Project

REDUCTION OF DHU USING SQC TOOLS

SSAL UNIT-4 , CHOKKAHALLI , HOSKOTE, BENGALURU

ARDRA S
BFT/18/371
NIFT BENGALURU
Reduction of DHU aross parts using SQC tools.

• Analysing the DHU report of parts for the last 3 months to know the most occuring defects.

• With the help of pareto chart finding the top 5 defects.

• Picking 5 top defects per part and analysing the root cause.

• Making a cause and effect diagram ( Fish Bone Diagram).

• Suggesting solutions.
 Defects of each part in the month of April.

FRONT : Bottom open 141

Button cross 60
Button hole down 10
Button hole miss 45
Button measurement out
20
Button miss 374
Button up & down 20
Center lineout 50
Color thread 356
Dust 15
Feeding out 20
Hem loose stitch 60
Notch center out 85
Placket cross 30
Placket looseness 487
Placket measurement out
20
Placket miss 25
Placket shapeout 87
Raw edge 10
Skip stitch 346
Variation 22
Pareto Chart -

Top 5 defects
Placket looseness 487
Button miss 374
Color thread 356
Skip stitch 346
Bottom open 141
 Back down stitch 5
Back Part - Face up wrong 35
Fit label center out 16
Fit label piping 25
Fit label stitch open 15
Fit label wrong 35
Label patch raw edge 110
M/L & fit label cross 90
M/L piping 25
M/L raw edge 15
M/L size jump 15
M/L wrong 35
Placket line out 60
S/L miss 219
S/L size jump 30
S/L wrong 10
Size label miss 34
Skip stitch 10
Slit miss 20
Yoke feeding out 57
Yoke puckering 20
Pareto Chart -
Top 5 defects
S/L miss 219
Label patch raw edge 110
M/L & fit label cross 90
Placket line out 60
Yoke feeding out 57
Sleeve -
Big placket piping 26
Big placket shade 38
Button cross 30
Button hole miss 42
Button hole skip 160
Button lock 354
Button miss 406
Button stitch minus 25
Button stitch open 20
Dog hopuse shape out 10
Dog house piping 11
Placket down stitch 15
Placket shade 10
Pleat miss 206
Tab button cross 20
Tab button miss 5
Tab miss 53
Tab ulta 10
Pareto Chart
Top 5 defects

Button miss 406

Button lock 354
Pleat miss 206
Button hole skip 160
Tab miss 53
Collar -

Band hem width uneven

5
Band top down 5
Band top raw edge 5
Collar pleat 35
Collar to band shade 75
Collar top piping 10
Collar up & down55
Fusing fold 10
Label centerout 125
Marking center out 20
Marking miss 175
Pick up & down 20
Stitch skip 40
Tape attaching uneven 5
Tape damage 10
Trimming uneven250
Pareto Chart
Top 5 defects
Trimming uneven250
Marking miss 175
Label centerout 125
Collar to band shade 75
Collar up & down55
Cuff -

Button attaching wrong32

Button cross 100
Button hole miss 53
Button miss 168
Button up & down 213
Button wrong 80
Iron down 5
Iron piping 40
Nose 5
Top piping 20
Pareto Chart
Top 5 defects
Button up & down 213
Button miss 168
Button cross 100
Button wrong 80
Button hole miss 53
Defects of each part in the month of May.
Button hole miss 58
Button lock 64
Button measurement out 60
Front - Button miss 70
Center lineout 230
Flap center out 175
Flap skip stitch 30
Flap stitch uneven 105
Flap top stitch uneven 35
Folding uneven 218
Hem loose stitch 30
Inside lineout 60
Label wrong 28
Notch center out 100
Placket cross 86
Placket downstitch 15
Placket lineout 56
Placket measurement out 153
Placket miss 20
Placket shade 30
Placket shapeout 30
Skip stitch 10
Spare button miss 45
Top line out 20
Top stitch uneven 50
Variation 80
Washing 10
Pareto Chart
Top 5 defects

Centerline out 230

Folding uneven 218
Flap centerout 175
Placket measurement out
153
Flap stitch uneven 105
Back - Back pleat down stitch 29
Center out 4
Fit label wrong 14
Face up wrong 10
Fit label center out 65
Fit label stitch open 4
Label patch raw edge 20
Label patch shade 30
M/L raw edge 25
M/L size jump 5
M/L wrong 29
S/L measurement out 50
S/L miss 138
Serial wrong 30
Side pleat measurement out
40
Side pleat ulta 20
Size label wrong 29
Stitch open 4
Yoke feeding out 39
Yoke to back shade 34
Yoke top stitch 39
Pareto Chart
Top 5 defects
S/L miss 138
F/L centerout 65
S/L measurement out 50
Side pleat measurement out
40
Yoke feeding out 39
Sleeve -
Big placket down stitch40
Big placket miss 25
Button cross 90
Button hole miss 39
Button miss 205
Button stitch open 45
Dog house shape out 90
Dog house measurement out
30
Pick open 5
Placket down stitch 20
Placket margin out 10
Placket measurement out
35
Placket shape out 6
Pleat miss 15
Sleeve to placket lineout
75
Pareto Chart
Top 5 defects
Button miss 205
Button cross 90
D/H shape out 90
Sleeve to placket lineout
75
Button stitch open 45
Collar -

Band hem width uneven

30
Band puckering 20
Band top down 15
Band top raw edge 10
Button cross 10
Button stitch minus 20
Collar top skip 10
Collar up & down52
Marking miss 145
Pick open 27
Pick shape out 218
Pick skip stitch 15
Pick stitch open 5
Trimming uneven135
Pareto Chart -
Top 5 defects
Pick shape out 218
Marking miss 145
Trimming uneven135
Collar up & down 52
Band hem width uneven
30
Cuff -
Button attaching wrong35
Button hole miss 40
Button miss 49
Button stitch miss 20
Button up & down 80
Cuff line out 10
Embroidery damage 3
Iron down 193
Iron piping 15
Iron uneven 20
Nose 110
Piping 5
Shape out 10
Stitch down 10
Tape gap uneven40
Top down stitch 20
Top inside thread10
Top piping 40
Trimming uneven20
• Cuff -
Top 5 defects
Iron down 193
Nose 110
Button up & down 80
Button miss 49
Tape gap uneven40
Button hole miss 40
Defects of each part in the month of June.

Front - Front serial wrong 27 Button hole missing 27

Incomplete flap stitch 29 Button loose 42
Misbalance pocket 39 Button missing 161
Placket measurement out 159 Button placement wrong85
Button stitch open/missing 104
Pocket back tack miss 46
Center line measurement out 53
Pocket box uneven 46 Flap cross 48
Pocket Centerline out 19 Flap raw edge 28
Pocket top stitch uneven 65 Flap top stitch uneven 71
Pocket flap ulta 39 Pocket slant/cross 161
Pocket line mismatching94 Pocket hem width uneven 128
Pocket piping 63 Pocket raw edges 241
Pocket shape out 407
Thread missing 20
Pocket stitch skip 30
Shade variation 90 Right hem loose66
Flap raw edge 28 Damage 5
Back tack missing 120 Flap line out 35
Button up & down 138 Line mismatch 155
Button cross 60 Piping 69
Placket Down 76
Placket feed going out 65
Placket Variation 170
Skip stitch 308
Stitch uneven 177
Variation 152
Pareto Chart
Top 5 Defects
Pocket Shape Out 407
Skip stitch 308
Pocket Raw edges 241
Button missing 161
Placket measurement out
159
Back -

SIL centerout 18
Label placement out 13 SIL miss 43
Label slant/cross 403 SIL wrong 9
Label stitch open 50 Size jump 60
Label wrong 28 Stitch open 35
Line mismatch 66 Uncut thread 20
Loop measurement out 11 wrong thread 10
MIL ulta 4 Yoke down stitch 82
MiIL wrong 5 Yoke faceup wrong 71
Misbalance 46 Yoke Fitting out 411
Notch missing & over notch 40 Yoke lineout 50
Piping 18 Yoke puckering 10
Piping at Yoke attach 12 Yoke shade variation 10
Pleat downstitch 13 Yoke shape out 47
Pleat notch mismatched 3 Yoke size wrong 5
Pleat width uneven 33 Yoke top stitch looseness 4
Yoke top stitch width uneven 4
Yoke top stitch skip 13
Pareto Chart

Top 5 defects
Yoke fitting out 411
Label slant/cross 403
Yoke down stitch 82
Yoke faceup wrong 71
Line mismatch 66
Sleeve -

Dog house measurement out 40

Dog house shape uneven, raw edges 303
Dog house stitch & piping 304
Incomplete stitch 31
Inner ply visible 16
Notch missing/Over notch 32
Placket downstitch 35
Placket stitchout 34
Pleat measurement wrong 201
Pleat missing 216
Shade variation 15
Sleeve pairing wrong 20
Button hole lock 130
Button hole missing 28
Button lock 85
Button missing 235
Button stitch open 124
Dog house height uneven/slant 92
Dog house line down 15
Dog house measurement out 31
• Sleeve -
Top 5 defects
Dog house stitch & piping
304
Dog house shape uneven, raw
edges 303
Button missing 235
Pleat missing 216
Pleat measurement wrong
201
Collar-

Band top width uneven 23

Button hole missing 83
Collar band puckering 16
Collar band centerout 61
Collar band hem open 38
Collar band loose stitch 20
Collar band puckering 89
Collar patch uneven 4
Collar pick shape off 190
Collar pick up down 216
Collar tape gap uneven 11
Collar top pleat/piping wrong 56
Collar top stitch uneven 53
Collar up down 5
Damage 30
Face up wrong 116
Line mismatch 47
Marker missing 167
Shade variation 72
Skip stitch 24
Trimming uneven 455
Width measurement wrong 6
Pareto Chart
Top 5 defects
Trimming uneven455
Collar pick up down 216
Collar pick shape off 190
Marker missing 167
Face up wrong 116
Cuff-
Button hole missing 5
Button measurement out 30
Button miss 17
Button stitch minus 107
Button up & down 38
Cuff hem width uneven 21
Cuff serial wrong 24
Cuff up & down 11
Embroidery finishing 25
Incomplete stitch 18
Inner ply visible 15
Iron nose 5
Misbalance 7
Paring wrong 7
Shape out 5
Top piping 44
Top stitch minus5
Top uneven 5
Trimming uneven 172
• Cuff -
Top 5 defects
Trimming uneven172
Button stitch minus 107
Top piping 44
Button up & down 38
Button measurement out
30
Top 5 defects of each part from analysing the data of past 3 months.

Placket looseness 487

Button miss 535
Color thread 356
Skip stitch 654
Bottom open 141
Centerline out 230
Folding uneven 218
Flap centerout 175
Placket measurement out 312
Flap stitch uneven 105
Pocket Shape Out 407
Pocket Raw edges 241
Pareto Chart

Top 5 defects of Front part

Skip stitch 654
Button miss 535
Placket looseness 487
Pocket shape out 407
Placket measurement out
312
Back -
S/L miss 357
Label patch raw edge 110
Placket line out 60
Yoke feeding out 507
F/L centerout 65
S/L measurement out 50
Side pleat measurement out 40
Label slant/cross 493
Yoke down stitch 82
Yoke faceup wrong 71
Line mismatch 66
Pareto Chart
Top 5 defects of Back part
Yoke feeding out 507
Label slant/cross 403
S/L miss 357
Label patch raw edge 110
Yoke down stitch 82
Sleeve -
Button miss 846
Button lock 354
Pleat miss 422
Button hole skip 160
Tab miss 53
Button cross 90
D/H shape out 90
Sleeve to placket lineout 75
Button stitch open 45
Dog house stitch & piping 304
Dog house shape uneven, raw edges 303
Pleat measurement wrong 201
Pareto Chart

Top 5 defects in Sleeve part

Button miss 846
Pleat miss 422
Button lock 354
D/H stitch & piping 304
D/H shape uneven, raw edge 303
Collar -

Trimming uneven 840

Marking miss 487
Label centerout 125
Collar to band shade 75
Collar up & down 107
Pick shape out 408
Band hem width uneven 30
Collar pick up down 216
Face up wrong 116
Pareto Chart
Top 5 defects of Collar
Trimming uneven840
Marking miss 487
Pick shape out 218
Collar pick up down 216
Collar pick shape off 190
Cuff -

Button up & down 336

Button miss 217
Button cross 100
Button wrong 80
Button hole miss 53
Iron down 193
Nose 110
Tape gap uneven, button hole miss 40
Trimming uneven 172
Button stitch minus 107
Top piping 44
Button measurement out 30
• Cuff -
Top 5 defects of Cuff part
Bottom up & down 336
Button miss 217
Iron down 193
Trimming Uneven 172
Nose 110
Top 5 Defects from Parts

Sleeve Button miss 846

Trimming uneven collar
840
Skip stitch (Front part) 654
Yoke feeding out 507
Marking miss 487
 Man handling
Machine

Missing out on bundle/cut pcs

Button miss
Unraveling of thread

Low quality thread

Method Material
 Man handling
Machine

Careless handling of cut pcs Old blade in machine

Collar trimming uneven

Method Material
 Man handling
Machine

Wrong threading

Skip stitch

Old/ bend needle

Method Material
 Man handling
Machine

Feeding into the folder Machine setting

Yoke feeding out

Method Material
 Man handling
Machine

Missing out on bundle/cut pcs

Marking Miss

Method Material
Point Allocation based Quality checking

• Self-defect checking by operators.

• Training for operators on quality and quality checking.
• Quality Circle - comprising operators who do the same process led by supervisor or the most
skilled/experienced operator. Meeting everyday morning to discuss on defects and how can it
be reduced.
• PAS Card & Incentive
Date No of defects committed No of defects found

1/8/21

. . .
. . .
. . .
. . .
. . .
Total defects committed
Total defects found
Net defects committed
How PAS card works :

• PAS card for all operators.

• If an operator found a defect which was done in a previous operation, they should report it to
the supervisor.

• Supervisor will give operator 1 token for each defect which are found and also marks under
the defects committed box in the PAS card of the operator who made the defect.

• Supervisors at the end of the day goes to the operators who received the token/tokens and
write the total of defects found and also defect committed in the PAS card of operators.

• At the end of the month, total defect committed and total defects found are calculated.

• Net defects was found by subtracting Total defects found from Total defects committed and
incentives for operator(s) with least Net defects.
• Operators concentrate more on their work and try hard to reduce the defects they are causing.

• To get more net defects they inspect the pcs for any defects caused by other operators and also
self-check so that they won’t cause any defect.

• As operators act as the quality checkers, the no of quality checkers can be reduced.( Cost saving)

• These quality checkers can be trained to be sewing operators.

• It takes less time as the defect is found by the operator and alters it then and there. Might
reduce the productivity of operator but reduce the waste of cost and time in alteration.

• Effective training program needed for implementation.

Operation Cycle time in sec(Before) Average With allowance MIN Conversion Capacity Difference
17.1
17.42
17.56
Yoke attach 17.47833333 20.10008333 0.34 179.10
17.76
17.54
17.49
Cycle time in sec (After) 46.72
23.76
23.42
23.49
Yoke attach 23.64666667 27.19366667 0.45 132.38
23.73
23.5
23.98
Yoke attach Self- checking
 Operation Cycle time in sec(Before) Average With allowance MIN Conversion Capacity Difference
7.08
6.97
6.77
Button attach 6.701666667 7.706916667 0.13 467.11
6.98
6.11
6.3
Cycle time in sec (After) 31.83
7.35
7.42
7.05
Button attach 7.191666667 8.270416667 0.14 435.29
7.16
7.06
7.11
Button attach self- checking before bundling
Operation Cycle time in sec(Before) Average With allowance MIN Conversion Capacity Difference
2.66
2.45
Marking in 2.61
2.838333333 3.264083333 0.05 1102.91
collar 3.09
2.81
3.41
Cycle time in sec (After) 779.80
9.4
9.77
Marking in 9.53
9.688333333 11.14158333 0.19 323.11
collar 9.82
9.99
9.62
Before-
Marking in collar self checking pc by pc
Operation Cycle time in sec(Before) Average With allowance MIN Conversion Capacity Difference
8.9
9.32
Trimming of 8.62
9.356666667 10.76016667 0.18 334.57
collar 9.84
9.78
9.68
Cycle time in sec (After) 34.96
10.48
10.95
Trimming of 10.2
10.44833333 12.01558333 0.20 299.61
collar 10.14
10.48
10.44
Before
After - Trimming self- checking
 Conclusion

• Instructed the operators to do self-checking and made sure they are aware of how to do it.

• They were not following it when no one is around to check on them.

• It takes time to implement this, as the operators tend to use the old ways.

• Operators who are really skilled and fast in their process can be trained on this as their
productivity won’t affect the self-checking much.
THANK YOU