Presentation on Thesis Report. Minimization of Sewing Defects through Implementation of PDCA in Garments Industry of Bangladesh - A case study “Standard Group” . Green University of Bangladesh

1. Minimization of Sewing Defects
through Implementation of PDCA
in Garments Industry of
Bangladesh - A case study
“Standard Group”
Md. Rakibul Hassan
Student ID: 183014057
Department of Textile Engineering
Presented by
Dr. Jagannath Biswas
Associate Professor
Department of Textile Engineering
Supervised by

2. Introduction 01
Objectives 02
Literature Review 03
Materials & Method 04
Data Analysis 05
Result & Discussion 06
Data Findings 07
Conclusion 08
Thesis Presentation
Outline

3. Introduction
Sewing Defects
I will discuss about
sewing defects.
PDCA
I will try cover Plan Do
Check Action technology.
Pareto Analysis
I will analysis pareto
chart to identify root
problems.
Minimize Sewing
Defects
By applying PDCA
technique, I will try to
minimize sewing defects.
01 02 03 04
Sewing is the heart of garments manufacturing process. And sewing defects are the barrier of sewing
section. In this project I tried to minimize the sewing defects by applying PDCA technique.

4. Main objectives of my thesis are noted bellow:
Objective #1
Identification of the current sewing defects.
Objective #2
Performing Pareto analysis on the sewing line to
find out the root causes of the current sewing
defects.
Objective #3
Implementing PDCA cycle on the sewing line, in
order to minimize sewing defects.
Objectives

5. 01
John Krafcik (1988)
“The tale of Lean manufacturing” &
Lean Manufacturing device.
02
Mary Poppendieck (2002)
“Seven wastes on Lean manufacturing
Philosophy.”
03
Md. Tahiduzzaman & Mustafizur
Rahman (2018)
“Approach Industrial engineering to
minimize Sewing Defects
Literature Review
Quick review of some literature regarding minimize of sewing defects. Here are:

6. Different Types of Sewing Defects
1. Skip Stitch
Reason:
• Failure of hook or lopper and needle to enter loop at correct time
• Asymmetrical thread strain on upper or lower loop.
2. Broken Stitch
Reason:
• Inappropriate thread tension
• Needle plate, pressure foot, needle holes’ may have sharp edges
• Weak thread
3. Down Stitch
Reason:
• Operator carelessness
• Improper folding
• Lack of adequate training
4. Oil Spot.
5. No Tuck
6. Open Seam etc.

7. Causes Effect Fishbone Diagram
Causes Effect Fishbone Diagram for Skip Stitch

8. Causes Effect Fishbone Diagram
Causes Effect Fishbone Diagram for Broken Stitch

9. Materials & Method
Factory
Selection
Data
Collection
Pareto
Analysis
Implementation
of PDCA
Data
Collection
2nd Phase
Result and
Discussion
Data
Findings
Factory Selection
This study was conducted on “Standard Group-TCEL Woven Unit” sister concern of
STANDARD GROUP. This study was started December 2021 and it was carried out
January 2022

10. Materials & Method
Data Collection
The work was started in a sewing line, which line produced knit T-shirt. The initial data collected from that
throughout the sewing line of December 2021
Defects Count Cumulative count Cumulative %
Broken stitch 13 13 10.7
Loose tension 12 25 20.6
Hem Length Up down 13 38 31.4
Dirty Spot 10 48 39.6
Down Stitch 8 56 46.3
Join Stitch 9 65 53.7
Label missing 9 74 61.2
Needle mark 7 81 66.9
Oil Spot 8 89 73.5
Open seam 6 95 78.5
Part shading 7 102 84.3
Pleat 6 108 89.3
Point up down 7 115 95.1
Print defect 6 121 100

11. Materials & Method
Pareto Analysis
13
12
13
10
8
9 9
7
8
6
7
6
7
6
10.7
20.7
31.4
39.7
46.3
53.7
61.2
66.9 73.6
78.5
84.3
89.3
95.0
100
0
2
4
6
8
10
12
14
Count
Cumulative
%
Pareto Chart Analysis of Sewing defects in a line (December)
Count Cumulative %

12. Materials & Method
Implementation of PDCA
PLAN Establish objectives and processes required to deliver the desired results.
DO
Process implementation according to PLAN:
- Install, adjust and use the machine properly.
- Using a good needle, quality-sewing thread and supported equipment’s.
- Recruit expert operator.
- Spend proper time for each operation.
CHECK
Inspection of the process:
- Planned monitoring and measure the process and the products.
- Check if the defects are reduced or not?
- If the defects are not occurring or reducing, then continue the action of the process
successfully.
- If defects are occurring, then go back to the PLAN stage and develop some more
ideas for solving and reducing defects and go through the cycle again.
ACTION
- Take action on the accurate process for continually improving process performance.
- If any defects are found, then start the PLAN stage for solving it.

13. Materials & Method
Data Collection 2nd Phase
By applying PDCA technique, I have collected data again from the same sewing line of January 2022.
Defects Count Cumulative count Cumulative %
Broken stitch 11 11 10.8
Loose tension 12 23 22.5
Hem Length Up down 10 33 32.4
Dirty Spot 9 42 41.2
Down Stitch 5 47 46.1
Join Stitch 7 54 52.9
Label missing 8 62 60.8
Needle mark 6 68 66.6
Oil Spot 7 75 73.5
Open seam 5 80 78.4
Part shading 6 86 84.3
Pleat 5 91 89.2
Point up down 6 97 95.1
Print defect 5 102 100

14. Materials & Method
Pareto Analysis
11
12
10
9
5
7
8
6
7
5
6
5
6
5
10.8
22.5
32.4
41.2 46.1
52.9
60.8
66.6
73.5 78.4
84.3
89.2
95.1
100
0
2
4
6
8
10
12
14
Count
Cumulative
%
Pareto Chart Analysis of Sewing defects in a line (January)
Count Cumulative %

15. Result and Discussion
After getting the number of defects from the sewing line (December 2021 & January 2022) in which I
applied PDCA technique. This table is showing that before applying PDCA the number of sewing defects
were 179, and after applying PDCA the number of sewing defects are 149. That means I have
successfully reduce 30 defects.
Defects 31st December 2021 (Before) 31st January 2022 (After)
Broken Stitch 22 18
Loose tension 17 16
Hem Length Up-Down 18 15
Dirty Spot 19 16
Down Stitch 13 11
Join Stitch 18 14
Label Missing 19 15
Needle Mark 20 16
Oil Spot 14 11
Open Seam 19 17
Total = 179 = 149

16. Result and Discussion
This pareto chart is clearly showing the difference between numbers of defects of two months.
22
17
18
19
13
18
19
20
14
19
18
16
15
16
11
14
15
16
11
17
-1
4
9
14
19
24
No.
Of
Defects
Pareto Analysis Between 2 months
31st December 2021 (Before) 31st January 2022 (After)

17. Data Findings
Lets get to the findings of the project:
Findings #1
Before implementation of
PDCA, number of sewing
defects were 179.
Findings #2
After implementation of
PDCA, number of sewing
defects are 149.
Findings #3
After implementing PDCA, I
have reduced 30 defects in
a sewing.

18. Overall, it is concluded that the PDCA cycle is a tool that facilitates the
identification of implementation of these opportunities in disability
reduction projects. Therefore, garment manufacturing companies in
Bangladesh are in dire need of these techniques.
Conclusion

19. QUESTIONS

20. THANK YOU !