Dbind Wire Products Pvt Ltd

Clients to vendors,
Binding to create oneness.

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Q/C PROCESS FOR INLINE PRODUCTION:

Traffic light system

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 Introduction:

 Traffic light system is the most effective inspection tool to reduce

defect generation 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 operators performance level in quality.

No operators like to be presented themselves as lower quality
makers.

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• Inline checking system will alert operators in concentrating their job.

• Start of the production an operator do not understand the specification, an

interaction with quality inspector will make an operator clear about the quality
requirement. 

• Traffic Light System is designed to flag the problem at source and allow
immediate corrective action rather than all potentially defective product to
continue to be manufactured.

The purpose of Traffic Light System

The purpose of this system is to determine the quality problems within the
needlepoint and to give remedies to stop it from recurring immediately.

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 How does It Works ?
Traffic Light System is a visual control for highlighting
quality issues in production line. 

1 2 Green indicates that Quality 3

meets the customers Standard.
Yellow indicates that a minor
fault has been found and caution is
required.
Three different colour Red indicates that the Quality
cards or LED light are placed Standard does not meet the One Inline Quality Checker
in each operators place. customers standard requirement. is to be allocated.

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 How does It Works ?
Traffic Light System is a visual control for highlighting
quality issues in production line. 

4 5 6

Straightness of wiro, marking,

coating, lift, centre pressure,
Pieces will be taken randomly as pitch, gap, closing, dia pass,
Inline quality inspector has to per sample size and check all the locking and other Measurement
check the wiro pieces from quality parameters required for etc. are to be verified by the
current boxes/spool once/twice that operation. Inline Quality checker.
in an hour .

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 How does It Works ?
Traffic Light System is a visual control for highlighting
quality issues in production line. 

7 8 9

While inspecting, depending Operator need to be explained Factory quality assurance later
upon the quality level, colour about the quality expected from modified sample size ,the rating
lights or cards are placed on him/ her and how to get that critical and added colour yellow
their machine. expected quality. keeping purpose right.

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 How does It Works ?
Traffic Light System is a visual control for highlighting
quality issues in production line. 

10

DHU will be recorded by the quality

assurance team thus a problematic operator
is highlighted and then give training for
improvement operator skills.

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Example Traffic light system :

0/7 PCE

1/7 PCE

2/7 PCE

Basic Concept of COLOR Light Card:

1 Green card Satisfied quality
Green light cards allow traffic to process

2 Yellow card Existing risk

The concerned parties (QA and Production Supervisors,
Technicians, Mechanics) should actively assist the operator to
solve quality problems when yellow light cards are attached.

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 3 Red card Unacceptable level
Products cannot be passed to the next production stage when the red light
cards are hanging. In case of red labelled process, Floor Management ( QA,
Technicians, and Mechanics) has to involve validating the process.

CARD CHANGING PROCESS:

1) Green light card

During the next inspection time, when 1 sample piece is to be defective or substandard, the
Green light card should be replaced by a Yellow light card During the next inspection time, if
they do not found any defective piece, the card remains in green light.

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2) Yellow light card

ct
No defe
During the next inspection time, while there is no defect
found, Yellow color can be changed to Green,
One or
more
If more than one defects, it should be changed to Red. defect

3) Red light card

When the successfully pass in consecutive inspections
for two times and the result is zero defects,the red light No defec
t

card can be replaced by a yellow light card. In case of

continuous red light, process should be Stopped and find One or
more ?
the solution to rectify immediately. Floor management has defect

to be involved.

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Flow chart for traffic light system

Check the sample inline

for an operation

More
No 1 than 1
defect defect defect
found found found

Green Yellow Red

Visit work Visit work Visit work

station 1 station 2 station 3
time/hour time/hour time/hour

Repeat Repeat
inspection inspection
process process

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 Flow chart for traffic light system

Repeat Repeat
inspection inspection
process process

No 1 More
No 1 More
defect defect than 1
defect defect than 1
found found defect
found found defect
found
found

Green Yellow Red Yellow

Green Red
Stop Repeat Repeat
production inspection inspection
process process

Red Red
again again

Stop Stop
production production

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FORMAT FOR TLS CHART

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 How to fill TLS chart
• The format shown above is used for a single operator or workstation.
• A single sheet will keep record for the whole month for an operator.
• Inline Quality checker, on the first day of the month have to fill details such as
Operator name, machine name/ number and name of the Month.
• The format is displayed in two sections to cover 31 days (whole month).
• Each row contains space to cover hourly or after two hour inspections in a
shift.
• The space is filled with respective colour pen.

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• At the end of the day quality auditor /supervisor has to sign in the report.

• At the end of month, performance of operator can be easily noted form colour
filled columns

Displaying traffic light/cards for worker/machine performance:

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 CLIENTS TO VENDORS,
B I N D I N G T O C R E AT E O N E N E S S .

THANK YOU

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