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Defect Analysis in Garment Industry PDF
Defect Analysis in Garment Industry PDF
Defect Analysis in Garment Industry PDF
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,
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
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
ii
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
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
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
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
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
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
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.
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For every industry or business, to get increased sales and better name amongst
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
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
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
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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
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
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
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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,
In these 2-decade long presences in the textile industry, they have seamlessly
company represents their group abroad, a role that they fulfill with utmost responsibility,
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
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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
products.
SCM Garments Pvt. Ltd is one of the worlds 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
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
MANUFACTURING UNITS
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MANUFACTURING FACILITIES
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
EXPORTING COUNTRIES
Through the years, they have been associated with renowned brands and retail
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
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VISION
and on time approach and further the cause of a sustainable future by promoting an eco
MISSION STATEMENT
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1.3 NEED FOR 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
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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
The study will help the organization to avoid the defects in the garment and to
save time.
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
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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
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
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
Observation
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
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2.2. TOOLS USED
and chi-square test has been to compare the style wise defects margin.
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
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CHAPTER-3
THEORY OVERVIEW
There are nearly 450 employees in Unit I and it comprises of 10 lines where 800-
1000 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 buyers requirement.
There are various styles of garments being produced in the sewing process. Of
Fig.3.2
COLLAR STITCH
SHOULDER ATTACH
PLACKET OPEN
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PLACKET FINISH
COLLAR ATTACH
SLEEVE ATTACH
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
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CHAPTER -4
For the purpose of analyzing the frequency of every defect in the production process
The total number of pieces produced under this 20 orders were 1,68,956 pieces
Types 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
TABLE 4.1
10. More threads joining in one place D10 477 3.1 112 1.2
16
11. Improper sleeve attachment D11 231 1.5 32 0.3
16. Yoke piece unevenly attached D16 555 3.6 141 1.5
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30. D1&D6 - - 205 2.1
18
51. D6&D14 - - 76 0.8
19
72. D18&D24 - - 48 0.5
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
Out of these 9636 pieces, there were 27 types of defects occurring. And in this
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
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4.2 COMPARITIVE ANALYSIS OF TOP 5 DEFECTS OUT OF TOTAL
DEFECTS
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.
TABLE 4.2
garment)
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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
The defect oil stains comes second in the rank which occurs around 1976 times,
The defect ADAS (holes in the garment) occurs around 1069 times, which is of
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
TABLE 4.3
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
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%.
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
This table shows the first 3 ranks of defective pieces and its frequency of
occurrence.
TABLE 4.4
INTERPRETATION
Based on the defective pieces, these 3 defects contribute about 23. 8% and based
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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
Under category A the defects based on defective pieces and their frequencies
CATEGORY A OF DEFECTS
TABLE 4.5
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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
CATEGORY B OF DEFECTS
TABLE 4.6
DEFECTS
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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.
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
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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
Null Hypothesis: There is no significant difference among the different styles. (H0)
Alternate Hypothesis: There is significant difference among the different styles. (H1)
TABLE 4.7
QTY PIECES
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8. Babies top with stripes 13935 836 6%
Assuming = 0.05. This means that when = 0.05, we will be making an error of
The computed value of X2 =0.29 is less than the critical value of X2 =10.117; we
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INTERPRETATION
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
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CHAPTER-5
5.1 FINDINGS
The 3 defects Skipped stitches, Oil stains, ADAS, contribute more in the total
The skipped stitch and oil stains contribute about 34% of the total defects based
The Skipped Stitches, Raw edges outside, Seam twisted gives puckering
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)
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).
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There are some of the reasons for the occurrence of these defects in the garment.
The availability of oil for the machine is quite high which left unnoticed and this
Trimming fault
Needle breakage
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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.
needed.
The technician can be appointed and he must keenly check the threads, needle,
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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
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3. RANKING OF DEFECTS BASED ON ITS OCCURENCE
TABLE.3
1. D1 3319 21.3
2. D7 1976 12.7
3. D6 1069 6.9
TABLE.4
PEICES
1. D1 1220 12.7
2. D7 724 7.5
3. D6 356 3.7
40. D3 84 0.9
41. D13 84 0.9
54. D9 50 0.5
57.. D8 43 0.4
72. D2 0 0.0
Step 1:
(H0)
(H1)
Step 2:
Assume = 0.05. This is the probability of making the Type I error. This means that
when = 0.05, we will be making an error of rejecting the null hypothesis when in fact it
Step 3:
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
= 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 = 0.05 and df= (k-1) =20-
1=19.
This value is given as 10.117. We compare our computed value of X2 with the
Since our computed value of X2 =0.29 is less than the critical value of X2 =10.117,
BOOKS
TECHNIQUES
www.scmgarments.com
www.economywatch.com
www.fabrics-manufacturers.com
www.fiber2fashion.com