This document discusses rework and rejection in apparel merchandising. It defines rework as fixing small errors, while rejection refers to unfixable damage. Defects are the main cause and come from materials or processes like cutting and stitching. To reduce reworks and rejections, the document recommends preparing a rejection analysis report to identify the most common errors. It then provides solutions for specific defects like uncut threads, open seams, and ink marks. The overall approach is a two-step process of analysis and critical review to prioritize solutions based on the most frequent defects.
2. Rework & Rejection
ORework is done when the errors are
small and can be rectified when
worked upon.
ORejection is the final decision taken
when the errors or damage is in
large scale and nothing can be
done to correct it.
3. Why this happens??!
O The main reason to this is DEFECT.
O Rework and rejection happens when the
garment gets deviated from its ‘perfect
state’ and gets occupied by defects.
O Defects are of two types:
1. Sewing defects
2. Non-sewing defects
4. Reasons for Rejection
O During inspection and packing garments are
rejected due to certain faults.
O Defects are due to two main categories.
1. Material defects (50% responsibility)
a) Fabric defects
b) Trims & Accessories defects
2. Process defects (50% responsibility)
a) Cutting
b) Stitching
c) Finishing
d) Packing
5. Reducing Rework & Rejection
O There is no readymade solution for
reducing rejection percentage. Each order
is different.
O But different solutions can be given on
how to handle this.
O Rejection percentage of an order=
(Total Rejected Garments*100)/(Total cut
quantity)
6. Reducing Reworks
O UNCUT THREAD
Under bed trimmers are used and good quality
thread cutters are used.
O OPEN SEAM
Proper threading, maintain tension, use quality
thread
O PUCKERING
Operator training, Using apt fabric and thread.
O BROKEN STITCHES
Use quality thread and needle and proper
alignment of needle
7. CONTN..
O IMPROPER FOLDER SETTING IN MACHINE
Adjust folder guide, Improper material handling is
avoided
O MARGIN NOT FOLLOWED WHILE
ATTATCHING WAIST BAND
Operator instructed to be careful while feeding the
fabric
O POOR QUALITY FUSING
Use quality fusing, use skilled operators
O IMPROPER NOTCHES WHILE PLEATING
Misalignment during cutting is avoided
8. CONTN..
O OILSPOTS
Applying a scrap paper under the presser
feet of the machine after day’s work so that
the machine leaks can be tracked.
O INK/CHALK MARKS
Use good quality markers, markers which are
washable.
O SOIL & DUST
Use plastic bags for storing and transporting
9. Reducing Rejection
O Reducing rejection is a two-step process
O The first step is to prepare a rejection
analysis report, from which the reasons of
rejection can be sorted out.
O And the next step is to give a critical
analysis of the rejection analysis report,
containing the solution.
10. Step-1
Rejection Analysis Report
O The main purpose of this report is
IMPROVEMENT.
O Getting improvements done in garments.
O To do this the first step is to identify the
reason for poor performance.
O This is done by analyzing all the rejected
pieces.
O A clear report is produced by calculating the
percentage of each occurred error and their
reoccurrence.
11. Step-2
Critical Analysis of rejection analysis report.
O Depending on the results of the rejection
analysis report, the reasons for rejection
are sorted out.
O Now depending on majority and minority
of reoccurrences the list is prepared.
O Now measures are taken based on priority
of the top most defect.
12. In review 2
O So far the steps to rework and rejection is
studied based on theories of other people.
O For the next review through personal
experience the ways to reduce rework and
rejection will be taken note of.
