Abstract: As Readymade Garments sector is a large industrial sector in Banglades
ID: 397914 • Letter: A
Question
Abstract:
As Readymade Garments sector is a large industrial sector in Bangladesh, quality improvement can play a vital role for improving productivity as well as economic development for the country. This paper represents a detail investigation on quality improvement of a garment factory by applying Pareto Analysis and Cause Effect Diagram. The aim of this study is to minimize defects that will reduce rework and rejection rate. Our studied organization is “Rainbow Apparel Limited”. In this organization we worked in a particular section (i.e. sewing section) for a particular product (i.e. woven pants). Four months defect data has been collected from the management and Pareto Analysis is performed on them. From this analysis 6 top defect positions are identified where 78.56% defects occur. On those top positions further Pareto Analysis is performed to identify the top defect types. That resulted in total 115 concerning areas where 71.40% defects occur, which should be the major concerning areas to reduce defect percentage. So hierarchies of causes for individual defect types are organized and Cause Effect Diagrams are constructed for those defect types. Then relative suggestions to those causes are also provided.In the end necessary clues and recommendations have been added for the advancement of the study Keywords: Defects, Parito Analysis, Root Cause, Parito Analysis, Quality I.Introduction The garment industry has played a pioneering role in the development of industrial sector of Bangladesh. Though it started in late 1970s but it soon established its reputation in the world market within a short span of time. Resultantly garment is now one of the main export items of the country. It accounts for 78% of country’s export earnings and contributes more than 10% to Gross Domestic Product (GDP). Besides enriching the country's economy it has played a very importantrole in alleviating unemployment. With 5,000 factories employing about 3.6 million workers (80% of them women),Bangladesh is clearly ahead of other Southeast Asian suppliers in terms of capacity of the Ready made Garments industry. Around 20 million people are directly and indirectly depending on this sector for their immediate livelihoods.The export quota system and the availability of cheap labor are the two main reasons behind the success of the industry. In the 1980s, the Readymade Garments industry of Bangladesh was concentrated mainly in manufacturing and exporting woven products. Since the early 1990s, the knit section of the industry has started to expand. Shirts, Tshirts,trousers, sweaters and jackets are the main products manufactured and exported by the industry.The phase out of the export-quota system from the beginning of 2005 has raised the competitiveness issue of the Bangladesh Ready made Garments industry as a top priority topics the global economic condition changing in a rapid motion, generally in an industry more focus is given on profit margin, customer demand for high quality product and improved productivity. In garment manufacturing, it is usual to see a lot of rejected garments after shipment. These non-repairable defects may occur due to low quality raw materials or faulty process or employee casual behavior.In the contemporary world of manufacturing,due to high competitive nature of the market, different companies have started to look for different approaches and practices to reduce the defect percentage.Pareto Analysis helps to identify different defects and classify them according to their significance. These defects often lead to the rejection of raw materials. To determine possible root causes of rejection, Cause-Effect Diagram is also a very useful tool. It helps to identify, sort, and display causes of a specific problem or quality characteristic. It graphically illustrates the relationship between a given outcome and all the factors that influence the outcome and hence to identify the possible root causes.In this paper, sewing section of a garment factory is studied where pants are produced in five production lines. In this study Pareto chart and Cause-Effect Diagram have been used with an objective to identify and classify the reasons that are responsible for various defects in the production lines.
II.Background Of The Study At present the success of the Readymade Garments sector highly depends on several factors such as manufacturing lead time, quality of product, production cost etc.These factors are hampered due to various defects in the products. These defects can be repairable that leads to rework or non-repairable that leads to rejection.Rework in the garments industry is a common work that hampers the smooth production rate and focus poor quality products having an impact on overall factory economy. Minimization of reworks is a must in quality and productivity improvement. Rework is a vital issue for poor quality product and low production rate. Reworks are the non-productive activities focusing on any activity that customer are not willing to pay for. Non-productive activities describe that the customer does not consider as adding value to his product. An Application of Pareto Analysis and Cause-Effect Diagram for Minimizing Defect Percentage in Sewing Section of a Garment Factory in Bangladesh International Journal of Modern Engineering Research (IJMER) www.ijmer.com.
Reference the above case study; Pareto Analysis… and comment on this statement: “However, we should bear in mind that 1% defective product for an organization is 100% defective for the customer who buys that defective product.” Your comment should relate to how Pareto Analysis can achieve zero defect manufacturing using the case study example as a reference
Explanation / Answer
Pareto analysis is a a graphical representation of area of defect to the level of effect it has on the overall problem, Pareto can help in following was to get down to zero defect manufacturing:
- to arrive on a Pareto graph, one has to take records, and understand all the areas of concern, when this is being don't one gets to know a problem in depth and so finding out solutions to it becomes better. Now considering the above case, in order to get zero defect all the departments will be studied, their major areas and minor areas of concern will be come up, so problems which were not addresses till date will also be visible.
- we come to know which defects are the major defects so improving them becomes easy, in this case for example if there is shade variation, and fabric defects are major defects then the supplier needs to be warned or changed, this will help to reach the zero defect goal.
- once the issues are addressed and worked upon, again a Pareto analysis can be performed to check on the results and then compare expected to the actual and again necessary steps can be taken, xonsiconsid the about if one of the issues was stich marks and their was an issue with the operator in the first analysis, then the operator was given training or the operator might be changed, so after that in the second analysis this can be checked and worked upon again of need to get zero defects.