ROVING QUALITY CONTROL

SYSTEM

What is Roving Quality Control ?

Control of in-line quality

Random inspection

Assurance at the needle point

Early identification of problems
not always the sewing operators fault

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Why do it ?

Reduce the amount of B grades

Improve the quality output of sewing operators

Find problems at the source not at end control too late

Use the quality resource where it can be most effective

Find out problems earlier and reduce costs

Increase the effective time and improve productivity

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What does this mean for Triumph

Vietnam?
The seventh (7th) in Triumph to have this training

The basis for a more sophisticated system with

PDAs later

The opportunity to improve quality quickly with

minimum costs

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Schedule

Training of key personnel (Theory)

- Week 46

Commence a pilot project on 1 line

- Week 46

Implementation of the pilot project (Practical) - Week 46

Continue implementation, problem solving

- Week 46

Data input, control and distribution

- Week 46

Follow up

- TBC

Decision on expansion

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What tools are needed by the Roving QC?

Green & Red
highlighters

Clipboard
Roving QC Daily Sheet

Roving QC Daily
Sheet
Tape measure

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Pencil

A good eye !!!!!!!!

What do we need at the sewing operation ?

Operator
OperatorDaily
DailySheet
Sheet

Green cone

Operators Daily Sheet

Sewing
Specification

Red cone
AD page or
Technical
Specification
for the
operation

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Operation
standard
7

What documents are used ?

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TRIUMPH ROVING QC SYSTEM

ROVING QC DAILY SHEET

ROVING QC NAME:DATE :

DAY:

QC SUPERVISOR:
Entered by QC
Clerk

LINE:
Operation

(Office use only)

Style

Operator
No

Qty
inspected

Result
X or 

Defect qty/code
rejected

Follow up

Remarks

Defect code:
RM = Raw Material faults / holes; SC = Stains/Contamination; MD = Molding faults; PG = Seam/stitch pucker or gather;
SB = Seam breakdown (non inclusion/cracking etc); SP = Seam position incorrect (twisting/stretched);
SD = Stitch density/tension; PT = Poor trimming/thread ends; ND = Needle damage; GB = Incorrect garment balance;
SE = Insecure or misaligned seams/edges; M = Measurement
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TRIUMPH ROVING QC SYSTEM

Month:

OPERATOR DAILY SHEET

Line:
Date

Time

01

Style:

02

03

04

(To be kept at the operators workstation at all times)

Operator No.:

05

06

07

08

Operator:

09

10

11

12

13

14

15

Morning

Remarks:
Roving QC:
Line Ldr/Supvsr:
Sen. Line Ldr/PM:

Afternoon

Remarks:
Roving QC:
Line Ldr/Supvsr:
Sen. Line Ldr/PM:

Night

Remarks:
Roving QC:
Line Ldr/Supvsr:
Sen. Line Ldr/PM:
Remarks:

Defect code:

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If style changed, mark a # in the cell

Green = all pass

If Green and no rejections, no signature needed; If green & some rejection QC signs: If Red, QC & Line Leader/Supervisor sign; If Red again immediately, Senior Line Leader/Production
Manager signs

If leave, mark L in the cell

Red = 1 major faults or 3 minor faults

RM = Raw Material faults / holes; SC = Stains/Contamination; MD = Molding faults; PG = Seam/stitch pucker or gather;
SB = Seam breakdown (non inclusion/cracking etc); SP = Seam position incorrect (twisting/stretched);
SD = Stitch density/tension; PT = Poor trimming/thread ends; ND = Needle damage; GB = Incorrect garment balance;
SE = Insecure or misaligned seams/edges; M = Measurement

10

How does the system work ?

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11

Production line
Roving QC

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12

TRIUMPH ROVING QC INSPECTION FLOWCHART

Equipment: Pencil, Highlighters (Green, Red),

Measuring tape
Frequency: At lease once in each shift daily
(morning, afternoon, overtime)

<OPERATOR DAILY SHEET>-Enter Month,

Line, Style, Operator No, Operator
<ROVING QC DAILY SHEET>-Enter Date, Line,
QC Supervisor, QC

At the start of each day, refer to the QC Supervisor to the operations in need of special attention

Randomly select & check 7 samples from the finished bundle of 40 units

How many
faults

No fault

1 or more major faults/

3 or more minor faults

1st time

2nd consecutive time

less than 3 minor

faults

Return the bundle to

Operator

In <ODS>, colour
the appropriate cell
in Green

Return the defective

pieces to Operator for
repair

In <ODS>, enter the

relevant Defect code &
quantity (eg 2/PT), colour
the appropriate cell in
Green, and sign it off

Instantly inform and

return defective
pieces to Line Leader

Line Leader
determines how to
handle & request
Operator to check the
whole bundle & repair

In <ODS>, enter the

relevant Defect code &
quantity (eg 3/PG), colour
the appropriate cell in Red,
& sign it off; Line Leader
signs off
In <RQCDS>, fill the
result in relevant
columns ()

In <RQCDS>, fill the result in

relevant columns (
)
In <RQCDS>, fill the result in
relevant columns (
)

Request Line Leader

to stop Operator &
inform Senior Line
Leader/ Production
Manager

Line Leader, Senior

Line Leader/
Production Manager
solve the problem
together

In <ODS>, enter the

relevant Defect code &
quantity(eg 2/GB), colour
the appropriate cell in Red;
Senior Line Leader/
Production Manager signs
off

In the column Follow-up of

<RQCDS>, fill in the
relevant Defect code &
quantity

Raise the Red cone & move

on to next Operator
Keep the Red cone & move
on to next Operator

Raise the Green cone

Move on to next
Operator

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Once Operator finished

checking & repairing, Line
Leader calls QC to re-check

After 2 consecutive Red

and problem solved, QC
checks Operator again

13
Revised 22/02/2007
CQA TIOL HKG

Roving Quality Control Procedures

or Work Instructions

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TRIUMPH ROVING QC SYSTEM

WORK INSTRUCTION - ROVING IN-LINE QUALITY INSPECTION (Roving QC)
 Equipment:

Pencil
Highlighters Green, Red
Measuring tape

 Reports:

<OPERATOR DAILY SHEET>

<ROVING QC DAILY SHEET>

 Frequency:

At least once in each shift daily (i.e. once@morning, afternoon &

overtime)
Specific operations as frequently as directed

 Related Parties:

Roving QC, Line Leader/Supervisor, QC Supervisor, Senior Line Leader,

Production Manager

 Method:
1. At the start of each day, the Roving QC refers to the QC Supervisor to determine those
operations which are in the Highest 3 or in need of close attention for some other reasons.
2. The Roving QC visits operators at random to eliminate any chance of them cheating the
system.
3. On the <OPERATOR DAILY SHEET>, the Roving QC enters Roving QC name, Month,
Line, Style, Operator No. and Operator. On the <ROVING QC DAILY SHEET>, the
Roving QC enters Date, Day, Line, and QC Supervisor.
4. Roving QC randomly selects the latest 7 finished samples from the bundle of 40 still at the
workstation, checks the work against the visual standard and specific requirements for:
4.1
Correct trim being used
4.2
Workmanship
4.3
General appearance
4.4
Measurement where the operation is elastication or there is a specified
measurement controlled by the operator
4.5
According to the number of faults, QC follows Step 5, 6 or 7
5. If no fault is found:
5.1
Roving QC returns the inspected garments to the Operator
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, Style, Operator No, Quantity Inspected,
Result 
5.4
QC raises Green cone at the work station and moves on to the next Operator

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15

1. If less than 3 minor faults are found: (a minor fault can be defined as a fault which will
not result in customer rejection or return, but one that is not within the specification or
tolerances required)
1.1
Roving QC returns the defective pieces to the Operator for repair
1.2
Roving QC fills in the appropriate space on the <OPERATOR DAILY SHEET> with
Green highlighter and enters the relevant Defect code and quantity as for example:
2/PT and sign it off
1.3
Roving QC fills in each column on the <ROVING QC DAILY SHEET>:
Operation abbreviation or code, Style, Operator No, Quantity Inspected
Result
, Defect qty/code, Remarks bundle number(if necessary)
1.4
Roving QC raises Green cone at the work station and moves on to the next
Operator
2. If 1 or more major faults / 3 or more minor 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 Line Leader/Supervisor to come to the operation
and returns the defective pieces to the Line Leader/Supervisor
2.2
Line Leader/Supervisor shall determine how to handle the defects and request the
Operator to check the rest of the bundle and rectify any further faults before
permitting the bundle to continue down the line
2.3
Roving QC colours the <OPERATOR DAILY SHEET> Red, and enters the relevant
Quantity and Defect code, for example: 3/SD and sign it off
2.4
Line Leader/Supervisor signs off on the <OPERATOR DAILY SHEET>
2.5
Roving QC fills in each column on the <ROVING QC DAILY SHEET>:
Operation abbreviation or code, Style, Operator No, Quantity Inspected
Result
, Defect qty/code, Remarks bundle number(if necessary)
2.6
Roving QC raises Red cone at the work station and moves on to the next Operator
2.7
Once the Operator has finished checking and repairing, the Line Leader/Supervisor
shall call the Roving QC back to the operator
2.8
Roving QC proceeds from Step 4 for the checked and repaired bundle
2.9
If no fault is found, proceed from Step 5;
If less than 3 minor faults are found, then proceed from Step 6;
If 1 or more major faults / 3 or more minor faults are found, then proceed as follows:2.10 Roving QC requests the Line Leader/Supervisor to stop the Operator and informs
the Senior Line Leader / Production Manager
2.11 Line Leader/Supervisor, Senior Line Leader / Production Manager solve the problem
together
2.12 Roving QC colours the <OPERATOR DAILY SHEET> Red, and enters the relevant
quantity and Defect code, for example: 4/SD
2.13 Senior Line Leader / Production Manager signs off on the <OPERATOR DAILY
SHEET>
2.14 Roving QC fills the Defect code and quantity in Follow up on the <ROVING QC
DAILY SHEET>
2.15 Roving QC keeps Red cone at the work station and moves on to the next Operator
2.16 Roving QC must ensure to check the Operator again after 2 consecutive Red
2.17 Once the operator has a Red, she must only be allowed to continue working
if a Red is immediately followed by a Green.
3. The Roving QC should particularly note the following points:
3.1
NEVER get involved with the Operator in trying to find out why the Operator is
wrong. That is the responsibility of Line Leader/Supervisor
3.2
NEVER wait at the operation whilst the problem is being resolved
3.3
NEVER try to suggest solutions to the Operator if anything goes wrong afterwards
you may be blamed
3.4
If you have any views about the cause or solution of a particular problem, the Line
Leader/Supervisor & QC Supervisor should be consulted and the matter left with
them.
Revised 22/02/2007 CQA TIOL HKG

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Page 1 of 2

16

WORK INSTRUCTION DAILY & WEEKLY CHECKING SUMMARY (QC Clerk)

 DAILY:
1. At 16.00 or 2 HOURS before the end of the shift, the QC Supervisor collects the
<ROVING QC DAILY SHEET> from all Roving QCs & submits them to QC Clerk.
2. In the computer file Roving QC Analysis, QC Clerk chooses the sheet Daily Chk
Sumry of the corresponding day.
3. QC Clerk enters the Week commencing & Unit.
4. On the <ROVING QC DAILY SHEET>, the QC Clerk ignores the entries with no fault.
For those entries with faults found , QC Clerk transfers the data to the Daily Chk
Sumry, including:
4.1
Line, Style, Operator No
4.2
Total handled(Exceptions) and the number of different defects
The QC Clerk initials the box on the <Roving QC Daily Sheet> to indicate she has
completed the entries for that sheet.
5. At 17:30 or 30 minutes before the end of the shift, the QC Clerk issues the Roving
QC Analysis with completed Daily Chk Sumry to Factory Managers, QA Manager,
Production Managers, QC Senior Supervisor, etc. through E-mail.
 WEEKLY:
At 08:30 on Monday,
1. The QC Supervisor collects the <ROVING QC DAILY SHEET> which includes the
data of the previous Saturday entered after 16:00 on Friday from all Roving QCs
& submits to QC Clerk. Per the above steps, QC Clerk completes the Daily Chk
Sumry of the previous Saturday.
2. The QC Clerk chooses the sheet Analysis only of the computer file Roving QC
Analysis.
3. The QC Clerk filters the column Operator No & selects operators in the order of their
number.
4. The QC Clerk copies from row A to row G for each operator.
5. The QC Clerk pastes into Wkly Chk Sumry by using Paste Special Values only.
6. In Wkly Chk Sumry, QC Clerk selects from Toolbar, Data-Sort-% Reject-Descending.

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7. The QC Clerk issues the Roving QC Analysis with completed Wkly Chk Sumry to
General Manager, Factory Managers, QA Manager, Production Managers, QC
Senior Supervisor, etc. through E-mail.

17

What reports are generated ?

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TRIUMPH ROVING QC SYSTEM

QSF

Weekly Checking Summary (Exceptions)

Unit:

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For email distribution

Week Commencing

Line

Style

Operator No

Total Checked
(Exceptions)

Total Rejected
(Exceptions)

% Reject (Exceptions)

Day

A
A
C
C
D
D
A
A
A
B
B
A
A
A
B
B
B
B
C
C
B
B
C
C
B
B
C
D
C
D
A
A
A
B
B
A
B
B
C
B
B
A
C
A
C
C
C
C
C
C
D
D
A
A
D

1234
1234
3456
3456
4567
4567
1234
1234
1234
2345
2345
1234
1234
1234
2345
2345
2345
2345
3456
3456
2345
2345
3456
3456
2345
2345
3456
4567
3456
4567
1234
1234
1234
2345
2345
1234
2345
2345
3456
2345
2345
1234
3456
1234
3456
3456
3456
3456
3456
3456
4567
4567
1234
1234
4567

AS
AS
BB
BB
CC
CC
DD
DD
IO
DV
DV
SS
ER
ER
GF
GF
GG
GG
GH
GH
HH
HH
HK
HK
HU
HU
II
II
II
II
IK
IK
IO
IO
IO
IO
IO
IO
MM
JJ
JJ
JK
JK
JK
KJ
KJ
LK
LK
MM
MM
MY
MY
OL
OL
PL

14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14

8
2
3
2
1
1
6
1
3
9
1
1
1
1
9
1
7
1
5
3
1
2
1
1
1
2
7
1
1
1
9
2
3
1
8
1
2
2
1
5
2
4
2
1
9
1
2
1
1
1
1
1
3
1
1

57.14%
14.29%
21.43%
14.29%
7.14%
7.14%
42.86%
7.14%
21.43%
64.29%
7.14%
7.14%
7.14%
7.14%
64.29%
7.14%
50.00%
7.14%
35.71%
21.43%
7.14%
14.29%
7.14%
7.14%
7.14%
14.29%
50.00%
7.14%
7.14%
7.14%
64.29%
14.29%
21.43%
7.14%
57.14%
7.14%
14.29%
14.29%
7.14%
35.71%
14.29%
28.57%
14.29%
7.14%
64.29%
7.14%
14.29%
7.14%
7.14%
7.14%
7.14%
7.14%
21.43%
7.14%
7.14%

MON
TUE
MON
TUE
MON
TUE
MON
TUE
MON
MON
TUE
MON
MON
TUE
MON
TUE
MON
TUE
MON
TUE
MON
TUE
MON
TUE
MON
TUE
MON
MON
TUE
TUE
MON
TUE
MON
MON
MON
TUE
TUE
TUE
MON
MON
TUE
MON
MON
TUE
MON
TUE
MON
TUE
MON
TUE
MON
TUE
MON
TUE
MON

20

Defect Codes

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RM

Raw Material Faults / Holes

SC

Stains and Contamination

MD

Molding Faults

PG

Seam / Stitch pucker or gather

SB

Seam Breakdown (non inclusion / cracking etc)

SP

Seam Position incorrect (twisting / stretched)

SD

Stitch Density / Tension

PT

Poor Trimming / Thread Ends

ND

Needle Damage (cuts)

GB

Incorrect Garment Balance

SE

Insecure or Misaligned Seams / Edges

Measurement
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Defect Codes Major and Minor classification.

RM

Raw Material Faults / Holes

MAJOR

SC

Stains and Contamination

MINOR

MD

Molding Faults

MAJOR

PG

Seam / Stitch pucker or gather

MAJOR

SB

Seam Breakdown (non inclusion /

cracking etc)

MAJOR

SP

Seam Position incorrect (twisting /

stretched)

MAJOR

SD

Stitch Density / Tension

MAJOR

PT

Poor Trimming / Thread Ends

MINOR

ND

Needle Damage (cuts)

MAJOR

GB

Incorrect Garment Balance

MAJOR

SE

Insecure or Misaligned Seams / Edges

MAJOR

Measurement

MAJOR

MO

Missing Operation

MAJOR

CT

Careless Trimming

MAJOR

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Some general rules and guidelines

At the start of the shift, every operator must be checked at least once morning, once afternoon
and once on overtime, some will require extra checks from the previous days results
Roving QC should select the 7 most recently sewn pieces only
Roving QC should never attempt to solve a problem only identify and report and MOVE ON
Roving QC should never discuss the reasons for a problem with the operator
Roving QC should not become familiar with an operator
When faults are found, always return them to the operator for repair immediately
Roving QC must never become predictable, must be random checks
There must be no favourites
Line supervisor must solve the problem before calling the Roving QC back for a second check
Roving QC must concentrate on conducting as many checks as possible
Roving QC should be transferred to another line 2 to 3 months
Every red that appears on the Operators daily sheet, must be followed by a green before work
re-commences
Two reds must involve the production manager
A red means an operation has stopped, so action is needed immediately
A red is not always the operators fault, just means a fault at that operation, so read the results
carefully
Check the days results before the end of the shift, so that plans for the next day can be made
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Thank you..

Any Questions ?

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