Adidas - Quality Concept Best Practice
Adidas - Quality Concept Best Practice
Adidas - Quality Concept Best Practice
Gears
Module 6:
MANUFACTURING CONCEPT
6.1. Quality Concept Best Practice
4 Self Inspection
REPAIR FREE LINE
World-wide Manufacturing Principles
SAFETY
1st Priority Machines/process/materials etc.
QUALITY
2nd Priority Beautiful product impressive customer.
SERVICES
3rd Priority Lead time, on time delivery.
EFFICIENCY
4th Priority More output with less manpower.
Quality Golden Rule
40
30
Seconds
R R
20
10
0
1 2 3 4 5
# of Operators
Why do We Need to do Repair Free Line
Ground rules
•Line should be stopped if the defect rate reaches is >5% of the
hourly output.
•No defective product allowed to go back to normal line.
Repair all the defective •QC needs to communicate the defects back to line.
products by the team •Repair is done by whole team understand what kind of
before new production defects have been made and how to avoid it.
•Defective review 2x per-day.
Repair Free/Performance Line Flow Chart
Quality Performance
Defects. (See Figure 1) Line Flow Chart
RFT %
Real
A- Grade
Box
Start
Production
QM & LM
Repair Defect Review Repair ing
Box 2 x Day Per iod
Defects
Report
New
Pr oduct /
Line Stop
End Line Inspection
Manual
F IGURE 1: QUALITY PERFORMANCE LINE F LOW C HART
RIGHT FIRST TIME
Definition & Calculation Method
Definition:
In making a product, it is better to perform an operation correctly the first time, rather than have to work on it
again in order to correct mistakes
Calculation:
End-line Reject
Quality issues found when the Product reaches final inspection at the end of the production line when the
product is completed.
Scope
• Prevent misunderstanding
• Prevent non adherence of process
• Prevent opportunities of error
Means causing
something not to How?
happen. • Study the work processes to increase understanding of how they
operate
• Understood the process requirements and identify how
requirements should be understood.
How?
Measure the • Measurement are everywhere.
performance against • Measuring allows us to find out what is happening.
the goal. • Measurement will help us to improve the way we meet our
performance.
ME Right-First-Time Template
TRAFFIC LIGHT SYSTEM
Introduction of Traffic Light System
15
Traffic Light System Criteria
16
Sequence of Movement Through Quality Levels
G
No
Action
Sample of Defect? taken
5
No
Yes
Minor >1 Minor No No Defect
defect?
Yes
defect? Y Sample of
5 ?
Yes
Action
taken
R
Immediate Actions
When a fault is detected, the inline QC will alter the colored display cards to the relevant
status.
.
The Line Supervisor will be informed whenever product falls outside the customers standard
The fault will be entered on the defect record and must be signed by the line Supervisor.
The Supervisor will take prompt action to correct the issue without delay.
A representative from the quality department will audit defective product prior to signing
clear for production.
18
18
Resource Required
19
SELF-INSPECTION
3 DON’Ts
The inspection is carried our by the operator to ensure responsibility for their own
work & quality. Defects should be corrected immediately instead of being passed
down the production line.
The main responsibility for quality inspection is done in-line by workers, because as
they handle a part they will subconsciously inspect it by sight and by touch.