Errors in Finishing Process

1 | P a g e
ERRORS IN FINISHING PROCESS

LIST OF ABBREVIATIONS USED
QC : Quality Checker
QA : Quality Auditor
PO : Purchase Order
EDI : Electronic Data Interface
DC : Delivery Chain
NQA : Nominated Quality Auditor
AQL : Accepted Quality Level
UPC : Unique Product Code
GOH : Garment on Hangers
METHODOLOGY
The work methodology of the project is carried out by following steps:
1. Selection of Buyers
2. In depth study of packing processes of respective buyers
3. Value Stream Mapping
4. List out the packing errors accounting for the major part of the claim
5. Making cause and effect diagram for each problem
6. Pareto chart
7. SIPOC (Supplier Input Process Output Customer)
8. Data collection plan
9. Data action plan
10. VSM of solutions (Value Stream Mapping)

Detailed Methodology:
Selection of Buyers:
Our main focus was on Eddie Bauer and Ralph Lauren. The selection was made
based on the amount of claims received from the Buyers in the last 6 months i.e.
November 2013 to March 2014.

2 | P a g e

In depth study of packing processes of respective buyers:

1. The process flow of Tommy-Hilfiger:
tommycopy.xlsx

2. The process flow of Kohls:
kohls.xlsx

3. The overall packing process:
PROCESS FLOW OF
PACKING copy.xlsx

4. The process flow of wash-care label:
wash care and size
label process.xlsx

Value Stream Mapping:
With the help of VSM we have shown the flow of material as well as information in
the whole process of packing.
3 | P a g e

List out the packing errors accounting for the major part of the claim:
The below shown table contains the total percentage of the individual error for which
claims have been received by Karle International in the last six months.

Errors of packing process in Kohls:
Shipment Month Buyer Ship Quantity
Wrong/Missing
Packing List Wrong Ratio
Wrong /Missing
UPC
Duplicate
Carton Label
Wrong Type of
Pack
Wrong
Carton
Label
December'11 Kohls $ 9,43,611.6 18.18% 0.49% 0.42% 3.55%
January'12 Kohls $ 2,32,796.9 27.92% 4.55% 100% 1.40%
February'12 Kohls $ 6,52,130.11 9.21% 3.47% 0.19% 0.95%
August'11 Tommy $ 3,895 1.91%
September'11 Tommy $ 2,887.5 0.20%
October'11 Tommy $ 3,95,198.51 75% 1.23% 0.89% 1.11%
December'11 Tommy 0.73% 0.72%
November'11 Tommy $ 9,48,327.08 1.19% 0.43%
January'12 Tommy $ 2,81,904.65 0.56% 0.86%
February'12 Tommy $ 1,29,024.8 0.08% 0.23% 0.16% 0.07%
March'12 Tommy $ 1,296 21.15% 0.05% 0.09%
April'12 Tommy 0.31%
4 | P a g e

The table is given below in which all the Kohls errors are mentioned:
Errors of Kohls Frequency % of error found Cumulative %
Wrong Ratio 4356 79.8 79.809
Wrong Packing 459 8.4 88.218
Wrong/Missing UPC 312 5.7 93.934
Wrong wash care
label 288 5.3 99.21
Wrong carton labels 39 0.7 99.924
Duplicate carton
labels 4 0.1 100

Errors of packing process in Tommy-Hilfiger:
The table is given below in which all the Tommy-Hilfigers error of packing is
mentioned:
Errors of Tommy Frequency % of error found Cumulative %
Wrong Ratio 2307 94.05% 94.05%
Wrong/Missing Poly-bag
Sticker
53 2.16% 96.21%
Wrong/Missing UPC 38 1.55% 97.76%
Duplicate Carton labels 30 1.22% 98.98%
Wrong Packing List 15 0.61% 99.59%
Packing list not sent 10 0.41% 100%
79.8
8.4
5.7 5.3
0.7 0.1
0.0
20.0
40.0
60.0
80.0
100.0
120.0
% of error found
Cumulative %
5 | P a g e

So, from the above tables we have listed down the below mentioned errors of which
we have carried out a detailed study and made cause and effect diagram -
Cause and Effect diagram of packing errors:

SIPOC:
We used this method to find the answers of some questions like-
1. Where does the process start and end?
2. What are the major steps in the process?
3. What are the primary process of inputs and outputs?
4. Who are the key customers of the process (both internal and external)?
5. Who are the key suppliers of the process (both internal and external)?
6. What are the requirements of the customers?
7. Where do the errors occur (in which steps)?
8. At which stage errors can be rectified?
9. At which stage errors can be detected?
This method is used for each and every step of the packing procedures which is
given below:
Cause and Effect
Diagram(1).vsd
6 | P a g e

SIPOC OF KOHLS

1. Pick garment piece from the table Garment picked
2. Lay the garment on the table Garment laid on its back
Ironing operator and endline
inspector
Iron and endline inspected
garment
3. Iron the sleeves and front Sleeves and front ironed
Sub-store Hanger 4. Pick up a hanger kept on the table Hanger picked
Sub-store and ironing
operator
Hanger and half ironed
garment piece
5. Put the hanger inside the garment Hanger inserted
Half ironed garment with
hanger inserted
6. Lay the garment again on the table Garment laid on its front
Iron and Half ironed garment
with hanger inserted
7. Iron the back of the garment and back
sleeve
Back and back sleeves ironed
Ironed garment with hanger
inserted in it
8. Keep the ironed garment on the side of the
table
Garment ironed and hanger
inserted
Ironing operator
End line inspector End line inspected garment
Size crown attaching operator
IRONING AND PUTTING HANGERS
SUPPLIER INPUT PROCESS OUTPUT CUSTOMER
7 | P a g e

1. Pick ironed garments from the ironing
table
Ironed garment picked from
ironing table
2. Keep the garments on the size crown
attaching table
Ironed garment kept on the
table
3. Pick one ironed garment One garment picked
4. See the size on the garment from the size
label
Size seen
Sub-store Size crowns
5. Pick appropriate size crown from the size
crown container
Size crown picked
Sub-store and ironing
operator
Size crown and ironed
garment
6. Put the size crown on the hanger
Size crown attached to the
hanger
Size crown attached ironed
garment
7. Hang the garment on the hanging rack
Size crown attached garments
hanged
Tagging Operator
Ironing operator Ironed garments
PUTTING SIZE CROWNS ON HANGERS
Size crown attached hanged
garment
1. See the size crown of the hanged garments
on the hanging rack
Size crown seen
Tagging operator Kimble gun 2. Holds the kimble gun on one hand Kimble gun held
Sub-store Tags
3. Picks up the appropriate tags from the
container
Tag picked
Sub-store, tagging operator
and size crown attaching
operator
Tag, kimble gun and size
crown attached hanged
garments
4. Tags the hanged garment with the kimble
gun
Garment tagged
Tagging operator Tagged garments
5. Keep the tagged garment hanging there
only
Tagged garment kept
Checking Operator
TAGGING
1. Pick tagged hanged garments from the
hanging rack
Garments hanged
2. Keep the garments on the checking table
Garments kept on checking
table
3. Lay the garment on the checking table Garment laid
4. Check the stiches, embroidery and the
matches the tags and the upc number
Garment checked
Sub-store and tagging
operator
Arrow sticker and defected
piece
5. Put the arrow sticker where defects occur Sticked attached
Tagging Operator Defected garments 6. Keep the defected pieces aside Defected pieces kept aside
Tagging Operator
Checked and approved
garments
7. Keep the checked and approved garments
back on the hanging rack
Checked and approved
garments kept on hanging rack
Tagged hanged garments Tagging Operator
CHECKING
8 | P a g e

1. Take the hanging racks loaded with hanged
garments to the packaging area
Hanging racks sent to packing
area
2. Check and match the size crowns of the
hanged garments with the size label (auditor)
Checked hanged garments
3. Enter the packing area Packing area entered
2. Keep the garments from the hanging racks
on the storage racks
Unloaded hanging racks brought
back
Empty hanging racks
3. Take the unloaded hanging racks back to
the production floor
Unloaded hanging racks brought
back
Hanging racks with hanged
checked garments
Ratio maker Transporter
TRANSPORTATION
Supervisor Ratio details 1. See the ratio details Details seen
2. Picks hanged garment from the storage
racks
Hanged garments picked
3. Keep it on the same storage rack on
another end
Hanged garment kept
4. Make appropriate ratio of hanged garments Ratio made
Ratio maker
Bunch of hanged garments in
ratio
5. Keep the bunch of arranged hanged
garments in ratio on the adjacent storage rack
Bunch pf arranged hanged
garments in ratio kept
Hanged garments Transporter
Poly-bag Packer
RATIO-MAKING
Sub-store Poly-bag 1. Pick A poly-bag Poly-bnag picked
Ratio-maker Hanged garments in ratio
2. Pick the Hanged garments in ratio from the
storage rack
Hanged garments picked
3. Put the hanger ends in the hole of the poly-
bag
Hanger end put in the hole of
Poly-bag
4. Insert the poly-bag over the garments on
hangers
Poly-bagged garments
Poly-bag packing operator
Poly-bagged ratio packed
garments
5. Put the poly-baged garments on the same
storage rack at another end of the rack
Poly-bagged garments stored at
the end of the rack
Poly-bag and Hanged
garments
carton packer
Sub-store and Ratio-maker
POLY BAG PACKING
9 | P a g e

Flat carton 1. Pick flat carton Flat carton picked
Flat carton and tape 2. Prepare the final carton Final carton prepared
Ratio maker Ratio packed polybag
3. Pick ratio packed poly-bags from the
storage racks as per packing details
Ratio-packed polybags pikced
Ratio maker and carton maker
Ratio packed polybag and final
carton
4. Put the appropriate ratio-packed polybags
in the final carton and lock hangers' end with
the thread loop
Ratio-packed polybags kept
5. Close the final carton Final carton closed
6. Store the final carton in the adjacent area
as per PO number in the form of a stack
Final carton stored
Carton packer and production
floor
Stack of packed cartons and
trolley
1. Put the stack of the packed cartons on the
trolley
Cartons kept on trolley
Loaded trolley with packed
final cartons
2. Move the trolley from the packing area to
the scanning area
Trolley moved
Loaded trolley with packed
final cartons
3. Unload the final cartons on the scanning
area
Cartons unloaded
Empty trolley 4. Take the trolley back to the packing area Trolley sent back
1. Pick a packed carton Carton picked
2. Keep the carton on the table Carton kept
Printer Sticker 3. Scans a sticker Sticker scanned
Printer and transporter Sticker and carton 4. Put the sticker on the carton Stickered carton
Carton 5. Open the carton carton opened
Hanger packs 6. Take out the ratio packed hanger packs
ratio packed hanger packs
takenb out
Hanging rack and hanger pack 7. Hang the hanger packs on the hanging rack
Hanger packs kept on hanging
rack
scanner and tagged garments
8. Scan the tag of each garment of the hanger
pack
tags scanned
9. Moves the scanned hanger packs to the
other end
hanger packs moved
10. Pick the scanned hanger packs from the
hanging rack
scanned hanger packs picked
Scanner hanger packs and
same carton
11. Keep the scanned hanger packs in the
same carton
scanned hanger packs kept in
carton
Packing operator and sub-
store
Packed carton and tape 12. Seal the carton with tape carton sealed
Sub-store and packing
operator
Token no. sticker and taped
carton pack
13. Put the token no. of the scanning
operator on the tape
token no. put on carton seal
store
Sealed cartons 14. Keep the carton aside in the form of stack sealed cartons kept aside
Transporter
Packed carton
Scanning operator and
transporter
Transporter
Transporter
Scanned hanger packed
garments and hanging rack
Scanning operator
Transporter
Scanner
SCANNING
Transporter
Packed final carton
Store
Carton packer
TRANSPORTATION TO SCANNING AREA
CARTON PACKING
Packing operator Sealed cartons and trolley 1. Load the sealed carton on the Trolley Sealed cartons loaded
2. Bring loaded Trolley to the CTPAT area Trolley brought to CTPAT area
3. Unload the Sealed cartons from the Trolley
Sealed Cartons unloaded from
the trolley
Sealed cartons
4. Keep the sealed cartons arranged as per PO
in CTPAT area
Sealed cartons properly
arranged as per PO
Buyer QA
Loaded trolley
Transporter
TRANSPORTING OF SEALED AND SCANNED TO CTPAT AREA
10 | P a g e

SIPOC OF TOMMY-HILFIGER

6. Finding the location for the tagging in
the garment
Tagged Garments
Tagged Garment
3. Segregate the ironed garments
according to sizes and keep aside on
table as a bundle
Size segregated ironed-
folded garments
Size segregated ironed-folded
garments
Iron and Folding Operator
4. take the particular bundle from the
table
bundle picked
Sub-Store
Next packing operator
Laid Garments
Ironed picked
Ironed Sleeve
Sleeve Balancing Checked
Ironed Garment
Garments kept on the tagging table
Tag Picked by the operator
TAGGING
PROCESS OUTPUT CUSTOMER INPUT SUPPLIER
Bundle of folded garments of
different sizes
Tags
1.pick ironed and folded garment from
ironing table
2. Keep garments on the Tagging Table
5. Picks Tags from tag container based on
the size of the garment checked last
7.Tag the garment with the Kimble Gun
8.Keep the bundle aside after tagging
Kimble Gun, tags, iron and
folded garments
Tagging Operator
Iron Operator
Folded garments
Measured & Ironed garment
Folded garment
Final Ironed & Folded garment
at side of the Table
2. Laying the garment on the table
3. Picking the iron
4. Iron the sleeve
5. Check the balancing of the sleeve
Ironed garments &
Measurement scale
Folding pattern & Ironed
garment
IRONING AND FOLDING
End line inspected
garments
Iron
Iron and End line
inspected garments
End line inspector
Iron Operator
End line inspector
Tagging Operator
6. Iron the front and back
7. Measure the garment with the help of
measurement scale
8. Keep the folding pattern on the
backside of the garment
9. Fold the garment
10. Pick the garment and keep it aside
1. Picking the garment from the table
11 | P a g e

Polypacking operator Size sticker applying Pattern Pattern Picked
5. Pick the size sticker applying pattern (L-
shaped)
6. Keep pattern on poly-packed garment
9. Put the size sticker on the polybag
Tagging Operator
Sub-store
Kanban Auditor
1. Picks up each Tagged garment
2. Remove Size and Sleeve descriptive
sticker
3. Picks up one Poly-bag
4. Put the garment in Poly-bag
10. put the Poly-packed garment on table
or in storage bin/sample carton
Tagged Garments
Poly-bag
Tagged Garments and polybag
Cartons Store
Tagged Garments Picked
Stickers removed
Poly-bag Picked
Poly-packed Garments
Poly-packed Garments kept on
table/bin
7. Pick the Size Sticker
PUTTING SIZE STRIPE ON THE TAGGED GARMENT
Pattern and Polypacked
garment
Size stripe sticker
Size stripe sticker and polybag
Sub-store
Sub-store and Tagging
Operator
Sticker Applying Operator
1. Pick the tagged folded garment
2. Pick the size stripe from the container
3. Remove the size stripe from the cover
4. Put the size stripe on the garment at a
specified position
5. Keep the size striped garment aside
Pattern Kept on polybag
Size Sticker picked
Bare size-sticker
Size Stickered polybag
Poly-packer
Tagged folded garment
Size sticker
Size sticker and Tagged
Folded Garment
Stickered Tagged Folded
Garment
Garment Kept on table
Sticker picked
Bare size stripe
Size-striped tagged garment
Size-striped garment kept aside
Putting garment in poly-bag(Solid Packing)
Tagging Operator and Sub-
store
Polypacking operator
Sub-store
Tagging Operator
Sub-store and Polypacking
Operator
8. Remove the size sticker from its cover
Ratio-bundle made
Bundle kept on packing pattern
Tagged Garments and ratio
details
Putting garment in poly-bag(Ratio Packing)
1. Take garment pieces from size
segregated bundles
3. Make a ratio bundle as per ratio details
Bundle and Packing Pattern
Poly-bag
Stack , Packing pattern and
Poly-bag
Blister Packed Garments
Tagging Operator
Tagging Operator and Packing
Supervisor
Packing operator
Sub-store
store
Packing operator
Tagged Garments
Poly-bag picked
Scanning operator
Garments picked
4. Keep the ratio arranged Bundle on
packing pattern
5. Pick the Poly-bag
6. Insert bundle in a poly-bag with the
help of packing pattern
7. Remove the packing pattern
8. Seal the Poly-bag
9. Keep sealed blister in storage bin
Garments inserted in the poly-bag
Packing pattern removed
Poly-bag sealed
Sealed blister kept in storage bin
12 | P a g e

Packing operator
2. keep those garments/pieces at a
specified cartons as per item no.
3. Send the empty unloaded cartons
back to the production floor
garments picked
garments kept in the specified
cartons
Empty unloaded cartons sent
Loaded Cartons from
production floor
Garment pieces from
unloaded cartons
Empty unloaded cartons
6. keep the final cartons in the scanning
area
Cartons Store
Poly-packed garments
card-board, Poly-packed
garments
Ratio-packed cartons
Production floor
Store, Production floor
Ratio-packer
1. See the details on the cartons
3. picks the Poly-packed garments from
the stored cartons
2. Prepare cartons
4. put garments into the final carton as
per packing details
5. Put the card-board on top of the poly-
packed garments
Details Observed
Prepared cartons
Poly-packed garments picked and
kept in final carton as per details
1. Brings the Trolley to the particular
Table
2. Load Cartons on the Trolley
3. Send loaded Trolley to Holding area
4. Unload the Cartons in Holding Area
Trolley
Approved Poly-packed
garments
Trolley loaded with cartons
Cartons received at CPTAT area
Stores
Stacked/stored cartons which may
or may not be in ratio
1. Take out garment/pieces from the
unloaded cartons
Packer on the production
floor
Transporter
Holding area
CUSTOMER
1. Pick up any polypack from carton or
from table
2. Open the polybag
3. Keep the garment on the table
SUPPLIER INPUT PROCESS OUTPUT
Poly opened
Garment laid Poly-packer
Transporter
6. Put signature on the sticker of the
polypack
poly-packed garments
stickers, Poly-packed garment
Carton packing done
Final packed cartons kept
HOLDING AREA
Scanner
Packing Area
Line QA
Solid Packing Final Cartons
Kanban Auditor
4. Check sewing and balancing
5. Put rejected garment pieces back to
end line inspection
Sewing and balancing checked
Rejected garments sent back
Approved garments Sub-store, Poly-packer
TRANSPORTATION OF CARTONS/PIECES TO CTPAT AREA
13 | P a g e

Prepared cartons
Details verified
Final packed carton
1. Prepare the final cartons
2. verify the details of the final cartons
3. keep the Blister packed garment in the
final carton
4. put the card-board on top of the blister
5. keep the final carton in the scanning
area
Final Cartons
Final Cartons and Blister
packed garment
Card-board and final carton
Store
Store & Production floor
Store
Packing operator
Bundle/Blister Packing Final Cartons
Final packed cartons kept
Scanner
Blister packed garments kept in
final cartons
Card-board kept
INPUT PROCESS OUTPUT CUSTOMER
SCANNING of SOLID PACKING
Manual Counting
1. Picks carton near the scanning table
2. open the carton
3. Unload cartons contents on the
scanning table
4. Scan the tag/polybag stickers of the
individual garments
5. Put the garments in same Poly-bag
6. put the poly-packed garments in the
same final carton
8. Put the carton sticker on the specified
position on the carton
9. Tapes the carton
Arranged sealed cartons
Poly-packed garments kept in the
cartons
Stickered Cartons
Ratio packer
Scanning Operator and Poly-
packer
Tagging Operator
Scanning Operator and Ratio
packer
Printer, scanner and ratio
packer
Sub-store and Scanning
operator
Scanning Operator
Taped Cartons
Poly-packed Scanned
Garment and carton
Carton sticker,printer and
final carton
Scanned garment & blister
Blister & final carton
2. Open the Carton
3. Unload carton contents
4. Open Blister
5. Take out garments
6. Scan tag of each garment
8. Put Blister in carton after scanning the
whole stack of garment
Packed final carton
Blister
Scanner & Tagged garment
Tape and stickered carton
scanned and sealed cartons
10. keep the scanned cartons according to
PO
Final Packed Cartons
Scanner and Poly-packed
Garments
Tagged Garments and Polybag
Cartons Brought
Cartons opened
Carton Unloaded
Tagged Scanned
Re-polypacked garments
SUPPLIER
Carton sticker & final carton
CUSTOMER
1. Picks carton near the scanning table
7. put the stack of garments in Blister
12. Keep cartons as per PO
Cartons picked
Carton opened
Carton contents unloaded
Blister opened
Garments taken out
Scanned tags
Re-packed Blister
Blister kept in carton
Stickered carton
Taped carton
Arranged carton
9. Take print out of carton sticker & tear
the sticker from printer
10. Paste the carton sticker on the carton
11. Tape carton
Printer Sticker generated Store
Store Printer
7. Take print out of carton sticker & tear
the sticker from printer
Sticker generated
Tape and final carton
Final carton
Packing area
Production floor
Packing area & Production
floor
Scanning operator &
production floor
Production floor & Packing
area
Printer & Packing area
Sub-store & Packing area
Packing area
SCANNING of BLISTER PACKING
SUPPLIER INPUT PROCESS OUTPUT
Buyer QA
14 | P a g e

7. Keep the cartons at the specific
position according to PO number
Buyer QA
CUSTOMER
1. Pick the scanned cartons from the
stored area
2. Unload the scanned carton on the table
3. Count manually
4. Check the garment's tags
5. After 100% counting, keep the
garments in the cartons
Cartons picked and unloaded
Counted & checked Garments
Garments kept in cartons
Taped cartons 6. Tapes the carton
OUTPUT
MANUAL COUNTING
Counting operator, Sub-store
& Scanning operator
Counted & checked garments
Counted Garments, Tape &
cartons
SUPPLIER
Scanning Operator
Counting operator
Arranged Taped Cartons Counting operator
INPUT PROCESS
Taped cartons
Scanned Cartons
Poly-packed scanned
garments
7. send cartons to the specified location
Buyer
Approved garments brought
Re-packed garments
Counted garments
Verified
Final cartons re-packed
Cartons sealed
Cartons sent
1. Bring Buyer QA Approved garments for
repacking
2. Repacks the garments in poly bag
3. Manual counting
4. Verify with the packing list
5. Put garments in the same final cartons
Sealed cartons
Buyer QA
Supervisor
Buyer QA
Re-packing Operator and sub-
store
Re-packing Operator
Approved garments
6. Seal cartons with Buyer tape
Packed cartons and buyer
tape
Approved garments and
polybag
Packing list
Verified garments and final
cartons
REPACKING
RE-PRINT
1. Check carton sticker
2. Make note of damaged stickers
3. Select the serial no. of cartons from
the software
4. generate stickers for those serial nos.
Audited cartons
Manual counter
Buyer
Store
Printer
5. Paste re-printed stickers on respective
cartons
Note made
Serial no. of damaged stickers
selected
Sticker re-printed
Re-printed stickers pasted
Buyer QA
Stored cartons
Damaged cartons
Software & Serial no.
Printer
Re-printed Sticker & cartons
15 | P a g e

Data Collection Plan:
The below mentioned formats have been generated to collect data about day to day
errors occurring in the packing process of Tommy and Kohls. With the help of these
we can also come to know that where the errors are being detected and how much
of each error is occurring on daily basis.
data collection.xlsx

Data Detection Plan:
In this plan, we have made random visits to each floor to check at which point the
operators are deviating from the SOPs (Standard Operating Procedures) of each
process of the respective buyers. We have visited all floor i.e. from 12A, 12B, 12C,
12D, 12E and 12F from 23
rd
June, 2012 to 30
th
June, 2012.
data detection
plan.xlsx

After making the random samples, we have calculated the percentage of deviating
procedures in each packing process.
16 | P a g e

40 - 75 BETWEEN 40 TO 75 PERCENT
>75 GREATER THAN 75 PERCENT
<40 LESS THAN 40 PERCENT
Process Attributes 12-A 12-B 12-C 12-D 12-E 12-F
No size segregation of garments before tagging 71.43% 60.00% 64.29% 88.89% 80.00% 80.00%
More than one tag container at one table 57.14% 0.00% 21.43% 22.22% 40.00% 50.00%
Tag container without cover 14.29% 86.67% 100.00% 100.00% 80.00% 90.00%
No size/colour marking on tag container 85.71% 93.33% 100.00% 77.78% 80.00% 90.00%
No divisions made for keeping the size segregated garments on the table 14.29% 100.00% 100.00% 100.00% 100.00% 100.00%
No checking of garments size label before tagging 0.00% 0.00% 7.14% 0.00% 0.00% 0.00%
Doing job with carelessness and insincerely 0.00% 13.33% 14.29% 22.22% 0.00% 30.00%
No display of sample of tags of running item no. on table 85.71% 100.00% 100.00% 88.89% 60.00% 80.00%
No tagging details displayed on the table 71.43% 100.00% 100.00% 88.89% 80.00% 80.00%
No round container 14.29% 80.00% 92.86% 88.89% 80.00% 90.00%
Tags kept on table instead of tag container 0.00% 6.67% 0.00% 0.00% 20.00% 0.00%
No size segregation of garments after tagging 71.43% 33.33% 71.43% 77.78% 60.00% 60.00%
Two or more style of tagged garments on one table 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%
No ratio details displayed on the table 0.00% 68.75% 33.33% 0.00% 25.00% 60.00%
No size segregated tagged garments on the table 0.00% 18.75% 66.67% 0.00% 25.00% 20.00%
No checking of size of garments before making ratio 0.00% 0.00% 0.00% 0.00% 0.00% 20.00%
No immediate packing of ratio bundle 0.00% 31.25% 100.00% 100.00% 25.00% 0.00%
No details of the current style no. 0.00% 68.75% 66.67% 0.00% 50.00% 60.00%
No divisions made for keeping the size segregated garments on the table 0.00% 100.00% 100.00% 100.00% 25.00% 80.00%
Not making ratio packs in the area allotted for the operation 0.00% 0.00% 33.33% 0.00% 0.00% 0.00%
No cartons to put the garments 0.00% 43.75% 33.33% 0.00% 0.00% 60.00%
Keeping two or more styles in one dummy cartons 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%
Keeping garments of two or more PO of same style in one dummy carton 0.00% 15.38% 33.33% 0.00% 0.00% 0.00%
No information of PO, item No and Quantity of blisters on the dummy
cartons
0.00% 92.31% 100.00% 100.00% 0.00% 50.00%
No mention of buyer on the dummy carton 0.00% 92.31% 100.00% 100.00% 66.67% 100.00%
No mention of destination on the dummy carton 0.00% 92.31% 100.00% 100.00% 66.67% 100.00%
No PO wise segregation of dummy cartons 0.00% 90.91% 0.00% 100.00% 0.00% 100.00%
No Country wise segregation of dummy cartons 0.00% 100.00% 0.00% 100.00% 0.00% 100.00%
No Item No wise segregation of dummy cartons 0.00% 90.91% 0.00% 100.00% 0.00% 80.00%
Keeping cartons of one buyer in another buyers allotted area 0.00% 0.00% 0.00% 50.00% 0.00% 20.00%
Pieces from the last shipment 0.00% 18.18% 0.00% 0.00% 100.00% 0.00%
Cartons having contents other than garment pieces 0.00% 36.36% 0.00% 0.00% 0.00% 0.00%
Colour mix up in cartons 0.00% 63.64% 0.00% 50.00% 0.00% 20.00%
Style mix up in cartons 0.00% 45.45% 0.00% 0.00% 0.00% 20.00%
Unloading second carton before first is packed 0.00% 66.67% 66.67% 0.00% 20.00% 50.00%
No complete scanning of garment pieces in a carton 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%
Scanning the tags instead of the size stripe in case of solid packing 0.00% 16.67% 16.67% 0.00% 0.00% 0.00%
No properly Scanning tags 100.00% 0.00% 0.00% 0.00% 0.00% 0.00%
Scanning one tag more than one time 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%
Scanning two or more style at one time 0.00% 0.00% 16.67% 0.00% 0.00% 0.00%
Two or more style of carton sticker at scanning table at the same time 0.00% 0.00% 0.00% 0.00% 20.00% 0.00%
Two or more item no. is repacking simultaneously 0.00% 100.00% 0.00% 0.00% 0.00% 0.00%
Re-packing insincerely or carelessly 0.00% 0.00% 0.00% 0.00% 100.00% 0.00%
No verification of carton details at the time of re-packing 0.00% 100.00% 0.00% 0.00% 100.00% 100.00%
Putting garment in a wrong size poly-bag in the case of solid packing 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%
Putting garments in wrong cartons 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%
Process Attributes 12-B 12-C 12-D 12-E 12-F
No ratio details displayed on the table 68.75% 33.33% 0.00% 33.33% 0.00%
No size segregated tagged garments on the table 18.75% 66.67% 0.00% 33.33% 0.00%
No checking of size of garments before making ratio 0.00% 0.00% 0.00% 0.00% 0.00%
No immediate packing of ratio bundle 31.25% 100.00% 100.00% 33.33% 0.00%
No details of the current style no. 68.75% 66.67% 0.00% 66.67% 50.00%
No divisions made for keeping the size segregated garments on the table
100.00% 100.00% 100.00% 33.33% 100.00%
Not making ratio packs in the area allotted for the operation 0.00% 33.33% 0.00% 0.00% 0.00%
Doing job with carelessness and insincerely 25.00% 0.00% 0.00% 33.33% 0.00%
No cartons to put the garments 43.75% 33.33% 0.00% 0.00% 50.00%
RATIO-PACKING
SCANNING
RE-PACKING
TAGGING
STORAGE AFTER
TAGGING
RATIO-MAKING
STORAGE AFTER
RATIO-MAKING
HOLD AREA
17 | P a g e

After this, we have made a table where we put together the deviating points and their
detection points as well as their percentage occurrence of each error (floor wise).

ERRORS DETECTION POINTS OBSERVATION POINT % ERROR
No size segregation of garments before tagging 71.43%
More than one tag container at one table 57.14%
Tag container without cover 14.29%
No size/colour marking on tag container 85.71%
No divisions made for keeping the size segregated garments on
the table
14.29%
No checking of garments size label before tagging 0.00%
Doing job with carelessness and insincerely 0.00%
No display of sample of tags of running item no. on table 85.71%
Carton packing No tagging details displayed on the table 71.43%
Each piece is scanned against a fixed ratio based on
the software being used
No round container 14.29%
FS Audit Tags kept on table instead of tag container 0.00%
Final Carton Audit
Buyer QA Audit
At the time of ironing and folding (in some cases)
No immediate packing of ratio bundle
No complete scanning of garment pieces in a carton 0.00%
At the time of packing in poly-bag
At the time of Scanning
At the time of FS Audit/ Carton Audit
Buyer QA Audit
FS Audit Doing job with carelessness and insincerely @ scanning 0.00%
Final Carton Audit
DETECTION POINT OF 12-A
The operator looks at the tag of the garment(in
maximum cases) and based on the information, picks
up the size stripe of the same size from the bunch of
the stripes kept on the table
Takes out the required sizes' pieces from the stack of
the garment(containing pieces of all the sizes in
disorgarnized order) by looking at size label/price
label OR Size tag at the time of packing
WRONG CARTON
LABEL
Buyer QA Audit
Mix up of two or more carton stickers on the scanning table 0.00%
DUPLICATE CARTON
LABELS
Final Carton Audit
WRONG TAG
MISSING TAGS
18 | P a g e

the table
100.00%
FS Audit
Final Carton Audit
Buyer QA Audit
At the time of ironing and folding (in some cases) Doing job with carelessness and insincerely @ tagging 13.33%
No immediate packing of ratio bundle 31.25%
At the time of solid-packing
Buyer QA Audit
At the time of scanning No ratio details displayed on the table 68.75%
Buyer QA Audit No size segregated tagged garments on the table 18.75%
No checking of size of garments before making ratio 0.00%
No details of the current style no. 68.75%
the table
100.00%
Not making ratio packs in the area allotted for the operation 0.00%
No cartons to put the garments 43.75%
Forgetting to replace rejected garments 0.00%
Final Carton Audit
Buyer QA Audit
Final Carton Audit
Buyer QA Audit
FS Audit
DETECTION POINT OF 12-B
label OR Size tag at the time of packing (ratio packing
or solid packing)
WRONG TAGS
Tags kept on table instead of tag container 6.67%
WRONG CARTON
LABEL Mix up of two or more carton stickers on the scanning table 0.00%
DUPLICATE CARTON
LABEL
0.00%
Doing job carelessly @ scanning 0.00%
WRONG RATIO
At the time of ratio packing
MISSING TAGS
Doing job carelessly @ scanning
19 | P a g e

the table
100.00%
FS Audit
Final Carton Audit
Buyer QA Audit
Buyer QA Audit
the table
100.00%
Final Carton Audit
Buyer QA Audit
Final Carton Audit
Buyer QA Audit
FS Audit
DETECTION POINT OF 12-C
0.00%
MISSING TAGS
16.67%
WRONG TAGS
label OR Size tag at the time of packing (ratio packing
or solid packing)
Tags kept on table instead of tag container
WRONG RATIO
Doing job carelessly @ scanning 16.67%
WRONG CARTON
LABEL Mix up of two or more carton stickers on the scanning table
DUPLICATE CARTON
LABEL
0.00%
20 | P a g e

the table
100.00%
FS Audit
Final Carton Audit
Buyer QA Audit
Buyer QA Audit
the table
100.00%
Final Carton Audit
Buyer QA Audit
Final Carton Audit
Buyer QA Audit
FS Audit
DETECTION POINT OF 12-D
WRONG TAGS
Tags kept on table instead of tag container 0.00%
WRONG CARTON
DUPLICATE CARTON
LABEL
0.00%
0.00%
0.00%
MISSING TAGS
WRONG RATIO
21 | P a g e

the table
100.00%
FS Audit
Final Carton Audit
Buyer QA Audit
Buyer QA Audit
the table
33.33%
Final Carton Audit
Buyer QA Audit
Final Carton Audit
Buyer QA Audit
FS Audit
DETECTION POINT OF 12-E
WRONG TAGS
MISSING TAGS
WRONG RATIO
WRONG CARTON
DUPLICATE CARTON
LABEL
20.00%
0.00%
0.00%
0.00%
22 | P a g e

the table
100.00%
FS Audit
Final Carton Audit
Buyer QA Audit
Buyer QA Audit
the table
100.00%
Final Carton Audit
Buyer QA Audit
Final Carton Audit
Buyer QA Audit
FS Audit
DETECTION POINT OF 12-F
WRONG TAGS
MISSING TAGS
WRONG RATIO
WRONG CARTON
DUPLICATE CARTON
LABEL
0.00%
0.00%
0.00%
0.00%
23 | P a g e

VSM Solutions:
Through VSM, we have shown that in a particular process, what things may go
wrong and whether it can be rectified or not. There are some solutions which we
have suggested through VSM.

24 | P a g e

CONCLUSION

Findings:
We have seen that, the main problem is that the information is not properly
communicated to the operators
Second point is that, even if the operator has been given information about
how to do the process, then also he/she will perform the work according to
their own ease, thus creating errors
At vital points in the whole process, there is lack of proper accountability
Some of the processes are as such, which are not easy to follow from the
operators point of view for example, picking the tag from the tag container. As
a result they invent their own kind of tag container, which is inappropriate
The operators do not follow the SOPs (Standard Operating Procedures)
Mostly the errors occur due to human errors, and the thinking of the operators
goes as such that, even if one mistake occurs that is justifiable. But the
operators are not given proper information about the consequences about the
errors.
We have found out the top five errors having maximum claims are
Wrong Ratio
Wrong Carton Label
Duplicate Carton Label
Missing UPC
Wrong UPC
Wrong Wash Care Label

We have also found the reasons behind each problem. It is given below in a tabular
form:
25 | P a g e

PROBLEM: WRONG RATIO
REASONS: No ratio details
Wrong size tags on garment pieces
Garment pieces of multiple countries at one table
Multiple ratio packs in one style
No or improper size segregated garments
No ratio details on the table
Hurry, carelessness and lethargy of the operator
Ineffective checkpoints such as scanning
In re-packing, sometimes failing to replace the rejected garments causes wrong ratio
Poor work-place
No proper checking and matching of tags during ratio-packing
CHANGES TO BE MADE: Scanning after re-packing
For proper scanning, the system can be fixed in the center of the table.
SOLUTION: The computer system can be fixed at the center of the table, so that the scanning operator can only unload the non-
scanned garment pieces on one side, and after scanning the garments to be kept on the other side of the table, so that no mix up of
unscanned and scanned pieces occur.
PROBLEM: WRONG CARTON LABELS
REASONS: Scanning second carton before the first is sealed
Putting stickers in a hurried and careless manner
Not putting carton stickers immediately after scanning
Keeping multiple cartons open after scanning
More than one type of stickers kept on tagging table
Not changing carton sticker and packing list in case of change in quantity
Changing pieces from one carton to another
Applying carton labels at the last moment all at once
Ineffective checking of the operator
Picking up of cartons of a different PO
26 | P a g e

PROBLEM: DUPLICATE CARTON LABELS
REASONS: Same sticker generated multiple times
Re-print not done for exact replacement quantity
No written request for replacement of stickers
Ineffective monitoring
Hurry and carelessness of operator
Damaged labels due to improper storage and poor storage space
Damaged labels due to improper printing (printing head, wrinkling of ribbon, electricity fluctuation)
Operator's unawareness of the consequences of wrong carton stickers leading to carelessness
CHANGES TO BE MADE: Make accountability
SOLUTION: There should be a written request or receipt for the carton stickers that should be re-printed and signature of the
carton
sticker printer should be there on the receipt, so that he will be accountable for the stickers that are re-printed.
PROBLEM: MISSING TAGS
REASONS: Improper way of tagging, for example faulty shot of kimble gun causes missing tags if the operator doesnt check
whether the tag has been attached to the garment or not after a shot.
Tag handling at various operation may cause the tags to fall and thus cause missing tags
Tagging in one or two stitches instead of four or five, thus causing the possibility of the tags falling down due to
breakage of stitch.
Loose stiches
Tagging in a hurried and careless manner
Unskilled manpower
Movement of tags in hanger packs during transportation
No checking of stitch strength while tagging
No chekcing of tags immediately after tagging and ineffective checking
Faulty kimble with thinner end
Tags having bigger holes than required
Heavier tags in hanger packs
27 | P a g e

28 | P a g e

SOLUTION: The attaching of the wash-care labels should be carried out in the cutting section only, instead of attaching them in the
sewing
line. After the ticketing process, there should be a sewing machine, where the attachment of the wash-care label takes
place, so
that there would not be any missing / wrong wash-care label.
PROBLEM: WRONG WASH-CARE LABELS
REASONS: Loading of non-ratio pieces due to recutting causes in wrong attachment of wash-care labels
Lack of correct information from the feeding helper during the loading of re-cut pieces
Mix up of different types of wash-care label on the operation table due to poor storage of washcare labels
Carelessness and hurry of the operator
Ineffective super-vision
Improper segregation of the wash-care labels
CHANGES TO BE MADE: Attaching of wash-care label should be in cutting only instead of occuring in the sewing line.

Errors in Finishing Process

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Errors in Finishing Process

Uploaded by

Copyright:

Available Formats

1 | P a g e

ERRORS IN FINISHING PROCESS

You might also like