EXECUTIVE SUMMARY
SCM Garments Private Limited forayed into the textile industry in 1989 at Tirupur. Initially established to cater to the increased demands of the export market, today, we are a vibrant presence in the hosiery map of India.
The study was carried out in Unit I of SCM garments with of 100 sewing machines, 20 ironing machines, and 20 cutting persons. Both manual and machine cutting is carried out in this unit. The company is producing 1500-2000 pieces per day. Defect occurrence is one of the main risks faced by them and it may occur by both machine and operator fault. In this situation, identifying the frequently occurring defects in the garment is highly important so as to minimize their occurrence.
The study has been conducted for around 45 days. In this study 20 orders were analyzed thoroughly. Defective pieces and the types of defects are been identified in these 20 orders. Analyses are made with the data and defects percentage is identified. Reasons for the defects are found out and analyzed during the study. This study is an effort to reduce the defects in the production process.
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If a company can bring down the defects in production process, then the company production rate increases with high profitability. The defect percentage is more than the acceptable norms of the company for defects margin, in order to rectify or ignore it, this project study is done.
The initial step in this research is a systematic study in the production department to identify the defects. The collected data have been classified and tabulated. Simple tables have been prepared and liberally used to exhibit the classified data to provide easy and better understanding of the study.
The frequently occurring defects and the defects which are contributing more in the total percentage of defects are identified by categorization analysis and chi-square analysis. The most occurring defects in the garments are found to be skipped stitch, oil stain and ADAS (holes in the garment). The major reasons for occurrence of these defects are improper tension in the disk, repetitive usage of machines, improper handling of the garment and needle fault.
It is suggested that the company can concentrate on these defects mainly and technically some suggestions are given to bring down the defects. This will pay way for increasing the level of productivity and save the time.
CHAPTER-1 INTRODUCTION 1.1 INTRODUCTION
The textile industry has unique place in the Indian economy. Its contribution to industrial production, employment and earnings is very significant. It is one of the oldest industries established 125 years ago. Since then the industry has made tremendous progress, despite the early struggles to survive competition from abroad.
In keeping pace with the trend in advanced countries of the world, the Indian textile industry progressed in many directions in the use of various fibers for fabric production and employed different techniques of production such as weaving and knitting. Today, the textile industry has emerged as a multi-fiber industry employing cotton and cellulosic and synthetic fibers to produce both knitted and woven fabrics.
The apparel sector plays a vital role in textile industry and mainly exports play an important role in the global business. There are many countries in the playground of apparel exports such as China, India, Bangladesh, SriLanka, Pakistan, Europe, Korea, Turkey, Thailand, Hong Kong, Vietnam, Nepal, Taiwan, Australia, Syria, Italy, USA, and Brazil. There are 2 types of garments in apparel sector. One is Woven garments. Another is Knitted garments.
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For every industry or business, to get increased sales and better name amongst consumers and fellow companies it is important to maintain a level of quality. Especially businesses engaged in export have to sustain a high level of quality to ensure better business globally. Generally quality control standards for export are set strictly, as this business also holds the prestige of the country, whose company is doing the export.
The major challenges which are being faced by all countries apparel exporters is to bring effective solution to increase quality of product in the apparel manufacturing. Quality is keyhole for global competition. Also having prime importance for every industry or business, to get increased sales and better name amongst consumers and fellow companies. For apparel industry product quality and productivities are calculated right from the initial stage of raw material to the stage of finished garment. The quality control of garment industry is normally depends on raw material, employee, machinery of the company.
For a garment exporter there are many strategies and rules that are required to be followed to achieve good business. The fabric quality, product quality, delivery, price, packaging and presentation are some of the many aspects that need to be taken care of in garment export business.
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Apparel manufacturing comprises a variety of product categories and when it is analyzed, the central process in the manufacturing is the joining together of components, which is the labor intensive part of this type of manufacturing known as the sewing process, where most of the defects occur in the garment.
Further more when the cost structure is analyzed, apart from material cost, the cost structure of sewing process is of critical importance and the cost of poor quality will also include with this. Every time work is redone, the cost of quality increases. In the apparel industry, reworking of the garment, retesting of performance of the apparel, rebuilding of garment machine, all these are done when the defect occurs.
Defect minimization aims to reduce and minimize the number of defects and errors in a process and to do things right from the first stage. The ultimate aim is to reduce the level of defects. However, this may not be possible in practice but what it means is that everything possible will be done to eliminate the likelihood of errors or defects occurring. The overall effect of this project is to identify and reduce the defects which lead to reduce the time and increase the productivity.
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1.2 COMPANY PROFILE This section discusses about the history and profile SCM garments Pvt. Ltd to provide insights so that the suggestion made in the study can be related in a better manner.
HISTORY: SCM Garments Private Limited forayed into the textile industry in 1989 at Tirupur. Initially established to cater to the increased demands of the export market, today, they are a vibrant presence in the hosiery map of India.
In these 2-decade long presences in the textile industry, they have seamlessly transcended time to establish themselves as a company with a global vision. The company represents their group abroad, a role that they fulfill with utmost responsibility, and will continue to do so.
The company has always adopted a process of continuous up gradation of the technology and processes. Its dedicated team of researchers and designers constantly keeps in touch with the current trends in the market place and the consumers requirements. The approach has lead to various technological innovations resulting in new product introduction.
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SCM Garments Pvt. Ltd. is promoted by eminent men of vision and foresight. At the help of the affairs Mr. K.Paramasivan as Chairman and HR manager Mr. Sekar .SCM has created brands that have made marketing history. What is more they managed it in a category, which was dominated by the unorganized sector with unbranded products.
SCM Garments Pvt. Ltd is one of the world’s largest knitted garment manufacturer and marketers commanding an impressive annual growth rate. It has to its credit six regional offices, three production bases, and state of the art technology right from developing cotton to making garments.
All this plus an extensive distribution set up spanning the length, breadth of the country. The company through its dedicated research team constantly keeps in with current trends in the market place & the consumers. This approach has let to various technological innovations resulting in new product introduction/extensions.
MANUFACTURING UNITS The company has manufacturing units at Tirupur, Avinashi, Erode, Coimbatore (all in Tamilnadu), and has around 25 production units, in all.
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MANUFACTURING FACILITIES SCM garments have its manufacturing facilities located at Tamilnadu. Their spinning division facilitates the production of the finest combed cotton yarn. While 50% of the facility is dedicated to manufacturing heavier count yarns like 30s, 34s & 40s, the remaining 50% produces finer yarn of counts 60s & 80s. With 28 combing machines, 45 ring frames and 20 Auto Coner machines, the spinning unit is well suited to handle huge loads. The use of organic cotton and imported machines help them give the quality of the yarn as desired by the buyers.
EXPORTING COUNTRIES Through the years, they have been associated with renowned brands and retail stores in Europe, USA, Canada, and France.
AWARDS This company is compliant with AQL 2.5 Level Quality & Standards and follows a 4 point system to ensure conformance of rigorous norms. The ISO 9001:2000, WRAP, Oeko TEX Class 1 & 2 and CU certification for Organic Cotton are testimonials to our commitment and compliance to global standards.
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VISION To deliver innovation and quality to their customers by following a progressive and on time approach and further the cause of a sustainable future by promoting an eco friendly approach in all our operations.
MISSION STATEMENT “Join Hands Together, To Become an International Symbol of Excellence through Continuous Innovation, Manpower Development, Productivity Improvement, Quality Improvement, Cost Reduction, Time Management”
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1.3 NEED FOR THE STUDY The company is facing risk in the occurrence of defects in the garments. Identifying the frequently occurring defects in the garment is highly important and also they have to be minimized.
1.4 OBJECTIVES OF THE STUDY The objective of the study is to study the frequency of the occurrence of defects. To explore the causes for the defects and to find out the possible ways for eliminating those defects.
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1.5 SCOPE OF THE STUDY
The study has been conducted in SCM garments during June and July month of 2010 to identify the reasons for the defects and suggest the remedies to the defects in the production process. The study will help the organization to avoid the defects in the garment and to save time.
1.6 LIMITATIONS OF THE STUDY The project was conducted for a company operating in export and domestic market. The study will not show the complete picture of apparel industry rather it will be confined to a single company only. The project was restricted for 2 months.
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CHAPTER - 2 RESEARCH METHODOLOGY
Data collection is a decisive step in the Research Process and this is the descriptive type of research. The first hand data needed for this study was obtained from the production department of the company for the standard acceptable percentage of defects in the garments. The details about the types of defects are collected from by the analysis and from the supervisors. 2.1 DATA COLLECTION The initial step in this research is a systematical study and concepts and its different tools and techniques, after that the production unit study has done to identify the current state of processes and activities happening in the unit. The next step is to analyze the defects in the garment as per the order and implementing reduction technique and tools to reduce and avoid the defects. Primary data source: Primary data sources are originated by the researches for specific purpose of addressing the problem at hand and it sought for their proximity to their truth and control over error. The primary data sources are •
Observation
•
Interaction with company manager and line supervisors.
The study is carried out for nearly 45 days and 23 orders have been executed in these time period. 20 orders were taken into study, as for 3 orders sufficient information and data was not available.
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2.2. TOOLS USED Percentage analysis is used to categorize the defects according to its percentage and chi-square test has been to compare the style wise defects margin.
2.3 PRESENTATION AND INTERPRETATION OF DATA The collected data have been classified and tabulated. Simple tables have been prepared and liberally used to exhibit the classified data to provide easy and better understanding of the study.
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CHAPTER-3 THEORY OVERVIEW 3.1 ABOUT THE PROCESS There are nearly 450 employees in Unit I and it comprises of 10 lines where 8001000 pieces are produced in one line per day. There are 8 buyers for whom the orders are carried out in a constant manner. And 8 teams of merchandisers handle these 8 buyers.
SEQUENCE OF OPERATION FIGURE 3.1 Cutting
Production
Random checking
Final checking
Packing
Dispatching
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The sequence of operation of the production department starts from the pattern making, continued with pattern layout. Once pattern layout has been done, Cutting process will be started according to the style of the garment. Next is the sewing process, were all the parts of the garments are attached. Then the sewed garments will be randomly checked by the line supervisors. After the random checking, final checking will be carried out by the inspection department and directly the garments will be taken to the packing department. Once the packing is fully completed as per the buyer’s requirement. Then it will be directly taken for dispatching.
3.2 PRODUCTION DEPARTMENT There are various styles of garments being produced in the sewing process. Of which the process flow of a particular garment is shown below
PROCESS FLOW OF A T-SHIRT PRODUCTION SEWING LINE Fig.3.2
COLLAR STITCH
SHOULDER ATTACH
PLACKET OPEN
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PLACKET FINISH
COLLAR ATTACH
SLEEVE ATTACH
SLEEVE TOP STITCH
SLEEVE HEM
SIDE ATTACH
BOTTOM HEM
In the production process of T-Shirt, the first step is to stitch the collar. Next operation is joining the shoulder with the body part. The placket will be made in the front for the opening and fasteners. The collar is attached to the neck of the T-shirt. The right and left sleeves are attached to the respective armholes. The top stitch and the hemming in the bottom is done for sleeves. The side seam of the T-shirt is stitched and the hem is done, by this the T-shirt will be produced.
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CHAPTER -4 ANALYSIS AND INTERPRETATION
For the purpose of analyzing the frequency of every defect in the production process
20 ORDERS were taken into study. The total number of pieces produced under this 20 orders were – 1,68,956 pieces The table of defects-4.1 shows the •
Types of defects
•
Defective Pieces and number of defects
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4.1. TABLE OF DEFECTS
This is the primary data collected from the company by analysis and the table shows the types of defects which occur in the garment in 20 orders and number of defective pieces and the frequency of occurrence are also shown.
OVERALL LIST OF DEFECTS TABLE 4.1 TYPES OF DEFCTS
NO. OF DEFECTS
DEFECTIVE PIECES
S.NO
DESCRIPTION
CODE
NO.
%
NO
%
1.
Skipped stitches in flat lock m/c
D1
3319
21.3
1220
12.7
2.
Misalignment of collar
D2
141
0.9
0
0.0
3.
Pattern stripes mismatched
D3
367
2.4
84
0.9
4.
Pocket box size variation
D4
211
1.4
122
1.3
5.
Label mismatched
D5
210
1.4
103
1.1
6.
ADAS (holes in garment)
D6
1069
6.9
356
3.7
7.
Oil Strains
D7
1976
12.7
724
7.5
8.
Uneven stitch
D8
538
3.5
43
0.4
9.
Bottom edge stitching irregular
D9
326
2.1
50
0.5
10.
More threads joining in one place
D10
477
3.1
112
1.2
Table 4.1 continued
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11.
Improper sleeve attachment
D11
231
1.5
32
0.3
12.
Improper ruffle attachment
D12
105
0.7
0
0.0
13.
Collar point mismatched
D13
239
1.5
84
0.9
14.
Raw edges outside
D14
952
6.1
216
2.2
15.
Misplacing the scrap in the garment
D15
83
0.5
31
0.3
16.
Yoke piece unevenly attached
D16
555
3.6
141
1.5
17.
Neck rib measurement changed
D17
340
2.2
0
0.0
18.
Puckering in the attachment
D18
858
5.5
241
2.5
19.
Mismatching of stripes
D19
673
4.3
165
1.7
20.
Printing defect
D20
137
0.9
81
0.8
21.
Seam
D21
771
4.9
251
twisted
gives
puckering
2.6
appearance 22.
Over pressing leads to unshaped of
D22
131
0.8
116 1.2
the garment 23.
Breakage of stitch
D23
628
4.0
146
1.5
24.
Un stiff button holes
D24
78
0.5
30
0.3
25.
Uneven length in the placket
D25
231
1.5
0
0.0
26.
Uneven stitch formation in the
D26
167
1.1
25 0.3
placket box 27.
Improper belt width
D27
281
1.8
87
0.9
28.
D1&D2
-
-
68
0.7
29.
D1&D4
-
-
89
0.9
Table 4.1 continued
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30.
D1&D6
-
-
205
2.1
31.
D1&D7
-
-
287
3.0
32.
D1&D9
-
-
62
0.6
33.
D1&D10
-
-
172
1.8
34.
D1&D12
-
-
38
0.4
35.
D1&D14
-
-
183
1.9
36.
D1&D18
-
-
46
0.5
37.
D1&D19
-
-
64
0.7
38.
D1&D21
-
-
146
1.5
39.
D1&D23
-
-
251
2.6
40.
D1&D25
-
-
142
1.5
41.
D1&D27
-
-
42
0.4
42.
D1&D6&D7
-
-
62
0.6
43.
D1&D7&D8
-
-
230
2.4
44.
D1&D6&D10
-
-
12
0.1
45.
D2&D5
-
-
73
0.8
46.
D3&D18
-
-
251
2.6
47.
D3&D16
-
-
32
0.3
48.
D5&D7&D13
-
-
34
0.4
49.
D6&D7
-
-
128
1.3
50.
D6&D10
-
-
92
1.0
Table 4.1 continued
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51.
D6&D14
-
-
76
0.8
52.
D6&D22
-
-
15
0.2
53.
D6&D19
-
-
123
1.3
54.
D7&D8
-
-
169
1.8
55.
D7&D11
-
-
132
1.4
56.
D7&D13
-
-
121
1.3
57.
D7&D20
-
-
56
0.6
58.
D7&D10
-
-
89
0.9
59.
D8&D21
-
-
96
1.0
60.
D9&D27
-
-
152
1.6
61.
D9&D18
-
-
34
0.4
62.
D9&D19
-
-
28
0.3
63.
D11&D12
-
-
67
0.7
64.
D14&D17
-
-
232
2.4
65.
D14&D16
-
-
192
2.0
66.
D14&D18
-
-
53
0.6
67.
D15&D17
-
-
52
0.5
68.
D16&D17
-
-
56
0.6
69.
D16&D18
-
-
134
1.4
70.
D18&D21
-
-
18
0.2
71.
D18&D19
-
-
33
0.3
Table 4.1 continued
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72.
D18&D24
-
-
48
0.5
73.
D19&D21
-
-
260
2.7
74.
D23&D25
-
-
89
0.9
75.
D23&D26
-
-
142
1.5
TOTAL
15094
100
9636
100
[Calculations furnished in annexure –table1&2]
This table shows the types of defects in the garment. There are 27 type of defects listed in the table with its code. These defects occur solely and also in combinations with the other defect. The combinations are also shown in the table which is mentioned in code. Number of defects and the defective pieces for every defect and also for combinations are shown separately with its percentage. Each piece in 20 orders is checked and the total number of defective pieces was 9636 pieces (which is around 5.7%) Out of these 9636 pieces, there were 27 types of defects occurring. And in this 9636 pieces number of defects occurs is around 15094 in the garments. The standard acceptable norms adopted in the company for defects margin is 3% The occurrence of defects is more than the standard norms. So the analysis is carried out to find the frequently occurring defects in the garments.
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4.2 COMPARITIVE ANALYSIS OF TOP 5 DEFECTS OUT OF TOTAL DEFECTS -
FREQUENCY OF DEFECTS & DEFECTIVE PIECES
The comparative analysis is done between the frequency of defects and the defective pieces. The defects are ranked on the basis of both and first 5 ranks are taken for the comparison as this contributes more from the total percentage.
4.2.1. FIRST 5 RANKS OF FREQUENCY OF DEFECTS This table shows the first 5 ranks of frequency of defects
FIRST 5 RANKS OF FREQUENCY OF DEFECTS TABLE 4.2
S.NO 1.
DEFECTS
NO.OF.DEFECTS
PERCENTAGE
3319
21.3
Skipped stitches in flat lock m/c
2.
Oil stains
1976
12.7
3.
ADAS (holes in the
1069
6.9
garment) 4.
Raw edges outside
952
6.1
5.
Puckering in the
858
5.5
attachment
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INTERPRETATION: These 27 defects have been occurred 15094 times in 9636 pieces individually and also in combinations, in which skipped stitch is the most occurring defect occurs around 3319 times, which is of 21.3% of total occurrence. The defect oil stains comes second in the rank which occurs around 1976 times, which is of 12.7% of the total occurrence. The defect ADAS (holes in the garment) occurs around 1069 times, which is of 6.9% of total occurrence. The defect raw edges outside occurs around 952 times, which is of 6.1%of total occurrence. The defect puckering in the attachment occurs around 858 times, which is of 5.5% of total occurrence. [For ranking please refer annexure, table 3].
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4.2.2. FIRST 5 RANKS OF DEFECTIVE PIECES This table shows the first 5 ranks of defective pieces
FIRST 5 RANKS OF DEFECTIVE PIECES TABLE 4.3 S.NO
DEFECTS
DEFECTIVE
PERCENTAGE
PEICES 1.
Skipped stitch
1220
12.7
2.
Oil stains
724
7.5
3.
ADAS
356
3.7
4.
Combination of Skipped & Oil stitch
287
3.0
5.
Combination of Mismatched stripes &
260
2.7
Seam Twisted
INTERPRETATION
The defect “SKIPPED STITCH” occurs comparatively higher than the other kinds of defects when analyzed individually. It has occurred in about 1220 pieces out of 9636 total defective pieces, which comes around 12.6% in the entire defects.
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The defect “OIL STAINS” comes second in the rank which is about 724 pieces out of 9636 total defective pieces, and it comes around 7.5% in the entire defects. The defect “ADAS” comes third in the rank which is about 356 pieces out of 9636 total defective pieces, and it comes around 3.6%. The combination of SKIPPED STITCH and OIL STAINS comes 4TH, which is about 287 pieces out of 9636 defective pieces, and it comes around 3%. The combination of defects “MISMATCHIN OF STRIPES” and “SEAM TWISTED” come 5TH which is about 260 pieces out of 9636 defective pieces, which comes around 2.7%. [for ranking please refer annexure, table 4].
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4.2.3 COMPARING FIRST 3 RANKS OF DEFECTIVE PIECES & ITS FREQUENCY From the table 4.2 and 4.3, it is seen that the top 3 defects are same in both defective pieces and its occurrence. This table shows the first 3 ranks of defective pieces and its frequency of occurrence.
FIRST 3 RANKS OF DEFECTIVE PIECES & ITS FREQUENCY TABLE 4.4 RANK
DEFECTS NAME
DEFECTIVE
DEFECTS
FREQUENCY (NO OF TIMES)
PIECES 1.
Skipped stitch
1220
Skipped stitches
3319
2.
Oil stains
724
Oil stains
1976
3.
ADAS
356
ADAS
1069
TOTAL
2300
6364
PERCENTAGE
23.86%
42.16%
INTERPRETATION Based on the defective pieces, these 3 defects contribute about 23. 8% and based on the frequency of occurrence it contributes about 42.16%.
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4.3 CATEGORIZING THE DEFECTS BASED ON ITS PERCENTAGE The total defects are categorized based on its percentage to the total occurrence and defective pieces. By which the defects are being segregated as follows:
4.3.1
CATEGORY A (above 7% of defects)
Under category A the defects based on defective pieces and their frequencies of occurrence which are more than the 7% are shown.
CATEGORY ‘A’ OF DEFECTS TABLE 4.5
S.NO BASED ON OCCURRENCE
DEFECTS
NO.OF.DEFECTS
PERCENTAGE
1.
Skipped Stitches
3319
21.3
2.
Oil Stains
1976
12.7
DEFECTIVE
PERCENTAGE
OF DEFECTS
S.NO
DEFECTS
PIECES
BASED ON DEFECTIVE PIECES
1.
Skipped Stitches
1220
12.7
2.
Oil Stains
724
7.5
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4.3.2
CATEGORY B (Between 3 – 7% of defects)
Under category B, the defects based on defective pieces and its frequency of occurrence which lies between 3-7% is shown.
CATEGORY ‘B’ OF DEFECTS TABLE 4.6 S.NO
DEFECTS
NO.OF.
PERCENTAGE
DEFECTS
1.
Skipped Stitches
1069
6.9
2.
Raw edges outside
952
6.1
3.
Seam twisted gives puckering
771
4.9
BASED ON OCCURRENCE
appearance OF DEFECTS
4.
Mismatching of stripes
673
4.3
5.
Breakage of stitch
628
4.0
6.
Yoke piece unevenly attached
555
3.6
7.
Uneven stitch
538
3.5
8.
More threads joining in one
477
3.1
DEFECTIVE
PERCENTAGE
place BASED ON
S.NO
DEFECTS
PIECES
DEFECTIVE PIECES
1.
ADAS (holes in garment)
356
3.7
2.
Combination of Skipped &
287
3.0
Oil stitch
27
4.3.3
CATEGORY C (Below 3% of defects)
The other defects from the Ranking of Defects table will come under the Category C.
INTERPRETATION
•
From the above categorization we can see that the Category A has more than 7% defects.
•
Also, from Category B, it has a defects range of 3 – 7%.
The Category A contributes about 34% of the total defects based on the number of defects. The Category B contributes about 44% of the total defects based on number of defects. By eliminating the total defects category A & B, we can reduce about 78% of the total defects and bring down the total defects rate below the standard acceptable norms of the company i.e. below 3%.
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4.4 CHI – SQUARE ANALYSIS FOR STYLE WISE DEFECTS MARGIN The chi-square analysis is carried out to compare the actual and expected data. In this the average percentage of defects among the styles and percentage of defect s of each style are compared and chi-square analysis is done to know the significant difference among the styles in occurrence of defects.
For this analysis null hypothesis and alternative hypothesis is formed. Null Hypothesis: There is no significant difference among the different styles. (H0) Alternate Hypothesis: There is significant difference among the different styles. (H1)
STYLE WISE DEFECTIVE PIECES TABLE 4.7 S.NO
STYLE
TOTAL
DEFECTIVE PERCENTAGE
QTY
PIECES
1.
Gangelo polo
8520
512
6%
2.
Babies top
3603
187
5%
3.
Ladies top
17566
1152
6.5%
4.
Night wear
6408
372
5.8%
5.
Girl’s frill top
8500
508
5.9%
6.
Men’s polo t-shirt
8040
446
5.5%
7.
Babies top
10806
703
6.5%
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8.
Babies top with stripes
13935
836
6%
9.
Babies top with rib
8970
522
5.8%
10.
Boy’s stripes polo t-shirt
7670
404
5.2%
11.
Ladies top
12288
693
5.6%
12.
Babies top
4500
234
5.2%
13.
Girl’s top
5800
302
5.2%
14.
Babies top
2575
132
5.1%
15.
Babies top
12992
656
5%
16.
Ladies top
10224
542
5.3%
17.
Men’s polo t-shirt
3660
188
5.1%
18.
Babies top
13824
732
5.2%
19.
Babies bottom
6500
377
5.8%
20.
Babies top with stripes
2575
138
5.3%
168956
9636
AVG:5.5%
TOTAL
Assuming α = 0.05. This means that when α = 0.05, we will be making an error of rejecting the null hypothesis when in fact it is true, 5% of the time. α = 0.05 and df= (k-1) =20-1=19. The computed value of X2 =0.29 is less than the critical value of X2 =10.117; we cannot reject the null hypothesis.
30
INTERPRETATION Based on chi-square analysis of style wise defects, there was no significant difference between the no. of defects among each style. Irrespective of all styles the defect percentage is same. Nearly 5 to 6% of defects are occurring in each style. [Calculations furnished in annexure-5]
31
CHAPTER-5 FINDINGS AND SUGGESTIONS
5.1 FINDINGS
•
The 3 defects Skipped stitches, Oil stains, ADAS, contribute more in the total percentage of defects. (4.2)
•
The skipped stitch and oil stains contribute about 34% of the total defects based on the number of defects. (Category A, 4.3)
•
The Skipped Stitches, Raw edges outside, Seam twisted gives puckering appearance, Mismatching of stripes, Breakage of stitch, Yoke piece unevenly attached, Uneven stitch, More threads joining in one place, these defects contributes about 44% of the total defects based on number of defects. (Category B, 4.3)
•
Irrespective of all styles the defect percentage is same. Nearly 5 to 6% of defects are occurring in each style. (4.4)
The most occurring defects in the garments are analyzed and percentage of that is interpreted and those defects are skipped stitch, oil stain and ADAS (holes in the garment).
32
There are some of the reasons for the occurrence of these defects in the garment.
REASONS FOR SKIPPED STITCH Improper threading in the sewing machine Tension in the disc is improper Repetitive usage of machines causing friction in the parts REASONS FOR OIL STAINS The availability of oil for the machine is quite high which left unnoticed and this ultimately leads to oil stain in the garments. Improper handling of the garments REASONS FOR ADAS (holes in the garment) Trimming fault Needle breakage
33
5.2 SUGGESTIONS
Currently the total defects margin is around 5.7% of the entire production. If we can cut down the top 3 defects from the entire process it can bring down the total defects under Standard acceptable defects margin. The total defects margin will come down to 2.7%, which is below the Standard acceptable defects margin i.e. 3%.
By eliminating the total defects category A & B, we can reduce about 78% of the total defects and bring down the total defects rate below the standard acceptable norms of the company i.e. below 3%. For eliminating the following suggestions are given.
•
For machineries and equipments continuous assessment and maintenance is needed.
•
The technician can be appointed and he must keenly check the threads, needle, and tension of the machine frequently according to the fabric texture.
•
The machines should be cleaned and maintained by that technician frequently.
34
5.3 CONCLUSION
From this study, the most occurring defects and its frequency of occurrence have been identified. It is suggested that the company can concentrate on these defects mainly and take steps to bring down and this will pay way for increasing the level of productivity and save the time.
35
3. RANKING OF DEFECTS BASED ON ITS OCCURENCE TABLE.3
S.NO
DEFECTS
NO.OF.DEFECTS
PERCENTAGE
1.
D1
3319
21.3
2.
D7
1976
12.7
3.
D6
1069
6.9
4.
D14
952
6.1
5.
D18
858
5.5
6.
D21
771
4.9
7.
D19
673
4.3
8.
D23
628
4.0
9.
D16
555
3.6
10.
D8
538
3.5
11.
D10
477
3.1
12.
D3
367
2.4
13.
D17
340
2.2
14.
D9
326
2.1
15.
D27
281
1.8
16.
D13
239
1.5
17.
D11
231
1.5
18.
D25
231
1.5
19.
D4
211
1.4
20.
D5
210
1.4
21.
D26
167
1.1
22.
D2
141
0.9
23.
D20
137
0.9
24.
D22
131
0.8
25.
D12
105
0.7
26.
D15
83
0.5
27.
D24
78
0.5
TOTAL
15094
100
4. RANKING OF DEFECTIVE PIECES TABLE.4 S.NO
DEFECTS
DEFECTIVE
PERCENTAGE
PEICES 1.
D1
1220
12.7
2.
D7
724
7.5
3.
D6
356
3.7
4.
D7,D1
287
3.0
5.
D21,D19
260
2.7
6.
D21
251
2.6
7.
D18,D3
251
2.6
8.
D1,D23
251
2.6
9.
D18
241
2.5
10.
D14,D17
232
2.4
11.
D1,D7,D8
230
2.4
12.
D14
216
2.2
13.
D6,D1
205
2.1
14.
D16,D14
192
2.0
15.
D14,D1
183
1.9
16.
D10,D1
172
1.8
17.
D7,D8
169
1.8
18.
D19
165
1.7
19.
D9,D27
152
1.6
20.
D23
146
1.5
21.
D1,D21
146
1.5
22.
D1,D25
142
1.5
23.
D26,D23
142
1.5
24.
D16
141
1.5
25.
D18,D16
134
1.4
26.
D11,D7
132
1.4
27.
D6,D7
128
1.3
28.
D19,D6
123
1.3
29.
D4
122
1.3
30.
D13,D7
121
1.3
31.
D22
116
1.2
32.
D10
112
1.2
33.
D5
103
1.1
34.
D21,D8
96
1.0
35.
D6,D10
92
1.0
36.
D1,D4
89
0.9
37.
D7,D10
89
0.9
38.
D25,D23
89
0.9
39.
D27
87
0.9
40.
D3
84
0.9
41.
D13
84
0.9
42.
D20
81
0.8
43.
D14,D6
76
0.8
44.
D5,D2
73
0.8
45.
D1,D2
68
0.7
46.
D12,D11
67
0.7
47..
D1,D19
64
0.7
48.
D6,D7,D1
62
0.6
49.
D1,D9
62
0.6
50.
16,17
56
0.6
51..
D20,D7
56
0.6
52.
D14,D18
53
0.6
53.
D17,D15
52
0.5
54.
D9
50
0.5
55.
D24,D18
48
0.5
56.
D1,D18
46
0.5
57..
D8
43
0.4
58.
D1,D27
42
0.4
59.
D12,D1
38
0.4
60.
D7,D5,D13
34
0.4
61..
D9,D18
34
0.4
62.
D18,D19
33
0.3
63.
D11
32
0.3
64.
D16,D3
32
0.3
65.
D15
31
0.3
66..
D24
30
0.3
67.
D19,D9
28
0.3
68.
D26
25
0.3
69.
D18,D21
18
0.2
70.
D22,D6
15
0.2
71.
D1,D6,D10
12
0.1
72.
D2
0
0.0
73.
D12
0
0.0
74.
D17
0
0.0
75.
D25
0
0.0
TOTAL
9636
100.0
5. CHI – SQUARE ANALYSIS FOR STYLE WISE DEFECTS MARGIN
Step – 1: Null Hypothesis:
There is no significant difference among the different styles.
(H0) Alternate Hypothesis:
There is significant difference among the different styles.
(H1)
Step – 2: Assume α = 0.05. This is the probability of making the Type I error. This means that when α = 0.05, we will be making an error of rejecting the null hypothesis when in fact it is true, 5% of the time.
Step – 3: Calculate the expected frequency fe, for each category.
Step – 4: In our case, X2 test is selected because we are comparing observed frequencies with expected frequencies in discrete categories. X2 test measures the discrepancy between the observed values and expected values for decision making purpose about the null hypothesis, so that:
X2 = ∑ (fo – fe) 2 fe
X2= {(6-5.5)/5.5)}+ {(5-5.5)/5.5)}+ {(6.5-5.5)/5.5)}+ {(5.8-5.5)/5.5)}+ {(5.9-5.5)/5.5)}+ {(5.5-5.5)/5.5)}+ {(6.5-5.5)/5.5)}+ {(6-5.5)/5.5)}+ {(5.8-5.5)/5.5)}+ {(5.2-5.5)/5.5)}+ {(5.65.5)/5.5)}+ {(5.2-5.5)/5.5)}+ {(5.2-5.5)/5.5)}+ {(5.1-5.5)/5.5)}+ {(5-5.5)/5.5)}+ {(5.35.5)/5.5)}+ {(5.1-5.5)/5.5)}+ {(5.2-5.5)/5.5)}+ {(5.8-5.5)/5.5)}+ {(5.3-5.5)/5.5)} =
0.09-0.09+0.18+0.05+0.07+0+0.18+0.09+0.05-0.05+0.018-0.05-0.05-0.07-0.09-
0.03-0.07-0.05+0.05-0.03 =0.298
Step 5: Check the critical value of X2 from the table against α = 0.05 and df= (k-1) =201=19. This value is given as 10.117. We compare our computed value of X2 with the critical value of X2 from the table. Since our computed value of X2 =0.29 is less than the critical value of X2 =10.117, we cannot reject the null hypothesis.
BIBLIOGRAPHY
BOOKS 1. Title of the book
: “STATISTICS for business & economics”
Author
: Jit S Chandan
Publications
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2. Title of the book
: “RESEARCH METHODOLOGY METHODS & TECHNIQUES”
Author
: C.R. Kothari
Publications
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3. Title of the book
: “MANAGING QUALITY IN THE APPAREL INDUSTRY”
Author
: Pradip V. Mehta, Satish K. Bhardwaj
Publications
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4. Title of the book
: “INDIAN TEXTILES-An intersectoral perspective”
Author
: Vinod Shanbhag, S.S. Mehta
Publications
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WEBSITES •
www.scmgarments.com
•
www.economywatch.com
•
www.fabrics-manufacturers.com
•
www.fiber2fashion.com
