Reducing the Defect Rate at Crisdeline Garments Company

through the use of Statistical Process Control Tools

and Mistake Proofing

____________________________

A Research Study presented to the

Faculty of College of Information Technology and Engineering

for the degree in Bachelor of Science in Industrial Engineering

________________________________

By:

Agaton, Von Joseph

Castillo, Mary Michelle

Guilas, Ma. Katrina

Ocampo, Rogeleen Anne

Paña, Mhervy Kent

May 11, 2019

 Chapter 1

THE PROBLEM AND THE REVIEW OF RELATED LITERATURE

In this section, it presents the background, problem statement, research

objectives, and theoretical framework, review of related literature and studies,

significance, scope and limitation and definition of terms of the study that prompted the

researchers to undertake the study.

Background of the Study

Among the world’s largest industry, garments have always been included.

In addition, it is always one of the major contributors to the economy of some

countries. According to Ong (2012) In 1950s, garments started as a cottage

industry in the Philippines. Supported by some intellectuals and skilled operators,

natural creativity and favorable legislation, the apparel industry grew and grew

until it reach its highest point in the 1990’s.

Crisdeline Garments is a local garments company built in the province of

Batangas, Philippines. It was owned by Mr. Regino Pastor and was established

at 16A Palindan Ibaan, Batangas on July 25, 2005. It is classified as a sewing

company made up of two lines with 163 employees, specifically a line supervisor,
 2

sewing supervisor, quality control supervisor, classifier, mover, line locale,

sewer, trimmer, mechanic and warehouseman. Working hours in this company

starts at seven o’clock in the morning to four o’clock in the afternoon with one

lunch break from 11:00 AM -12:00 PM and two tea/coffee break which is one in

the morning at 9:00 AM - 9:15 AM and one in the afternoon at 2:00 PM -2:15 PM.

Moreover, if the low production output exists there will be an additional

unplanned overtime of two hour.

In a garment factory, there are cases of needed reworks because of some

defects found in the sewing process that will lead to rejection and rework. In the

case of Crisdeline Garments, they are in need of a rework of all the products that

has defects because the raw materials that was given to them by Metro

Garments is limited. Moreover, different types of defects are found in Crisdeline

Garments while sewing the products such as seam not caught, skipped, loose,

drop, cracking, overlap, folded, bowing, short band, long band, unsymmetrical

and un-even. These types of defects would lead to reworking of the products. As

a result, if rework rates continue to increase, there will be a negative effect on the

production of the company.

 3

Statement of the Problem

It is extremely challenging to achieve consistency in each piece of

garments during production, as the factors that can affect in producing the

product is not limited to just one reason. It was documented that there is a

number of 5,926 units of nonconforming products at Crisdeline Garments which

has an equivalent of 4.66% defects in the total production in the month of

February. Accordingly, this percentage is beyond the target defect rate of the

company by 46.35%. In line with the total numbers of non-conforming unit in

production, 30.51% of this defect is caused by long-band.

Research Objectives

The research intends to reduce the non-conforming units from being

produce. In line with this general objective, there are set of specific objectives as

follows:

1. To determine the highest contributor of defects in the production;

2. To analyze a specific process in the production where the highest

defects accumulate and determine the factors that affects the defect;

3. To propose a solution and implement Poka Yoke that will reduce the

defects accumulated in a specific process.

 4

Research Framework

After identifying the research objectives, the next step is to finalize the

process to achieve the objectives and the research framework will be followed

and laid out. The research framework developed for the current study is highly

influenced from an article called Quality improvement through Poka-Yoke: from

engineering design to information system design by Abraham Zhang.

Figure 1. Theoretical Framework

Ray Andersson defines the defect rate that it plays a major role in

improving yield and financial performance. It causes a direct effect on the

product's profit margin and decreases the cost of quality during product
 5

manufacture. Each company strives to reduce the product's defect rate as much

as possible during the manufacturing process to avoid the targeted quota delay.

The researchers gathered from the company: series of defects that

occurred in sewing. To further elaborate the defects, the researchers will use

Statistical Process Control as a tool to evaluate and control a process. With the

help of the Fishbone Diagram it will identify the major cause of defects and from

then the Why-why Analysis will be used to know the true cause that needs to be

solve. The third step is the implementation of Poka Yoke. But before that,

researchers will consider on improving the method which can help the process to

prevent non-conformity of the highest contributor of defect. After implementing

the Poka Yoke, the last step is to maintain and improve the proposed solution.

From then, it will undergo a cycle for a continuous improvement for the overall

process.

Review of Related Literature and Studies

In earlier days, covering and protecting the body from climate change was

the basic necessity of clothing. But people today became more concerned about

the wearing comfort and also about the durability of the garment. Therefore, the

clothing industry began to consider the application of modernization, various

engineering tools and techniques in the manufacture of clothing to increase

 6

productivity and efficiency (Rajput, Kakde, Chandurkar, & Raichurkar, 2018). A

garment is a product of clothing made of fiber and textile material that is

essentially worn by humans (Hoshen, 2014). Before the country's large garment

factories were built, home sewing was famous in the 1950s. It was a typical

source of living for a low-income family with the mother usually the seamstress

who buys fabric and makes it into uniforms, clothes, pants, etc. (Maddawin,

2017). Today, the apparel industry is one of the most important industries in

global trade with global manufacturing and marketing activities (Hoshen, 2014).

Brenton et al. (2007) suggest a number of reasons for the role of the clothing

sector in economic development. Large numbers of unskilled labor have been

absorbed by the sectors, typically drawing them from rural farm households to

rural locations. Improving the production and quality of clothing to sustain in the

huge competitive market is the primary goal of the clothing industry.

Manufacturing of garments involves the number of operations performed by the

operators at different locations. All these activities must be carried out in a

synchronized, planned and timely manner in order to achieve the desired goal

and avoid delays (Jadhav, Sharma, Daberao, & Gulhane, 2017).

As part of the section on the garment industry, the sewing process is one

of the most important stages in labour-intensive ready-made clothing businesses

while being the leading and most difficult to operate (Rahman, Dey, Kapuria, &

Tahiduzzaman, 2018). In this context, the sewing section defects hamper the
 7

overall quality of the factory, because of these defects the rework rate may

exceed 5% based on the daily rework rate of the company and this rework rate is

caused by various reasons such as poor thread quality, fabric flagging, material

handling, machine breakdown and others (Beyene, 2016).

In order to further understand what a defect is, it means that the contents

of a product are excessively measurable (Hashi, 2016). Most manufacturers

believe that clothing is soft and non-repairable defects can occur due to low raw

material quality or faulty process or casual behavior of employees (N. S. Patil,

Rajkumar, Chandurkar, & Kolte, 2017)

According to Islam, Khan, & Khan (2013) these are the category of defects that

they found:

Sewing defects: Usually these defects are caused by errors caused by

sewing machines working incorrectly.

Seaming defects: These defects are usually caused by errors resulting

from the operator's and machine's interaction in clothing handling.

Placement defects: Usually these defects are caused by marking and

cutting errors as well as sewing in the sewing room.

Fabric Defects: Usually these defects are caused by fabric processing

errors such as knitting and dyeing.

Embroidery defects: Usually these defects are caused by errors resulting

from Garments' embroidery processing.

 8

According Kapuria, Rahman & Haldar (2017) defects found are: Loose

tension, Skip Stitch, Broken Stitch, Hem Length Up down, Dirty Spot, Down

Stitch, Join Stitch, Label missing, Needle mark, Oil Spot, Open Seam, Part

Shading, Pleat, Point Up down, Print defect and Tack Missing.

Moreover, as indicated by Hashi (2016), that was not yet mentioned, the

different types of defects are Bartack Missing, Disappearing Stitches, Bottom

Hem, Double Crease, Down Stitch / Fall Of Stitch, Excess Fabric on Stitch,

Elastic Uneven, Fraying, High Low, Needle Cut, Needle Mark, Oil Mark, Over

Stitch, Open Stitch, Poor Pressing, Puckering, Ragged/Inconsistent Edge,

Rawedge, Run of Stitch, Shining Mark, Slanted, Stitch Breakage, Twisting,

Uneven Shape, Uneven Stitch, Untrimmed Threads, Wrong Size, Yarn Gathering,

and Wavy Seams.

Since the defects are found in sewing and it takes further studies to

prevent it reworks will occur. Reworks are the non-productive activities focusing

on any operations that customer are not willing to pay for it. Non-productive

activities describe/shows that the customer does not consider as adding value to

this product (Alam & Huda, 2018). Rework means correcting of defective, failed,

or non-conforming item, during or after inspection and it includes all follow-on

efforts such as disassembly, repair, replacement, reassembly, etc. And it is also

defined as work that is made to conform to the original requirements by

 9

completion or correction at least one extra time due to non-conformance with

requirements (Mcdonald, n.d.)

Rework in the garment industry can be a common work that hinders the

sleek rate of production and focuses on poor quality products that influence the

overall factory economy (Islam, Khan, & Khan, 2013). Rework is the non-

productive activity that focuses on any activity that customers do not seem willing

to buy (Biswas, T. 2017). Minimizing reworks is a must in terms of improving

quality and productivity. Rework is an important issue for poor product quality

and low production rates (Islam et al., 2013).

One of the reason of rework is the quality of the products. The lower

quality products are hampered productivity. These flaws can be repairable that

leads to rework or non-repairable that will leads to rejection (Alam & Huda, 2018).

In garments manufacturing, it is usual few rejected garments after shipment. The

reason is most of the manufacturers believe that garments are soft goods and

non-repairable defects may occur due to low quality raw materials or employee

casual behavior or faulty process. Rework is a vital issue for lack quality product

and low production rate (Upasham, 2016).

According to the research conducted by Rahman et al., (2018), they found

different type of defects in the study like, skip stitch, broken stitch, lack skilled
 10

operators, and lack of proper training to the operators. Broken stitch is created

and increasing defect for the tendency of producing more and garment become

tampered. Skip stitch this can be caused by rough handling of materials. The

main causes for occurring down stitch is lack of proper training to the operators

and making the skilled operators. Incorrect material handling and wrong calming

can cause defects and it will turn into rework.

Moreover, on the research study conducted by Choudhary, Sikka, &

Bansal, (2018) they stated that there are factors that affect the seam damages

and causing defects and turn into rejection or rework. Those factors are fiber,

yarn, fabric structure, sewing needle, sewing thread and machine parameters.

Sewing damage/defects are caused when fabric restricts the penetration of the

sewing needle. This not only depends upon the spaces in the fabric but also on

needle size, needle profile, sewing thread and sewing machine setting.

Consequently, according to Ahmed, et al., (2013) they identified the top 7 defect

types in sewing process a in the Garment Factory in Bangladesh. Those defect

types are skipped stitch, uneven stitch, broken stitch, raw edge. Uncut thread,

spot and visible top stitch, this are the defects that they found and causing

rework. Those different types of defects happen because of improper handling of

the machine and some machines are defective.

 11

As stated by Tahiduzzaman, Rahman, Dey, and Kapuria (2018), In

garments factory, Fixable defects result in rework in the garments factory and

non-repairable defects end up in rejection, to reduce the rate of rework, factory

staff must keep their eyes on defect rates from the start. In short, the rework rate

has a negative impact on the rate of production and rejection causes the

company to lose huge gross margin. It is essential to determine and maintain

clear, complete and contemporary written inspection and check process data for

each operation in order to be powerful in defects and rejection reduction. To

achieve the ultimate goal of minimizing defects and rejecting completed

merchandise, its miles required to set up a document and maintain a machine

capable of ensuring that products comply with the specifications of requirements

in general.

According to Biswas (2017), In order to reduce these reworks and

increase productivity, a set of defective information needs to be made to

understand the rework percentage that can provide a complete understanding of

the exact amount of non-productive work that is taking place. So, studying data

and analyzing its potential causes and results through some statistical process

control tools could result in future defect control.

In line with the defects and reworks happened in the production, an

analysis must be conducted to find the cause of the problem. Root Cause
 12

Analysis (RCA) is a method for solving problem by fixing the root cause

underlying it. With the proper use of Root Cause Analysis, investigators can

explore, examine and analyze contributing factors to determine what actually

happened in the beginning that leads to problem’s manifestation. This process is

valuable because it aims is to go deeper into the root cause of the case and

determine the cause and effect which leads to the identification of the starting

factor that created the problem rather than simply implementing the most obvious

solution to the problem (Goa, 2015). Root Cause Analysis appears simple but it

is very rooted analysis and it is proved to be a successful process in defect

prevention. It emphasize on identifying the root causes of defects and initiate

action to correct them (Chandani & Gupta, 2014).

Root Cause Analysis tool must have the function and characteristic to

build an exploration about the problem and must be comprehensible and be a

medium for evaluating integrity (Menon,2016). The Five Why method is one of

the common method to utilized Root Cause Analysis. It was developed by

Sakichi Toyoda which was the founder of Toyota Industries. The method has the

goal to find the root causes and is applied in the third process of root cause

analysis. The method at it’s core is to define the problem first and then

repeatedly ask “why to answer the problem. Various casual factors are

determined for each “why” asked. This goes on until the problem is investigated

deeply enough to make a root cause visible.(Goa, 2015).

 13

It is very useful in identifying the defect through the use of Defect Causal

Analysis implementation, Pareto charts and cause effect diagram. Indicators

supporting DCA were also discussed such as number of defects found by unit

size, mean number of defects found per hour of inspection, quality of phase input,

quality of phase output helping to determine the effectiveness of DP activities

(Chandani & Gupta, 2014).

Quality is equated to a product and service excellence discipline. Both

manufacturing and service companies has a quality programs. Quality is closely

related to product and process variations, and to study this variation, the use of

statistic is needed. Quality programs are data driven, this data are commonly

studied using statistic due to the occurence or variation. One of the main goal of

quality program is to reduce the variation in the product and to the extent that

producing a defect is absolutely not existing. (Sahay, 2015)

According to the book entitled "Managing and Quality Improvement:

Integrating Quality, Statistical Methods and Process Control," a system usually

consists of a group of interacting, interrelated or interdependent processes that

form a complex whole. A system is therefore a collection of processes with a

specific purpose or mission. The process is defined as a sequence or network of

activities representing the flow of the entire process required to transform the

inputs into outputs (useful product or service).The transformation is

 14

accomplished through flows through the network of activities carried out by

different resources.

As stated by Srinivasu, Reddy, & Rikkula (2011), Quality Control (QC)

serves as an important function in a company since inspection must be done

before shipping the product to the customers. Quality Control has a tool, called

Statistical Process Control, that can be used to detect if the production process is

in control.

The use of SPC tools such as checklist, cause and effect diagram and

control charts for quality improvement in garment industry helps to reduce

defects which will also minimize the rejection and reworks rate (Upasham, 2016).

By using such tools, identifying the highest waste occurring and giving

suggestion for improvement can reduce defects (Mengesha, Singh, & Yimer,

2013). These tools including Pareto Chart may also be used to identify the

causes for rejection, poor quality and remedies in proposing optimal solutions to

be implemented for better quality (Joseph & Mallya, 2016).

There are various ways of implementing SPC tools, namely SPC software,

Excel sheet SPC and manual application SPC. SPC software is convenient and

simple to understand and retrieve data. At the same time, SPC in Excel sheet is

easy, simple and provides a basic graphic facility. However, SPC with manual
 15

application involves plotting of data on control chart using a graphing paper.

Moreover, seven basic QC tools can be used to improve a process are the

Pareto chart, Cause-and-Effect diagram, Scatter diagram, Flowchart, Histogram,

Check sheets, and Control charts. The implementation of SPC system was the

main essence of the study. The sewing section process was critically observed,

studied and analyze after that it was seen that there are defects found in the lines.

Implementation of the manual SPC methods was utilize and control charts are

created manually. The company gained several advantages from the

implementation of SPC, such as, general quality awareness being created

among the operators, and therefore the training on SPC are information on

quality ideas, higher understanding of processes, analyzing processes using

statistical methods and operators were considered a part of the quality

improvement process (Abtew, Kropi, Hong, & Pu, 2018).

According to Syduzzaman, Rahman, Islam, Habib, & Ahmed (2014) In

today's world where competition is at the highest level, companies that can

flexibly manufacture their products while considering market variability gain very

high competitive power by providing their customers with products of higher

quality that meet standards and are available at lower prices. To achieve this,

Total Quality Management (TQM) has been applied, which maintains a vital role

in improving productivity, product quality and reducing production costs by

reducing rework and scrape.

 16

A study called "Quality Improvement in Garments Industry through TQM

Approach" state that there are some variables like Operator, Skill, Process,

Machine etc. when manufacturing products are on a large scale. Operator

(human) performs most of the operations in a garment industry in Bangladesh so

the quality requirement deviation is high, mostly from the operator, machine,

method, material and work environment. A factory has to do a remarkable rework

for quality problem that increases the cost of manufacturing as well as decreases

productivity. The use of TQM Approaches such as Pareto Chart, Scatter Chart,

Control Chart, Cause and Effect Chart can improve the quality of the Bangladesh

garment industry (Rahman M.M., Masud A.K.M., 2011).

Quality is the most important issue for customer satisfaction. Not only in

industry producing clothing, but also in any production. The flaws in the apparel

industries are a variety of major losses or minimize profit. Any manufacturer

should be primarily concerned with supplying and delivering quality products at

the right time. Product defects, however, usually lead to rejection, rework, long,

extra working hours and discontent with the customer. Lean tools are applied in

attire industries to solve all these problems and minimize waste. Analysis of

Pareto was performed to identify the sewing defects. The top three defects were

also analyzed using the Cause-and-Effect diagram based on the Pareto chart.

(Rahman et al., 2018).

 17

In order to reduce defects that occurs in sewing, the researchers decided

to implement the use of Mistake Proofing (Poka Yoke) that will contribute to

lessen the company’s rework and avoid delays in production. For starters, the

birth of Poka Yoke started in Japan in the 60s by Shigeo Shingo, it means

‘mistake proofing’ or simply avoiding inadvertent errors. Not only Poka Yoke can

avoid some workers to make mistakes but also can make the process to run

smoothly, minimizing the defect rates, avoid large takt time and can improve the

life quality. As stated by Wang & Lu (2015) more specifically, there is a series of

preventive measure that will work effectively or reducing the adverse effects due

to human errors is called “Poka Yoke”. Poka Yoke also known as mistake

proofing is a tool that can build into process to prevent human errors or mistakes

occurring. There are three aims of Poka Yoke such as reducing the risk of human

errors or mistakes arising, minimizing the effort to execute the work and detecting

mistakes that can affect the worker, equipment and materials. (Eaton, 2013)

In addition, as stated by Eaton (2013) in his book “The Lean Practitioner’s

Handbook” there is a concept about the hierarchy of Poka Yoke with an effective

decreasing level. Moreover, Eaton introduced the five levels of the hierarchy of

mistake proofing. First off, “Eliminate” is a very effective, and can also completely

remove the source of risk. Although in actual situations, it is very hard to

completely remove the risk. On the other hand, if the risk can’t remove or

eliminate, try it with a less risky process which is “Redesign”. However,

 18

sometimes it is impossible to just remake or redesign the problem that it is

needed to be “Reduce”. In some cases, the problem has already occurred and it

doesn’t need to prevent mistakes but to “Detect”. Lastly, “Mitigate” is trying to

eliminate some damage caused by the mistakes or errors arising.

The basic functions of Poka-Yoke as stated by Magrab (1997) in his book

entitled “Integrated Product and Process Design and Development: The Product

Realization Process” A defect can be detected in two states. First, is when the

defect is about to exist, and the second is the defect has already existed.

Furthermore, it is called prediction when recognizing that a defect is soon to

happen and detection is when the defect has already happened. The three basic

functions to counter defects are shutdown, control and warning. The first basic

function is shutdown, when an error is about or soon to happen, the process, or

the machine needs to be shutdown. Next, controlling the process is not allowed

to move forward when an error occurs or not possible. Lastly, a visual or audio

warning when an error is about to occur or after it has occurred.

The difference between the three basic functions to counter defects that in

shutdown and warning method as mentioned by Patil, Parit, & Burali (2013) in

their article, that by the applying shutdown method it guarantee a 100% defect

free to the products. On the other hand, by applying the warning method it can

detect the presence of a defect in a product, but it doesn’t guarantee and does
 19

not create a 100% quality. And as mentioned by Anderson (2002) by applying the

control method it can give a product 100% detect free like the shutdown method.

Poka-Yoke is a tool that is useful when a process go wrong or an error is

about to occur or already has occurred. It is a technique that involves to any kind

of process in the manufacturing industry. There are many types of errors that can

be identified; processing error is a process which the operation isn’t

accomplished per the standard of the procedure. Setup error is classified as an

incorrect adjustments caused by using the wrong setting or tooling machine.

Missing part is an error when some of the parts of the process are missing or not

included. Improper part or item is a process that includes a wrong part. An

operations error is incorrectly doing the operation or having an invalid model of

the specification. Lastly, when an error occurs in the settings of a machine or a

wrong measurement of a part came from a supplier is called the Measurement

error (P. S. Parikshit, Nair, & Nikunj, 2013).

After knowing the functions and causes of defects, the step by step

process in applying Mistake Proofing as mentioned by Parikshit, Nair, & Nikunj

(2013) are, identify the process or operation based on the Pareto chart, analyze

the 5-whys and figure out the ways that the process can go wrong, choose the

right poka-yoke approach, such as using a shut-out type (to prevent an error that

can occur), or an attention type (emphasizing that an error has already occurred),
 20

To determine whether a contact will need some physical attributes for detection,

constant number or error triggered if a number of actions are not performed by a

sequence method or a checklist is used to ensure that all process steps are

completed. Conduct a test to see if the method is going to work and finally train

the operator, review their performance and measure their success.

There are four different approaches in the process of Mistake Proofing in

reducing human error which is introduced briefly and discussed by Grout (2007)

which are: mistake prevention in the work environment, mistake detection

(Shingo's informative inspection), mistake prevention (Shingo's source

inspection), and preventing the influence of mistakes.

Moreover, a study have been made for manufacturing companies to be

competitive in the global market by innovation and improving its process. Many

techniques have been developed over the years to reduce errors. The objective

of quality control in each production system is to eliminate non-conformities and

their consequences, to eliminate rework and wasted resources and at the lowest

possible cost in achieving these goals. Variation, errors, and complexity are three

distinctly different sources of non-conformities that were identified. The process

variation can be controlled by means of Statistical Quality Control techniques, but

errors can not be controlled by them. It is possible to completely avoid mistakes

that lead to defects. Deploying error proofing devices has been shown to reduce
 21

the dissatisfaction of the customer and the high cost of defects. Replacing the

inspection with the inspection of the source will prevent defects down the line.

(Soundararajan & Jackson, 2011).

As a summary for this section, the history of the garment industry was

introduced until the modernization of today, from which home sewing was

famous in the 1950s before the large garment factories were built in the country.

Today, the apparel industry is one of the most important manufacturing and

marketing industries scattered around the globe in global trade sectors. In a

garment industry, there are various types of sections that can be found that are

cutting, sewing, finishing, quality control, etc. However, when it comes to sewing

the product, the Crisdeline Garments is the major contributor.

Sewing process can be classified as the most difficult operation in a

garment industry, defects that cause rework and can lead to production delay,

due to sewing defects, the rework rate can exceed 5% based on the daily rework

rate of the company and this rework rate is caused by various reasons such as

poor thread quality, material handling, machine breakdown and others. The

definition of defect was defined as the contents involved in an excessively

measurable-limited product, which may result in the clothing that is a soft product

and non-repairable defects due to low raw material quality or faulty process or

causal behavior of the employee. Types of defects occur in sewing were found
 22

such as Loose tension, Skip Stitch, Broken Stitch, Hem Length Up down, Dirty

Spot, Down Stitch, Join Stitch, Label missing, Needle mark, Oil Spot, Open

Seam, Part Shading, Pleat, Point Up down, Print defect and Tack Missing and

etc.

Since it is already stated that defects always cause reworking, rework

means correcting defective, failed or non-conforming items during or after

inspection and it includes all follow-up efforts such as disassembly, repair,

replacement, reassembly, etc. Based on the related studies, reworks in the

clothing industry can be common works that hamper the sleek rate of production

and focus poor quality products that influence the overall factory economy (Islam,

Khan, A. and Khan, M., 2013). It has been found It is essential to determine and

maintain clear, complete and contemporary written inspection and check process

data for each operation in order to be powerful in defects and rejection

reduction.that miscalming and incorrect handling of materials can cause defects

and turn into rework.

Low product quality is one of the factors that affect rework. Quality, as

clearly defined, is a discipline that focuses on excellence in product and service.

One of the quality programs ' main objectives is to reduce the variation in the

product and process to the extent that the likelihood of producing a defect.

According to the related studies, when manufacturing products are on a large

 23

scale, some of the variables in the Bangladesh clothing industry are performed

by Operator (human) so that the deviation of quality requirements is high, mostly

from the operator, machine, method, material and work environment. A factory

has to do a remarkable rework for quality problem that increases the cost of

manufacturing as well as decreases productivity.The use of SPC tools for quality

improvement in the garment industry such as checklist, cause and effect diagram

and control charts helps to reduce defects which will also minimize the rate of

rejection and reworks. Using such tools can reduce defects by identifying the

highest waste that occurs and offering suggestions for improvement. In line with

this, a Root Cause Analysis can reduce defects and reworks.

Through this, the researchers could examine and analyze the problem's

causal factors and then identify an apparent solution to the problem. The

researchers decided to use Mistake Proofing (Poka Yoke) to reduce the sewing

defects that will help reduce the company's rework and avoid delays in

production. The researchers decided to implement the use of Mistake Proofing

(Poka Yoke) to reduce the defects that occur in sewing, which will help reduce

the company's rework and avoid production delays. Poka Yoke is a technique

and a tool that can be used in manufacturing or service industries for any type of

process.It can avoid mistakes by workers, but it can also make the process run

smoothly, minimize the rate of defects, and improve the quality of life. Four types

of approaches in the process of Mistake Proofing in reducing human error is

 24

classified as: mistake prevention in the work environment, detection of mistake

by Shingo’s informative inspection, mistake prevention by source inspection and

lastly preventing the influence of mistakes. The researchers will design a product

with the help of the step by step procedure of mistake proofing at the same time

the product will be implemented if the design can be effective in achieving the

objective by reducing the defect rate.

Significance of the Study

The study focused on reducing the defect of a company and can

contribute to the improvement of the garment industry. Moreover, the results of

the study will be of great benefit to the following:

The company

This study will reduce the company’s defect rate. This study will

benefit the company to prevent the delay in the production. They would be

able to use this study in analyzing the defects they encountered and how

they can reduce it.

The researchers

This study will provide information with some knowledge on using

engineering tools and how it can contribute to the researchers. It will give
 25

the researchers an actual application of Statistical Process Control Tools

and Root Cause Analysis. At the end of the study, the researchers will

have a better understanding on the application of Mistake Proofing in

reducing defects.

Other Garment Industry

The given data would guide other garment industry on what to do

with reworks and defects. The garment industry would be able to

understand why the defects occur and how to resolve it.

Future Researchers

The findings of the study will serve as a reference material and a

guide for future researchers who wants to conduct the same experimental

study, or any study related to reducing the defects.

Scope and Limitation

The study involves data that was gathered from the company yet some of

it was considered as exclusive and will not be indicated on the paper but will

serve as basis. As for the scope of the study, the research would only focus on

the factors that affects rework (specifically in the process that contributes to the

highest percentage of defect) which includes in the analysis of the behavior of

 26

raw materials, process and the quality of output only. Besides, the research will

only consider a specific process that has the highest contributor of defect

percentage. Moreover, the research will be using the Statistical Process Control

Tools to identify the true factor affecting rework in the system. This would be

helpful to assess and fully understand the cause and effect of the investigated

factor. Also, the main objective of the study is to reduce rework and defect in the

system. In order to achieve it, Mistake Proofing or Poka Yoke will be applied to

prevent it from recurring and will lead to an improved process.

In spite of best efforts to minimize all limitations in the research, the

researchers would not focus on the supplier itself. Furthermore, the researchers

would not consider the environment where the workers work and the repetition of

their work. Additionally, the researchers would not give emphasis on the

transportation from the supplier to the company. Thus, the finished product to the

packaging.

Operational Definition of Terms

Quality means that desired specification of the company is achieved.

Nonconformity is a quality characteristic that does not meet the unit

specifications set by the company.

 27

Nonconforming unit means that the unit is unable to meet the intended

standards.

Defect is a quality characteristic that does not meet certain standards associated

with it.

Specification it is set of requirements and description on the desired output that

the company aims in order to meet the standard.

Standard is a prescribed conditions and requirements sets by the company.

Specification limits are acceptable bounds on individual quality characteristics.

Quality control may generally be defined as a system that maintains a desired

level of quality.

Quality improvement relates to the detection and elimination of common

causes of defects.

Rework is defined as fixing the unit due to the existence of incorrect specification.

Pareto Chart is effective in analyzing what problems need to be solve. Moreover,

it can easily identify the highest and lowest percentage in a series of defects
 28

which represent as the frequency, it also shows which variables are having the

greatest cumulative effect on a given structure.

Fishbone Diagram is also known as the cause-and-effect diagram, it helps the

researchers track down the major cause of variations, imperfections, defects, or

errors.

Poka Yoke is also known as mistake-proofing, before the process is executed,

poka yoke will check if it is on the right conditions to perform. In addition, by

proposing a countermeasure, it can prevent the defects from existing.

Statistical Process Control (SPC) is used by the researchers to control or

evaluate the process or production. With the use of SPC tools and procedures it

can help to detect the process behavior, including the defects and some other

issues in the internal system.

 Chapter 2

RESEARCH METHODOLOGY

This section describes and explains the different procedures of research

methodology including the research design, operational framework, data gathering

procedure such as sources of data, locale of the study, research tools and instruments,

as well as the data analysis and interpretation.

Research Design

Applied research is the chosen design because it aims in finding a solution

for an immediate problem facing a society, or an industrial/business organization.

Applied research can be helpful in solving specific problems even in small scale

businesses and other settings. According to McLeod & Holstein (2013), in

applied research in order to meet a specific requirement, it needs to carry the

findings of a fundamental research where they can be utilized. In addition, Saini

(2016) noted that collecting and analyzing of data to examine the effectiveness of

theory in solving real or actual problems is called “Applied Research”. Moreover,

she stated in her journal some examples of applied research, such as to improve

the production of crops, energy of homes, offices, and transportation and to

 30

diagnose a certain collection in a bookstore or library. Therefore, based

from the definition and some examples of applied research, it is applicable to

utilize by the researchers as the main purpose of the study was to reduce the

defect rate of the Crsideline Garments Company.

Operational Framework

In this part of the study, researchers intend to establish a framework and

discuss the issues related to the company’s reworks. A constructive IPO Chart

was designed, that provides a general structure and guide for the direction of the

study. Also, it shows distinct components required to transfer inputs to outputs.

The major goal of this study is to reduce the defect rate. First off, an interview of

the supervisor and gathering of data has been done to identify the problem. With

the gathered data, an analysis will be done using the Statistical Process Control

in order to identify the highest contributor of defects. The highest contributor of

defect that causes rework will be determined, but before that an observation of

the process will be performed to identify the factors affecting the occurrence of

defect. An analysis will be accomplished such as Root Cause Analysis, Cause

and Effect Diagram and Why-why Analysis to identify the problem that needs to

be minimize or improve. The researchers would suggest on improving the

method of the process where the highest defect occur as a way of implementing

Mistake Proofing. A decision will be done whether the method is not effective, it
 31

will repeat the cycle of the Analysis until the method is improve. However, if the

method is effective it will lead to the objective of the study which is reducing of

defect rate.

Figure 2. IPO Process Flow Chart

 32

Data Gathering

i. Sources of Data

For study purpose, the researchers used different methods in

gathering information. The two types are primary and secondary data.

Researchers gathered primary data through personal interview and

observations in the company that are original and relevant to the topic

of the research study. It takes a lot of time and effort in collecting the

data, but it is specific to the researchers’ needs. The secondary data

are from the company’s records of the inspection report in the

production. The data are from the past and can be collected in a short

span of time. Secondary data may be specific to the researchers’

needs since it can help identify the causes of rework.

ii. Locale of the Study

The study was conducted in a sewing company called Crisdeline

Garments, which is located at Palindan, Ibaan, Batangas. The

company has two production lines wherein the sewing process takes

place and production of outputs are made. This production line was

controlled and monitored by a line supervisor and a quality control

 33

supervisor. In line with this, the company has five end line quality

inspector who are responsible in inspecting and measuring the

products being produced and to ensure that it meets the production

standards.

iii. Research Tools and Instrument

The main instrument used by the researchers for data gathering

were:

1. Personal Interview was conducted with the Line Supervisor of the

production to have a background on the production problem that

was encountered, to know the production schedule requirements

and the routine production activities. The Quality Control

Supervisor was also interviewed with regards to the inspection of

raw material used in the production, the production process issue,

critical process and the quality specification. Moreover, there is a

discussion about the defects accumulated in the production.

2. Actual Observation of the production worker’s procedure in

processing the raw material and how the unit was produced and

inspected.
 34

3. Data concerned with the nonconforming units was gathered with

the use of the inspection reports of the company. This report was

done by the quality inspector and was justified through the

standard specification required by the company.

Data Analysis and Interpretation

To interpret and analyzed the data effectively, the researchers would use

descriptive statistics primarily focused on frequency distribution. Frequency

distributions provide the initial organization and information that is the starting

point for many other statistical methods. In line with this, the researchers would

use percentage and pareto analysis of the data.

1. Percentage will be used to determine the frequency counts and

percentage on the distribution of the non- conforming units in the

production

Formula:

% = (F/N) X 100

% is the percentage

F is the number of nonconforming units

N is the total number of products produced

100 a constant value

 35

2. Pareto Chart will be used to determine the frequency occurrence of the

number of defective units in the production. It will represent the highest

occurring type of defects.

Steps in making Pareto Chart:

1. Form an occurrence frequency as a percentage

2. Arrange the rows at the highest frequency in decreasing order.

3. Add cumulative column percentage to the table and then plot the

information.

4. Plot (#1) a curve with causes on x- and cumulative percentage.

5. Plot (#2) a bar graph with cause on x- and percent frequency on y-axis.

6. Draw a dotted horizontal line to intersect the curve at 80 percent from

the y axis. Then draw from the point of intersection to the x-axis a vertical

dotted line.

7. Review the chart explicitly to ensure that the cause is captured for at

least 80 percent of the issues.

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 APPENDIX A

Table 1. Defect Percentage

The column one indicates the different types of defects, column two is

the number of defects, column three is the percentage of defect and the column

four is the cumulative percentage of defects. The Long Band has the large

number of defects with the average number of 1808 which has a percentage of

30.51 percent, for the Not Caught the total number of defects is 1004, for the

Rebust Seam the total number of defects is 658, for the Skip the total number of

defects is 591, for the Loose the total number of defects is 334, for the defect
 43

Something Inside the total number of defects is 183, for the Folded the total

number of defects is 173, for the Short Band the total number of defects is 169,

for the Cracking the total number of defects is 158, for the Stain the total number

of defects is 152, for the Un-even the total number of defects is 144, for the Not-

Aligned the total number of defects is 116, for the Overlap the total number of

defects is 110, for the Drop the total number of defects is 110, for the High and

Low the total number of defects is 60, for the Unbalanced the total number of

defects is 58, for the Unsymmetrical the total number of defects is 50, for the

Missing Operation the total number of defects is 19, for the Puckering the total

number of defects is 13, for the Twisted the total number of defects is 10, for the

Wrong Label the total number of defects is 5, for the Overlay the total number of

defects is 1.
 APPENDIX B

First Transcript

Miss Rubis – Ahmmm.. nag start kami july 25, 2005… ang may-ari nito ay si Mr.

Regine Pastor, so kami ay subcontract ng metro index garment. So ang

ginagawa naming ay *** so kung nadoon na kayo sa production line bawal n’yo

picturan or pag nag-gawa kayo ng report hindi nyo pwede ilagay/banggitin yung

name nung product so gumamit kayo ng (BRAND X/BRAND Y) basta wag nyo

sasabihin yung name nung products. Pwede kayo magpicture let’s say na

malayuan na picture okey lang basta wag lang ifofocus kasi hindi pwede.

Pupwede naman halimbawa magpipicture kayo kasama yung workers para may

proof na nagpunta kayo sa company pwede yun. Basta yung individual na

ginagawa yung product mismo hindi pwede yun picturan. So usually yung mga IE

na pumupunta dito na katulad nyo na student…. Kasi kami sewing garments lang

kami e… hindi kami katulad nung iba na company na andito yung cutting, malaki

company yun kami sewing lang…

Mich – Ahh! So parang ano po.. parang yung mga raw materials po na dinadala

sa inyo ay tinatahi nyo lang ng tinatahi??

 45

Miss Rubis – YAH! YES! Oo tinatahi lang namin sya. Nacut na sya hindi sya dito

kinacut..

Mich – So bale ano po process? Kunwari po nabigay na yung mga raw materials

dun sa area. Ano po yung kada process?

Miss Rubi - Magstart tayo dun… First operation yung dulong makina so kasi

yan makikita mo LINE 1 & 2 hindi ibig sabihan nyan dalawang linya na sya.

Dalawang linya sya but yung output nya iisa kasi kumbaga yung isang line na ito

dagdag sya para kasi ang target mo (halimbawa ang target ko sa kanila is 50

bundles a day ang laman ng isang bundle is 50pcs so kung isang linya lang sya

at bawat operation ay iisang machine tapos ang quota mo ay 6 bundles lang

paano ka makaka50 bundles? So kailangan mong magdagdag. Kaya makikita

mo sya hanggang dun sa konti ng LINE 3 yan ay additional lang dun sa mga

bawat operation para mameet mo yung target.)

Kent - ahhh… okey po

Mich - bakit po wala pong laman yung po yung…..

Miss Rubis - so wala sya kasi nga isang ano lang yan… kumbaga idinadagdag

lang naming yan. Halimbawa malaki yung kailangan ko so kulang kung lilima

yung operator ko tapos ang output lang nila per day ay halimbawa 30 bundles

lang sila eh kailangan mo 50 so magaadditional kapa na dalawa pang machine

para mameet mo yung targe mo, so ganun sya. Kumbaga hindi na kasi kasya e

kung dun pa naming isisingit hindi na sya kakasya so nandun sya sa ibang line
 46

so isa lang output nyan pag ganun, mula sa likod sunod sunod na operation

hanggang sa makarating dito last operation.

Rina - Pareparehas lang po hanggang LINE 5?

Miss Rubis - iba naman line yun… parang 2 lines lang ako parang ganun

Mich - ah okey po… ano po yun kada product po.. nag iiba po? Kunwari po

nagkakatatlo line?

Miss Rubis - hindi ganan na sya kasi may target kami per month na haimbawa

target mo per month is 130,000pcs so by 50 you need 2,600 mga ganun.

Rina – Dun po sa ibang lines po iba na po ang supervisor?

Miss Rubis - oo, ang supervisor dito .. sewing supervisor ay dalawa tapos may

isa akong QC supervisor… tapos yung mga nakatayo na nagtitingin ng mga

reject meron tayong IPI ahMM… Inline inspector nagchecheck sa bawat

operation, umiikot sya para macheck nya time to time kung okey ba yung tahi ng

bawat isa so bukod dun na kailangan si sewer mismo chinecheck nya yung

quality at the same time may umiikot tapos dito sa harap ito yung end line.

Trimmer na yan tapos yung gitna na yun yung end line. Pagkatapos kay trimmer

pupunta na sa kanila yung finish products at 100 percent quality nila yun. After

100 percent, pwede mo na sya ideliver so kinukuha na sya dito nung nagbibigay

samin ng gawa.

Mich – Ano po kaya yung frequent problem na lagi nyo nararanasan?

Miss Rubis - Usually ang frequent problem na nararansan ay minsan hindi ko

mameet yung target “why” kasi laging may “why” kasi once na may umabsent
 47

sayo kulang kana sa tao mahihirapan kana kahit habulin mo sa OT dito sa ganito

production kasi ang hindi natin control ay absenteeism atsaka yung material

minsan kasi yung material na dumadatig galing sa kanila minsan may defect

kaya short sila sa issual hindi pa dumarating yung kanila deliver ng supplier nila

maSTOP kasi wala kami gamit.

Mich – Parang ang nagfoforcast po ng mga raw materials is sila po nag

papadala lang po ditto.

Miss Rubis - Oo nagpapadala sila dito tapos bibigyan ka nila ng projection mo

na eto na yung 6 months projection mo so icompute mo na kung ilan per day ang

dapat mo output para mameet mo yung 1 month yung nakaano sayo na 130,000.

Dun lang tayo nagkakaproblem sa delay ng accessories at sa absenteeism ng

tao kung hindi mo mahabol yung pagabsent nila kasi hindi mo macocontrol yung

pagabsent ng operators.

Rina – kayo na po yung last na pinupuntahan ng products na’to or after po nito

ay meron pa?

Miss Rubis – After nito babalik na sya sa nagbigay samin kasi ipapack pa nila

yan, after packing saka nila ishipment kay **** na nakapack na, pambenta na sya.

Mich – wala po kayo nagiging problem sa machine?

Miss Rubis - sa machines, kasi ang machine naming matanda pa sakin pero

kahit yan ganyan okey sya pinapaltan lang sya ng mga parts na nasisira.

Mich - ano po yun? May schedule po kayo ng maintenance nyo pp?

 48

Miss Rubis - may maintenance kami yung mekaniko naming meron syang

listahan after 3 months para icheck yung machine.

Mich – may nag conduct nap o ban g study ditto dati?

Miss Rubis – Marami pumunta dito na from other school tinitingnan nila yung

quota kumukuha sila ng quota

Mich - Nagbibigay naman po kayo ng data?

Miss Rubis – nagbibigay naman ako kasi si Mr. Pastor tumutulong talaga sya,

kasi gusto nya makatulong sa mga bata na nag-aaral. Kasi yung mga anak ng

mga workers dito nag-aaral din naman sila e minsan dito sila pumupunta so

pinapayagan naman ni Mr. Pastor basta ang lagi lang nya sinasabi wag na wag

Imention yung pinagkukuhan namin, okey lang na crisdeline pero yung products

wag nyo babanggitin na **** kasi si **** masyado exclusive kami nga bawal

gumawa ng iba product exclusive lang kami kaya von.

Mich - Subcontractor po ni ****. Bale po kung papayagan nyo po kami pumasok

dun sa production pwede po kami magVideo?

Miss Rubis - Vivideo nyo yung ano?

Mich - Hindi po as in directly, parang ano po…

Miss Rubis – halimbawa dito kayo sa harap ivivideo nyo sila pwede, pero yung

zoom-in hindi pwede

Mich – ahhh bawal po yung ivivideo yung pagwork nung tao.. ahh bawal po

Miss Rubis – Oo, kasi maano yung product eh, kasi kita yan sa kulay kung

paano yung operation na gingagwa ganun lang bawal. Halimbawa, basta

 49

magtetext muna kayo kung kelan kayo pupunta kasi minsan may surprise visit

kami sa subcontractor namin. So ayoko na makita nila na ganun.

Mich - sino po kaya pwede naming icontact pag pupunta kami?

Miss Rubis – 0933******* Magtext nalang muna kayo kung kelan kayo pupunta

kasi pag busy ako at naghahabol sa sewing ng delivery hindi ako nakakaasikaso

kasi syempre nadidistruct yung mga workers kasi syempre mapapatingin sila.

Mich – ano po yun kayo po mag bibigay ng sched?

Miss Rubis - hindi, magtext kayo (ma’am pwede po ba kami punta dyan sa

ganito araw…..) sasabihin ko kung pwede kung parehas tayo available

Researchers – Thank you po!