Zero Defect In Mayfair

Garment Factory
Hilary Yue/Julia

May 31, 2023

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Content
• Factory Project Committee
• 3 Years Dashboard Summary
• Mayfair Garment Ltd. - ZD TREND
• Mayfair Garment Ltd. - TOP DEFECTS
• Mayfair Garment Ltd. - KPI UPDATE – MTD2023
• Challenges & Benefits
• Human Approach
• Machine Automation
• Data Mining - Quality ERP System
• Material Controlling
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 Factory Project Committee
Mayfair Garment Ltd.
GMP : 93.17% (A)

Hilary Yue
Project Lead – Hong Kong office
hilary.ck.yue@ap-group.com

Julia Dong Xiang Long

Harry
He Bin Production Manager Factory QA Manager IE Manager
Factory Manager harry.xh.vu@may-fair.vn qa.mgr@may-fair.vn
Project Support Project Support
Project Support Project Lead

Nam Nguyen
qa@may-fair.vn
Data Entry

Project Calendar
7/2021 – 4/2023 8/2023 – 10/2023 11/2023 – Onward
3 Lines ( # 05/21/23) Pilot 2 more lines Applied total 5 lines
Mayfair Ltd.
 3 Years Dashboard Summary

Average OQL %
Years Cutting Inline EOL Kanban Pre final Final
1.45
1.08% %
Target 2.00% 3.00% 2.00% 1.50% 1.50% 1.50% 1.17%

2021 1.76% 3.49% 3.32% 0.94% 0.91% 0.32% 0.86%

2022 1.16% 3.58% 3.74% 0.68% 1.75% 1.47% 3.39%

2023 1.43% 3.09% 3.40% 0.96% 0.86% 1.45% 3.49%

Average 1.45% 3.39% 3.49% 0.86% 1.17% 1.08%

Cutting Inline EOL

Kanban Pre final Final

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 Mayfair Garment Ltd. - ZD TREND

Cutting Inline Endline

Kanban Final
Pre-Final
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 Mayfair Garment Ltd. - TOP DEFECTS

INLINE ENDLINE
60.00% 56.52% 60.00%

50.00% 50.97%
50.00% 48.75%
47.22%
42.52%
39.13% 40.00%
40.00% 41.11% 36.87% 36.14%
35.67%
34.78% 30.00% 31.50%
32.11% 33.70% 28.12%
30.00% 26.09% 26.25%
25.79%
28.95% 22.56%
25.64% 20.00% 14.64%
12.50%
20.00% 21.74% 8.64% 9.92%
10.00%
11.11% 15.22% 5.48% 2.36%
3.16%
10.00% 10.00% 8.70% 0.00% 0.78% 0.00% 0.00%
6.67% Feb-23 Mar-23 Apr-23 May-2023 May-2023
week 1 week 2
0.00% 0.00% 0.53% 1.09%
0.00% 0.00% 0.00%
Feb-23 Mar-23 Apr-23 May-2023 May-2023
week 1 week 2 G02 - Asymmetrical features
E04 - Seam or thread twist, roping, puckering, pleated
G02 - Asymmetrical features E04 - Seam or thread twist, roping, puckering, pleated F04 - Soiling, grease or dirty marks/ stains
F04 - Soiling, grease or dirty marks/ stains E01 - Stiching defect, missing or positioning E01 - Stiching defect, missing or positioning
E09 - Crooked stitch or inconsistent E09 - Crooked stitch or inconsistent

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 Mayfair Garment Ltd. - KPI UPDATE – MTD2023

Rolled Throughput Yield_RTY% First Time Yield _ FTY Outgoing Quality Level - OQL%
94% 94% 99.8%
100% 92% 94% 94% 100.0%
98.8% 98.5% 1400000 1247246 2.00%
90% 99.0% 98.3% 98.3% 1.82%
1.80%
80% 97.7% 1200000
98.0% 1.60%
70% 97.0% 1000000 1.40%
60% 96.0% 800000 1.20%
50% 1.14% 1.00%
95.0%
40%
600000 0.80%
94.0%
30% 94.0% 400000 0.60%
93.0%
20% 0.40%
92.0% 200000 69210
10% 0% 0.20%
0% 0% 0% 0% 0% 0% 0% 91.0% 0 0.00%
0% 90.0% Baseline ZD Lines
Base- Jan- Feb- Mar- Apr- May- Jun- Jul- Aug- Sep- Oct- Nov- Dec-
line 23 23 23 23 23 23 23 23 23 23 23 23

RTY Linear (RTY) FTY Linear (FTY) Units Shipped OQL

COQ Efficiency Garment Rejection

120% 0.06%
$386.70
95% 97% 97%
$316.60 100%
82% 84%
78%
80% 0.04%
0.04%
$235.05 60%
$225.56
$176.84 $109.59 40%

20% 0.02%
0.01%
0%
Base- Jan- Feb- Mar- Apr- May- Jun- Jul-23 Aug- Sep- Oct- Nov- Dec- Base Jan- Feb- Mar- Apr- May- Jun- Jul- Aug- Sep- Oct- Nov- Dec-
line 23 23 23 23 23 23 23 23 23 23 23 line 23 23 23 23 23 23 23 23 23 23 23 23
0.00%
COQ Actual Efficiency Linear (Actual Efficiency) Baseline 7
ZD Lines
Challenges & Benefits
*** Challenges
- No previous experience to
follow
- Lot of try and error
- Questioning on KPI
- Too many theories
- Difficulty in collecting data.
- Lack of quality mindset
(not fully understand about
0 defect -> not enough
motivation, not enough
attention)
- Standard debate.
*** Benefits
- Understand on quality and how to perform
qualified product
- Can see a fully picture about quality level at
factory.
- Improved about analyst data skill and using
chart and diagram.
- Have experience to run project (planning,
prepare for production, analysis risk/issue and
find out solution, improving team work skill)
- Invest equipment and systems to easy control
and update data.
- Reduce rework and cost to raise the efficiency.
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Human Approach
• Carry PDCA cycle
• Understand the brand and product by
- Online shopping
- Mind set of customer not producer
- Set up qualified productivity bonus system
- Assign individual responsibility on job performance
- Benefit to all of us – win / win solution
- Enhance QA manpower

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Machine Automation

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Data Mining - Quality ERP System
Speed Garment System – Software Version

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Quality ERP System
Speed Garment System – Web Version

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Quality ERP System
Speed Garment System – Mobile Version

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Material Controlling
• Carry material inspected calibration to suppliers
• Set up know-how library
• Enhance material controlling by region
• Set up on site material inspection team in Vietnam
• Sharing material issue to PVH QA team

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Thank You !

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