Quality Manual Conclusion

Conclusion:

Quality has always been a primary requirement and considered to be the life, comfort and fashion of Footwear. There is no denying  fact that "Your Company name" had been following Quality Control System in the production process since its inception. Compiling this quality manual is a humble effort to put almost all necessary details of Quality Control System to ensure that the factory has a Manual/ Guideline in black and white to follow. In the beginning will not concentrate on the statistical Quality Control System. Should follow this after a while when have enough and required manpower to exercise that. Any positive inclusion in this manual which will help the factory in improving quality  is always welcome; but has to be done with prior approval from the  top management of your company. All need to educate and train their work force in line with this Quality Manual to try and streamline our quality system. Sincere and team effort only can help to improve in quality the sector.

Conclusion

Note:-
Authority reserve's the right  from time to time for  correction or amendment any portion of this manual as per QMS standard.

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Quality Manual- Control of nonconforming products

Control of nonconforming products

Purpose:

To prevent the dispatch of nonconforming products to the customer.

Scope: 

This section applies to the products which do not conform the required quality.

Nonconforming product

ACTIVITIES:

Non-conforming goods are identified during the checking of receiving section¬, Process inspection and final inspection.

• When a major non conformance is discovered i.e. (one that requires a managerial executive decision regarding its disposition) it is so identified and segregated," subject to the appropriate management decision, the defective goods are reworked, accepted on concession, re-graded or rejected.
• Where appropriate, the customer is consulted concerning any concession.

IN A NUT SHELL QUALITY IN PRACTICE:

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

• During product development utmost care is taken both in terms of aesthetic and technical details.
• 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.
• All equipment's, machine and instruments are maintained at top working condition.
• Trained operatives are organized before production is planned.
• Production file is prepared along with costing.
• 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
• During in process control if anything is found below level of performance corrective actions are taken.
• 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’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
7. Third party inspector (Wherever required).

Further to this we   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. Dept. at development stages and afterwards from regular production line.

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Quality Manual- Process inspection- finial Inspection

Purpose: 

To establish and maintain documented procedures for final inspection in order to verify that the specified requirements for the product are met.

Scope:

This section applies to the product being produced in the factory.



Checking by the quality checker after ratio packing in the master cartoon as per AQL requirement and making report. To make recheck if the consignment fails AQL requirement.


After final quality checking, quality passed products are kept in a restricted  confined area called finished goods warehouse.



Over and above, in many instances checking is also done by buyer’s representative. Sometimes by the third party as suggested by the Buyer.



All the above checking are carried out on the basis of approved reference sample. Besides that on the basis of the quality report preventive/corrective actions are initiated by the quality dept. They also check the processing parameters such as time, temperature and pressure on daily basis.

Here maintain some documents to finalize the product.

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Quality Manual-Inspection Process- Lasting and finishing

This is the final process of a shoe making

• After every critical operation there is a checker, up to the finishing. Then checking of ready shoe on the line pair by pair by quality checker before packing and making report.
• Random checking by the quality supervisor as per AQL requirement after checking by the quality checker before packing and making report.
• Sole bonding test after finishing and making report.
• Checking by the quality assurance in-charge after ratio packing in the master cartoon as per AQL requirement and making report. To make recheck if the consignment fails AQL requirement.

Process inspection of Lasting and finishing dept.

Check points:

• After lasting
• After buffing
• After un-lasting
• After finishing on quality table
• Roaming check by quality supervisor.

Documents used:

• Daily Quality Report by individual checker.
• Daily Quality Report recapitulation as per Department.
• Random inspection report.
• Corrective & Preventive action report.
• Daily Process parameter test report.

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Quality Manual-Process Inspection Outsole and Solefinishing

Outsole Dept:

Rubber Outsole Process

Rubber Sole Process

Specification

Compounding Specification

Solefinishing dept:

Practical finishing  of outsole:

After making the outsole, some of them need to fabricate (Cutting, buffing, joining sole & heel, sole & wedge, fixing welt, attaching different/same materials, shaping, profiling, beveling, coloring etc) and finish them as per requirement depending on the type of outsole to make them usable following the approved sample.

 Insole to be prepared in the similar fashion.

Flow chart of Outsole and Sole finishing Dept.

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Quality Manual Process Inspection Sewing

Sewing Quality Process Inspection.

It is an inspection of the work-in-progress done at the sewing section. The main objective of the Sewing Inspection is to ensure conformity to quality in terms of material performance and Workmanship.

1. Checking of stitched components piece by piece after every sewing operation. 
2. After sewing, checking of stitched upper pair by pair by quality checker.
3. Random checking by the quality supervisor before supplying to the lasting/ hand sewing dept. and making report.

Check points:

• During loading of the conveyor.
• Roaming check by supervisor on the conveyor
• Final in line inspection by quality checker on the quality table.

Sewing Process Inspection

Documents used:

• Daily Quality Report by individual checker.
• Daily Quality Report recapitulation as per Department.
• Random inspection report. 
• Corrective & Preventive action report.

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Quality Manual- Process Inspection- Cutting and prefabrication

Cutting and pre-fabrication Quality Process Inspection.

Component Inspection: 

1. Checking of components piece by piece after cutting and keeping of records.
2. Roaming supervisor checks randomly.
3. After pre-fabrication (splitting, lamination, skiving, printing) 100% checking pair by pair by quality checker and keeping record.
4. Final checking by the Cutting quality in-charge as per AQL requirement before supplying to the sewing dept.

Check points:

1. After every cutter.
2. After re-cutting.
3. After completion of the entire prefabrication job before supply to sewing dept.

Documents used:

• Daily Quality Report by individual checker.
• Daily Quality Report recapitulation as per Department.
• Random inspection report. 
• Corrective & Preventive action report.

Cutting and Pre-Fabrication Quality Process Inspection,

Here also use some formatted documents.

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Quality manual- Process inspection

Process inspection of Quality manual.

Purpose:

To establish and maintain documented procedures for process inspection in order to verify that the specified requirements for the product are met.

Scope: 

This section applies to the product being produced in the factory.


Quality control is one of the most important functions in production. It cannot be   “Inspected into shoes at the end of the line”.

Quality must be built into the shoes at every step in the manufacturing process.  Substandard quality must be identified and corrected when it occurs in the manufacturing process.

This process quality control concept rest on three basic principles

1. Only good materials are used
2. Operations are performed correctly
3. Any defects are corrected when they occur during manufacturing

This quality control system moves the quality supervisor into the main stream of production and makes him a process quality controller.


In line with that operator should

• Receive Good Work
• Perform Good Work
• Supply Good Work

During the production of shoe the operator’s finished work is checked by line supervisor. A Roaming QC supervisor moves from one operator to another at random inspecting the quality of products.


The basic flow of quality in the entire factory can be depicted graphically as below:

Total QC Process at a glance

From next post we discuss quality process inspection in individual dept

1. Cutting and pre-fabrication
2. Sewing
3. Outsole and Sole finishing 
4. Lasting and finishing

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Quality Manual-Receiving Inspection-Leather and PU

It's very important to make quality inspection of all kind of in-house material.

Let's Proceed to Receiving Procedure.

Purpose: 

To establish and maintain documented procedures for receiving inspection in order to verify that the specified requirements for the product are met.

Scope:

This section applies to all the materials used for producing shoes in your factory are quality checked.

Raw material plays a very important role in making a quality product. Even the most outstanding manufacturing methods cannot compensate for defective materials. In line with that the raw material and accessories in housed are inspected before adding on the stock.

Leather:

• Leather is checked with the approved swatch (color, shade, thickness, texture etc). If it doesn’t match, is returned. Then the leather is selected in three different grades on the basis of usability avoiding defects.
• Grade A – usability 90 – 100%
• Grade B – Usability 80 – 89%
• Grade C – Usability 70 – 79%

After making this grading, it has been reported to the Top Management for his decision. Normally Grade C is returned.

Sometimes Grade B is sending back for correction to improve the usability or negotiated with the supplier for reduction to a reasonable extent.

Possible defects in the leathers are:

Flow Chart Of Leather Store

• Scratches or blemishes in the grain.
• Brand marks in the butt.
• Growth marks in the neck.
• Warble and tick marks.
• Loose grain.
• Holes in the butt.
• Loose flank-bigger flanks.
• Stain marks in the reverse side.
• Poor trimming.
• Coarse finish break.
• Butcher cuts etc.

Leather Inspection Report should like this

Leather Inspection Report

 Fabric/ PU Store:

Fabric/PU comes on roll form. While receiving rolls are counted and matched with the purchase order and the approved swatch and also get it approved by the sample dept. Quantity written on the roll is recorded.  Length is checked while making lay during use in the cutting dept. and accordingly communicated to the supplier for necessary settlement.

Flow Chart of Fabric or PU Store.

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Quality Manual-Suppliers Selection, Approval & Evaluations

Purpose: 

To ensure that Suppliers are selected on the basis of their capability to meet the requirements of "Your Company" and therefore evaluated and controlled properly.

Scope:

This procedure is applicable to the selection and periodic assessment of Suppliers who supply raw, packaging, machinery, equipment, and other locally available materials to"Your Company".

Definition:

Supplier/Vendor: Person or organization, which has the potential of supplying materials for use by "Your Company".
Indenters: Local Representatives of overseas suppliers.

Responsibility:

It shall be the joint responsibility of Purchasing, Production, Quality Assurance participate in the selection and evaluation of any Supplier/Indenter.
Procurement department in recognition of Top Management is responsible for selection of Suppliers for local & foreign purchase.

Procurement Manager, Production manager, Quality Assurance Manager  and Store are responsible to verify quality of  Supplier’s products.

Method:

Supplier/Vendor Selection:

• "Your Company"d shall purchase raw and packaging materials and other items through both  local and foreign Suppliers.       
• The need for a new Supplier can be determined by Quality Assurance, Production,           Maintenance, and Purchasing Departments.       
• New Suppliers shall be selected on the basis of their past experience and ability to supply quality  products, with competitive price and required delivery time.

 Selection Procedures of Local Suppliers/Vendors:

• Procurement Manager or authorized nominee shall select local Suppliers on the basis of their past experience, quality of products supplied, their prices and delivery.
• For selecting new local Suppliers, Procurement Manager or authorized nominee shall verify the specifications of the purchasable materials, samples (as appropriate) and compare with the existing specifications. In case of local Suppliers having manufacturing facilities, the facilities shall be audited (if needed) before selecting them as approved Suppliers.
• If the specifications of the products or materials are found to be satisfactory, Procurement Manager shall then ask the Suppliers to submit prices for comparison with current prices of other Suppliers. If the prices are found within acceptable limits, and test sample are acceptable, then he will recommend the Supplier(s) to  Top Management for inclusion of the name in the Approved Suppliers List (ASL) of local Suppliers.
• After getting approval from Top Management, Procurement Manager  shall then enlist the Suppliers in the Lists of Approved Suppliers List (ASL). The ASL may be categorized item-wise.   

Selection Procedures for Foreign Suppliers/Vendors: 

• After a prospective foreign Supplier or Indenter is identified as a possible source of a material, Procurement Manager shall ask the prospective Supplier for supplying documentary evidence that may prove to be a good Supplier. Subject to satisfactory survey report about past experience, Procurement Manage shall ask the prospective Suppliers or their local representatives/indenter to submit samples of raw and other materials with their product specifications, certificates of quality test etc. 
• In case of new raw materials and new Supplier, Quality Assurance/Production Dept. shall verify the quality of the Supplier’s products by detailed test and analysis and submit report to Procurement Manager  . After getting satisfactory report from the QA, Production Dept., Procurement Manager shall ask the Suppliers/indenters for quotes of samples.
• Request for quote shall clearly indicate the detailed specifications of materials or products, their quantities, source of origin, name of manufacturers and suppliers, Name of local indenters/representatives and delivery schedule.
• If the specification and quality of the product are acceptable, quotation is competitive and the price is well within the range, the Suppliers might be provisionally selected.         
• Later on after successful shipment and acceptance of a particular consignment of raw materials and machinery parts for the plant; the Supplier will be placed in the Approved Suppliers List (ASL) of Overseas Suppliers provided other selection criteria are met.
• At times depending on urgency and circumstances, the Top Management may use his discretion to enlist name of any overseas Supplier provisionally pending its performance and subsequent placement in the ASL.   

  

  Choose Your Supplier 

Selection of Suppliers/Vendors for a Particular Import Order:

First of all Procurement Manager  will ask the Suppliers/indenters of ASL to supply pre-purchase-samples with their specifications, quality test reports/certificates.  Subject to satisfactory quality report by "Your Company" of QA, Production Dept. the Suppliers shall be requested to quote in bulk quantity.

• Depending on the price and terms and conditions of delivery, the Top Management shall approve one or more Suppliers for importing a particular batch or consignment of raw materials, equipment, machinery parts, or other importable items. 
• After the selection of Supplier(s) Procurement Manager will start processing to open Letter(s) of Credit. After the shipment and arrival of the consignment(s) at the port, subsequent clearance will be made and samples will be sent again for quality testing by "Your Company" QA, Production Dept.
• At the end of the month upon receipt of the satisfactory quality report from Quality Assurance Dept. or from the Material Receive Register maintained by Store Dept. be used ‘Supplier History Form’ will be filled by the Head/Executive of Procurement Dept.

Comparative Performance study of Local Suppliers/Vendors:

• Procurement Executive shall maintain ‘Supplier History Form for all local and foreign suppliers. This form shall be updated once a supply is received from Supplier.
• Summarizing all Supplier History Forms, Procurement Manager will evaluate the local and foreign suppliers once in every year. Following system shall be used to evaluate the suppliers of "Your Company".
• Procurement Manager will fill up the Supplier Evaluation Form based on the respective Supplier History Form.
• Evaluation will be done material wise and in the following three categories.

                     Quality: Good Satisfactory Unsatisfactory
                     Delivery: Prompt Satisfactory Unsatisfactory
                     Price: Highly Competitive Reasonable High

A Sample format for supplier

• To be on the ASL, a supplier should have at least “Satisfactory” in the ‘Quality’ and ‘Delivery’ category and “Reasonable” in ‘Price’ category.
• Based on the overall performance of the supplier, Procurement Manager will write comments/recommendation on the Supplier Evaluation Form.
• Top Management shall be responsible to approve the Supplier Evaluation Form 
• Only the approved Suppliers will be in the Approved Supplier List (ASL).
• An Evaluation Form will be used for a particular supplier to evaluate its last one-year performance. Procurement Manager will update the Approved Supplier List (ASL) based on the evaluation form of each supplier. 
• Purchase will be carried out from the ASL; however purchase could be done from other Suppliers, which aren’t in the ASL with prior approval from Top Management.  

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Quality Manual-Sampling procedure

Introduction :

Product development is the core function of any manufacturing company. It is the basic tool to attract customer and eventually to come to a business contract. Initially a designer translates his idea, concept, perception and experience (gathered from his surroundings by visiting fairs, shoe markets, reading magazines, searching online etc) into a product considering a target group of customers. This initially developed sample under goes many modification through different stages, finally it is perfected by accommodating the suggestions from both the customers and the manufacturers.

Before placing any order to the facility, the Buyer/Customer wants to know whether the factory is capable of producing the styles with the desired quality level or not. The sample shows the ability of exporter to deal with any given styles of shoes .The Buyer/Customer accesses the capability of exporter only with the help of samples. If the samples are good quality, price competitive and time bounded naturally the Buyer/Customers will be willing to place the order to the factory.  The future of any style depends on the sample.

So it is very important to understand the sample development process to control quality and cost in the initial stage. Designer plays the vital role in the sampling process as the only person between the Buyer/Customer and the factory who understands the Buyer/Customer specification, technical details, and time line of sampling. The process of the sampling is about the eventual satisfaction of specific needs. Therefore, it is essential that the samples should be made with utmost care.

1. Objective: 
• To create   innovative product range to attract potential customers.
• It must be competitive in the market.
• It can be produced in the existing manufacturing facility.
• It should be promptly responsive to the customer. 
2. Main Function: 
• To innovate a product range that can attract the potential customer to satisfy their desired need.
• While developing a product following points are considered,
• Aesthetics view of the product (Sales appeal to the potential Buyer/Customers).
• Technicality of the product.
3. Cost involvement.
• To make liaison with the customer and accommodate their suggestion till finalization of the sample.
• To update their technical knowledge so that they can build maximum comfort in the shoe.
• To become versatile regarding the shoe material available in the market, their proper application and their cost.
• To propose and arrange potential equipment and demonstrate their uses in the factory.
• To remain updated regarding the manufacturing facility available in the factory.
• To issue and remain responsible for all types of sample, swatches for material,  patterns, knives etc.
• To follow-up pilot production.
• As a shoe engineer, to assist in solving any sort of technical / quality problem that may arise during manufacturing. 
• To maintain a lateral relationship with the following dept. such as Planning/ Merchandising, Procurement, Raw material stores, production and Quality assurance team etc.
• Before finalization of sample, different steps are followed depending on the Buyer/Customer to Buyer/Customer and style to style. The steps are as follows:

1. Initial Sample
2. Salesman sample
3. Advertisement/Press Sample
4. Fitting Sample
5. Confirmation Sample &
6. Pre-Production /Gold seal Sample

These samples are sent to the Buyer/Customer one after another for approval.



Assessment of sample:

Upon receiving the samples, Buyer/Customers check the sample quality,  fitting, finishing etc and gives the feed back within 5-7 days through e-mail . Feedback from the Buyer/Customer comes in three different forms

1. Accepted,
2. Not accepted or 
3. Accepted with comments.

After getting their approval, it proceeds step by step. Sometimes the Buyer/Customer suggests some changes in the prepared sample both in terms of technicality and material.  Revised samples are made incorporating those suggestions and get it approved. This process continues till the sample is finally approved. After getting the final approval Buyer/Customer place the final order. And then PD dept. along with the Merchandising dept prepares a manufacturing sheet stating all the technical details including the material specification and their quantity per pair for doing the costing of the shoe.

See Process flow of a sample department.

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Quality Manual- Management Responsibility

Purpose:

The organization’s quality policy is documented and communicated to each person in the organization. The organizational structure, responsibilities and authorities have been described to ensure every key personnel know his job and the same could be cross checked by his higher management. To check the effectiveness of the quality system, it has been suggested to conduct a meeting after every fortnight with the responsible officers taking care of quality system in their assigned position.

Scope:

This section covers the organizational structure and responsibilities of all personnel who supervises, perform and verify works at different stages for the improvement and maintenance of quality.

JOB DESCRIPTION OF RESPONSIBLE PERSONS FOR QUALITY:

1. Top Management: will ensure the absolute adherence to the quality control system by exercising their authority through their channel of command.
2. QUALITY ASSURANCE MANAGER (Q.A.M): Number one for whole facility.
1. Preparing quality manual.
2. Taking approval from the top management for implementation of the system stated in the manual.
3. Implementation of statistical quality control system in the factory where it is applicable.
4. Training of QC personnel for continuous improvement to achieve quality level as desired by customer.
5. Collections of buyer’s quality specification /guide lines from buyer’s side (through discussion, mail, website or manual) and convey it to QA/QC for monitoring the proper implementation to attain buyer’s quality level.
6. Maintain liaison with buyers QA personnel to share technical affairs wherever needed.
7. Monitoring the job of QA & QC of the factory to evaluate their performance and report it to concern authority.
8. To help authority to recruit right person for right job of QA department.
9. To inform  top management  the overall quality position of the factory as and when necessary.
10. Inform top management if factory personnel are unable to perform up to the desired quality level to take corrective action
11. Making of sample, spec. sheet stating every technical details, swatch cards, leather test report, fabric test report etc.
12. Study quality related books, journals, manuals and research for continuous improvement.
3. Quality Assurance In-charge.
1. Collection of approved sample, buyer’s quality guideline documents, going through these and explain these to Quality Controller and Quality In-charge of different sections, and monitoring the same for correct implementation. Not to allow any deviation from the approved sample unless there is written confirmation from the buyer.
2. Collection of production sample to judge whether sample is acceptable for production and trace out defect and other factors and to make the arrangement for sending those to buyers.
3. Briefly describe the buyer requirement and quality control procedure to Quality Controller & In-charge for proper monitoring to produce shoes as per requirement of buyer.
4. Conduct inspection of packed shoes at the end of day in finishing as per AQL requirement and make report. If the lot is not accepted go for correction and make corrective  & preventive report 
5. Compile all reports from different section and make corrective & preventive report and preserve them. 
6. Compile all quality documents to get it checked by the third party Quality Inspector as selected by the customer.
7. Arrange training program with the quality checker at least twice a month and make report.
8. Perform sole adhesion test and make report.
9. To help authority in recruitment  of  necessary quality personnel.
4. Quality Controller;
1. Assign   job to  his QC team to monitor the quality production of all stage at the facility and to train them how to check quality at different stages of manufacturing.
2. In line inspection to see whether the Product quality is as per buyers requirement or not. In case of any deviation, take corrective and preventive action.
3. Appraise to QAM, all his findings and inspection report for taking corrective actions and monitoring.
4. In case of any change in the style or design by the buyer he will communicate the floor people for the confirmation of change.
5. Moving around the section where the conversion takes place, operation to operation so that he/she can look after the job of quality In-charge at the same time the impact of quality control procedure. If any deviation occurs immediately he/she can intervene with corrective action.
6. To check periodically the processing parameters such as time, temp, pressure etc.
7. Monitoring the work of quality In-charge in Cutting. Sewing, Lasting & Finishing and evaluate their performance. 
8. Conduct training and make all his subordinates accountable to him for their performance to achieve the target of quality level. 
9. To make recap of the reports made by the quality checkers at different sections.
10. Reporting day-to-day quality status and trend to QAM & top management.
11. Keep close co-ordination with QA, QAM & top management for continuous improvement. 
5. Quality In-charge( In each section): 
1. Carry out instruction receive from the Quality Controller. 
2. Go through approved sample, swatch board, spec. sheet and instruct his people to do the job accordingly. 
3. Implementations of design change approved by buyer and instructed by Quality controller. 
4. Management, administration, training, motivation of his stuff for continuous improvement. 
5. Conduct daily inline inspection and report to the Quality Controller. 
6. Quality Supervisor:
1. To assist Quality In-charge in making quality report.
2. Random checking the quality in the line.
3. Segregate non-conforming shoes and hand over to the production supervisor.
4. Initiate corrective and preventive action as necessary.
7. Inline Quality Checker:  
1. Stands beside the quality Table with the approved Sample.
2. Checks each and every individual pairs regarding the material, workmanship, technical affairs by comparing with the approved sample. 
3. If the product does not match with the approved sample, it is rejected.
4. For any minor deviation he/she consults with the In-charge if he/she thinks that it is within the tolerance level.
5. He/she keeps the record and submits it to Quality supervisor at the end of the day.

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Acquired Quality Level (AQL)

AQL SYSTEM FOR  ACCEPTANCE  SAMPLING (US-MIL-STD 105E) 

The AQL (Acceptable Quality Level) concept was first devised in connection with the development of statistical acceptance sampling for the Ordinance department of the U.S. Army in 1942, modified as MIL-STD- 105A in 1950, MIL-STD-105B in 1958, MIL¬STD-105C in 1961, MIL-STD-105D in 1963. American, British, Canadian military agencies has accepted it as common standard of  acceptance sampling, that is why it is also called ABC, standard. Later on this standard has accepted by most of American and European organizations. Latest development of these series is MIL-STD-105E in 10 may 1989.

HOW TO USE  (US-MIL-STD-105E) 

For the use of 'US-MIL-STD-105E we have to choose level of AQL first, next step is to find out sample size code letter according to lot size from the sample size code letter table, then: with" the help of sample size code letter and AQL level, to find out acceptance number and rejection number from the normal or tighten, single or double sampling table of US-MIL-STD-105E.

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Total Quality Management(TQM)

An integrated management system which involves the application of concepts and tools to direct the efforts of all employees towards continuous improvement of systems and processes to satisfy both internal and external customers.

Total Quality Management (TQM) approach:

1. Make products to satisfy customers.
2. Each person in the company is aware of the customer and how their product/ service meet the customer’s needs.
3. The job is done when the customer is satisfied.
4. Individual are responsible for continuous improvement.

The requirements of TQM

1. Management commitment and leadership.
2. Quality culture:
1. Establish customer’s needs in specific and measurable terms.
2. Doing the job right the first time.
3. Team work and open communication.
4. Decision –making based on facts.
3. Direct link between TQM project and business strategy.
4. Education and training.
5. Support, information and direction network.
6. Communication:
1. With customers and suppliers.
2. Internal communication.
7. Perseverance

SOURCE: UNITED STATES GENERAL ACCOUNTING OFFICE, MANAGEMENT PRACTICES REPORT 2001.

Benefits of Total Quality Management ( Case Studies)

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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.

It is the operational techniques and activities that are used to full fill requirements for quality.

Note:

1. In order to avoid confusion care should be taken to include a modifying term when refer   to a sub set of quality control such as “manufacturing quality control” or referring to a broader concept such as “company –wide quality control”
2. Quality control involves operational technique and activities aimed both at monitoring a process and at elementary causes of unsatisfactory performance at relevant stages of the quality loop in order to result in economic effectiveness.
3. The quality system should only be as comprehensive as needed to meet the quality objective.
4. For contractual, mandatory and assessment purpose demonstration of the implementation of identified elements in the system may be required.

Three rules of quality control:

1. No inspection or measurement without proper recording.
2. No recording without analysis.
3. No analysis without action.

The field of quality control:

It asks four questions:

1. Can we make it ok? (Process capability analysis)
2. Are we making it ok? (Process control monitoring)
3. Have we made it ok? (Quality assurance)
4. Can we make it better? (Product research and development and process evaluation)

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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.

The content of quality assurance

          If a company accepts the need for quality assurance, the next stage is to decide on a suitable form. A system may entails   more than final examination or extend to every  facet of an organization. It may be an informal system carried largely in the heads of supervisors or it can be a completely documented systems.

A documented quality system is one in which all aspects relative to quality assurance are approved and recorded. It includes objectives, policies, procedures, responsibilities work instructions, specifications and tolerances.

A document or a group of documents will formally demonstrate  to all interested parties, the attitude of a  company  to the subject of quality assurance. If a company can show that its documented quality system has satisfied an independent     assessing authority, then it can be regarded as one of “assessed capability”.

Note:

1. Quality assurance is not complete unless given requirements fully reflects the needs of the users.
2. For effectiveness, quality assurance usually requires a continuing  evaluation of  factors that affect the   adequacy of the design or specification for intended application as well as verification's and audits of production, installation and inspection operations  providing confidence producing evidence.
3. Within an organization quality assurance serves as a management tool. In contractual situations, quality assurance also serves to provide confidence in the supplier.   

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Definition of Quality

What is Quality ? 

Quality is 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.”

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.

Quality characteristics

1. Technological -Hardness, fittings, thickness, chemical  impact on use etc.
2. Psychological -Beauty, taste, status etc.
3. Time oriented -Delivery time, durability, reliability, maintainability etc.
4. Contractual -Guarantee provision, after sales service etc.
5. Ethical         -Courtesy of sales personnel, honesty of service shops. Etc.

Parameters of fitness for use

1. Quality of design
2. Quality conformance of raw materials and components.
3. Abilities
4. Field of services
5. Reliability
6. Maintainability etc.

Note: 

1. In a contractual situation needs are specified, where as in other environment implied needs should be identified and defined.

2. In many instances, needs can change with time. This implies periodic revision of specifications.

3. Needs are usually translated into features and characteristics with specified criteria. Needs may include aspects of usability, safety, availability, reliability, maintainability, economics and environment.

4. The term “Quality” is not used to express a degree of excellence in a comparative   sense nor it is used in a qualitative    sense for technical evaluation. In these cases a qualifying adjective shall be used e.g Relative quality, qualitative level etc.

5. Product or service quality is influenced by many stages of interactive      activities       such as design, production, service, operation and maintenance.

6. Economic achievement of satisfactory quality involves all stages of the quality loop as a whole. The contributions to quality of the various stages within the quality loop are sometimes identified separately for emphasis. Two examples, Quality attributable to design, quality attributable to implementation.

7. In some reference sources quality is referred to as fitness for use or satisfying the needs and expectations of the customer. Fitness for use is determined by those features of the product which is beneficial to the users like

1. Freshly backed taste of bread.
2. Clear picture in TV screen.
3. Punctuality of transport services (Bus, Train, and Plane etc).
4. Beauty and serenity of painting, sculpture and music.
5. Fashion elements, comfort feature and life of garments & shoes etc.

Fitness for use must be judged by user, not by the “maker” or “manufacturer”.

What are the quality characteristics? 

• Technical- Hardness, indictany, 
• Psychological- taste, beauty, status
• Time oriented- reliability, maintainability
• Contractual
• Ethical- courtesy of sales personnel honesty of service shops.

Quality function: 

The quality function is the entire collection of activities of separate deeds or actions in logical progressions through which we achieve fitness for use. The activities are

• Research
• Development
• Design
• Specification
• Planning for manufacture
• Purchase
• Instrumentation
• Production
• Process control
• Inspection.

Quality starts from progressive and forward looking research and guarded down to inspection stage.

*In industrial terminology the quality of a product during manufacturing may be defined as the degree in which succession of production item falls within the specified limit of tolerance in respect of acceptability.

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Quality Policy

A manufacturing company is committed to achieve customer’s satisfaction by producing the highest quality footwear and providing best possible service to its customer.

 In line with that it is assured to provide adequate resources and trained manpower to make it happen.

Authority of manufacturing company is also committed to put its endeavor for continuous improvement with a premise that even the best can be improved.

QC Policy

Objective of the Quality Policy

• To understand customer’s perspective of quality.
• To provide better quality of products and service accordingly.
• Best possible machinery and material to be used.
• To provide good and safe working environment to the workers, this includes human values, respect, justice, cleanliness, discipline and equality among the workers.
• To fulfill the compliance requirement.
• 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 of our product.
• To implement quality control system with the aim to achieve zero defect level through efficient management, research & development and continuous improvement.

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Introduction of QC Manual

Quality is the primary requirement for any product or service.  Survival of a business depends on the quality of its products. In the modern competitive world the importance of quality is felt more seriously. Quality cannot be ensured just by inspecting the product at the end of the line, it has to be built in to the product at every stage of manufacturing.

A manufacturer must be intended to ensure that the goods produced are of salable quality, are fit for their intended purpose and offer value for money i.e. Quality in any product or service is judged by its fitness for use.

In this connection, an adequate quality system need to be tailored to ensure quality of the product. Here we need quality assurance.  Quality assurance is a wide ranging subject, far wider than a simple check on the final appearance of product before dispatch to a customer.

 Quality assurance system embraces every aspects of manufacturing from the purchase of raw material to the finished article. It also takes account of such facet of management as documentation, process control, inspection, testing, corrective action and training. It will help to earn customer’s confidence that the product produced through the system will be definitely the quality product. This documented procedure compiled as a quality manual. This quality manual will guide to produce standard quality footwear in a consistent manner.

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Standard Operating Procedure For Footwear Industry-In process Quality Control

Hello everyone. This is the quality final part of the SOP. Lets see the In Process Quality Control.

If you aren't read the quality first part click to read First part

Quality control is one of the most important function in production. It cannot be "inspected into shoe ate the end of the line."

Quality must be built into the shoes at every step in the manufacturing process. Substandard quality be identified and corrected when it occurs in the manufacturing process.

This process quality control concept rest on three basic principles.

1. Only good materials are used
2. Operations are performed correctly
3. Any defects are corrected when they occur during manufacturing.

This quality control system moves the quality checker into the main stream of production and makes him process quality controller.

The process quality controller makes a statistical quality control check at several critical check points in the process, at regular intervals. He measures and counts he does not guess.

In line with that Operator should

1. Receive good work
2. Perform good work
3. Supply good work

In-Line Inspection: During the production of shoe the operator's finished work is checked by line supervisor. A quality inspector moves from one operator to another at random inspecting a predetermined number of parts from a finished lot.

At the final stage checking by the quality checker after ration packing in the master cartoon as per AQL(Accepted Quality Level)  requirement and making report. To make recheck if the consignment fails AQL Requirement.

AQL Chart

All the above checking is carried out on the basis of approved reference sample. Besides that on the basis of the quality report preventive/corrective action are initiated the the quality dept. They also check the processing parameters such as time, temperature and pressure on daily basis.


Ok thats all. I think it will help a footwear manufacturer to help make their own company SOP.

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