Outlines of Presentation

Introduction  The Pareto chart for showing the number of defect

and the cumulative percentage
 Aim and objectives
 The cause and effect diagram for solving the defect
Literature Review
 The bar chart for showing the defect reduce
Methodology flow Chart percentage between before using quality control tool
and after using quality control tool

 The operation process Layout of Lady Pencil Skirt in  The summary

Zhejiang Clothing Company Limited
 Conclusion
 The Check sheet for data collection  Future Plan
 Time schedule
 The histogram for knowing the hierarchical defect  Reference

2
 Introduction
The definition of quality improvement- to change or to get rid of parts
of the process that do not work well.

The steps in the quality improvement process

 List and prioritize improvement opportunities
 Define the improvement objectives
 Define the requirement
 Collect and organize data
 Select the root cause
 Generate the potential solutions
 Select the best solution
 Implement the solution and evaluate the result
 Continue to track
3
 The definition of quality management system

-a formalized system that documents processes, procedures, and

responsibilities for achieving quality policies and objectives.
The benefit of quality management system
 Meeting the customer requirement
 Defining, improving, and controlling processes
 Reducing waste
 Preventing mistakes
 Lowering costs
 Facilitating and identifying training opportunities
 Engaging staff
 Communicating a readiness to produce consistent results
4
Aim and Objectives
Aim
 To reduce the defect rate

Objectives
 Study the Statistical Process Control tools
 Collect the data in Zhejiang Clothing company limited
 Use the quality control methods to get the quality improvement of product

5
 Literature Review
No. Year Title Name of Remarks
Researchers
1 2015 Quality Management Prabir Aim is to standardize processes, adopt industry’s best practices, and
System improve straight through percentage (rework).
Implementation in Method- Quality Management System, Total Quality Management,, Six
Apparel Industry Sigma Quality Systems
Result- Fire-fighting environment in apparel factory and slow adaption of
best practices, make substance of Quality Management System difficult in
the apparel industry

2. 2016 Quality Management Syed Aim- Organization development through improved quality performance and
System Ehtesham client satisfaction by providing customer with high quality products and
Husain services
By improving the processes
Method – Quality Management System
Result- Improved flexibility, effectiveness and competitiveness
An organization can save a lot of precious time by avoiding wasted efforts
of the employees.

6
3. 2015 Quality Aemon Aim- To make sure that the customers get the best quality
management Saleem product and can attain the maximum utility from buying that
System in product.
Garment Method- Quality Management System
Industry Result- Ensuring efficiency and perfection in all processes
ranging from product design and development to selling and
after sales service.

4. 2019 Quality A.M Aim – to meet buyer requirements and improve its effectiveness
Management Amirul and efficiency on a continuous basis quality control and
System in Islam improvement.
Garments (Washim) Method- Quality Management System
Manufacturing Result- To the right path of quality goal , to keep standard of
export garments quality

7
5. 2019 Quality control Mazharul Aim- To maximize the production of goods within the specified
System in Islam Kiron tolerances correctly the first time.
garment industry To achieve a satisfactory design of the fabric or garment in
Quality control relation to the level of choice in design, styles, colours,
system in Apparel suitability of components and fitness of product for the market.
Industry. Quality Method- Quality control System, Plan-do-act-check
control system for To achieve a sati
Knitted Garment Result- The customer’s quality requirements can understand.
Industry Quality control department can organize and train.
The proper flow of quality requirements to the QC department
can ensure.
The Proper flow of quality requirements to the production
department can ensure.
6 2017 Quality Control Ahmad Aim-To Control quality to get better product
Manual of Naufal Method- Quality Control System, Quality Management System
Garments Adnan, Result- Increases the effectiveness of quality control by
Nurul Ain providing guidelines to the related parties
Arbaai

8
 Methodology
Quality improvement tools
 Seven simple tools can be used by any professional to ease the quality
improvement process.

The 7 basic quality tools are as follows

 Flow chart
 Histogram
 Cause- and-effect diagram
 Check sheet
 Scatter diagram
 Control Charts
 Pareto Charts
9
Methodology Flow Chart of Quality Improvement
Select the Production Line

Data Collection

Use the Histogram

Use the Pareto Chart

Use Cause and effect Diagram

Solve Improvement
Fig 1. Methodology Flow Chart of Quality Improvement 10
 Table 1. Operations at each stations in Zhejiang Tongli Clothing Company, Lady Pencil Skirt

Sr Stations Process Machine Type

1 1A Input deposit Manual
2 1B Numbering check Manual
3 1A= 5A Attach the back side Single Needle
4 3B=4A Press the back side for decking 0.1 Two Needle
5 2A Attach the front side of skirt Single Needle
6 2B Press the front side and back side for decking Single Needle

7 3A Ironing (Stitching the front side and back side for decking, ironing) Iron Machine
8 4B Folding the bottom head Single Needle
9 4A Ironing (Attaching the lateral side, Lining the inside, ironing) Iron machine
10 5B Affix the sharing, folding the placket, ironing Two Needle
11 6 A=6 B Attach the bottom share and Lining Single Needle
12 7B Over loop the attaching share and Lining 3 Pin Over loop
Piping the belt

11
 13 7A Close up the above of share and Lining Single Needle
14 8B= 8A Press the waistband for decking Two Needle
15 9B 10 A 10 B Attach the mold pattern for waistband
16 11A Ironing the waistband Iron machine
17 11 B Attach the lining 5 thread over lock
18 12 B Stitching the waistband for cutter 5 thread over lock
19 12 A Checking the Quality Control Manual
20 13 B Press the above of waistband for decking 0.1
21 17 A Attaching the waist band and the body Single Needle
22 13A Press the waistband for decking Two Needle
23 14A Hemline Single Needle
24 14 B Assembling the label Single Needle

Fig 2. The operation process Layout of Lady Pencil Skirt in Zhejiang Clothing Company
Limited
12
 Table 2. The Check sheet for Data Collection
(from 2.8.2020 to 11.8.2020) (for First Day 10) (defect categories of lady pencil skirt)
No Defect categories 1 2 3 4 5 6 7 8 9 10 Total
1 The Short and long placket is not equal 22 20 8 15 25 90
2 The head of belt ascend and descent 24 24
3 The hemline are size is not equal 24 24
4 The waistband thread fall apart 39 8 47
5 The full placket size is not get 43 43
6 The hemline joint clip 30 30
7 The oval turning wrong 10 10
8 The thread fall apart 6 6
9 The batiste arc is not equal 6 6
10 The hemline thread skip 1 16
6
11 The oval thread fall apart 1 8 21
3
12 The bottom v shape batiste loll out 1 10
0
13
13 The zipper side size is not equal 12 12
14 The waistband twisting 4
15 The waistband incline 5 5
16 Two needle thread fall apart 19 30 27 76
17 Attach the body and the waistband 8 8
contort
18 The extra placket loll out 15 15
Total Defects 70 82 50 22 39 24 21 42 45 52
Inspection 653 795 815 300 371 425 430 390 525 600
Passed 583 713 765 278 332 401 409 348 480 548
Defect Percentage 11% 10 6% 7% 11% 6% 5% 11% 9% 9%
%
Average Defect Percentage 9%

14
Fig 3 . The bar chart showing the defect percentage
15
Fig 4. The Histogram for knowing the hierarchical defect

15
 Table 3. The Calculation for drawing the Pareto Chart
No Defect categories Number of Shirt Percentage Cumulative %
of all shirt
1 The Short and long placket is not equal 90/447 20.13% 20.13%
2 The waistband thread fall apart 76 17.00% 37.13%
3 Two needle thread fall apart 47 10.51% 47.64
4 The full placket size is not get 43 9.62% 57.26%
5 The hemline joint clip 30 6.71% 63.97%
6 The head of belt ascend and descent 24 5.37% 69.34%
7 The hemline are size is not equal 24 5.37% 74.71%
8 The oval thread fall apart 21 4.69% 79.4%
9 The hemline thread skip 16 3.58% 82.98%
10 The extra placket loll out 15 3.36% 86.34%
11 The zipper side size is not equal 12 2.68% 89.02%

17
12 The bottom v shape batiste loll out 10 2.24% 91.26%
13 The oval turning wrong 10 2.24% 93.5%
14 Attach the body and the waistband contort 8 1.78% 95.28%
15 The batiste arc is not equal 6 1.34% 96.62%
16 The thread fall apart 6 1.34% 97.96%
17 The waistband head incline 5 1.12% 99.08%
18 The waistband twisting 4 .89% 100%

18
Fig 5. The Pareto Chart Showing the number of defect and the cumulative
percentage
19
 Man Power
Environment Method
Lack of skill
Insufficient Light Improper marker
Lack of Training
marking
Noisy Handling mistakes
Disturbance Irregular thread
Recklessness
stitching
The short and long
placket is not equal
Needle Type Fabric type
Needle Direction
Many fabric layer
High Speed
Machine Breakdown

Machine Material

Fig 6. The Cause and effect diagram for short and long placket is not equal
20
Environment Method Man Power
Lack of skill
Insufficient Light Improper folding
Lack of Training
Noisy Handling mistakes
Irregular thread stitching
Disturbance Recklessness
Two needle thread
Needle Type fall apart

Needle Direction
High Speed Fabric type
Machine error

Machine Material

Fig 7. The Cause and effect diagram for two needle thread fall apart

21
 Table 4 .The Check sheet for Data Collection
(from 2.8.2020 to 11.8.2020 defect categories of lady pencil skirt)
No Defect categories 1 2 3 4 5 6 7 8 9 10 Total
1 Press the placket for decking 20 20
2 The head of belt ascend and descent 7 7
3 The waistband thread fall apart 7 5 3 15
4 The Short and long placket is not equal 6 2 3 2 13
5 The extra bottom placket loll out 9 9
6 The hemline thread skip 9 9
7 The two needle thread fall apart 8 8
8 The bottom placket loll out 10 10
9 The hemline thread fall apart 9 9
10 The head of belt incline 3 3
11 The placket thread fall apart 5 7 12
12 The Waistband twisting 9 7 3 19
13 The hemline joint clip 9 5 14

22
14 The head of belt size is not equal 12
15 The hemline arc size is not equal 3 3
16 Press the waistband for decking 4 4
17 The bottom batiste loll out 9 9
18 The Straight hemline thread 3 3
19 Press the placket for decking 7 7
20 The inside belt arc is not equal 4 4
Total Defects 34 20 14 30 17 18 22 16 10 9
Inspection 700 648 540 725 650 718 600 400 525 630
Passed 666 628 526 695 633 700 578 384 515 621
Defect Percentage 5% 3% 3% 4% 3% 3% 4% 4% 2% 1%

Average defect percentage 3%

The defect reduce rate after using 9-3=6%

quality control tools

23
Fig 8. The bar chart showing the defect percentage

24
 The Histogram for knowing the hierarchical defect
25

20
20 19

15
15 14
13
12 12
Number of defect

10
10 9 9 9 9
8
7 7

5 4 4
3 3 3

Defect Categories

Fig 9. The Histogram for knowing the hierarchical defect

25
 Table 5. The Calculation for drawing the Pareto Chart
No Defect categories Number of Shirt Percentage Cumulative %
of all shirt
1 Press the placket for decking 20/190 10.53% 10.53%
2 The Waistband twisting 19 10% 20.53%
3 The waistband thread fall apart 15 7.89% 28.42%
4 The hemline joint clip 14 7.37% 35.79%
5 The Short and long placket is not equal 13 6.84% 42.63%
6 The head of belt size is not equal 12 6.32% 48.95%
7 The placket thread fall apart 12 6.32% 55.27%
8 The bottom placket loll out 10 5.26% 60.53%
9 The hemline thread fall apart 9 4.73% 65.26%
10 The hemline thread skip 9 4.73% 69.99%
11 The extra bottom placket loll out 9 4.73% 74.72%

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12 The bottom batiste loll out 9 4.73% 79.45%
13 The two needle thread fall apart 8 4.21% 83.66%
14 Press the placket for decking 7 3.68% 87.34%
15 The head of belt ascend and descent 7 3.68% 91.02%
16 The inside belt arc is not equal 4 2.11% 93.13%
17 Press the waistband for decking 4 2.11% 95.24%
18 The Straight hemline thread 3 1.58% 96.82%
19 The hemline arc size is not equal 3 1.58% 98.4%
20 The head of belt incline 3 1.58% 100%

27
Fig 10. The Pareto Chart Showing the number of defect and the cumulative percentage
28
Environment Method Man Power
Lack of skill
Insufficient Light Improper pressing
Lack of Training
Noisy
Unsure pressing
Improper
Disturbance material Recklessness
handling
Press the placket for
decking (The sewing
Needle Direction line is not flexible)
High Speed
Machine Breakdown Fabric type

Needle Type

Machine Material

Fig 11. The Cause and effect diagram for Press the placket for decking
29
 Method Man Power
Environment Improper material Lack of skill
Insufficient Light handling Lack of Training
Noisy Irregular thread tension Handling mistakes
Disturbance Improper putting Recklessness
Improper ironing The waistband
twisting
Needle Type
Needle Direction Fabric type
High Speed
Machine error Many fabric layer

Machine setting

Machine Material

Fig 12. The Cause and effect diagram for the waistband twisting
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 Table 6. The Check sheet for Data Collection
(from 2.8.2020 to 11.8.2020) (for third Day 10) (defect categories of lady pencil skirt)
No Defect categories 1 2 3 4 5 6 7 8 9 10 Total
1 The Short and long placket is not equal 2 1 3
2 The bottom batiste loll out 5 5
3 The Waistband twisting 3 3
4 The inside waistband arc is not equal 6 6
5 The inside lining bag 5 5
6 Press the waistband for decking 7 7
7 The lip batiste is not equal 5 2 7
8 The hemline joint clip 2 1 3
9 The Two needle thread fall apart 1 1
10 The batiste arc is not equal 4 4
11 The hemline thread clip 3 3
12 The head of belt ascend and descent 4 4

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13 The hemline arc size is not equal 2 2
14 The zipper size is not equal 5 5
15 The hemline arc size is not equal 3 3
16 The full placket size is not get 4 4
Total Defects 7 9 12 5 3 6 7 7 4 4
Inspection 615 700 738 600 565 570 720 635 725 615
Passed 608 691 726 595 562 564 713 628 721 611
Defect Percentage 1% 1% 2% 1% 1% 1% 1% 1% 1% 1%

Average Defect Percentage 1%

32
Fig 13. The bar chart showing the defect percentage
33
Before Using Quality control tools

Average defect percentage for first 10 days= 9%

After Using Quality control tools (e.g. Histogram, Pareto chart, Cause and effect diagram)

Average defect percentage for second 10 days= 3%

The reduce defect percentage after using quality control tools= 9-3= 6%

After Using Quality control tools (e.g. Histogram, Pareto chart, Cause and effect diagram)

Average defect percentage for third 10 days= 1%

The reduce defect percentage after using quality control tools= 3-1= 2%

34
Fig 14. The bar chart showing the defect reduce percentage between
before using quality control tool and after using quality control tool
35
 Summary
The data in each factory are collected.
The production process layout of Lady Pencil Skirt in Zhejiang Tongli
Clothing company limited is drawn.
 The Data Collection is made by using the quality control technique (Check
sheet).
The Histogram diagram is drawn for knowing the hierarchical defect
The Pareto chart is drawn for determining the priorities of problem
solving.
The cause and effect diagram is drawn for solving the defects.
The defect can reduce significantly after using the quality control tools.
So The quality of Product is improved.

36
 Future Plan
Collect the data in two factories
Check the defects of other products in two factories
Reduce the defect rate
Make to develop the Quality Management System

37
 Time Schedule
2019 2020 2021
Activities
Months Months Month
10  11   12  1  2  3  4 5  6  7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
   
 
                 
1. Literature Review for proposal  
Proposal   Done
 
2. Studying the factory location background                  
and methodology that use in the factory.  Title  Done
 
3. Collect the data and calculation for quality                     second
improvement     first Done progress
4. Studying the proposed method and                    
collecting data    
                   
5. Calculation for the quality improvement
  Third
  Fourth
6. Calculation for the quality improvement
ICSE
7. ICSE paper fifth
8. Apply the various QC method
9. Apply the various quality improvement
six
method
10. Result Analysis seven
11. Thesis Book Submission Pre-defense
12. Overall
13. Overall
defense

38
 References
[1] Prabir, “Quality Management System Implementation in Apparel Industry” International Society
Organization 15 June- 2015
[2]Syed Ehtesham Husain, “Quality Management Systems” , A commercial Mall at Khobar, Saudi Arabia
View Project, March 2016

[3] Aemon Saleem, “Quality management System in Garment Industry” International Journal of Quality
Management System, June 2015

[4] A.M Amiral Islam, “Quality Management System in Garments Manufacturing”, International Journal of
Quality Management System”, June 2015

39
[5] Mazhural Islam Kiron, “Quality control System in garment industry Quality
Control System in Apparel Industry. Quality Control System for Knitted Garment
Industry” International Journal of Industrial engineering, 2019

[6] Ahmad Naufal Adnan, Nurul Ain Arbaai, “Quality Control Manual
Garment”, “http:// ordnur.com” 2017

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41