8D Project on – Uncut Thread

Product: Men’s Short, Line No# 01 (I-2)

Vendor: KDS Garments Ltd.

Factory: KDS IDR Ltd.

PSQA Lead
Factory Lead Mijanur Rahman
Prashant Mithare SPE, PSQA Bangladesh
[Honorable. VP Sir] December ’2017
 Define

Issue Charter
Business context:
KDS Garments Industries Ltd. (KDS IDR Ltd) is one of the greatest vendor
of Target Sourcing Services – L. L. C., Chittagong, Bangladesh. Producing
Knit items of Target are in good practice of the facility.
Problems:
Un cut Thread at operations having down the inspection performance.
Goal statement:
Reduce DHU of Un cut Thread from garment at 0% at manufacturing
process by next months .
Scope:
Sewing
Benefit:
Identify Un cut Thread at process and resolve what will bring a good
performance.
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 D1.Team Members ( Name / Business Process)

Project Team:
1. Saimul Islam Production Manager (Project Leader )
2. Abdul Gani Assistant Manager QA (Assistant Project Leader)
3. Gihan Lahiru' Sr. Executive IE (Member)
4. Siddiqur Rahman Sr.Exe QA (Member)
5. Kanchan Production Exe (Member)
6. Alok Barua Jr.Exe QA (Member)
7. Anik Barua Jr.Exe IE (Member)
8. Rubel Islam Technician (Member)
9. Zahirul Islam Jr.Exe QA(Member)
10. Amit Dey Exe I/A (Member)
11. Sajib Biswhangri Jr.Exe (Member)
12. Ariful Islam Jr. Exe MINT (Member)
13. Bellal Line Supervisor (Member)
14. Ruma Line QA ( Member)

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 D2. Problem Descriptions (Defect Description)

Pareto Analysis of Sewing Line

99.32%100%
97.84%
1000 952 93.44% 100.00%
90.48%
88.02%
85.71%
900 81.51% 90.00%
80.28%
76.46%
800 80.00%
69.98%
690
700 63.48% 70.00%

600 53.08% 60.00%

500 471 50.00%

414
35.74%
400 40.00%

300 23.91% 259 258 30.00%

200 167 175 20.00%

152
98 118
92
100 49 59 10.00%
27
0 0.00%

Defect Qty Cumulative %

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 D2. Problem Descriptions (Defect Description)

Total Total Un Cut Un Cut Thread Remarks

Months Checked Defective Thread Qty DHU %
Qty(Pcs) (Pcs) (Pcs)

November’17 3469 555 171 Pcs 4.93% Total DHU- 16.00%

December' 17 17934 2877 694 Pcs 3.87% Total DHU- 12.25%

Total 21403 3422 865 Pcs 4.04% Total DHU- 14.12%

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 D2. Problem Descriptions (Defect Description)

Uncut Thread
Month Wk-1 Wk-2 Wk-3 Wk-4

November, 2017 1.99% 5.65%

December, 2017 5.19% 3.30% 4.45%

Graphical
6.00% 5.65% 5.19%
4.00% 4.45%
3.30%
2.00% 1.99%
0.00%
Nov Nov Dec Dec Dec Dec Dec
Week-4 Week-5 Week-1 Week-2 Week-3 Week-4 Week-5

Un cut Thread DHU %

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 D3. Interim Corrective Actions/Correction Action Plan

Short term/Correction Action Responsibility Impl. Date

on Product

Cut Extra thread (Un cut Saimul Islam 30 Dec 2017

thread) Process to Process. (Production Manager)

Saimul Islam
Had a meeting with the line
(Production Manager)
supervisor and other teams in
'Kanchan
the line responsible due to 30 Dec 2017
(Exe. Production)
avoid the Uncut thread.
Siddiqur Rahman
(Sr. Exe QA)

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D4. Root Causes Analysis

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 D5.Chosen permanent corrective action(s)

Permanent corrective Responsibility Image of Corrective

action
The operators and other sewing
team has been educated to cut
threads in the process to avoid
uncut thread in the garment.
Action
Saimul Islam (Production
Manager)
'Kanchan (Exe. Production)
Siddiqur Rahman (Sr.Exe QA)

Train Up Top Three Un cut

Saimul Islam (Production
Thread Related Process
Manager)
Operator, Motivation the
Siddiqur Rahman (Sr. Exe QA)
Operator Cut Extra Thread
'Kanchan (Exe.Production)
Process to Process Properly

The QA's on the line have been

instructed to stop any operation
which is having uncut thread
also they have been instructed Siddiqur Rahman (Sr.Exe QA)
to stop machine in case any
thread is found in any particular
operation.

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 D6. Implement permanent corrective action (s)

Lack of Knife
sharpness

Lack of Auto Trimmer

Machine

Not to cut thread from

sourcing point

Inaccurate reject repair

Inaccurate joint stitch

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 D6. Implement permanent corrective action (s)

Not Maintain Clockwise

Thread Cut

Over load production

target

Lack of awareness
training

Insufficient Lighting at
trimming table

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D7. Prevent recurrence – Write Result of next lot

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 D7. Prevent recurrence – Write Result of next lot

Uncut Thread Control Plan

Process Trimming Point Checking Point
Button Hole for draw cord insertion To be trimmed by machine. To be checked in end line checking

Main Label Attachment Trimmed by Operator. To be checked in end line checking

To be trimmed by security tack
Back Pocket over lock run off threads To check in the end line checking
operator.
Back Pocket SN Top edge Stitch To be trimmed by operator. To check in the end line checking

Back Pocket Barrack To be trimmed by machine. To check in the end line checking
Waist Band attaching to body with over
Operator has to trim the thread. To check in the end line checking
lock
Side Pocket Bar Tacking To trimmed by the machine. To check in the end line checking

Fly Barrack To be trimmed by the machine. To check in the end line checking

Barrack at crotch point To be trimmed by the machine. To check in the end line checking

Bottom Rolling by single needle lock stitch To be trimmed in the process. To check in the end line checking

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D8. Team Recognitions / Celebrations

Not At Done

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