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Indo Count Industries Limited (Sewing Factory)

Increase Process Traceability for Better Quality Control

Industry: Textile and Apparels
Service: Action 5/10 Program

Indo Count Industries Limited (Indo Count) is an India-based home textile product manufacturer. It is one of the suppliers of the global sourcing leader Li & Fung which targeted to improve its supply chain’s operation efficiency and effectiveness. Indo Count therefore invited TQM to implement Action 5/10 Program to assess its current operations and improve its quality control processes.

Project Scope

  • Assess performance of inspection lights, in terms of light source, light intensity, color, etc.

  • Identify contamination sources and provide rectifying measures

  • Identify causes of uncut thread defects

  • Define uncut thread IQC Standard for cut panel

  • Introduce in-process control and review performance

  • Introduce traceability to work processes such as production line operations and QC inspections

Achievements

  • Verified light source to ensure sufficient intensity with light boxes

  • Installed temporary floor on top of dirty/ muddy surroundings  to prevent dirt/ mud being transferred into the factory

  • Implemented preventive measures to cater possible failure modes of auto thread-cutting machine

  • Added fabric samples at the workstation for “in-process colour check” to establish an objective standard for quality control

  • Implemented preventive measures to cater for  failure modes of auto thread-cutting machines

  • Finalized the control plan and introduced records/ logbooks to ensure all procedures are followed

  • Designed daily/hourly system on top of existing system to provide instant feedback to workers upon discovery of defects