What Is 100% Quality Inspection? How Inline and End-of-Line Quality Control Work
The purpose of quality control is not to find the defect after the product is finished, but to detect it at the station of the operation that caused it and have it repaired before the semi-finished piece becomes a product. argemas does this in two layers: statistical inline process control and end-of-line 100% quality inspection.
Statistical inline process control
In single rounds, every operation is checked at a set sample size such as AQL 2.5 or AQL 4. If defects are found below a defined threshold, the operator who did the work repairs them; above the threshold, the operation is stopped and the supervisor is alerted. In double rounds, the inspector returns to operations that failed in the previous round and to risky operations to verify the correction was made.
Together with the Arge Bilişim consulting team and the work-method development unit, every defect type encountered in the plant is defined in argemas to form a defect pool. The quality inspector scans the kanban trolley on a handheld terminal, selects the operation to check, starts inspecting according to the AQL sample size and enters defects on the terminal. Because the system knows who performed the operation, inline process reports can be filtered by operator, operation, date range or defect type.
End-of-line 100% quality control
The aim is to prevent a defective semi-finished piece from passing to the next process. The end-of-line inspector checks every operation on the garment using the clockwise method. At these points measurement is done on the @rgeHypatia terminal.
The inspector's card and the operation card are registered on the device once and need not be scanned again unless something changes. The kanban trolley is scanned and its pieces are inspected. When a defect is found, the defect type is selected first, then the operation that caused it is marked in the work-plan list shown on screen. The screen displays who performed that operation, and the defective piece is returned to that operator for repair.
From data to improvement
A wide range of quality reports is generated from the collected data. Operation-based defect analysis feeds kaizen work; the operations and methods producing the most defects become visible.