The PDCA Approach with Seven Quality Tools for Quality Improvement Men’s Formal Jackets in Indonesia Garment Industry (original) (raw)

Minimization of Sewing Defects of an Apparel Industry in Bangladesh with 5S & PDCA

The readymade garment industry is the leading industry in Bangladesh that's why the Quality improvement of garments can play a vital role. The main purpose of this paper is to reduce the defects that will minimize the rework rate. We worked at " Interstoff Apparels Limited " , Bangladesh identifying sewing defects for a particular product (knit T-Shirts). Pareto analysis is performed to identify top defect positions from all the defects and seven are identified where 80% defects occur which should be the major concerning areas to minimize defects percentage. Cause-effect diagrams are constructed to show the root cause, effect, and 5S & PDCA is used to minimize the defects effectively. Recommendations have been added at the end of the study.

Investigating Root Causes of Sewing Defects Using TQM Tools for Quality Improvement in the Knit Garment Industry

Textile & Leather Review

To increase customer satisfaction in the highly dynamic and competitive apparel industry, it is essential to manufacture garments of superior quality. The study aimed to investigate the underlying causes of sewing faults and offer solutions for enhancing quality to a 100% export-oriented knit garment industry in Bangladesh. The study employed a comprehensive approach using quantitative and qualitative research methods to evaluate garment faults systematically. The whole garment inspection procedure was done on five common garment styles to collect the quantitative data. Some novel TQM (Total Quality Management) tools, Pareto analysis, WH questionnaire, cause-effect diagram, and a highly potential focus group panel were employed. The findings indicate the most prevalent faults like an open seam, skip stitch, and label mistake, accounting for 50 per cent, 29 per cent, and 7 per cent of all observed defects, respectively, and their remedies. The research's significance lies in its ...

Analysis of sewing defects and control measures for apparel industry

International Journal of Polymer and Textile Engineering (SSRG-IJPTE), 2020

Sewing is the stage in apparel manufacturing process sequence where large number of work force is employed compared to other stages of manufacturing processes. The quality of garments made in sewing depends upon various factors such as skill of sewing machine operator, machine settings, fabric and thread quality etc. Since many factors involved in determining the quality of product, possibility for occurrences of defects is also very high. In order to achieve maximum productivity and efficiency in sewing room, it is important to control and minimize the defects in sewing process. In this project an attempt is made to study the various defects occurs in sewing room for 10 different garment styles. The data collected has been analysed and suitable remedial measures have been supported. The study reveals but there is scope for improvement of productivity by effective management and quality of production.

Critical Analyses of Sewing Defects and Minimization of Sewing Reworks in the Apparel Industries

Global Journal of Research In Engineering, 2018

Improving productivity is major concern of apparel industries. There are many factors to increase productivity. The efficiency of workers, tactic and sewing defects of production are interrelation of productivity. Entirely sewing faults are not possible to reduce, but it can improve to minimize the defects of productivity with the help of some technics. This paper considers the quality and productivity enhancement in a manufacturing process through practical study. An experimental investigation for the sewing defects is collect sufficient data from industries. Statistical tools Bar chart, Fishbone diagram, and Regression values help to analysis sewing faults of apparel industries. The outcome of this study is find out the reasons, effects, and remedies of garments sewing defects.

Defects and its rectification methods in garment production

Lab Lambert Academic Publishing, 2022

For any garment industry the production and quality management or wastage reductions have a major impingement on overall factory economy. In garment industry maximum quality and production constraints arise in the sewing department. The minimization of reworks and line efficiency improvement in sewing department of any apparel industry for quality and production improvement plays a significant role on overall factory economy. This book discusses about the importance of quality assurance and quality control in apparel and garment industry using the AQL standards. This book also discuss about root defects which occurs during the construction process and its rectification procedures

Production Quality Control as An Important Factor to Meet Buyer Quality Standards at The Garment Company PT. Sukabumi Single Estuary

Devotion Journal of Community Service

The objectives of this study were achieved through the use of qualitative descriptive analysis, quantitative statistical ana-lysis, and quality control. To meet the quality target set by the Buyer, which is below 1.9%, it is necessary to know how many types of defects are found in the Finishing section and in the Final Inspection and how to reduce defects through the use of control strategies and methods applied by PT. Single Estuary. The data for this study comes from the statistics of production and damage to the Finishing department between May and August. Based on the findings of the study, it can be said that the implementation of quality control in this enterprise has been carried out quite successfully, with a noticeable improvement and a good quality improvement and is worthy of appreciation. These results show the seriousness or level of commitment of the management of PT. Muara Tunggal to continuously improve the quality according to the requests of buyers or buyers. The r...

IMPLEMENTING TOTAL QUALITY MANAGEMENT APPROACH IN GARMENTS INDUSTRY

Rapid developments in international competition have obliged textile enterprises to take new approaches in order to gain a competitive advantage. The limits of acceptable quality levels for the enterprises have fallen back down to critical points due to the effects of liberal policies in international markets. Total Quality Management (TQM) keeps vital role in improving productivity, product quality and reduces manufacturing cost by reducing rework and scrape. TQM method has a great applicability in RMG sector. As RMG sector is the largest industrial sector of Bangladesh, Product Quality improvement can play a vital role in opening the doors of great opportunities for the country. To perform this study we take help of the tools of TQM such as Flow chart, Check sheet, Histogram, Pareto Chart, Scatter Diagram, Control Chart, Cause and effect diagram from various garment industries of Bangladesh to analyse collected data which were collected through observation method and it is found that a significant amount of rework and scrape per style, per month has minimized by applying this method. Implementing Total quality control applications are gaining in importance

DEVELOPMENT AND ANALYSIS OF METHODOLOGY FOR SUSTAINABLE QUALITY IN APPAREL INDUSTRY

2017

The purpose of this paper is to present an analysis of developed and implemented methodology in apparel manufacturing organization in Bulgaria for improving the work quality during the process of apparel assembling. Through presenting a suitable technical documentation, the workers improved the quality in their work. The methodology was developed after making necessary observations and calculations, using personal interviews, secondary data and research using a casebased approach. It was administered with one of the leading apparel manufacturers in South-west Bulgaria.The developed methodology and documentation was introduced and verified in the company.

An Exertion to Alleviate Stitch Defects During Garments Production

In garments industry sewing is the most critical phase during an apparel production. Different types of sewing and stitching defects are occured in this phase due to various problems. As today's world each customer is expecting a very high quality garments with product variety, it has become a very challenging task for garments quality management. Here all the data were collected from Gardenia Wears Limited situated at Barmi-Sreepur, Gazipur, Dhaka and data were analyzed for reducing Defects per Hundred Unit (DHU%) and also top 10 stitch defects were identified and analyzed later. Finally the work shows reduction of DHU% from 5.23% to 3.48% and also reduce the top ten stitch defects with comparison to before trial and after trial data of ten days and it is proved that an industry can achieve higher production capability & profitability with improved quality product and also saving cost due to reducing DHU%.

Reduction of Fabric Defects Through the Application of Lean Tools

ICERIE 2023: 7th International Conference on Engineering Research, Innovation, and Education, 2023

Readymade garment (RMG) industry is making a great contribution to rebuilding the economy of Bangladesh, where 83% of total export earnings come from it. One of the major wastages in this industry is “Cut Panel Rejection” due to fabric defects. The purpose of this study is to analyze and reduce fabric defects by applying lean tools. Data on the fabric defects were distributed with a U chart to show the defect variation. After analyzing the total six-month cut panel rejection data due to fabric defects, six major defects are identified by Pareto analysis. “Five Whys”, a lean tool, is applied to find out the causes and effects of fabric defects. Further, the application of the remedies made the cut panel rejection within 5% by the application of 5S, Logical solution, and Control chart, which was almost 6.5% previously. This study was conducted by applying specific lean tools combined with a QC tool which can vary with other lean tools.