SUMMER INTERNSHIP PROJECT

PRODUCTIVITY IMPROVEMENT BY REDUCING REWORK

 OBJECTIVE OF PROJECT
 To increase the production of sewing line.
 To minimize the rework in quality.
 To identify the factors that lead to increase in rejections and reworks.
 To determine the critical operations and factors that leads to increased level of
rejections and rework.
 To search for possible solutions or alternatives for critical and semi-critical operations.
 To bring down and sustain rejections to a minimum level.

 SCOPE OF PROJECT
 Decrease in level of rejections and reworks and reduced fabric usage.
 Increased productivity
 Reduction in lead time
 Cost reduction and increased profit.

 PROBLEM IDENTIFICATION

 The sewing line was producing number of different type of defects- minor defects,
major defects.
 Alteration frequency was more than 22.7%.
 Overall productivity loss 2 day.
 Rejection per day was 40-42 garments.

 PROJECT METHODOLOGY
 Review of the existing quality inspection system in sewing department.
 Identification of defects in the sewing line by collecting data from old records
  Analysis of data collected in order to identify majorly occurring defects and alterations.
 Categorization of defects
 Assessing root cause analysis of defects.
 Development of a model Quality Inspection System as traffic light system.
 Implementation of check sheets at work station to capture operator’s performance
quality level.
 Analysis the data of operator’s quality performance after suggestion implementation.

2.1 Review of the existing quality inspection system in sewing department

 There are two quality inspection check point: Inline & end line check point.
 After passing of pieces from two check points, the end line inspection checker checks all
the measurement and all type of defects in garment.
 Every hour the end line checker checks all 30-42 pieces and point out no. of defective
pieces and note down in inspection report.
 The lot of 30-42 pieces is checked by Q. A. audit as 10% of the lot is inspected by Q.A.

2.2 Identification of defects in the sewing line by collecting data from old records

 There are mainly three inspection report

 One report of inline inspection, one of end line inspection and one of Q.A. audit
report.

2.3 Analysis of data collected in order to identify majorly occurring defects and alterations

 The defects are analysis according to style’s check point.

 There are two reports prepared – Alteration percentage and Rejection percentage.
 Alteration percentage report
 Rejection percentage

2.4 Types of defects

 Uneven width at collar end.

 Corner edges not properly sharped (round or curved corners).
 Uneven space at both armhole lace from lace.
 Uneven bottom fold.
 Pinch at armhole finish.
  Open stitch and uneven bottom.
 Uneven sleeve gather.
 Uneven attachment of front lace.
 Neck lace gap not proper.
 Uneven loops.
 Open stitch at bottom fold.
 Main label wrong size attach.
 Uneven bottom lace.
 Improper placement of lace.

 Alteration percentage report – No. defects

Defect %
45
39
40

35
30
30

25
21
19 18 19
20

15 13

10

0
Tuesday Wednesday Thursday Friday Saturday Monday Tuesday

Defect %

 Alteration Report – No. of defective pieces

 Number of Defective piece
70

60

50

40

30

20

10

0
Tuesday Wednesday Thursday Friday Saturday Monday Tuesday

Number of Defective piece

 Rejection percentage – DHU %

DHU %
25

20

15

10

0
Tuesday Wednesday Thursday Friday Saturday Monday Tuesday

DHU %

2.5 Cause & Effect diagram for major occurring defects as alteration and rejections and their
implemented solutions

a. Cause and effect diagram for major defects –alterations

 1. Loose and open bottom hemming

MAN MACHINE INSTRUCTION

Operator training how to do not clear

High speed of m/c

Loose and open
bottom
Material handling hemming

MATERIAL METHOD

Loose and open

bottom hemming

Root Cause Solution

 Material handling  Training and self-checking
  Control over machine speed

2. Uneven width at collar end

MAN MACHINE INSTRUCTION

Instruction not follow

Uneven width
at collar end
Improper handling

Material handling

MATERIAL METHOD

Root Cause Solution

 Instruction not followed  Training provided and proper
instruction given

3. Sleeve pinching

MAN MACHINE INSTRUCTION

Careless of operator
M/c speed high

Sleeve pinching

Handling of sleeve part

MATERIAL METHOD
Root Cause Solution
 Careless of operator  Self-assessment and handling

4. Improper placement of lace

MAN MACHINE INSTRUCTION

Careless of operator during attach

Improper
placement of
lace

Visibility of white mark not Handling of sleeve during attach

clear

MATERIAL METHOD
 Improper
placement of lace

Root Cause Solution

 Visibility of mark not clear  Placement of dark colour fabric on
sewing table to make it clearly visible

5. Uneven loops

MAN MACHINE INSTRUCTION

Instruction not proper

Uneven loops

Cutting of thin elastic not equal Handling of material not proper

MATERIAL METHOD
 Uneven loops
Root Cause Solution
 Cutting of thin lace not equal  Proper instructions given to cut the
elastic

6. Placement of lace from neck not proper

MAN MACHINE INSTRUCTION

Improper training

Placement of
Lace from neck
not proper
Marking not visible Material handling-spacing

MATERIAL METHOD
 Placement of lace from
neck not proper

Root Cause Solution

 Marking is not visible  Placement of dark colour fabric on
sewing table to make it clearly visible

7. Attachment of front lace not proper

MAN MACHINE INSTRUCTION

Improper feeding of fabric Instruction not followed

and lace

Attachment of
front lace not
proper

MATERIAL METHOD
 Attachment of front
lace not proper
Root Cause Solution
 Instruction not followed  Again instructions are given and keep
on checking time to time

8. Ticket number is not matching

MAN MACHINE INSTRUCTION

Instructions not followed
Carelessness of helper

Ticket number is
not matching

MATERIAL METHOD
 Ticket number is not
Root Cause matching Solution
 Instruction not followed  Again instructions are given and keep
on checking time to time

2.6 Development of a model Quality Inspection System as traffic light system

 To measure operator’s quality performance a format is printed on a slightly thick A4 sheet

and hanged on the sewing machines of line.
 In this system quality auditor visit each operator’s workplace 4 times in a day (considering
8 hours shift day) and inspects stitched garments.
 The quality auditor fills space with color according to the inspection result.
 The quality auditor instructed to inspect 5 pieces from the stitch garments and if auditor
found more than 2any defective piece, respective space to be filled by RED color. If red
color is marked on the inspection sheet, all stitched pieces must be checked by auditor.
And operator need to be explained about the quality expected from him/her and how to
get that expected quality and needed action to be taken.
 Standard Sample Size: 5 pieces. Garment Inspection should be done after every two hour.
  Color marking procedures: Space will be filled with color
 GREEN: If found No defect
 YELLOW: If found 1 defect
 RED: If found 2 defects

2.7 Implementation of check sheets at work station to capture operator’s performance quality
level

Selection of 3 critical Operator's quality

operation where more performance format is
defects are ocurred hanged on work station

Auditor takes 5 random

sample from 30-35 Every hour quality
pieces and inspects auditor inspects work
according to check station's prodcutivity
points

If no defective piece is If one defective piece is If two or more defective

found, mark found, mark pieces are found, mark

GREEN YELLOW RED

OPERATOR’S PERFORMANCE FORMAT
2.8 Analysis the data before and after implementation

Date Daily Total Daily Total Number Number Defective Defect WIP
input input output output of of pass pcs %
checked pcs
pcs
11/7/17 550 550 15 15 40 23 17 42.5 535
12/7/17 550 1100 104 119 137 96 41 30 981
13/7/17 300 1400 160 279 205 160 45 21 1121
14/7/17 200 1600 205 484 236 190 46 19 1116
15/7/17 50 1650 247 731 255 220 35 13 919
16/7/17 Sunday - - - - - - - -
17/7/17 150 1800 230 961 264 215 49 18 839
18/7/17 272 2072 250 1211 303 245 58 19 861
19/7/17 228 2300 270 1481 300 258 42 14 826
20/7/17 350 2650 238 1719 263 227 36 13.6 938
21/7/17 250 2900 254 1973 287 242 45 15.6 934
22/7/17 184 3084 240 2213 225 202 23 10.2 878
23/7/17 Sunday - - - - - - - -
24/7/17 closed 3084 290 2503 300 279 30 10.5 588
25/7/17 closed 3084 284 2787 290 254 36 12.5 304
26/7/17 closed 3084 304 3091 312 242 42 13.4 0

Results and findings

A. Alterations percentage reduction – No of defects

Before
Implementation
Days Tuesday Wednesday Thursday Friday Saturday Monday Tuesday Average
Percentage
Alteration% 42.5 30 21 19 13 18 19 23.2
After
Implementation
Alteration% 14 13.6 15.6 10.2 10.5 12.5 13.4 12.82

B. Alterations reduction – No of defective pieces

Before
implementation
Days Tues Wednes Thurs Fri Satur Mon Tues Average
day day day day day day day
Alteration
17 41 45 46 35 49 58 41.57
After
implementation
Alteration
42 36 45 23 30 36 42 36.28

C. DHU percentage reduction

Before
implementation
Days Tues Wednes Thurs Fri Satur Mon Tues Average
day day day day day day day
Alteration
17 41 45 46 35 49 58 41.57
After
implementation
Alteration
42 36 45 23 30 36 42 36.28

Before
implementation
Days Tues Wednes Thurs Fri Satur Mon Tues Average
day day day day day day day Productivity
Productivity
23 96 160 190 220 215 245 164
 After
implementation
Productivity
258 227 242 202 279 254 242 267
D. Productivity improvement

 Conclusion

 Traffic light system is a system that can be implemented in any garment manufacturing
company and help to improve the quality status, improve the lead time and thus
strengthen the supply chain performance without increasing the resource.
 We know save of days is nothing but decreasing the lead time and the more the lead
time the better the supply chain performance is.
 Implementation of the traffic light system for the global change is also proposed to the
factory management to get the ultimate benefit.
 After implementing the lean traffic light system the quality status is improved.