Quality Assurance System
LONG WAY ENTERPRISE CO., LTD is a typical family business owns
by five (5) brothers established on 1975. It started by
producting textile, gloves, shoes, cloth and some accessories
for knitting cuff, elastic strap, belts and webbing which
service thru Taiwan local supplier company.
In 1977, as skateboard business begins to grows, Long way
becomes interested to produce safety protective gear equipment
wherein most of webbing is utilize. We import Velcro from Japan
and USA as part for its components and design plastic parts for
needs of the markers. As the demands for Velcro increase,
Longway has become interested in the technology wherein
research and development department was created for this
In 1982, it was success and become the pioneer industry
in Taiwan. In 1983, Velcro hook and loop) manufacturing was
built up not only for our own safety gear used but as well the
demand for both local and export worldwide market.
In 1985-1988, high demands was turn into a completed “TURN KEY
PROJECT” wherein machines and technology were sold to eight
In 1983, Long way added another project to the manufacturing
lines of Soccer Shin pads, vollyball, football pads and other
related pads using most components of knitting materials,
elastic webbing,hook and loop.
In 1987, as a good results of Velcro Turn Key Projects,
Long Way also invested in Real Estate business till 1990 with
main projects on apartments and housing construction which is
successful till the present. For Sports industry, due to high
demand and its growing business, Taiwan manufacturing operation
can’t fully service the demands due to high rate of labor
shortage during year 1988-1989.
In order to cope up the marker demand, Long Way has decided to
make investment of operation in Shenzhen, China for advantage
of low rate labor cost for pricing competitive for the market,
Long Way was the first Taiwan company to set up for
manufacturing operation of sporting gear products plant in
China in 1989 by the same of Deyork limited and rental basis
for 2 years till 1990.
As sporting industry continues to grows, we then decided to
design and construct our own factory and started operation of
1st plant in 1992 with service employees of 800. The 2nd plant
was then decided to construct which started operation on 1993
and can accommodate 1,500 maximun employees.
The Quality Assurance Plan was created in 1993 spring when the
new plant started fully operation on manufacturing the complete
sporting gear pads and protectors lines with applied patent
The company has also added another manufacturing lines in
November,1992 producing Gummy Candies for China domestic market
and has been successful too on this venture.
Long Way had have been able to deal honestly and established
long term relationships with well-known sporting companies
worldwide and will still continues to grow. Our Research and
Development team is working hand on hand with client’s high
support for its quality design by producing good quality and
1.1 Research & Development Department Introduction
1)Design Graphic Center
Computer available if MAC and PC
With well experience designers of more than 5 years and also
with ability of prototype making
Our China factory has also the same facilities
2)Pattern Maker Designer
From this pattern computer, we’re able to:
- Grade sizing
- Calculate material yield consumption
By sculptor type, we’re able to service any 2D or 3D drawing
to model type within 4 to 14 days
We have 4 sets of CNC machine at our shop in suburb about 15km
from Long Way office.
4)Management Information System (MIS))
We created all datas based for our internal use both at
office and for China factory
5)Graphic Film Developer Machine
We create and develop graphic in our MAC and PC Computer
stations. The film can be develop within an hour and explore
the film for 1st sample discussion in house within 48 hours.
We also use the same machine system in our China factory.
6)Film Explorer Machine and Color Spray
Exploring the silk screen for first sample processing,
color idea spray develop for first color proposal.
We can change to any color with 1/2 to 1 1/2 hours.
For servicing samples of our Skates Liner, shoes skate and
Our China factory also use the same equipments.
8)Shoes Pattern Maker Designer
Most of samples required, we’re able to supply within 1 to 10
days for the first article
9)Sales Samples Assembling Line
We have a sample assembling line for sales samples requirement
located at Keelung, Taiwan (40 km from the office).
Or processed the sales samples at China factory with our
R&D teams heading the direction.
Once sales samples approved, a guide book be established for
the manufacturing and Q/C manual for guidelines which follows
our quality assurance plan book established accordingly.
1.2 CNC Center Introduction
Located at Taipei suburb approximately 15 km from office
( 25 minutes by car)
Possible to service any 2D drawing and converse to 3D model.
?At present, has 4 sets of CNC specifications as follows:
X Y Z
A) 800 500 500
B) 800 450 500
C) 1000 500 700
D) 1400 700 700
E) Prototype copy mold of Japan made machine with European and
One prototype mold can produce 18 to 20 pcs with leadtime of:
1 – 3 pcs = 5 to 7 days
4 – 10 pcs = 7 to 12 days
11 - 18 pcs = 7 to 15 days
?At future by 1998, will add another machine of SCAN Digital.
We’re able to service the 3D model with CNC milling parts or
SLA parts. SLA is not available in this facility but have the
capacity to sub-contract it.
For most clients software, we’re able to used the following:
-Pro E, Cimatron, Master Cam, Cam Max and any IGES file for PC
can be converse.
Delivery leadtime with 3D file will take 3 to 7 days, with
2D file, will take 7-12 days.
1)This quality Assurance Plan is based on “ISO 9003” Quality
2)To describe the system, administration and process
3)How to control quality
4)To achieve customer’s expectations, etc……
2.1 Incoming material control
To get the vendors parts and semi-assembly to meet the needs
of products ’ specification . Selecting the qualified materials
to ensured consumer’s satisfaction at Longway’s products.
2.2 Purchase control
Due to the purchased material, the quality, price and delivery
has direct and indirect influences on the plant. So Longway
should have a vendor’s QA. And inspection system for material
2.2.1 Control Points
To analyze the function of product’s components, materials and
find ways to solve concerned problems .
To coordinate with the vendors regarding their product quality,
price and delivery .
2.2.2 Purpose Process
1)Survey – The purpose of survey is to see whether the
vendor’s process capability and product quality meet
Longway’s product specification.
2)Check – The results of survey are discussed and decided by
the concerned section to select the vendors.
3)Sample approval – the production developer section provides
the converned specification and engineering drawing to vendors
for pilot run. After approved by Longway, materials will be
ordered with same specification.
4)Coordination – It includes the purchase contract,
negotiating process and other terms.
5)Incoming Material Control – To make data from incoming
product quality and delivery for vendor’s evaluation.
6)Audit for source of material – To audit whether the material
purchased by materials section and accepted by the I.Q.C are
supplied by approved vendors.
2.3 Vendor’s Control and Assistance
2.3.1 Vendor’s Data Concentration and Management .
1) Longway’s Vendor Survey table
2) Sample Specification Sheet
2.3.2 For the purpose of assistance to vendors, Longway
provides them with various necessary support for quality
control system be established.
2.3.3 If product quality and delivery date are changed, the
surveyor must take immediate actions. Every coordination record
should be kept for follow-ups quality control survey table and
must be submitted to QA manager. On the other hand, it can be
regarded as a criteria of encouraging to select other vendors.
2.4 Vendor Quality Survey
2.4.1 Objective of Vendor Survey
1) To find our sources of supply of parts and materials
2) To evaluate and select vendors
3) To assist vendors on their product’s quality control
2.4.2 Object of Survey
The major object of survey is the domestic direct vendors who
supply mostly fabric, EVA foam, plastic parts, elastic
knitting, Velcro, etc…
2.4.3 Surveyor – consists of engineer, quality controller and
2.4.4 Frequency of survey
1)First survey must be taken for new vendors
2)A survey must be taken at random of every 6 months or a year.
Every new vendors must be surveyed at the beginning
3)If vendor’s product quality and delivery varies, immediate
action is needed
2.4.5 Survey items
1) Quality Plan and Practice
2) Manufacturing Flow and Process Control
3) Transmission and Reservation for materials
4) Inspection and Operation Standard
5) Engineering Drawing and Data Processing
6) Incoming Material Control
7) Process Quality Control
8) Quality Assurance and Reliability
2.5 INSPECTION SPECIFICATION
2.5.1 Incoming Inspection Instruction
According to the formal engineering drawing, int’l standard
and other concerned specification.
2.5.2 Sampling Inspection Switching Procedure
1)Inspection Level: MIL-STD-105D Level II, Sampling Plan
2)AQL: Per components quality plan, unless otherwise specified
0 Defect Safety / Reliability items
0.4 Measurement / Function items
1.5 Mechanic / Non-Function items
2.5 Appearance items
18.104.22.168 Switching Procedure
1)Normal to tighten – when 2 out of 5 consecutive normal
inspected lots has been rejected
2)Tighten to normal – when 5 consecutive normal inspected lots
have been accepted
3)Normal to reduce – when 10 consecutive normal inspected lots
have been accepted
4)Reduce to normal – any lot has been rejected during reduce
inspection period or over 3% of major defects have been found
out at in-process line
5)Reduce to non-audit – quality guarantee granted from vendor
and approved by QA manager and keeping good records without any
rejection as long as 6 months and total receiving of over 15
lots with no major defects at in-process lines
2.6 VENDOR RATING SYSTEM
2.6.1 Longway must evaluate each vendors monthly for their
product quality and delivery. If they fail as required, Longway
must assist them.
2.6.2 In order to encourage vendors to develop their product
quality and delivery, rating and encouragement regulation has
been made by Longway.
The evaluation method regulation can be deveded into quality
and delivery with respect to percentage as follows:
1) Quality: Percent defective 70% 2) Delivery: Accuracy 80%
Vendors inspection record 20% Coordination 20%
2.7 REVIE PRICEDURE
In order to settle the unqualified incoming materials and to
avoid loss from wrong review, the sample board had been
established. The manager decides whether the lot is acceptable,
sorting our or need re-work. Then, to submit the decision to
plant manager for review .
2.8 DATE PROCESSING AND UTILIZATION
Date processing consists of monthly report, vendor data card
and inferior material report, etc…
2.8.1 Monthly Report:
(1)Vendor Quality Situation Report According to their daily
delivery and product quality situation, monthly statistical
report is made and submitted to purchase section as criteria
for vendors evaluation.
(2)Vendor Rating Report
According to the vendor rating and encouragement regulation,
monthly evaluation is required. To calculate their satisfactory
results, good vendors will be offer with short payment terms.
2.8.2 Vendor Quality History Card
It is the card on which the lot inspected parts are recorded
by the inspector for future Reference.
2.8.3 Inferior Material Report
For the purpose of getting material improvement in future,
an inferior material report Copy is sent to vendor to check
its causes for necessary improvements.
3.0 IN-PROCESS CONTROL
To control the product quality during manufacturing process
with purpose to manufacture products in accordance with
specification and to prevent any occurrence of defect products.
The product quality can be assured as well can meet the need
of consumers functional specification.
3.1 IN PROCESS CONTROL PROGRAM
3.1.1 Control Station
According to carious steps of operation and inspection,
Long way sets different department such as cutting, assembling,
trimming, packaging on line and appoints inspectors to inspect
during manufacturing process as well the sample.
The main jobs of inspectors as follows:
1)Mechanical function test
2)Appearance and safety inspection
3)To make reasonable judgment and feedback
4)To make inspection record for process capability analysis
5)To assist manufacturing line for developing self-assurance
3.1.2 Sampling Method – in order to assure quality of product
assemble, we use the MIL-STD-105D sampling inspection
22.214.171.124 Inspection Content – Visual and mechanical function
126.96.36.199 To consider the lot per day products as sampling lot
188.8.131.52 The inspection standard is to use lever 2, AQL for QC
sampling as follows:
CRITICAL MAJOR MINOR
0% 2.5% 4.0%
Quantity to Quantity to be Maximum umber of
Be shipped: checked at random: defect allowed:
151 - 280 32 3 5
281 - 500 50 5 7
501 - 1,200 80 7 10
1,201- 3,200 126 10 14
3,201- 10,000 200 14 21
10,001- 35,000 315 21 21
35,001- 150,000 500
A)Regular standard quantity control
B)For new products and quantity based – major quantity control
3.2 STANDARD OPERATING PROCEDURE
Operation instruction is developed by technical section and
finished by production section in accordance to the process
and method, It also includes operating process and records.
The necessary instrument must be hung up before every operator
for standard operating procedures.
3.3 PATROL INSPECTION
1)Frequency – 2 times a day
2)Person in charge – QA Manager
3)Job content – to perform patrol inspection by focusing on
quality key points of production process. To keep records
according to check list.
3.4 DATE RECORDING AND UTILIZATION
In order to make feedback system efficiently, every engineering
station has inspection
And test data classified and analysis by production and quality
control section for improvement methods. The process control
forms as follows:
1)Process Quality Report
2)Failure Analysis, corrected action and follow-ups
3)Sampling Inspection Report
5)Final Inspection Report
6)Patrol Inspection Record
With the above methods, the products quality can be maintained
4.0 FINISHED GOODS CONTROL
In order to expand international market and obtain continuous
development, Long way controls the quality of finished goods to
meet every customer’s specification and requirement.
4.1 INSPECTION PROCEDURE
To assure the finished goods quality, their have three
inspection methods to follow:
4.1.1 Total Inspection
Long way takes 100% inspection of finished goods to assure
quality before packing. All defective quantity must be returned
to manufacturing section for re-checking.
4.1.2 Sampling Inspection
For finished goods to be judged on it’s quality, inspectors
must takes several test such as impact, tensile, peel and shear
4.1.3 Detailed Inspection
This inspection is applied to new develop items taken from
production line. After judging the quality, the inspection
result shall be transferred to concern section.
4.1.4 Out-Going Inspection
Unless otherwise specified, the sample size which was accepted
or any rejected quantity are selected in accordance with
specification MIL-STD-105D, single sampling plan for normal
inspection or general level-II.
CRITICAL MAJOR MINOR
0% 2.5% 4.0%
Quantity to Quantity to be Maximum umber of
Be shipped: checked at random: defect allowed:
A B A B
151 - 280 32 64 2 3
281 - 500 50 100 2 3
501 - 1,200 80 160 3 4
1,201- 3,200 126 252 4 5
3,201- 10,000 200 400 6 8
10,001- 35,000 315 630 8 12
35,001- 150,000 500 1,000 11 18
4.2 INSPECTION SPECIFICATION
According to the customer’s engineering and design
specification and safety standard, Long way sets the finished
4.2.1 Inspection items
1) Mechanical function test
2) Visual inspection
3) Packing inspection
4.2.2 The practice and regulation before goods delivery:
When finished goods are not qualified, it should be submitted
to plant for decision. After re-work or re-inspection by
manufacturing section, it is returned to QA for sampling
4.3 INSPECTION AND TEST RECORDS
4.3.1 Daily Report
The inspector analyses the inspection record daily. This should
use the final inspection to make statistics of defect rate and
circumstances daily. This should be submitted for attention of
the next day.
4.3.2 Monthly Report
To arrange date and submit them to the concerned section
monthly, Then to make options and prevention method for the
last month’s product Quality. The date includes the followings:
1) Process Quality Situation
2) Finished Goods Quality
3) Test Report
4.3.3 Records are to be retained for a period of one year
1) Vendor Quality History Card
2) Final Inspection Record
3) Detailed Inspection Record
4) Sampling Inspection Record
5) Test Record
5.0 STORAGE AND SHIPPING CINTROL
To provide secure storage and proper delivery, Longway arranges
every quality product protection and proper identification
5.1 STORAGE FINISHED GOODS IDENTIFICATION CARD
1) white card for 1-3 months storage goods
2) yellow card for 4-6 months storage goods
3) Red card for over 6 months storage goods
5.2 STORAGE FINISHED GOODS AUDIT
In order to avoid any defective on storage goods, Longway sets
storage finished goods regulations.
5.2.1 Storage Finished Goods Re-inspection
1)If finished goods have been stored for over3 months, the
Qasection must be re-inspect master carton before shipping.
2)If finished goods have been stored for over 6 months, the QA
section must be re-inspect them as a brand new lot before
5.2.2 Re0inspection Method
1)According to out-going inspection (AQL)
2)If product quality is regarded as defected as defect, the
goods must be arranged for total re-inspection and re-work by
5.3 STORAGE SECURITY INSPECTION
To audit whether the anti-rob or anti-fire equipments are
workable, all combustible goods are well stored in a safety
5.4 LOADING AUDIT
To avoid product damaging in loading process and keep them in
good condition, the warehouse personnel must put goods into