workplace 4 times in a day (considering 8 hours shift day) and inspects stitched garments and fill circles with color according to the inspection result. In the initial stage when this format had been introduced by JCPenny for their supplier, they instructed to inspect 7 pieces from the stitch garments and if auditor found any defective piece respective circle to be filled by RED color. If red color is marked on the inspection sheet, all stitched pieces must be checked by auditor. And operator need to be explained about the quality expected from him/her and how to get that expected quality. In some case operators need more practice to get right quality pieces.

Factory QAs later modified sample size, the rating criteria and added yellow color keeping purpose right. Sample size is reduced as quality auditor does not get 7 pieces at a time of inspection at most of the workstations. This happens due to low work in process (WIP) in between two work station.

I have recently visited a factory in Delhi and found that factory uses Traffic Light System. Inspection formats in the floor were spread over to all machines. The criteria set by that factory have been shown in the following image (Copy of the format).

Standard Sample Size: 5 pieces. Garment Inspection to be done after every two hours.

Color marking procedures: Circles will be filled with color

GREEN: If found No defect

YELLOW: If found 1 defect

RED: If found 2 defects


Image: Traffic Light System Format



How to fill/use the format:

The above format is used for a single operator or workstation. A single sheet will keep record for the whole month for an operator. As a quality auditor, on the first day of the month you have to fill details such as Operator name, Operation name, Line number, Floor number and name of the Month. Inspection instructions have been given on the format itself with rating procedures. The format is displayed in two sections to cover 31 days (whole month). Write date in the cells of top row. Each column contains 4 circles, represents four inspections in a day. After inspection fill the respective circle (date and number of inspection of the day) according to the rating criteria. At the end of the day quality auditor has to sign report on below the circles.