SQC enables plants using Satelite Plus to perform data entry for defects using the same realtime terminals that the operators use to record production or alternatively at CRT displays. The entry is simple and requires as few key strokes as possible.

SQC is developed to run on a PC-Server or IBM AS/400 system. SQC interacts with users in an on-line, conversational manner with minimal training. SQC users are directed to each data field automatically by the system. Data is verified immediately and error messages are output in clear language for easy understanding.

  1. SQC and QC FUNCTIONS COMPARED
The SQC function is oriented toward the current production process as compared to the Quality Control Audit functions (QC1 and QC2) which are targeted at completed bundles. Therefore, the SQC function is performed at strategically placed realtime or CRT terminals within the production environment. Each SQC entry operator is responsible for locating defects for a given set of jobs on each bundle that is inspected. The object is to record the defects for rapid analysis during the production cycle and to have the garments repaired as soon as the defects are found.

The Quality Control Audit (QC) function is geared to the status of each bundle at completion after all in-line checks and balances have been performed. Basically, each bundle is assumed to have been cleared of all defects that may have been located during the previous SQC inspections. Data entry for a QC operator consists of the same type of defect information as that done at each SQC terminal except that the QC entry is not limited to a subset of jobs. QC records the final defects found on all jobs within a bundle.

Quality audit is actually separated into two phases; the primary Quality audit phase inspects 100% of the bundles for each cut. The secondary phase inspects selected bundles on a portion of the cuts. The secondary phase acts as a verification of the primary quality audit.

  2. STATISTICAL DATA PRESENTATION
The SQC system is designed to gather statistical quality information in real-time as it is entered by the inspectors. Analysis required to develop DHU (defects per 100 units), week-to-date and period-to-date information is developed during the end-of-day processing function.

  3. CRT QUERIES vs. REPORTS
As with all Leadtec products SQC was designed to minimize the requirement to print reports. Most SQC and QC information is available to system users via the CRT terminals. (These are the 24 line by 80 column terminals, not to be confused with the 2 line by 16 column real-time data entry terminals.) In most cases there is a comparable hard-copy report output version of each of the standard query functions.

Accurately reports defects at the operator, cut, job and style level.

Defect analysis in either summary or detail versions.

Up-to-the-minute operator accountability for quick and accurate repair control.

Improved quality levels within the plant and reduced expense involved in reworking garments.

Significantly reduced cost and administrative effort required to perform SQC and Quality Auditing functions within the factory.

What Does the SQC System Do?

First, SQC provides the ability to maintain complete and up-to-date quality records for both in-line inspection and up to 2 levels of quality auditing. This information can be displayed on any of the system's CRT screens or printed in hard-copy report format.

Second, SQC provides a Measurement Tolerance Audit function which provides the facility to enter measurement tolerance information at a CRT and analyze this data using reports and inquiries.

Third, SQC provides, as an option, the ability to enter Irregular Unit Classification information at a CRT. Irregular unit classification includes the ability to assign a defect code, classification (2nd, 3rd or 4th quality) and origin (factory, mill or finishing) to each defect.

Fourth, SQC provides the ability to perform data entry at either a Satelite Plus realtime terminal or alternatively at a CRT display.

Fifth, SQC provides a series of management inquiries and reports. A brief list of these include:

  The Data Entry Terminal
SQC sample information includes the number of each sampled bundle and a code indicating the defect type for each job on which a defect is found. The design of the system is such that sample data entry requires as few key strokes as possible in order to reduce the burden on the sampling clerk.

When a Satelite Plus realtime terminal is used as a "quality entry device" as opposed to a "sewing data entry device", the system will be able to recognize different data characteristics. Since "sample data entry" is the most prevalent operation in the SQC/QC system, the design is such that the mere scanning of a bundle card without any function key entry will automatically signal a sample data entry transaction.

This is analogous to the mechanism used for a "sewing" terminal. Since "bundle start" operations are the most prevalent for a sewing terminal, the system automatically defaults to a bundle start operation whenever a bundle number is scanned or keyed in without any function key entry. This capability can only be accomplished if the system knows what kind of terminal is making the system request. The kind of terminal is referred to as the terminal's "personality". This personality is used to distinguish a "sewing" terminal from an "quality" terminal.

Once the terminal is defined as a quality entry device there are two additional pieces of information that the system must maintain with respect to the terminal. The first is the identity of the SQC/QC station that is signed-on to the terminal. This information allows the system to identify which jobs and defects are acceptable for entry on the terminal.

The second element of information identifies which type of sampling data is to be entered. This can be SQC sampling data, primary quality control audit (QC1) data or secondary quality control audit (QC2) data. Each type, although entered in an identical manner, causes the system to update its internal files in a slightly different fashion.

  "Sample" Data Entry
Sample data entry consists of a series of steps and procedures similar to bundle data entry for sewing operators. The sequence of steps include those shown below, regardless of the entry type: SQC, primary quality audit or secondary quality audit.

1. The operator will scan an identification card indicating that the terminal is operative and the mode: SQC, primary quality audit or secondary quality audit.

2. The inspector selects the next bundle to be inspected and scans the bundle card through the slot reader. This completes any prior bundle's sampling entry (if there was a prior bundle started)and begins the sample entry for the current bundle.

With the entry of the bundle number the system can determine the cut and style associated with the bundle. The sample size is either determined from the SQC station number or computed using a predefined algorithm. Given the job at which the defect occurred, the system can determine the station's line and the operator that did the job. Further, various on-line verifications are made. The system can verify that the bundle number entered is valid and if the job in which a defect is found may be inspected at the current SQC station. The system can also verify that the defect code can be associated with the job.

3. The inspector then selects each garment one at a time from the bundle sample to be inspected.

4. The selected garment is inspected for each possible defect for each job for which the inspector is responsible. Thus a single garment could conceivably have more than 1 defect for each job being inspected.

5. The inspector enters information into the terminal each time a defect is found on the garment being inspected. Defect information will consist of the job number where the defect was found and the code identifying the defect type. If a number of defects is not entered the system will assume 1 for the job and defect code entered. Optionally, the operator may enter a defect count of 1-99.

The first shows the number of defects and the number of defects per 100 units (DHU). An alternate screen shows the number of defects and the associated sample size. This alternate screen can be accessed by pressing a "2" in response to the SELECT prompt when the primary screen is displayed.

Note also that there is a great difference between a value of zero for the number of defects or for the DHU, and a "no sample" entry. The former always means that there was a sample taken but no defects were found. The latter indicates that there was no sample taken for the period in which the "no sample" description appears, but there was probably a sample taken for one or more of the other periods.

When the Defect Analysis function is chosen the user is given the following choices. Each selection provides various detail and summary analyses of historical information.

Operator Analysis Functions Operator Performance By Job Bundles Worked On by Job Bundle Operation History Zero Defects Job Analysis Functions Job Performance By Operator Job Defect Analysis (Detail) Job Defect Analysis (Summary) Cut Analysis Functions Cut By Job - Detail Cut By Job - Summary Cut Defects By Bundle Cut Defects Summary Cut Audit Summary Style Analysis Functions Style Defects Analysis (Detail) Style Defects Analysis (Summary) Style Audit Summary