APPAREL INTERNSHIP

PROJECT TITLE

DHU REDUCTION THROUGH CHECKING PROCESS STANDARDISATION,WORK STATION

OPTIMIZATION & PROCESS INNOVATION IN MTM.
 PROBLEM STATEMENT
 HIGH RATE DHU.
 DELAY IN DELIVERIES
 UNORGANIZED CHECKING PROCESS
 INEFFICIENT WORKING PROCESS
 POOR DEFECTS IDENTIFICATION AT INTIIAL STAGES.
 UNORGANIZED WORK STATION

3
OBJECTIVE 01 REDUCTION IN DHU

ROOT CAUSE ANALYSIS OF

02 TOP 5 DEFECTS

03 STANDARDISATION OF
CHECKING WORK
PROCESS

04 IMPLEMENTATION OF
CLOCKWISE INSPECTION
MODEL

04 STANDARD WORK STATION

 1.
QUALITY CHECKPOINT-CUTTING

5
 TOP 5 DEFECTS
 S.no  JACKET  TROUSER  VESTCOAT

1 Fabric parts missing Fabric parts missing Fabric parts missing

2 Lining parts missing Knee lining problem Lining parts missing

3 Notch missing Waistband problem Checks up/down

4 Collar checks mismatch Knee lining bottom open Block cut wrong

5 Fabric face side wrong Style wrong Fabric face side wrong
6
INITIAL CHECKING SEQUENCE

JACKET TROUSER VESTCOAT 7

 ROOT CAUSE ANALYSIS-JACKET & VESTCOAT
FABRIC PARTS Small parts are intangled in Cutting is not done Check and change/Sharpen the knife on regular
1 MISSING Cutter All parts are not picked waste properly Knife sharpness issue   interval
Not trained properly
Partial knowledge about regardng garment Need to train regarding parts name and
        parts parts     appearance
                 
Small parts arts are sticking inside Fusings are coming out of Fusing are bigger in Need to segrgate the fusing / Cut extra fusing/
    Fusing machine the machine the fabric size Size wise not kept   Pass it in paper
Partial knowledge of
Inaapropriate Fusing lacement and its No proper Need to train regarding fusing palcements and
          Placement effect training parts
                 
carelessness/ fabric Need to make them understand regarding effect
    Recutting Identified missing part are not cut constraint       along with continous monitoring
      Re-bundling handling         need to train regarding garments parts
Small parts are intangled in No education on effect No proper
2 LINING PARTS MISSING Cutter All parts are not picked waste Carelessness of mistakes training Provide training/ Parts visual display
          Bundle single garment at a time
Knife
Parts not cut properly Machines requires continuous monitoring and
CUTTER Lining damage due to yarn pull Pulling of parts in m/c No regular maintenance sharpness
by the cutter maintenance by technician
  issue
                 
No knowledge about No proper training
3 CHECKS UP/DOWN Cutter Checks not matching at the cutter Wrong spreading grid alignment   Need to re-educate and continuous monitoring
                 
Felt manual Track sheet reading
4 COLLAR FELT WRONG cutting Cut by wrong pattern problem Less educated     Need to provide training
                 
Felt manual Distorted due to rotary Regular use of paper
    cutting gets distorted cutter pattern     Direct cut on cutter
                 
Store operator
5 FACESIDE WRONG Cutter Wrong laying face side confusion No face side marked carelessness   Continous monioring
                 
Cutter operator
    Fusing Face side confusion No marking @ cutter carelessness     Continous monioring
Partial knowledge of face No proper traing and
        side follow up     Provide training & Continuous monioring
Wrong side marking @ Cutter operator
        cutter carelessness     Continuous monitoring 8
 ROOT CAUSE ANALYSIS-TROUSER
FABRIC PARTS Small parts are Cutting is not done Knife sharpness Check and change/Sharpen the knife on
1 Cutter All parts are not picked  
MISSING intangled in waste properly issue regular interval
Not trained properly
Partial knowledge about Need to train regarding parts name and
        regardng garment    
parts appearance
parts
                 
Identified missing part Carelessness/ Need to make them understand regarding
    Recutting Re-bundling handling    
are not cut fabric constraint effect along with continous monitoring
              Need to train regarding garments parts
                 
Operator did not
Not trained properly
2 Knee lining problem Cutter Knee lining missing Not cut@cutter check while regardng garment   Training required
spreading parts
           
Wrong color issued Operators did not
    Knee lining wrong Wrong color lining cut
@store check
Carelessness Monitoring required by the supervisor
                 
Knife sharpness
3 Waistband problem Cutter Waistband wrong Distorted shape Rash cutting issue
  Regular Machine maintenance required

Faceside Less knowledge

    Fusing Wrong side fusing attached Wrong faceside marked   Training required
identification issue about faceside
                 
Spreading not
Knee lining bottom 0.5mm gap not left between Wrong spreading by
4 Cutter checked before Carelessness  
open pattern and fabric operator
cutting
                 
Parts missing/Extra
Partial knowledge about No proper trainng
5 Style wrong CAD parts/wrong parts in the     Provide training/ Parts visual display
style for style and parts
marker
                 
No education on
    Cutter Track sheet exchange Carelessness
effect of mistakes
    Bundle single garment at a time 9
DHU% CUTTING

10
IMPLEMENTATIONS
11

CHALLENGES
1.FACESIDE WRONG
2. DIFFICULTY IN READING
TRACKSHEET ( DUE TO SMALL FONTS )
FABRIC STORE
ACTION OUTCOMES/PROGRESS
1.MARKING FACESIDE ON FABRIC BEFORE 1.NO CONFUSION OF FACESIDE
CUTTING FROM ROLL. DURING SPREADING.
2.VISUAL DISPLAY OF TRACKSHEET WITH 2.LESS/NO DIFFICULTY IN READING
ENLARGED SECTION TO BE CHECKED TRACKSHEET

TRACKSHEET
BEFORE AFTER READING

CHALLENGES
1. GARMENT PARTS MISSING
2. STYLE WRONG
3. WRONG FUSING / PLACEMENT
CUTTING
ACTION OUTCOMES/PROGRESS
1. PREPRATION OF TRAINING 1. DECREASE IN NO. OF
MODULE.
MISTAKES
2. REGULAR TRAINING REGARDING
PARTS/STYLE/FUSING WITH 2. OPERATOR LEARNING-
VISUALS/DISPLAY STYLES/PARTS/FUSING

FUSING
VISUAL DISPLAY TRACKSHEET PLACEMENT TRAINING
STANDARD WORK PROCESS &VM

FABRIC IDENTIFICATION DISPLAY

WORK PROCESS VISUAL INSPECTION PARTS IDENTIFICATION 14

DISPLAY
 2.
QUALITY CHECKPOINT-SEWING

15
 TOP 5 DEFECTS
S.NO JACKET TROUSER VESTCOAT

1 Shade/ damage/ weaving defect Overlock pulling Measurement defect

2 Lapel peak shape out/bend Button Pen mark/stain

3 Vent stitch open , up & down/tight W/B Seam open

4 Sleeve inseam stitching open & tacking miss/hiking Damage Pick stitch miss

5 Back seam open/improper/pleat/puckering Pin tacking Seam puckering

16
 ROOT CAUSE ANALYSIS
S.
Problem (What) Reason (Why1) Why2 Why3 Why4 Why5 Corrective action (How)
No.
Incorrect loading of Poor suitability of Improper cutting or Wrong way of Uniform process flow of bundle
1 Shade/ damage/weaving Wrong fabric issues
fabric into machine M/C bundling material handling handling from cutting to sewing
               

Margin Uneven while Less knowledge about Proper training and monitoring
2 Sleeve hiking Sleeve inseam lining tight Handling mistake  
stitching inseam sleeve margin width required

Uneven margin Recived wrong

Non-uniform margin in
        received from length and width Marker re-checking
marker
cutting from CAD

Lacking proper Poor garments

Poor machine maintenance as Proper hundle handling and regular
3 Pen mark/stain Improper workplace machine Wrong bundle handling handling at Cutting
a result of oil leakage   M/C maintenance required
maintenance and sewing
               

Irregular thread Improper stitch Incorrect feeding Supervise feeding system and
4 Pick stitch miss Skipped stitch Incorrect M/C threading
tension  balance system proper M/C maintenance

High tension of
M/C tension not Machine not adjusted Needs uniform Use of finer sewing thread which
5 Back seam open/puckering Wrong SPI machine while
adjusted with fabric thickness maintenance will retain sufficient seam strength.
stitching

SPI (stitches per inch) should be

             
reduced,
             
17
Use of right quality needle
 DHU%

0.00%
5.00%
10.00%
15.00%
20.00%
25.00%
30.00%
35.00%
01-Jun
02-Jun
03-Jun
04-Jun
05-Jun
06-Jun
07-Jun
08-Jun
09-Jun
10-Jun
11-Jun
12-Jun
SEWING DHU%

13-Jun
14-Jun
15-Jun
16-Jun
DATES

17-Jun
18-Jun
OVERALLDHU%JUNE'19

19-Jun
20-Jun
21-Jun
22-Jun
23-Jun
24-Jun
25-Jun
26-Jun
27-Jun
28-Jun
29-Jun
30-Jun
18
DHU%
IMPLMENTATIONS
19
 SEWING

ACTIONS
CHALLENGES 1.TRACKSHEET READING
1. IMPROPER CHECKING 2. SOP OF CHECKING TRACKSHEET
3. EVALUATION OF OPERATORS
4. CLOCKWISE CHECKING METHODOLOGY
OUTCOMES/PROGRESS
1.”WHAT TO CHECK” INFORMATION
2. CHECKING METHOD STANDARDISATION

SOP-CHECKING CLOCKWISE TRACKSHEET

SEQUENCE CHECKING METHOD READING
CLOCKWISE CHECKING SEQUENCE

JACKET TROUSER VESTCOAT 21

 SEWING
CHALLENGES ACTIONS
OUTCOMES/PROGRESS
1. TO IDENTIFY CRITICAL OPERATIONS 1.CRITICAL OPERATION IDENTIFICATION
1. NO SIZE MIXING OF CANVAS
2.IRREGULAR FULLNESS-CANVAS 2.STANDARDISED CHEST PIECE FULLNESS
ATTACHING ACROSS ALL LINES 2. SIZE WISE ADEQUATE FULLNESS
3.NO PROPER MONITORING OF NEW 3. CANVAS MARKING/LAPEL MAKING 3. EASY MONITORING AND TRAINING
OPERATORS 4. NEW OPERATOR IDENTIFICATION FOR NEW OPERATORS

CRITICAL
OPERATION

CRITICAL NEW /UNDER

OPERATION TRAINING TOP 5 DEFECT
CONTRIBUTING
CANVAS
IDENTIFICATION OPERATOR
IDENTIFICATION OPERATION MARKING

CHALLENGES
1. TO IDENTIFY AREA OF DEFECT
IDENTIFICATION LACKNESS OF QC.
2.GRADING OF CHECKERS
TRAINING
OUTCOMES/PROGRESS
ACTION 1. CHECKER’S KNOWLEDGE GRID
1.EVALUATION OF QUALITY 2. CHECKER’S GRADE UPGRADATION
CHECKERS
3. CHECKER’S SKILL LEVEL

EVALUATION MATRIX EVALUATION

 TWO HANDED PROCESS CHART TWO HANDED PROCESS CHART

TWO HANDED PROCESS

OPERATION - ENDLINE INSPECTION
OPERATION - LINING INSPECTION CHART STARTS -HOLDS GARMENT AT HANGER
CHART STARTS - HOLDS GARMENT AT HANGER CHART ENDS - PASSED FOR FINISHING
METHOD - STANDARD QUALITY CHECKING METHOD
CHART ENDS - PLACING GARMENT BACKAT HANGER
METHOD - STANDARD CLOCKWISE QUALITYCHECKING METHOD
LEFT HAND DESCRIPTION RIGHT HAND DESCRIPTION
LINING
Holds garment at hanger Holds garment at hanger
LEFT HAND DESCRIPTION RIGHT HAND DESCRIPTION Places it on another hanger for checking
Checks right shoulder seam
Places it on hanger for checking
Checks left shoulder seam
Checks right lapel Checks right lapel
Hold garment at hanger Holds garment at hanger Downwards moevement of checking Downwards movement of checking
Holds bottom Checks bottom
Brings garment to table Brings garment to the table Holds right bottom pocket Checks Pocket/pocket bag
Checks darts Checks darts
Checking collar by joining ends Checking collar by joining the ends Holds garment Checks pocket/pocket bag
Checks right side seams Holds garment
Holds garment upwards Aligns the edges for checking Holds armhole Checks right armhole
Downwards movement of checking Downwards movement of checking
Places garment back to table Places garment back to the table Holds sleeve Checks sleeve seams
CHART
Checks sleeve bottom hem Holds sleeve hem
Moves garment towards Right Moves garment towards right Move towards left side Move towards left side
Downwards movement while checking center back Downwards movement while checking center back
Moves garment downwards Checking right side seams Checks left shoulder seam Checks left shoulder seam
Checks left lapel Checks left lapel
Holds the garment in place Checking pocket and pocket bag Downwards movement of checking Downwards movement of checking
Holds bottom Checks bottom
Moves garment downwards Checking right panel seams and vents Holds left pocket Checks Pocket/pocket bag
Holds garment Checks pocket/pocket bag
Moves garment towards left Moves garment towards left Checks left side seams Holds garment
Holds armhole Checks left armhole
Checking of center back Checking center back Downwards movement of checking Downwards movement of checking
Holds sleeve Checks sleeve seams
Moves garment upwards Moves garment upwards Hold sleeve bottom hem Checks sleeve bottom hem
FLIP GARMENT OVER TO TOPSIDE FLIP GARMENT OVER TO TOPSIDE
Moves garment downwards Checking side seams TOPSIDE
Holds garment Checks right sleeve shape
Holds the garment in place Checking left pocket and pocket bag Checks left sleeve shape Holds garment
Hangs garment at hanger for checking Hangs garment at hanger for checking
Moves garment downwards Checking left panel seams and vents Checks sleeve buttons by joining both sides together Checks sleeve buttons by joining both sides together
Checks right shoulder seam Checks right shoulder seam
FLIPS GARMENT OVER FLIPS GARMENT OVER Holds garment Checks right lapel
Holds garment Checks button hole
Holds pocket Checks pocket /pocket flap
Holding garment and Checking collar Holding garment and Checking collar
Checks darts Checks darts
Checks side panels/side seams Checks side panels/side seams
Moves garment towards Right Checking right side seams
Holds right armhole Checks armhole
Holds right sleeve Checks sleeve
Holds the garment in place Checking right pocket bag Move towards left side Move towards left side
Check center back Checks center back
Moves garment towards left Checking seams Checks left shoulder seam Checks left shoulder seam
Holds garment Checks left lapel
Holds the garment in place Checking left pocket bag Holds garment Checks button hole
Holds pocket Checks pocket /pocket flap
Holds the collar Takes sticker and checks details Checks darts Checks darts
Checks side panels/side seams Checks side panels/side seams
Holds the sticker Details checked with washcare and main label Holds tracksheet Checks breast pocket/pocket bag
Holds left armhole Checks armhole
Holds the collar Signs the tafetta label and seals Holds left sleeve Checks sleeve
Turns garment around Checks label attached at collar
Holds and moves garment towards hanger Holds and places garment at hanger Holds washcare label attached inside Sign label
Removes garment from hanger Removes garment from hanger

24
Passed for finishing Passed for finishing

TOTAL TIME TAKEN FOR 1 GMT 1.08min TOTALTIME FOR 1 GMT 3.15 min
SEWING DHU%(AFTER)
MONTH/SECTION JACKET TROUSER VESTCOAT

JUNE 18.38% 18.38% 25.11%

SEWING DHU%
30.00%

25.11%
25.00%

20.00% 18.38% 18.38%

JULY 11.39% 11.39% 14.44%
14.44%

DHU%
14.01%
15.00% JUNE
11.39% 11.39% JULY
AUGUST
10.00% 8.43% 8.43%

5.00%

AUGUST 8.43% 8.43% 14.01%

0.00%
JACKET TROUSER VESTCOAT
GARMENT SECTION
25