MID TERM

ASSIGNMENT
Subject: Apparel Quality Management

National Institute of Fashion Technology

Department of Fashion Technology

FMEA CHART OF SHIRT

SUBMITTED TO: SUBMITTED BY:

Prof. Vimal Singh P. Ravi Kumar (BFT/20/196)
Ritika Garg (BFT/20/197)
Srishti Sinha (BFT/20/)
ABSTRACT

The Failure Modes and Effects Analysis (FMEA) is a widely used method for
identifying, analyzing, and mitigating potential failures in products and systems.
In this assignment, we applied the FMEA method to a shirt to identify potential failure
modes and their associated effects.
Through a detailed analysis of the shirt's design, materials, and manufacturing
process, we identified several potential issues that could impact the shirt's
performance, quality, and reliability. These issues included defects in stitching,
material defects, and inconsistencies in sizing.
By using the FMEA method, we were able to proactively address these issues and
develop effective corrective actions to prevent failures from occurring in the future.
Our analysis provided insights into how FMEA can be used to improve the quality and
reliability of products, as well as the importance of a thorough understanding of a
product's design, materials, and manufacturing process.
Overall, the FMEA method is a valuable tool for improving product quality and
reliability, and our analysis of a shirt demonstrates how this method can be applied to
a real-world product to identify and address potential failures.
INTRODUCTION

What is FMEA?
The Failure Modes and Effects Analysis (FMEA) is a powerful tool used to identify,
analyze, and mitigate potential failures in a wide range of products and systems.
In this assignment, we will be applying the FMEA method to a shirt to identify
potential failure modes and their associated effects.
By analyzing the shirt's design, materials, and manufacturing process, we can identify
potential issues that may impact the shirt's performance, quality, and reliability.
This process will help us to proactively address these issues and develop effective
corrective actions to prevent failures from occurring in the future. Throughout this
assignment, we will explore the different components of an FMEA chart, discuss how
to apply the method to a shirt, and provide examples of how FMEA can be used to
improve product quality and reliability.

How to calculate FMEA?

-Process steps in FMEA

• Step 1: Identify potential failures and effects

• Step 2: Determine severity

• Step 3: Gauge likelihood of occurrence

• Step 4: Failure detection

• Risk priority number (RPN)

Step 1: Identify potential failures and effects

The first FMEA step is to analyze functional requirements and their effects to identify
all failure modes. Examples: warping, electrical short circuit, oxidation, fracture.
Failure modes in one component can induce them in others. List all failure modes per
function in technical terms, considering the ultimate effect(s) of each failure mode and
noting the failure effect(s). Examples of failure effects include: overheating, noise,
abnormal shutdown, user injury.

Step 2: Determine the severity

Severity is the seriousness of failure consequences of failure effects. Usual practice
rates failure effect severity (S) on a scale of one to 10 where one is the lowest severity
and 10 is

highest.

Step 3: Gauge likelihood of occurrence

Examine the cause(s) of each failure mode and how often failure occurs. Look at
similar processes or products and their documented failure modes. All potential failure
causes should be identified and documented in technical terms. Failure causes are
often indicative of weaknesses in the design. Examples of causes include incorrect
algorithm, insufficient or excess voltage, operating environment too hot, cold, humid,
etc. Failure modes are assigned an occurrence ranking (O), again from one to 10

Step 4: Failure detection

After remedial actions are determined, they should be tested for efficacy and
efficiency. Also, the design should be verified and inspections procedures specified. 1.
Engineers inspect current system controls that prevent failure mode occurrence or
detect failures before they impact the user/customer. 2. Identify techniques used with
similar products/systems to detect failures. These steps enable engineers to determine
the likelihood of identifying or detecting failures. Then, each combination from steps
one and two are assigned a detection value (D), which indicates how likely it is that
failures will be detected and ranks the ability of identified actions to remedy or
remove defects or detect failures. The higher the value of D, the more likely the
failure will not be detected.

Risk priority number (RPN)

After the foregoing basic steps, risk assessors calculate Risk Priority Numbers
(RPNs). These influence the choice of action against failure modes. RPN is calculated
from the values of S,O and D as follows:

RPN should be calculated for the entire design and/or process and documented in the
FMEA. Results should reveal the most problematic areas, and the highest RPNs
should get highest priority for corrective measures. These measures can include a
variety of actions: new inspections, tests or procedures, design changes, different
components, added redundancy, modified limits, etc. Goals of corrective measures
include,in order of desirability:

• Eliminate failure modes (some are more preventable than others)

• Minimize the severity of failure modes

• Reduce the occurrence of failure modes

• Improve detection of failure modes

When corrective measures are implemented, RPN is calculated again, and the results
are documented in the FMEA.

THE PRODUCTION PROCESS OF FORMAL SHIRT

In a factory or a tailoring shop, industrial sewing machines can be used to make shirts.
No matter where the garment is made, the main steps are the same. Receiving an order
is the first step, followed by locating materials, cutting fabrics, sewing together the
components of shirts, finishing, and packing, and lastly mailing the order.

● Pattern Making
Shop shirts are produced in a tailor's shop using the wearer's measurements
(Made to Measure). Every shirt is different. Thus, shirt patterns are typically
not created at tailoring businesses. Instead, professional tailors mark and cut
fabric right on the fabric.
The pattern is crucial in factories where hundreds of clothes are produced in the
same size and measurement. To ensure that patterns are created accurately,
sample shirts are initially prepared. Pattern grading is carried out and patterns
are created for all sizes because the firm needs to produce shirts in a variety of
sizes. A CAD system can be used for pattern grading.

● Fabric Cutting and Material Fusing

Once the fabric is located and the pattern is prepared for usage, cutting of the
fabric can begin. On a level surface, the fabric has been spread out. Several
layers of fabric are cut as plies. The outlines of shirt parts are traced using
paper patterns. Following marking, fabric is cut with a cutting machine.
 The most expensive component of a garment is the fabric. To maximise fabric
usage, it makes sense to make a marker before cutting. The production and
cutting of markers can be done by a computer-controlled device.
Customers like that the checks and stripes match on the shoulder and sleeve,
the left and right front panels, and even the side seams. Clothing elements must
be trimmed in the same way for checks to match.
Fusible interlinings are used to make the collar and cuffs. Interlining
components are attached to collar and cuff components using a fusing machine.

● Stitching of Shirts
Each component of the front, sleeves, pockets, cuffs, and collars is produced
independently. The rear yoke or collar band is where the primary label (Brand
labels) is sewed during the part preparation process.
After the constituent parts have been created, a shirt is assembled. A wash care
label is sewn onto the side seam of the assembly part.
Shirts are made on sewing lines used in industrial production. One person in a
tailor shop creates a whole shirt. There are different ways to set up a sewing
line for the manufacture of shirts, depending on the line layout and production
method. Instead of producing individual shirts on an assembly line, bundles are
made.

● Finishing a Shirt
During the finishing phase, buttons are attached to the front placket, collar, and
cuffs. These pieces feature buttonholing. Trimming is done to uncut thread
tails. Other finishing sub-processes include pressing, shirt alteration, and stain
treatment. manufacturers will wash shirts if necessary to achieve the ideal hand
feel and visual look.
In tailoring establishments, there is no shirt-washing procedure. At sewing
shops, the processes for holing and mounting buttons are still done by hand (the
 cost of button holing and button attaching machines is not cost-effective for
tailoring shops).

● Inspection of quality
The finished shirts are prepared for folding and packing. Before being packed,
shirts are examined to make sure that the buyer won't receive any that are
damaged. A garment is altered or repaired if damage is discovered.

● Packaging of Shirts
For the manufacturers, this marks the end of the shirt-making process. To fold
the shirts nicely, cardboard, tissue paper, and pins are used. The hangtags and
price tags are applied to the folded shirts. Before being put in a cardboard box,
shirts are folded and put in a polythene bag. According to the buyer's
requirements, a shirt is packaged.

QUALITY PARAMETERS

● Adopting proper procedure of work — defining the complete process of the

product manufacture from raw material to finished goods and elaborating on
operating procedures for each department.
● Selection and use of appropriate machinery.
● Training of manpower — This is done at all levels, i.e., operators, supervisors,
and management — on machinery, maintenance, quality systems, production,
and the product.
● Inspection of product at various stages of production — For this, crucial stages
are selected.

The FMEA Chart of formal shirt is attached with this document in excel file. Please
review it.
REFERENCES

https://www.intouch-quality.com/blog/top-6-most-common-garment-defects

https://textilemirror60.blogspot.com/2020/09/failure-mode-and-effect-analysis-fmea.h
tml

https://lindstromgroup.com/wpcontent/uploads/2017/03/2_1_6_defect_list_workwear.
pdf