An in-line control model proposal developed to reduce manufacturing defects in garment industry sewing line

Abstract

This study was conducted in order to reveal the efficiency level of the 1/7 in-line control system (ICS) developed to determine the factors affecting the quality of the products produced in the garment industry sewing line and to reduce the defect rates. The production of a tights model produced from interlock fabric which contains 60% Pes, 35%Viscose and 5%Lycra was examined. During the first 12 days of production observation, the production flow has not been intervened. During the second 12-day experiment, the developed ICS was applied on the line. The products coming out of the band were checked according to the sewing control form and the error rates on operation basis and the effect of these errors on the cost were calculated. The defect rates on operation basis and the effect of these defects on the cost were calculated. One-way analysis of variance (Oneway Anova), Duncan test, correlation analysis and Paired Samples T-test were applied to the obtained data. According to the statistical results, it has been determined that the recommended ICS reduces the daily number of defective products by 81% and as a result, it provides a 77% reduction in the total defect related cost.