Faculty of Home Economics

Department of Clothing and Textiles

Innovating System for Decreasing Fabric Consumption

in Ready Made Garment Factories

By
Shady Ramadan Hassan
Master Degree in clothing &Textiles
Textile Major 2009

A Thesis Submitted to the

Faculty of Home Economics, Helwan University
Clothing and Textile Department
In partial Fulfillment of The Requirement for
The PHD Degree in Clothing &Textiles
Textile Major

Under The Supervision of

Prof .Dr . Seham Zaky Abdallah Moussa Prof . Dr.Ahmed Hossany Hattab Neagm
Professor of Textiles; Textile and clothing Dept. Professor of Apparel Manufacturing Technology:
Former Dean, Faculty of Home Economics Apparel Dept.
Helwan university, Former Chairman of the Faculty of Applied Art
promotion committee of professors and assistant Helwan University
professors

Faculty of Home Economic Helwan University

Cairo Egypt
2015
 Abstract

Researcher's Name: Shadi Ramadan Hassan Ibrahim

Research Title: "Innovating a System for Decreasing
Fabric Consumption in Ready Made Garment Factories".
Research Objectives:
Treatment deficiencies in the garment factories through an integrated
system to increase the capacity of factories, increasing their
competitiveness and improve design. The system contains a program
to improve (e.g. reduce) the consumption of fabrics per unit of
production at all .stage in process such as contracting for raw
materials, "screening fabrics and hiring even the packaging," . The
integrated system includes:

• Improve consumption fabrics with good planning.

• Development of an improved fabric inspection system and
production requirements using 4point system.
• To Raise the efficiency of the stores to keep appropriate on
of fabrics and accessories at all time by redesigning stores
commensurate with the type of fabric and measuring the
store’s ability to keep appropriate amounts of cloth to meet
production requirements.
• An Improved documentary cycle to give fabrics
consumption per unit of output and rebuild the documentary
cycle where necessary.
• Create or modify the training center "training programs" to
training members from each of the departments in the factory
to use the new system.
• To measure the yield of the final product and to compare the
costs of the new system with the old.
Methodology of the research
- Statistical Approach: collect the internal data to factories
(e.g. cost/ unit of production).
- Analytical Approach: Analysis of the work inside the
factory to identify deficiencies and then develop a plan for the
design of integrated treatment system

II
 - Experimental Approach: The experience of the proposed
system to the factories.
Tests:
- The application of the international "4 point” testing system
to examine the cloth to be used in the garment factories.
Search Tools: -
1. References and scientific journals.
2. Field visits to factories in order to collect data and turn it
into information for the development plan.
3. Data for the waste of cloth and accessories in order to
identify priorities for improvement.
4. Evaluating proposed solutions and measuring their
effectiveness.

Keywords:
Consumption - Fabrics - Knitting - Reduction- Ready - System

III
 Summary

Innovating a System for Decreasing Fabric

Consumption in Ready Made Garment Factories
The Ready Made Garment "RMG" industry is a very important industry
especially in developing Countries. The RMG industry is labor-Intensive
and the first step in the transfer from an agricultural to an industrial society.
The RMG in Egypt face a lot of problems especially weakness in the
technical staff and management systems. The weakness of management
systems is the main defect as this prevents improvement of executive,
administration and technical staff. Effective management system
support staff by providing the correct data at the right time and
determined the training needs to decrease defects and support
customer needs. Properly integrated system allows the company to
control depreciation and maintain good fabric of the vital problems
which affect the competitiveness use. This is important as fabric
represents 40% to 60% of the final cost of the product and any
problems in its use affect the competiveness of company.

Research questions:
• How effective is the common examination of the fabrics and
accessory production systems in garment factories?
• What are the sections and stages of the production most damaging
to fabrics and production requirements?
• What is the effectiveness of the documentary cycle to reduce the
consumption of fabrics?
• What is the percentage of fabric used in production that is wasted?
• What is the capacity of factory to mange fabric and accessories in
each away to reduce defects and consumption?

Research objectives:

To correct deficiencies in the garment factories through designing an

integrated system. This integrated system is to develop the capacity
of the factories in terms of competitiveness and design including a
program to reduce the consumption of fabrics at all, such as
contracting for raw materials, screening fabrics including screening
the fabrics, hiring and even the packaging.

IV
The integrated system includes:

• The provider of fabrics to RMG factories using good

planning the development of a fabric inspection system and
production requirements using the 4 point system shown
below:
1. Raising the efficiency of the stores to keep on the
track fabrics and accessories redesigning the stores
commensurate with the type of fabric. This means the
stores should have the ability to match amounts and
types of fabric with production requirements.
2. Improving the documentary cycle to help match stores
inventories with production requirements.
3. Create or modify the training center programs to train
members from each of the departments in the factory
in applying the new integrated systems.
4. To measure the yield of the final product and compare
the costs of the new system with the old.

Research Methodology:

- Statistical Approach: collect the internal data to factories

(e.g. cost/ unit of production).
- Analytical Approach: Analysis of the work inside the
factory to identify deficiencies and then develop a plan for the
design of integrated treatment system
- Experimental Approach: The experience of the proposed
system to the factories.
Tests:
- The application of the international "4 point” testing system
to examine the cloth to be used in the garment factories.
Search Tools: -
1. References and scientific journals.
2. Field visits to factories in order to collect data and turn it
into information for the development plan.
3. Data for the waste of cloth and accessories in order to
identify priorities for improvement.
4. Evaluating proposed solutions and measuring their
effectiveness.

V
The thesis is divided into seven chapters :
Chapter one:
This chapter contains the plan of the research: Introduction, problem
of the research, objective procedures including terms and limitations
of the research to gather with indicants of the relevant and applicable
methodology. The chapter also included a review of previous studies
both Arabic and foreign.

Previous studies can be divided into two gropes:

1. Includes direct studies e.g. management systems, Quality
and Production in RMG industry.
2. Includes covered undirected studies.

Chapter Two:
This Chapter discusses the theoretical framework of production
management systems.
To implement the proposed shadow system global production system
had to be examined, including the flexible production systems, lean
Manufacturing, the Toyota Production System TPS and its contents
from the optical tracking system Kanban manufacturing and Just-in –
time system.
Chapter Three:
This chapter discusses the global systems including quality
management of 6 Sigma and Continuous Improvement "keizen",
international standards of ISO 9001-2008 and Acceptable Quality
limit (AQL) system, the four points to check the fabric and quality
systems used in the garment industry of 0-7 traffic lights and samples
management random samples.

Chapter Four:
This chapter discusses international planning systems used in the
production process, such as the Materials Requirement planning
system ( MRP) and Enterprise Resource Planning systems ( ERPs)
together with supply chain management.

Chapter Five:

This chapter discusses the definition of the proposed shadow system

,together with shadow system procedures and how to achieve it
within the factory departments.

VI
Chapter six:

This chapter includes the results of study and application in all stages
of production of the proposed shadow system including methods of
calculating losses in the total weight through a combination of laws
and rates of change and losses in the total weight of the fabric during
dyeing and weaving process.

Chapter seven:

This chapter includes the results of analysis and recommendations.

VII