Thursday, May 14, 2015

Standard Operating Procedure For Footwear Industry-Quality Department-01

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Hello everyone. This is the Quality Part of the SOP. It is one of the most important department of a manufacturing company. There are no compromise about Quality. Lets see what quality dept. done.

Quality can be defined as the measure of excellence or state of being free from defects, deficiencies, and significant variations. It can be defined as “The totality of all features and Characteristics of a product or service that bears on its ability to satisfy stated or implied needs.”

Quality assurance:

All those planned and systematic actions necessary to provide adequate confidence that a product or service will satisfy given requirement for quality is called quality assurance.

Quality control:

The quality of product at every stages of manufacturing can therefore, be ensured by introducing some sort of controlling and monitoring mechanism in the production process. This controlling and monitoring mechanism is regarded as quality control system.

The word quality has multiple meanings. Two of those meanings are critical, namely, product performance and freedom from deficiencies '.

Product performance: Product Satisfaction

In the sense of performance, quality refers to the performance features of a product. Such features are decisive as to product performance and as to product satisfaction. Such features compete with each other in the market place. External customers, especially ultimate users, compare the competing performances. Their comparisons then become a factor in deciding whose product will be bought. Because of the competition in the market place, a primary goal for product performance is to be equal or superior to the quality of competing products.

Freedom from deficiencies: Product Dissatisfaction

The word quality also refers to freedom from deficiencies, which take many forms as late deliveries, customer claims and returns, high rate of rework and even cancellation of sales. These collectively are forms of product dissatisfaction.

Some deficiencies impact external customers and hence are a threat to future sales as well as a source of higher costs. Other deficiency impact internal customers only and hence are mainly a source of higher costs.

For quality in the sense of freedom from deficiencies, the long-range goal is perfection.

a. Objectives: 

  • To ensure each and every pair of shoe is acceptable standard quality level. 
  • To build and maintain a quality standard procedure so that it can earn customers confidence regarding the quality product.

Quality in Practice:

In a company quality assurance activities start from forward looking design and guarded down to the inspection stage.

A. During product development utmost care is taken both in terms of aesthetic and technical details.
B. When ordering materials or components specifications are made known to the vendor. If necessary he is educated, materials are accepted after the necessary checking is OK.
C. All equipments, machine and instruments are maintained at top working condition.
D. Trained operatives are organized before production is planned.
E. Production file is prepared along with costing.
F. Regular spot checking of key operations followed by final checking in

  • Cutting of upper & bottom.
  • Prefabrication of components.
  • Compounding , rolling & moulding of rubber/crepe components
  • Injection of TPR/PVC soles.
  • Lasting conveyors.
  • Shoe finishing and branding of socks.
  • Packaging

G. During in process control if anything is found below level of performance corrective actions are taken.
H. End products are checked and inspected in three/ four stages:

  • By checkers in lasting line.
  • By inspectors at the end of lasting line
  • By quality control  personnel at the warehouse
  • Third party inspection as per Buyer/Customer’s requirement.
 Responsibility of “quality assurance” therefore, is shared by almost entire management of our company i.e.
  1. Product development
  2. Procurement
  3. Store personnel
  4. Floor supervisors/ production managers
  5. Quality team
  6. Buyer/Customer
  7. Third party inspector.( Wherever required).

Further the company   statistically analyze the customers claim if any and corrective actions taken through P.D. Dept. and production floor.

To guard this, wear test of the product is regularly conducted by the P.D. development stages and afterwards from regular production line.

To continue the final part of Quality as well as SOP

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