Efficiency Improvement by Reducing Rework and Rejection on the Shop Floor

Abstract

For any garment industry the production and quality management or wastages reductions have a major impingement on overall factory economy. In garment industry maximum quality constraints arise in the sewing department. The minimization of reworks in sewing department of any apparel industry for quality improvement plays a significant role on overall factory economy. This project discusses the quality improvement of garment industry by applying quality tools such as checklist, cause and effect diagram and Traffic Light System. The purpose of the implementation is to reduce the reworks rate with improved quality by eliminating loopholes of quality. This work provides the guidelines to control the rejection and reworks through reduction of defects in garment industry by identifying the root causes and traffic light system. The DHU percentage was compared with respect to the initial and final state and it was analysed that there was a fall of 47.6% in the DHU. The outcome of this observation depict that an industry may gain higher productivity and profitability, by reducing the costs and improving the quality constraints through minimization of rework activities.