PROJECT- QUALITY CONTROL IN SEWING DEPARTMENT BY

INCREASING PASS PERCENTAGE OF GARMENTS

Presented By:
Rohan.J
BFT/15/314
 PART 1
COMPANY PROFILE:
Overview:
Partnering leading global brands as an original denim manufacturer,
Suryalakshmi Cotton creates value added denim garments in a
variety of styles, colors and finishes. We are a major denim wear
supplier to high street retailers, fashion houses and independent
designers across the globe, for children’s wear, women swear and
menswear. Working in close collaboration with customers’ design
teams, suryalakshmi cater to fast fashion requirements with quick
turnaround times.
Suryalakshmi at a Glance:
1000 crores turnover.
2 factories with 13,000+ machines running across them
25,000 direct employees
5,000 garment pieces per day
90 thousand garments produced in a year.
They export to more than 29 countries.
• Vision
• “To become a global leader and preferred partner in
premium yarn and denim fabric manufacturing by
leveraging long-term growth opportunities and creating
superior value for all stakeholders.”
• Mission
• “To be one of the Top Global Players in the specialized
denim and premium yarn sector, bringing inspiration and
innovation to every fabric and garment we create.”
• Values:
• Customer First : -
• We put the needs of our customers first and are focused
on delivering value by providing the highest quality
products.
• Integrity: -
• We are committed to remain transparent, honest and accountable in our
relationships with all stakeholders, both on the inside and outside.
• Innovation-led Design Thinking: -
• We will leverage design thinking, technology innovation for delivering fast
fashion to our customers.
• We exercise the highest levels of professionalism in our work &
relationships and are committed to continuous improvement in our
pursuit of excellence.
• Responsibility: -
• We pay attention to what we create, how we create it and the way it
impacts people and the environment.
• People Welfare: -
• We exercise global standards of worker and human resource welfare to
create an efficient, healthy, happy and satisfied workforce.
CLIENTS:
 PART - 2
DEPARTMENT STUDY:

• The different departments in suryalakshmi cotton mills(Garments division)

are:
• -Spreading and cutting department
• -Sewing department
• -Finishing department
• -Washing department
• Fabric store
• Trim store
• -Human resource department
• -Industrial engineering department
• Maintenance department
• Product safety department
• Research and development
• Industrial engineering
• Central warehouse
• CAD
 FABRIC STORE:

Fabric store consists of 50 racks. The factory usually keeps stock for 4-5 days.
Capacity of the store varies based on the diameter of rolls. Racks are given
specific numbers for identification. With each rack one bin card is attached
which contains details such as buyers name, P.O. no., style no, color, shade and
article.
• SHRINKAGE CHECKING PROCESS
• The factory has its shrinkage procedure as follows:
• Bit cutting for shrinkage 60 cm.
• Shrinkage 50 cm (length- width) marking using template.
• Template marking 50cm x 50cm.
• Shrinkage bit overlocked with 3 sides.
• Overlock bit in tubular form
• Wet and dry process as per wash standards.
• Shrinkage bit cut open in fabric store.
• Ironed as per garment wash
Shrinkage test performing on fabric and checking
 TRIM STORE:
• In trims and accessories store all the accessories
are stored in large quantity. All the accessories
have details mention on it.
• Pre-production processes:
• In pre-production process all trims must be
according to the standard.
• In this process shade must be according to
standard.
• In this process measurement should be
according to standard.
• After all trims, accessories, wash and
measurement checking, sample is send to buyer
for any changes and their comment.
• If there are any changes then again sample is
made.
• After sample pre-production meeting is held.
• Then Size set is done
• Then bulk production is carried out

Trim card contain all the accessories needed for sewing and finishing.
 SPREADING AND CUTTING:
Fabric issued from the fabric store:
The lay slip and fabric rolls (relaxed if required) are issued
from the fabric store
LAY SLIPS: Lay Slips are made in accordance to need of
width of fabric, length of fabric, to identify fabric sort
number, and efficiency, and then it is issued from the fabric
department to CAD department. Based on the information
the markers are made. The slip is sent to the spreader with
the markers. Once the laying of the fabric is finished it is
submitted back to the fabric section. Based on the
information, the pro-cut is updated and FCR (FABRIC
CONSUMPTION REPORT) is made and submitted to the
head office.
Lay slips have information regarding length, shrinkage,
width of the fabric roll.
 SEWING DEPARTMENT:
Procedure of stitching line:
• IE manager allot a plan for all batches
according to planning and style wise
• Target will be fixed to planning
• Line balancing is done in morning by IE
department
• Operation breakdown is done by IE
department.
• Operator should be placed according to
operation.
• Hourly time study of each operator is
done
• If 1st hour production have problem, then
one senior operator / floater is allotted to
that particular operation to meet the
production
• Monitoring is done at each hour by
supervisor.
• Tracking of product is done according to
tracking sheet.
• Report is sent to production manager
daily.
• SAM, manpower, Tack time, and
bottleneck all are handled by IE
Hourly Production Target
The hourly production targets are decided
by the planning manager according to
the maximum efficiency with which the
garment can be made. The efficiency
depends on the types of operations and
the material handling and number of
workstations. Standard operation procedure
The SAM value of the sewing operations is
used and time taken to produce the order
quantity is calculated.

Hourly production report batch

wise
 WASHING DEPARTMENT:
Classification of denim washes techniques:
Several types of garment washing for denim fabric are carried out to
create varied effects in denim garments to meet the needs of today’s
denim fashion trends. However, each washing technique has its own
advantages and limitations. Denim is either rubbed or worn with stones
and other abrasive materials, called mechanical washing, or treated
with bleach and other kinds of color-altering substances, known as
chemical washing
Mechanical washes include:
• Rinse wash
• Stone wash
• Whickering
• Microsanding including sandblasting
• Mechanical abrasion
• Laser treatment
Chemical washing includes:
• Acid wash, ice or snow wash
• Hydrogen peroxide wash or Bleach washing
• Enzyme wash
• Ozone fading
• Spray techniques
• Chemicals used in this Industry: -
• LAVASPERS KDS: - ABS (Anti back staining
agent)
• NTE: - Neutral enzyme
• DW16LT: - Desize agent
• LAVACELL NTE: - Stone enzyme
• LAVAZYME AENOL: - Desize agent
• NPS: - Stone effect
• SMBS: - Sodium metabi sulphate (Neutral
Washing department evacuation plan
powder for neutral wash)
• GSL: - Anti back staining agent
• ATb96: - Enzyme
 Maintenance Department
• This department takes care of all sorts of maintenance needs of the factory, be it
machine maintenance, utility equipment maintenance, civil maintenance or even the
carpentry and plumbing works.
• There are two types of maintenance:
• Preventive maintenance
• Breakdown maintenance
• Preventive maintenance
• Regular routine maintenance that assists in reliable machine performance.
• Scheduling daily, weekly, monthly and 6 monthly check
• Daily maintenance: SPI, outside cleaning, oil level check 6 monthly maintenance: oil
changing.
• Preventive maintenance check list are fixed in each machine to ensure maintenance
schedule.
• Breakdown maintenance
• It is unanticipated maintenance activity resulting in stoppage of machine and
production. There is one mechanic dedicated to each line.
• Breakdown maintenance is done online & offline. If a minor problem occurs then it is
corrected in line itself. For major problems machine is taken out of the line and
maintenance is done offline.
• Supplier’s manual is available in the plant in case guidance is required.
• In the event of major breakdown which the company cannot handle, it will be informed
to the supplier’s service section.
• Minor adjustments, which operator can perform are listed out and the same will be
attached on the stitching machines
• Commissioning of the machines:
• All the machines are pre-set and completely assembled. As such minor adjustments are
required for commissioning
• Installation work has been done by authorized dealers of the respective machines and
utilities.
 PRODUCT SAFETY DEPARTMENT
• The product safety department in each manufacturing unit ensures
that the products being manufactured are 100% metal free before
being sent for packaging. This procedure happens at varies stages of
production and reports are maintained for the same. The
responsibilities of the Product Safety Department are listed below:
•
• Product Safety Officer Check the needle log is being maintained
properly and all the needles are accounted for on a daily basis.
• The snaps and button attachment strength test is carried (using the
pull test machine) out regularly before starting the style and readings
are recorded in the Snap Attachment Strength Test report and Button
Attachment Strength Test report respectively.
• Eyelet / Snap attachment test for Visual / Physical is carried out
regularly.
• Metal detection machine is calibrated on an hourly basis as the
record for the same is maintained.
• Product safety In-charge ensures that all the scissors and trimmers
have to be tied to the machine / workstation in the factory.
• Awareness training is given to the newly joined employees on same
day and is recorded in the new employee’s awareness register and
refreshment training is also given once in 3 months.
• Every 15 days once PSO performs product safety audit and
necessary action are taken based on the audit result.
 PART-3

PROJECT:

QUALITY CONTROL IN SEWING DEPARTMENT BY INCREASING PASS

PERCENTAGE OF GARMENTS
 INTRODUCTION:
Quality means customer needs is to be satisfied. Failure to maintain an
adequate quality standard can therefore be unsuccessful. But maintaining
an adequate standard of quality also costs effort. From the first investigation
to find out what the potential customer for a new product really wants,
through the processes of design, specification, controlled manufacture and
sale.
There are a number of factors on which quality fitness of garment industry is
based such as - performance, reliability, durability, visual and perceived
quality of the garment. Quality needs to be defined in terms of a particular
framework of cost.
Quality Control:
Quality is of prime importance in any aspect of business. Customers
demand and expect value for money. As producers of apparel there must
be a constant endeavor to produce work of good quality.
"The systems required for programming and coordinating the efforts of the
various groups in an organization to maintain the requisite quality". As such
Quality Control is seen as the agent of Quality Assurance or Total Quality
Control.
Need for the project:
-To lower the alteration rate and rejection of garments in sewing
lines
-Reducing the delay in production completion.
-Ultimately increasing the production rate by controlling quality
and reducing defects.
Project Objective:
Knowing the customer need and designing to meet them.
Faultless construction to maximize the production of goods.
Certified performance and safety
To maximize the production of goods within the specified
tolerances correctly the first time.
To achieve a satisfactory design of the fabric or garment in
relation to the level of choice in design, styles, colours, suitability
of components and fitness of product for the market.
 METHODOLOGY
Basic quality control procedure in sewing line:
(a) 100% inline parts checking The operations which are difficult to re-
process after assembling is checked 100% to avoid damages and waste of
time.
(b) Inline inspection
During the production of garments the operator’s finished work is audited in
an inline inspection. A quality inspector moves from one operator to another
at random inspecting a pre-determined number of parts from a finished
bundle. This helps to control quality at needle point.
(c) 100% end-line inspection
At the end of a line or section there should be a checker to inspect all the
parts before they leave the section. The inspections should be effective in
identifying all defects in a garment. The checkers should have their forms
filled correctly. A good source of information to determine the quality
performance of the section is the point of 100% inspection. The section
supervisor should check the quality level at the point of 100% inspection
periodically. With this information, the supervisor should address the
problems, correct the possible causes and make plans to prevent them.
(d) Pre-final audit
A pre-final audit should be performed on packed items on a
daily basis to ensure that the good packed items are meeting
the quality standards. Any problem seen can be arrested at the
early stage. If pre-final audits are done properly, the final audit of
the buyer should also be carried out without any issues.
QUALITY CONTROL FLOW CHART IN SEWING SECTION:
Input material checking
↓
Cut panel and accessories checking
↓
Machine is in well condition
↓
Thread count check
↓
Special work like embroidery, printing panel check
↓
Needle size checking
↓
Stitching fault should be checked
↓
Garments measurement check
↓
Seam fault check
↓
Size mistake check
↓
Mismatching matching of trimming
↓
Shade variation within the cloth
↓
Wrong placement of interlining
↓
Creased or wrinkle appearance control
 • Seven basic tools of quality:
The Seven Basic Tools of Quality (also known as 7 QC Tools) originated in
Japan when the country was undergoing major quality revolution and had
become a mandatory topic as part of Japanese’s industrial training
program. These tools which comprised of simple graphical and statistical
techniques were helpful in solving critical quality related issues. These tools
were often referred as Seven Basics Tools of Quality because these tools
could be implemented by any person with very basic training in statistics
and were simple to apply to solve quality-related complex issues.
The seven QC tools are:
1. Stratification (Divide and Conquer)
2. Check Sheet (Tally Sheet)
3. Cause-and-effect diagram (“fishbone” or Ishikawa diagram)
4. Pareto chart (80/20 Rule)
5. Scatter diagram (Shewhart Chart)
6. Histogram
7. Control chart
Top defects occurring in sewing section/Common
Denim seam quality defects:
1. Broken stitches
2. Skipped stitches
3. Miss Match of crotch joint
4. Uneven piping/stitch
5. Twisted leg
6. Needle damage
7. Waistband line out
8. Uncut Thread
9. Bar tack missing
10. Run up stitch
 INSPECTION OF NUMBER OF DEFECTS AND THEIR TYPES:
Line A
Style no.—L evis007
Garment checked 105 211 235 219 135 905
S.no. DEFECTS 26-08-2019 27-08-2019 28-08-2019 29-08-2019 30-08-2019 TOTAL DEFECTS
1 Raw edges 24 54 0 4 0 82
2 Crotch mismatch 0 6 7 15 9 37
3 Uneven piping 25 0 29 0 32 86
4 Long back tack 9 18 14 5 22 68
5 Loose stitch 15 9 0 7 9 40
6 Skipped stitch 42 20 48 19 32 161
7 Uneven stitch 39 30 20 33 27 149
8 Broken stitch 23 18 35 25 15 116
9 Run up stitch 22 19 12 11 8 72
TOTAL ` 811

Line B
STYLE NO.--368100
Garment checked 205 422 421 406 282 1736
DEFECTS 26-08-2019 27-08-2019 28-08-2019 29-08-2019 30-08-2019 TOTAL DEFECTS
Skipped stitch 42 98 23 10 6 179
crotch miss match 5 18 22 38 18 101
Waistband lineout 25 15 29 22 32 123
Long back tack 18 36 28 12 46 140
Loose stitch 15 9 0 7 9 40
Uncut thread 70 39 82 38 61 290
Uneven stitch 64 59 47 64 55 289
Stitch break 45 39 70 52 31 237
No side loop 44 38 24 22 16 144
Thread break 2 0 3 0 1 6
TOTAL 1549
 Line C
STYLE NO.—370883

Garment checked 292 376 353 290 380 1691

S.no. DEFECTS 31-08-2019 02-09-2019 03-09-2019 04-09-2019 05-09-2019 TOTAL DEFECTS
1 Uncut thread 39 70 23 15 26 173
2 crotch miss match 5 28 32 40 18 123
3 Not in position 21 30 12 22 32 117
4 Uneven piping 18 43 33 20 46 160
5 Loose stitch 15 9 0 7 9 40
6 Raw edge 56 38 63 31 59 247
7 Uneven stitch 43 38 52 60 55 248
8 Stitch break 44 52 65 39 29 229
9 No side loop 39 42 36 12 15 144
10 Thread break 2 0 3 0 1 6
TOTAL 1487

Line D
STYLE NO.--357954
Garment checked 459 397 269 272 402 1799
S.no. DEFECTS 31-08-2019 02-09-2019 03-09-2019 04-09-2019 05-09-2019 TOTAL DEFECTS
1 Uncut thread 76 98 51 77 71 373
2 Crotch miss match 43 39 54 21 15 172
3 Run up stitch 62 81 56 47 35 281
4 Long back tack 78 68 70 45 39 300
5 Loose stitch 24 28 37 30 27 146
6 Waistband lineout 29 35 32 29 30 155
7 Uneven stitch 43 34 37 41 39 194
TOTAL 1621
By the above data the DHU% of sewing lines and the major five
defects as of 4th week of august are:

S.NO. LINE DHU % MAJOR DEFECTS

1. LINE A 10.4% • Broken stitch

• Stitch break

• Uneven stitch

• Raw edges

• Uneven piping
2. LINE B 11.16% • Skipped stitch

• Waist band lineout

• Crotch mismatch

• Uncut thread

• Long back tack

3. LINE C 11.38% • Uncut thread

• Crotch mismatch

• Uneven piping

• Long back tack

• Loose stitch
4. LINE D 9.5% • Raw edges

• Long back tack

• Uncut thread

• Crotch mismatch

• Loose stitch
PARETO ANALYSIS CHARTS OF LINES AS PER THE DATA
COLLECTED
After the pareto analysis major defects and the critical
operations were identified and started collecting data operation
wise and the results are as follows.
Major defects and their critical operations:

Line A
Date-04/09/1-
06/09/19
TOTAL CHECKED
Skipped Uneven
GARMENT--104 Broken Raw Uneven
Operation
stitch stitch stitch edges piping
Hem 0 10 11 0 0
Back yoke attach 17 0 0 7 0
Topstitch inseam 10 0 0 0 14
Pocket attach 0 15 12 11 0
Coin pocket attach 0 7 0 8 0
TOTAL 27 22 23 26 14
 Line B
Date--04/09/19--
06/09/19
TOTAL CHECKED GARMENT--127
skipped Waistband Crotch Uncut Long
Operation
stitch lineout mismatch thread backtack
Pocket hemming 0 0 0 7 4
Waist band attach 12 15 0 0 8
Front pocket mouth
10 0 0 12 7
hem
crotch attach 0 0 16 0 0
TOTAL 22 15 16 19 19

Line--C
Date--04/09/19--06/09/19
TOTAL CHECKED GARMENT—115
Uneven Crotch Uncut Long back Loose
Operation
piping mismatch thread tack stitch
Loop attach 0 0 15 8 14
Topstitch inseam 9 0 7 6 0
Crotch join 0 18 0 0 0
Front pocket
0 12
attach 0 11 7
Inseam 8 0 0 0 0
Total 17 18 34 25 21
 Line D
Date -04/09/19--
06/09/19
Operation Raw edges TOTAL
Long back tack CHECKED
UncutGARMENT--139
thread Crotch mismatch Loose stitch
Waistband attach 6 0 8 0 0
Back yoke 12 12 5 0 2
Front pocket attach 9 0 4 0 7
Bottom hemming 1 3 0 0 12
crotch attach 0 0 0 16 0
TOTAL 28 15 17 16 21

INSPECTION OF GARMENTS WERE STARTED AND THERE WERE FOUND

SOME DEFECTS ON EACH LINE. ACCORDING TO THE COLLECTED
DATA, DHU% & MAJOR DEFECTS OF EACH LINE ARE GIVEN ABOVE:-
AFTER THIS, EACH LINE WAS ANALYZED FOR FINDING THE ROOT
CAUSE BEHIND ALL THE MAJOR DEFECTS
CAUSE AND EFFECT ANALYSIS CHARTS OF TOP 5 DEFECTS:

Broken stitches:

Causes:
M- Inappropriate thread tension. Needle plate,
pressure foot, needle holes may have sharp edges.
M-Wrong needle size and thread size
M-Weak thread
Skipped stitches:

Causes:
M-Operator in efficiency
M-Hook or needle is not able to hold the thread loop in
proper time, Needle deflection or bending, Tension
variation in needle thread.
M-Loop size or needle is small, Improper handling of cut
pieces.
 Uneven piping

Causes:
M -Operator speeding up machine too rapidly, Operator
holding back or pulling fabric through in variance with correct
machine feed, Operator inefficiency.
M –Needle deflection or bending, Tension variation in looper
and needle thread.
M –Loop size or needle is small, Improper handling of cut
pieces
Untrimmed thread

Causes:
M- Improper trimming
M- Improper finishing
Raw edges

Causes:
M –Improper seaming by the operator
M –Improper folding
Inspection of garments was started and there was found some
defects on each line.
According to my collected data, DHU% & Pass percentage of
garments of each line are given below:-
Broken Stitches:
Someplace in the stitch line where the stitch doesn’t get formed
Where the thread is being broken where one seam crosses another
seam (Example bar tacks on top of waistband stitching, seat seam on
top of riser seam) resulting in stitch failure

Solution for stitch break:

-Making sure the proper stitch balance is used. On a chain stitch seam
on denim, you normally would like to maintain a 60%/40% relationship
of needle thread to looper thread in the seam.
-The sewing tension in the needle should be properly maintained
(neither too high nor too low)
 IMPLEMENTATION IN BROKEN STITCH:

• It was observed that one individual machine(Pocket attach) got

stuck and gave more number of stitch break in garments.
• This problem occurred due to empty bobbin and the operator
did not got to know about it.
• After this problem I researched on this and got know that every
42nd garments the bobbin gets empty ,so to avoid this defect the
operator should change the bobbin in the 41st garment itself. and
results are follow:-
Skipped stitches:
Where the stitch forming device misses the needle loop or the needle
misses the looper loop. Skips are usually found where one seam crosses
another seam and most of the time occurs right before or right after the
heavy thickness.

Solution:
-Using minimum thread tension to get a balanced stitch
-Using the ideal foot, feed and plate that help to minimize flagging
-Training sewing operators not to stop on the thickness.
Implementation in skipped stitches:
The needle was slightly bent even though we cannot see the bend, it
was developing a dull point from use. Due to this many of the stitches
were skipped while sewing. After the observation needles were made to
alter at regular intervals and the results are as follows
From 09/09/19 – 11/09/19

Operation Skipped stitch

Hem 0
Back yoke attach 7
Topstitch inseam 3
Pocket attach 2
Coin pocket attach 0
TOTAL 12
Twisted legs:
It is where the side seam twists around to the front of the pant and
distorts the appearance of the jeans
Solution:
-Usually caused by poor operator handling. Instructing the sewing
operator to match the front and back properly so they come out the
same length. Sometimes notches are used to insure proper alignment.
-Making sure the cut parts are of equal length coming to the assembly
operation.
-Making sure the sewing machine is adjusted properly for uniform
feeding of the top and bottom plies.
Implementation in twisted legs:
Instruction was given to the sewing operators to match the front and
back parts of the garment perfectly.
There was a mark made on the knee before sewing the garment to
assure proper alignment of the front and back parts.
Run up stitch:
It is the area on the stitched seam where there is a splice on the stitch
line. If this occurs on topstitching, then the seam doesn’t appear to be
1st quality merchandise.

Solution:
-Insure correct machine maintenance and sewing machine
adjustments
-Observe sewing operators for correct material handling
techniques
Implementation in Run up stitch:
Some of the operators were not correctly able to look at the stitch
while sewing due to lack of light on the stitch.
The lights were installed in few of the machines by replacing the
light bulb with the machines which were not in use.
Uneven piping:
Where the seam doesn’t lay flay and is wavy due to the fabric stretching
as it was sewn or during subsequent laundering or handling operations

Solution:
-Using minimum presser foot pressure.
-Instruct sewing operators to use proper handling techniques
and not stretch the fabric as they are making the seam.
-Where available use differential feed to compensate for the
stretch of the fabric
Implementation in Uneven piping
This problem came due to the miss alignment of front and back
attaches operation during sewing. so it was suggested to use stopper
which will stop the fabric at 1/4th inch so that operator can stitch easily
without miss alignment.
Operation Uneven piping
Hem 0
Back yoke attach 2
Topstitch inseam 7
Pocket attach 0
Coin pocket attach 0
TOTAL 9
As on 09/09/19 – 11/09/19
Un trim thread:
Few of the garments picked up by the operator for the removal of
unnecessary threads or trims are not properly done.

Solution:
-Providing adequate training to the operators and providing
thread cutter to every operator and make used to it.
-To cut thread properly, start regularly checking system to
check the auto trimming machine is properly functioning or
not.
Implementation for un trim thread:
Quality in charge was made to check and monitor the work of
inspectors. All garments found with the uncut thread based on
inspection report must be advised to all concerned operators and
sewing supervisors for proper corrective action to avoid garments
passed to next process with the uncut thread.
Quality inspector was made to ensure that workers are following the
proper method of trimming and operators are doing self-trimming.
Control phase:
The main purpose of this step is to obtain the gains, monitoring the
improvements to ensure continued and sustainable success. Create a
control plan. Update documents, business processes and training records
wherever it is as required. After implementation of the solutions, the positive
results are discussed with the managers and the progressive outcomes were
shared with the management. The main defects were recognized and
partially reduced in amount. Now the challenge is to withstand the
progresses and to sustain the improvements made in improving the
processes refining the system continuously.
Control Plan: The following are the mandatory actions that have to be
taken by the management to maintain the results after implementation in
the garment industry
1. The operators of garment industry must be given training on a continuous
basis on the issue of quality.
2. Always use of the good quality needles, threads, and the other garment
accessories
3. Tight quality controls should be enforced on those products coming from
subcontractors
4. The drawings of the product must be made available at all the machines.
The final garment pattern should be referred by all the operators.
5. The administration ought to give the incentives for high quality
performance.
6. The focus should be on preventing defects rather than correcting defects.
7. Training the subcontractors on the importance of quality on continuous
basis.
8. The organization should develop a proper quality management system.
Deploy improvements Control –
Engineers and production managers always search for an approach
to enhance processing factory’s labor productivity. But they look-
over things that lower labor productivity. “Higher line setting time” as
it is one of the most visible reasons at present the factory’s overall
productivity. When it sets aside longer time for setting a line, most of
the operators sit idle. That means operators are not utilized in
producing garment and operator productivity falls resulting high
labor cost.
 RESULTS AND DISCUSSION:

The minimization of defects is very important for guaranteeing the

quality of products. This study found that the sewing section of selected
garment factory was operating at a defect percentage of 11.01%
After implementing all the possible solutions for the detected defects it
was noticed that the pass percentage of end table garments in the lines
A,B,C and D were increased by approximately 3% and the defect rate
was decreased by approximately 3 % in each of the lines. So this
method is very extremely compelling the minimization of defects. As the
minimization of defects is the continuous process for further
implementation of the methodology, it will help the company to identify
the more reduction on defects rate and increases productivity.
SEWING END TABLE DHU AND PASS PERCENTAGE AS ON 2ND
WEEK OF SEPTEMBER:
The above study analyse the performance of the apparel
industry with respect to various garment defects. For
improvement in the performance we have analysed the
garment defects in stitching line. The defects which are
responsible for the increase in defect rate were analysed during
garment inspection. Maximum rejection takes place due to
following defects, then analyse the root causes and remedies for
these defects; which are mentioned in the following tables. The
performances of the stitching line were improved by
implementing the corrective action. It is found that Pass
percentage of the stitching lines was Increased by 2.8%.
 CONCLUSION:
Quality control plays an important role in readymade garments
production. Now a days buyer requires specific quality in all major parts
of the finished products. What special in this report is the info data and
description very much objective and practical. I have tried to complete
my project work as much as I can.
In conclusion the key quality control points are not the only reasons for
the success of a small manufacturing co-
operative such as the one referred to in this study. It should be noted
that there are other contributing factors to
operational excellence and performance in terms of quality in the
operations of a small clothing manufacturer focused
on sewing, these factors include tacit knowledge, flexibility of the sewing
process, repeat orders and the small quantity
of orders processed.
The key quality control points are not the only reasons for the success in
garment manufacturing companies. It should be noted that there are
other contributing factors to operational excellence and performance
in terms of quality in the operations of a small clothing manufacturer
focused on sewing, these factors include tactic knowledge, flexibility of
the sewing process, repeat orders and the small quantity of orders
THANK YOU