EXECUTIVE SUMMARY

SCM Garments Private Limited forayed into the textile industry in 1989 at
Tirupur. Initially established to cater to the increased demands of the export market,
today, we are a vibrant presence in the hosiery map of India.

The study was carried out in Unit I of SCM garments with of 100 sewing
machines, 20 ironing machines, and 20 cutting persons. Both manual and machine cutting
is carried out in this unit. The company is producing 1500-2000 pieces per day. Defect
occurrence is one of the main risks faced by them and it may occur by both machine and
operator fault. In this situation, identifying the frequently occurring defects in the
garment is highly important so as to minimize their occurrence.

The study has been conducted for around 45 days. In this study 20 orders were
analyzed thoroughly. Defective pieces and the types of defects are been identified in
these 20 orders. Analyses are made with the data and defects percentage is identified.
Reasons for the defects are found out and analyzed during the study. This study is an
effort to reduce the defects in the production process.






ii
If a company can bring down the defects in production process, then the
company production rate increases with high profitability. The defect percentage is more
than the acceptable norms of the company for defects margin, in order to rectify or ignore
it, this project study is done.

The initial step in this research is a systematic study in the production department
to identify the defects. The collected data have been classified and tabulated. Simple
tables have been prepared and liberally used to exhibit the classified data to provide easy
and better understanding of the study.

The frequently occurring defects and the defects which are contributing more in
the total percentage of defects are identified by categorization analysis and chi-square
analysis. The most occurring defects in the garments are found to be skipped stitch, oil
stain and ADAS (holes in the garment). The major reasons for occurrence of these
defects are improper tension in the disk, repetitive usage of machines, improper handling
of the garment and needle fault.

It is suggested that the company can concentrate on these defects mainly and
technically some suggestions are given to bring down the defects. This will pay way for
increasing the level of productivity and save the time.





1

CHAPTER-1
INTRODUCTION
1.1 INTRODUCTION

The textile industry has unique place in the Indian economy. Its contribution to
industrial production, employment and earnings is very significant. It is one of the oldest
industries established 125 years ago. Since then the industry has made tremendous
progress, despite the early struggles to survive competition from abroad.

In keeping pace with the trend in advanced countries of the world, the Indian
textile industry progressed in many directions in the use of various fibers for fabric
production and employed different techniques of production such as weaving and
knitting. Today, the textile industry has emerged as a multi-fiber industry employing
cotton and cellulosic and synthetic fibers to produce both knitted and woven fabrics.

The apparel sector plays a vital role in textile industry and mainly exports play an
important role in the global business. There are many countries in the playground of
apparel exports such as China, India, Bangladesh, SriLanka, Pakistan, Europe, Korea,
Turkey, Thailand, Hong Kong, Vietnam, Nepal, Taiwan, Australia, Syria, Italy, USA,
and Brazil. There are 2 types of garments in apparel sector. One is Woven garments.
Another is Knitted garments.
2

For every industry or business, to get increased sales and better name amongst
consumers and fellow companies it is important to maintain a level of quality. Especially
businesses engaged in export have to sustain a high level of quality to ensure better
business globally. Generally quality control standards for export are set strictly, as this
business also holds the prestige of the country, whose company is doing the export.
The major challenges which are being faced by all countries apparel exporters is
to bring effective solution to increase quality of product in the apparel manufacturing.
Quality is keyhole for global competition. Also having prime importance for every
industry or business, to get increased sales and better name amongst consumers and
fellow companies. For apparel industry product quality and productivities are calculated
right from the initial stage of raw material to the stage of finished garment. The quality
control of garment industry is normally depends on raw material, employee, machinery of
the company.
For a garment exporter there are many strategies and rules that are required to be
followed to achieve good business. The fabric quality, product quality, delivery, price,
packaging and presentation are some of the many aspects that need to be taken care of in
garment export business.



3
Apparel manufacturing comprises a variety of product categories and when it is
analyzed, the central process in the manufacturing is the joining together of components,
which is the labor intensive part of this type of manufacturing known as the sewing
process, where most of the defects occur in the garment.

Further more when the cost structure is analyzed, apart from material cost, the cost
structure of sewing process is of critical importance and the cost of poor quality will also
include with this. Every time work is redone, the cost of quality increases. In the apparel
industry, reworking of the garment, retesting of performance of the apparel, rebuilding of
garment machine, all these are done when the defect occurs.

Defect minimization aims to reduce and minimize the number of defects and errors in
a process and to do things right from the first stage. The ultimate aim is to reduce the
level of defects. However, this may not be possible in practice but what it means is that
everything possible will be done to eliminate the likelihood of errors or defects occurring.
The overall effect of this project is to identify and reduce the defects which lead to reduce
the time and increase the productivity.





4

1.2 COMPANY PROFILE
This section discusses about the history and profile SCM garments Pvt. Ltd to
provide insights so that the suggestion made in the study can be related in a better
manner.

HISTORY:
SCM Garments Private Limited forayed into the textile industry in 1989 at
Tirupur. Initially established to cater to the increased demands of the export market,
today, they are a vibrant presence in the hosiery map of India.

In these 2-decade long presences in the textile industry, they have seamlessly
transcended time to establish themselves as a company with a global vision. The
company represents their group abroad, a role that they fulfill with utmost responsibility,
and will continue to do so.

The company has always adopted a process of continuous up gradation of the
technology and processes. Its dedicated team of researchers and designers constantly
keeps in touch with the current trends in the market place and the consumers
requirements. The approach has lead to various technological innovations resulting in
new product introduction.
5

SCM Garments Pvt. Ltd. is promoted by eminent men of vision and foresight. At
the help of the affairs Mr. K.Paramasivan as Chairman and HR manager Mr. Sekar
.SCM has created brands that have made marketing history. What is more they managed
it in a category, which was dominated by the unorganized sector with unbranded
products.
SCM Garments Pvt. Ltd is one of the worlds largest knitted garment
manufacturer and marketers commanding an impressive annual growth rate. It has to its
credit six regional offices, three production bases, and state of the art technology right
from developing cotton to making garments.
All this plus an extensive distribution set up spanning the length, breadth of the
country. The company through its dedicated research team constantly keeps in with
current trends in the market place & the consumers. This approach has let to various
technological innovations resulting in new product introduction/extensions.

MANUFACTURING UNITS
The company has manufacturing units at Tirupur, Avinashi, Erode, Coimbatore
(all in Tamilnadu), and has around 25 production units, in all.



6

MANUFACTURING FACILITIES
SCM garments have its manufacturing facilities located at Tamilnadu. Their
spinning division facilitates the production of the finest combed cotton yarn. While 50%
of the facility is dedicated to manufacturing heavier count yarns like 30s, 34s & 40s, the
remaining 50% produces finer yarn of counts 60s & 80s. With 28 combing machines, 45
ring frames and 20 Auto Coner machines, the spinning unit is well suited to handle huge
loads. The use of organic cotton and imported machines help them give the quality of the
yarn as desired by the buyers.

EXPORTING COUNTRIES
Through the years, they have been associated with renowned brands and retail
stores in Europe, USA, Canada, and France.

AWARDS
This company is compliant with AQL 2.5 Level Quality & Standards and follows
a 4 point system to ensure conformance of rigorous norms. The ISO 9001:2000, WRAP,
Oeko TEX Class 1 & 2 and CU certification for Organic Cotton are testimonials to our
commitment and compliance to global standards.



7
VISION
To deliver innovation and quality to their customers by following a progressive
and on time approach and further the cause of a sustainable future by promoting an eco
friendly approach in all our operations.

MISSION STATEMENT
Join Hands Together, To Become an International Symbol of Excellence
through Continuous Innovation, Manpower Development, Productivity Improvement,
Quality Improvement, Cost Reduction, Time Management












8

1.3 NEED FOR THE STUDY
The company is facing risk in the occurrence of defects in the garments.
Identifying the frequently occurring defects in the garment is highly
important and also they have to be minimized.


1.4 OBJECTIVES OF THE STUDY
The objective of the study is to study the frequency of the occurrence of defects.
To explore the causes for the defects and to find out the possible ways for
eliminating those defects.







9
1.5 SCOPE OF THE STUDY

The study has been conducted in SCM garments during June and July month of
2010 to identify the reasons for the defects and suggest the remedies to the
defects in the production process.
The study will help the organization to avoid the defects in the garment and to
save time.


1.6 LIMITATIONS OF THE STUDY
The project was conducted for a company operating in export and domestic
market. The study will not show the complete picture of apparel industry rather it
will be confined to a single company only.
The project was restricted for 2 months.






10
CHAPTER - 2
RESEARCH METHODOLOGY

Data collection is a decisive step in the Research Process and this is the
descriptive type of research. The first hand data needed for this study was obtained from
the production department of the company for the standard acceptable percentage of
defects in the garments. The details about the types of defects are collected from by the
analysis and from the supervisors.
2.1 DATA COLLECTION
The initial step in this research is a systematical study and concepts and its
different tools and techniques, after that the production unit study has done to identify the
current state of processes and activities happening in the unit. The next step is to analyze
the defects in the garment as per the order and implementing reduction technique and
tools to reduce and avoid the defects.
Primary data source:
Primary data sources are originated by the researches for specific purpose of addressing
the problem at hand and it sought for their proximity to their truth and control over
error. The primary data sources are
Observation
Interaction with company manager and line supervisors.
The study is carried out for nearly 45 days and 23 orders have been executed in these
time period. 20 orders were taken into study, as for 3 orders sufficient information and
data was not available.
11

2.2. TOOLS USED
Percentage analysis is used to categorize the defects according to its percentage
and chi-square test has been to compare the style wise defects margin.

2.3 PRESENTATION AND INTERPRETATION OF DATA
The collected data have been classified and tabulated. Simple tables have been
prepared and liberally used to exhibit the classified data to provide easy and better
understanding of the study.
12
CHAPTER-3
THEORY OVERVIEW
3.1 ABOUT THE PROCESS
There are nearly 450 employees in Unit I and it comprises of 10 lines where 800-
1000 pieces are produced in one line per day. There are 8 buyers for whom the orders are
carried out in a constant manner. And 8 teams of merchandisers handle these 8 buyers.
SEQUENCE OF OPERATION
FIGURE 3.1
Cutting

Production

Random checking

Final checking

Packing

Dispatching


13
The sequence of operation of the production department starts from the pattern
making, continued with pattern layout. Once pattern layout has been done, Cutting
process will be started according to the style of the garment. Next is the sewing process,
were all the parts of the garments are attached. Then the sewed garments will be
randomly checked by the line supervisors. After the random checking, final checking will
be carried out by the inspection department and directly the garments will be taken to the
packing department. Once the packing is fully completed as per the buyers requirement.
Then it will be directly taken for dispatching.

3.2 PRODUCTION DEPARTMENT
There are various styles of garments being produced in the sewing process. Of
which the process flow of a particular garment is shown below

PROCESS FLOW OF A T-SHIRT PRODUCTION SEWING LINE
Fig.3.2

COLLAR STITCH

SHOULDER ATTACH

PLACKET OPEN

14
PLACKET FINISH

COLLAR ATTACH

SLEEVE ATTACH

SLEEVE TOP STITCH

SLEEVE HEM

SIDE ATTACH

BOTTOM HEM


In the production process of T-Shirt, the first step is to stitch the collar. Next
operation is joining the shoulder with the body part. The placket will be made in the front
for the opening and fasteners. The collar is attached to the neck of the T-shirt. The right
and left sleeves are attached to the respective armholes. The top stitch and the hemming
in the bottom is done for sleeves. The side seam of the T-shirt is stitched and the hem is
done, by this the T-shirt will be produced.

15
CHAPTER -4
ANALYSIS AND INTERPRETATION


For the purpose of analyzing the frequency of every defect in the production process

20 ORDERS were taken into study.
The total number of pieces produced under this 20 orders were 1,68,956 pieces
The table of defects-4.1 shows the
Types of defects
Defective Pieces and number of defects











16
4.1. TABLE OF DEFECTS

This is the primary data collected from the company by analysis and the table
shows the types of defects which occur in the garment in 20 orders and number of
defective pieces and the frequency of occurrence are also shown.

OVERALL LIST OF DEFECTS
TABLE 4.1
TYPES OF DEFCTS NO. OF DEFECTS DEFECTIVE
PIECES
S.NO DESCRIPTION CODE NO. % NO %
1. Skipped stitches in flat lock m/c D1 3319 21.3 1220 12.7
2. Misalignment of collar D2 141 0.9 0 0.0
3. Pattern stripes mismatched D3 367 2.4 84 0.9
4. Pocket box size variation D4 211 1.4 122 1.3
5. Label mismatched D5 210 1.4 103 1.1
6. ADAS (holes in garment) D6 1069 6.9 356 3.7
7. Oil Strains D7 1976 12.7 724 7.5
8. Uneven stitch D8 538 3.5 43 0.4
9. Bottom edge stitching irregular D9 326 2.1 50 0.5
10. More threads joining in one place D10 477 3.1 112 1.2
Table 4.1 continued
17
11. Improper sleeve attachment D11 231 1.5 32 0.3
12. Improper ruffle attachment D12 105 0.7 0 0.0
13. Collar point mismatched D13 239 1.5 84 0.9
14. Raw edges outside D14 952 6.1 216 2.2
15. Misplacing the scrap in the garment D15 83 0.5 31 0.3
16. Yoke piece unevenly attached D16 555 3.6 141 1.5
17. Neck rib measurement changed D17 340 2.2 0 0.0
18. Puckering in the attachment D18 858 5.5 241 2.5
19. Mismatching of stripes D19 673 4.3 165 1.7
20. Printing defect D20 137 0.9 81 0.8
21. Seam twisted gives puckering
appearance
D21 771 4.9 251
2.6
22. Over pressing leads to unshaped of
the garment
D22 131 0.8 116
1.2
23. Breakage of stitch D23 628 4.0 146 1.5
24. Un stiff button holes D24 78 0.5 30 0.3
25. Uneven length in the placket D25 231 1.5 0 0.0
26. Uneven stitch formation in the
placket box
D26 167 1.1 25
0.3
27. Improper belt width D27 281 1.8 87 0.9
28. D1&D2 - - 68 0.7
29. D1&D4 - - 89 0.9
Table 4.1 continued
18
30. D1&D6 - - 205 2.1
31. D1&D7 - - 287 3.0
32. D1&D9 - - 62 0.6
33. D1&D10 - - 172 1.8
34. D1&D12 - - 38 0.4
35. D1&D14 - - 183 1.9
36. D1&D18 - - 46 0.5
37. D1&D19 - - 64 0.7
38. D1&D21 - - 146 1.5
39. D1&D23 - - 251 2.6
40. D1&D25 - - 142 1.5
41. D1&D27 - - 42 0.4
42. D1&D6&D7 - - 62 0.6
43. D1&D7&D8 - - 230 2.4
44. D1&D6&D10 - - 12 0.1
45. D2&D5 - - 73 0.8
46. D3&D18 - - 251 2.6
47. D3&D16 - - 32 0.3
48. D5&D7&D13 - - 34 0.4
49. D6&D7 - - 128 1.3
50. D6&D10 - - 92 1.0
Table 4.1 continued
19
51. D6&D14 - - 76 0.8
52. D6&D22 - - 15 0.2
53. D6&D19 - - 123 1.3
54. D7&D8 - - 169 1.8
55. D7&D11 - - 132 1.4
56. D7&D13 - - 121 1.3
57. D7&D20 - - 56 0.6
58. D7&D10 - - 89 0.9
59. D8&D21 - - 96 1.0
60. D9&D27 - - 152 1.6
61. D9&D18 - - 34 0.4
62. D9&D19 - - 28 0.3
63. D11&D12 - - 67 0.7
64. D14&D17 - - 232 2.4
65. D14&D16 - - 192 2.0
66. D14&D18 - - 53 0.6
67. D15&D17 - - 52 0.5
68. D16&D17 - - 56 0.6
69. D16&D18 - - 134 1.4
70. D18&D21 - - 18 0.2
71. D18&D19 - - 33 0.3
Table 4.1 continued
20
72. D18&D24 - - 48 0.5
73. D19&D21 - - 260 2.7
74. D23&D25 - - 89 0.9
75. D23&D26 - - 142 1.5
TOTAL 15094 100 9636 100
[Calculations furnished in annexure table1&2]

This table shows the types of defects in the garment. There are 27 type of defects
listed in the table with its code. These defects occur solely and also in
combinations with the other defect. The combinations are also shown in the table
which is mentioned in code. Number of defects and the defective pieces for every
defect and also for combinations are shown separately with its percentage.
Each piece in 20 orders is checked and the total number of defective pieces was
9636 pieces (which is around 5.7%)
Out of these 9636 pieces, there were 27 types of defects occurring. And in this
9636 pieces number of defects occurs is around 15094 in the garments.
The standard acceptable norms adopted in the company for defects margin is 3%
The occurrence of defects is more than the standard norms. So the analysis is
carried out to find the frequently occurring defects in the garments.


21
4.2 COMPARITIVE ANALYSIS OF TOP 5 DEFECTS OUT OF TOTAL
DEFECTS
- FREQUENCY OF DEFECTS & DEFECTIVE PIECES
The comparative analysis is done between the frequency of defects and the
defective pieces. The defects are ranked on the basis of both and first 5 ranks are taken
for the comparison as this contributes more from the total percentage.


4.2.1. FIRST 5 RANKS OF FREQUENCY OF DEFECTS
This table shows the first 5 ranks of frequency of defects
FIRST 5 RANKS OF FREQUENCY OF DEFECTS
TABLE 4.2
S.NO DEFECTS NO.OF.DEFECTS PERCENTAGE
1. Skipped stitches in
flat lock m/c
3319 21.3
2. Oil stains 1976 12.7
3. ADAS (holes in the
garment)
1069 6.9
4. Raw edges outside 952 6.1
5. Puckering in the
attachment
858 5.5

22
INTERPRETATION:
These 27 defects have been occurred 15094 times in 9636 pieces individually and
also in combinations, in which skipped stitch is the most occurring defect occurs
around 3319 times, which is of 21.3% of total occurrence.
The defect oil stains comes second in the rank which occurs around 1976 times,
which is of 12.7% of the total occurrence.
The defect ADAS (holes in the garment) occurs around 1069 times, which is of
6.9% of total occurrence.
The defect raw edges outside occurs around 952 times, which is of 6.1%of total
occurrence.
The defect puckering in the attachment occurs around 858 times, which is of
5.5% of total occurrence. [For ranking please refer annexure, table 3].










23

4.2.2. FIRST 5 RANKS OF DEFECTIVE PIECES
This table shows the first 5 ranks of defective pieces

FIRST 5 RANKS OF DEFECTIVE PIECES
TABLE 4.3


INTERPRETATION

The defect SKIPPED STITCH occurs comparatively higher than the other
kinds of defects when analyzed individually. It has occurred in about 1220 pieces
out of 9636 total defective pieces, which comes around 12.6% in the entire
defects.
S.NO DEFECTS DEFECTIVE
PEICES
PERCENTAGE
1. Skipped stitch 1220 12.7
2. Oil stains 724 7.5
3. ADAS 356 3.7
4. Combination of Skipped & Oil stitch 287 3.0
5. Combination of Mismatched stripes &
Seam Twisted
260 2.7
24
The defect OIL STAINS comes second in the rank which is about 724 pieces
out of 9636 total defective pieces, and it comes around 7.5% in the entire defects.
The defect ADAS comes third in the rank which is about 356 pieces out of
9636 total defective pieces, and it comes around 3.6%.
The combination of SKIPPED STITCH and OIL STAINS comes 4
TH
, which is
about 287 pieces out of 9636 defective pieces, and it comes around 3%.
The combination of defects MISMATCHIN OF STRIPES and SEAM
TWISTED come 5
TH
which is about 260 pieces out of 9636 defective pieces,
which comes around 2.7%. [for ranking please refer annexure, table 4].














25
4.2.3 COMPARING FIRST 3 RANKS OF DEFECTIVE PIECES & ITS
FREQUENCY
From the table 4.2 and 4.3, it is seen that the top 3 defects are same in both
defective pieces and its occurrence.
This table shows the first 3 ranks of defective pieces and its frequency of
occurrence.

FIRST 3 RANKS OF DEFECTIVE PIECES & ITS FREQUENCY
TABLE 4.4



INTERPRETATION
Based on the defective pieces, these 3 defects contribute about 23. 8% and based
on the frequency of occurrence it contributes about 42.16%.

RANK DEFECTS NAME DEFECTIVE
PIECES
DEFECTS FREQUENCY
(NO OF TIMES)
1. Skipped stitch 1220 Skipped stitches 3319
2. Oil stains 724 Oil stains 1976
3. ADAS 356 ADAS 1069
TOTAL 2300 6364
PERCENTAGE 23.86% 42.16%
26
4.3 CATEGORIZING THE DEFECTS BASED ON ITS PERCENTAGE
The total defects are categorized based on its percentage to the total occurrence and
defective pieces. By which the defects are being segregated as follows:


4.3.1 CATEGORY A (above 7% of defects)
Under category A the defects based on defective pieces and their frequencies
of occurrence which are more than the 7% are shown.

CATEGORY A OF DEFECTS
TABLE 4.5


BASED ON
OCCURRENCE
OF DEFECTS
S.NO DEFECTS NO.OF.DEFECTS PERCENTAGE
1. Skipped Stitches 3319 21.3
2. Oil Stains 1976 12.7

BASED ON
DEFECTIVE
PIECES
S.NO DEFECTS DEFECTIVE
PIECES
PERCENTAGE
1. Skipped Stitches 1220 12.7
2. Oil Stains 724 7.5



27
4.3.2 CATEGORY B (Between 3 7% of defects)
Under category B, the defects based on defective pieces and its frequency of
occurrence which lies between 3-7% is shown.

CATEGORY B OF DEFECTS
TABLE 4.6




BASED ON
OCCURRENCE
OF DEFECTS
S.NO DEFECTS NO.OF.
DEFECTS
PERCENTAGE
1. Skipped Stitches 1069 6.9
2. Raw edges outside 952 6.1
3. Seam twisted gives puckering
appearance
771 4.9
4. Mismatching of stripes 673 4.3
5. Breakage of stitch 628 4.0
6. Yoke piece unevenly attached 555 3.6
7. Uneven stitch 538 3.5
8. More threads joining in one
place
477 3.1
BASED ON
DEFECTIVE
PIECES
S.NO DEFECTS DEFECTIVE
PIECES
PERCENTAGE
1. ADAS (holes in garment) 356 3.7
2. Combination of Skipped &
Oil stitch
287 3.0

28

4.3.3 CATEGORY C (Below 3% of defects)
The other defects from the Ranking of Defects table will come under the
Category C.

INTERPRETATION

From the above categorization we can see that the Category A has more than 7%
defects.
Also, from Category B, it has a defects range of 3 7%.
The Category A contributes about 34% of the total defects based on the number of
defects. The Category B contributes about 44% of the total defects based on number of
defects.
By eliminating the total defects category A & B, we can reduce about 78% of the
total defects and bring down the total defects rate below the standard acceptable norms of
the company i.e. below 3%.






29
4.4 CHI SQUARE ANALYSIS FOR STYLE WISE DEFECTS MARGIN
The chi-square analysis is carried out to compare the actual and expected
data. In this the average percentage of defects among the styles and percentage of defect s
of each style are compared and chi-square analysis is done to know the significant
difference among the styles in occurrence of defects.

For this analysis null hypothesis and alternative hypothesis is formed.
Null Hypothesis: There is no significant difference among the different styles. (H
0
)
Alternate Hypothesis: There is significant difference among the different styles. (H
1
)

STYLE WISE DEFECTIVE PIECES
TABLE 4.7
S.NO STYLE TOTAL
QTY
DEFECTIVE
PIECES
PERCENTAGE
1. Gangelo polo 8520 512 6%
2. Babies top 3603 187 5%
3. Ladies top 17566 1152 6.5%
4. Night wear 6408 372 5.8%
5. Girls frill top 8500 508 5.9%
6. Mens polo t-shirt 8040 446 5.5%
7. Babies top 10806 703 6.5%
30
8. Babies top with stripes 13935 836 6%
9. Babies top with rib 8970 522 5.8%
10. Boys stripes polo t-shirt 7670 404 5.2%
11. Ladies top 12288 693 5.6%
12. Babies top 4500 234 5.2%
13. Girls top 5800 302 5.2%
14. Babies top 2575 132 5.1%
15. Babies top 12992 656 5%
16. Ladies top 10224 542 5.3%
17. Mens polo t-shirt 3660 188 5.1%
18. Babies top 13824 732 5.2%
19. Babies bottom 6500 377 5.8%
20. Babies top with stripes 2575 138 5.3%
TOTAL 168956 9636 AVG:5.5%


Assuming = 0.05. This means that when = 0.05, we will be making an error of
rejecting the null hypothesis when in fact it is true, 5% of the time.
= 0.05 and df= (k-1) =20-1=19.
The computed value of X
2
=0.29 is less than the critical value of X
2
=10.117; we
cannot reject the null hypothesis.
31

INTERPRETATION
Based on chi-square analysis of style wise defects, there was no
significant difference between the no. of defects among each style. Irrespective of all
styles the defect percentage is same. Nearly 5 to 6% of defects are occurring in each
style. [Calculations furnished in annexure-5]















32

CHAPTER-5
FINDINGS AND SUGGESTIONS

5.1 FINDINGS

The 3 defects Skipped stitches, Oil stains, ADAS, contribute more in the total
percentage of defects. (4.2)
The skipped stitch and oil stains contribute about 34% of the total defects based
on the number of defects. (Category A, 4.3)
The Skipped Stitches, Raw edges outside, Seam twisted gives puckering
appearance, Mismatching of stripes, Breakage of stitch, Yoke piece unevenly
attached, Uneven stitch, More threads joining in one place, these defects
contributes about 44% of the total defects based on number of defects. (Category
B, 4.3)
Irrespective of all styles the defect percentage is same. Nearly 5 to 6% of defects
are occurring in each style. (4.4)
The most occurring defects in the garments are analyzed and percentage of that is
interpreted and those defects are skipped stitch, oil stain and ADAS (holes in the
garment).


33


There are some of the reasons for the occurrence of these defects in the garment.

REASONS FOR SKIPPED STITCH
Improper threading in the sewing machine
Tension in the disc is improper
Repetitive usage of machines causing friction in the parts
REASONS FOR OIL STAINS
The availability of oil for the machine is quite high which left unnoticed and this
ultimately leads to oil stain in the garments.
Improper handling of the garments
REASONS FOR ADAS (holes in the garment)
Trimming fault
Needle breakage







34
5.2 SUGGESTIONS

Currently the total defects margin is around 5.7% of the entire production. If we
can cut down the top 3 defects from the entire process it can bring down the total
defects under Standard acceptable defects margin. The total defects margin will come
down to 2.7%, which is below the Standard acceptable defects margin i.e. 3%.

By eliminating the total defects category A & B, we can reduce about 78% of the
total defects and bring down the total defects rate below the standard acceptable
norms of the company i.e. below 3%. For eliminating the following suggestions are
given.

For machineries and equipments continuous assessment and maintenance is
needed.

The technician can be appointed and he must keenly check the threads, needle,
and tension of the machine frequently according to the fabric texture.

The machines should be cleaned and maintained by that technician frequently.




35

5.3 CONCLUSION

From this study, the most occurring defects and its frequency of occurrence have
been identified. It is suggested that the company can concentrate on these defects mainly
and take steps to bring down and this will pay way for increasing the level of productivity
and save the time.














3. RANKING OF DEFECTS BASED ON ITS OCCURENCE
TABLE.3

S.NO DEFECTS NO.OF.DEFECTS PERCENTAGE
1. D1 3319 21.3
2. D7 1976 12.7
3. D6 1069 6.9
4. D14 952 6.1
5. D18 858 5.5
6. D21 771 4.9
7. D19 673 4.3
8. D23 628 4.0
9. D16 555 3.6
10. D8 538 3.5
11. D10 477 3.1
12. D3 367 2.4
13. D17 340 2.2
14. D9 326 2.1
15. D27 281 1.8
16. D13 239 1.5
17. D11 231 1.5
18. D25 231 1.5
19. D4 211 1.4
20. D5 210 1.4
21. D26 167 1.1
22. D2 141 0.9
23. D20 137 0.9
24. D22 131 0.8
25. D12 105 0.7
26. D15 83 0.5
27. D24 78 0.5
TOTAL 15094 100






4. RANKING OF DEFECTIVE PIECES
TABLE.4
S.NO DEFECTS DEFECTIVE
PEICES
PERCENTAGE
1. D1 1220 12.7
2. D7 724 7.5
3. D6 356 3.7
4. D7,D1 287 3.0
5. D21,D19 260 2.7
6. D21 251 2.6
7. D18,D3 251 2.6
8. D1,D23 251 2.6
9. D18 241 2.5
10. D14,D17 232 2.4
11. D1,D7,D8 230 2.4
12. D14 216 2.2
13. D6,D1 205 2.1
14. D16,D14 192 2.0
15. D14,D1 183 1.9
16. D10,D1 172 1.8
17. D7,D8 169 1.8
18. D19 165 1.7
19. D9,D27 152 1.6
20. D23 146 1.5
21. D1,D21 146 1.5
22. D1,D25 142 1.5
23. D26,D23 142 1.5
24. D16 141 1.5
25. D18,D16 134 1.4
26. D11,D7 132 1.4
27. D6,D7 128 1.3
28. D19,D6 123 1.3
29. D4 122 1.3
30. D13,D7 121 1.3
31. D22 116 1.2
32. D10 112 1.2
33. D5 103 1.1
34. D21,D8 96 1.0
35. D6,D10 92 1.0
36. D1,D4 89 0.9
37. D7,D10 89 0.9
38. D25,D23 89 0.9
39. D27 87 0.9
40. D3 84 0.9
41. D13 84 0.9
42. D20 81 0.8
43. D14,D6 76 0.8
44. D5,D2 73 0.8
45. D1,D2 68 0.7
46. D12,D11 67 0.7
47.. D1,D19 64 0.7
48. D6,D7,D1 62 0.6
49. D1,D9 62 0.6
50. 16,17 56 0.6
51.. D20,D7 56 0.6
52. D14,D18 53 0.6
53. D17,D15 52 0.5
54. D9 50 0.5
55. D24,D18 48 0.5
56. D1,D18 46 0.5
57.. D8 43 0.4
58. D1,D27 42 0.4
59. D12,D1 38 0.4
60. D7,D5,D13 34 0.4
61.. D9,D18 34 0.4
62. D18,D19 33 0.3

63. D11 32 0.3
64. D16,D3 32 0.3
65. D15 31 0.3
66.. D24 30 0.3
67. D19,D9 28 0.3
68. D26 25 0.3
69. D18,D21 18 0.2
70. D22,D6 15 0.2
71. D1,D6,D10 12 0.1
72. D2 0 0.0
73. D12 0 0.0
74. D17 0 0.0
75. D25 0 0.0
TOTAL 9636 100.0
5. CHI SQUARE ANALYSIS FOR STYLE WISE DEFECTS MARGIN

Step 1:
Null Hypothesis: There is no significant difference among the different styles.
(H
0
)
Alternate Hypothesis: There is significant difference among the different styles.
(H
1
)

Step 2:
Assume = 0.05. This is the probability of making the Type I error. This means that
when = 0.05, we will be making an error of rejecting the null hypothesis when in fact it
is true, 5% of the time.

Step 3:
Calculate the expected frequency f
e
, for each category.

Step 4:
In our case, X
2
test is selected because we are comparing observed frequencies with
expected frequencies in discrete categories. X
2
test measures the discrepancy between the
observed values and expected values for decision making purpose about the null
hypothesis, so that:


X
2
= (f
o
f
e
)
2

f
e




X
2
= {(6-5.5)/5.5)}+ {(5-5.5)/5.5)}+ {(6.5-5.5)/5.5)}+ {(5.8-5.5)/5.5)}+ {(5.9-5.5)/5.5)}+
{(5.5-5.5)/5.5)}+ {(6.5-5.5)/5.5)}+ {(6-5.5)/5.5)}+ {(5.8-5.5)/5.5)}+ {(5.2-5.5)/5.5)}+ {(5.6-
5.5)/5.5)}+ {(5.2-5.5)/5.5)}+ {(5.2-5.5)/5.5)}+ {(5.1-5.5)/5.5)}+ {(5-5.5)/5.5)}+ {(5.3-
5.5)/5.5)}+ {(5.1-5.5)/5.5)}+ {(5.2-5.5)/5.5)}+ {(5.8-5.5)/5.5)}+ {(5.3-5.5)/5.5)}
= 0.09-0.09+0.18+0.05+0.07+0+0.18+0.09+0.05-0.05+0.018-0.05-0.05-0.07-0.09-
0.03-0.07-0.05+0.05-0.03
=0.298

Step 5:
Check the critical value of X
2
from the table against = 0.05 and df= (k-1) =20-
1=19.
This value is given as 10.117. We compare our computed value of X
2
with the
critical value of X
2
from the table.
Since our computed value of X
2
=0.29 is less than the critical value of X
2
=10.117,
we cannot reject the null hypothesis.
BIBLIOGRAPHY

BOOKS
1. Title of the book : STATISTICS for business & economics
Author : Jit S Chandan
Publications : Vikas Publishing House Pvt. Ltd.

2. Title of the book : RESEARCH METHODOLOGY METHODS &
TECHNIQUES
Author : C.R. Kothari
Publications : New Age International Publisher
3. Title of the book : MANAGING QUALITY IN THE APPAREL INDUSTRY
Author : Pradip V. Mehta, Satish K. Bhardwaj
Publications : New Age International Publisher


4. Title of the book : INDIAN TEXTILES-An intersectoral perspective
Author : Vinod Shanbhag, S.S. Mehta
Publications : Oxford &IBH Publishing Co. Pvt. Ltd



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