The document compares theories about reducing rework and rejection in manufacturing to practical experiences. It discusses categories of errors, common causes, and differences between what is expected and what occurs in practice. Key differences include non-sewing defects being more common than expected and employees sometimes discarding pieces with errors instead of reworking them. The document advocates learning from practical experience rather than just online sources and motivating employees to admit errors for correction.

1. Reduce Rework and Rejection

2. •In this review, its all about
how we thought it was and
how it is. i.e, the basic
comparison between theory
and practical experience.
•The best part is that, in most
of the cases it matches.

3. Theory
• Three Categories:
• Minor
• Major
• Critical
• Cause of error:
• Sewing
• Non-Sewing
Practical
• Three Categories:
• Minor
• Major
• Critical
• Cause of error:
• Material(slubs, neps)
• Process(sewing, printing,
dyeing)

4. Theory
• Studies say sewing
defects are more common
and are seen mostly.
Practical
• When analyzed in
industry, they non-sewing
defects are seen
randomly.
• Sewing defects does not
happen mostly, only
skilled tailors are used.

5. Theory
• Once a mistake is done,
time consumption is more
as they have to remove
the old work and then
rework it again.
Practical
• Employees at times do a
serious error, once a stitch
goes wrong they throw
away their material aside
and continue with the next
one.
• This causes a serious
error of missing piece.
• So this must be avoided.

6. Theory
• Skilled professionals go
through the entire length
of the fabric finding each
error that passes by and
then marking that place by
a sticker.
Practical
• Skilled professionals go
through the entire length
of the fabric finding each
error that passes by and
then marking that place by
a sticker.

7. Theory
• Once they find out the
error, the part of the fabric
with the error is cut off
and the remaining fabric is
used.
Practical
• Once they find out many
errors in a single fabric,
they keep that piece aside
to be collected by the
buyer and get a replaced
one.
• Mostly the buyers don’t
collect them and they are
thrown into garbage.

8. Theory
• Rejection Percentage=
• (Total Rejected
Garments*100)/(Total cut
quantity)
Practical
• Rejection can’t be
determined.
• Mostly it does not happen.
• If the buyer is
considerable enough they
give enough chances to
the manufacturer.
• If not they get bashed out
in the first check itself.

9. Theory
• They provide regular
training to employees.
• They check garments
after each process to
make sure of no errors.
• In case of regular errors,
rework is done.
Practical
• They monitor the
employees.
• Employees are arranged
based on the area in
which they are
specialized.
• In case of regular errors,
either the employee is
changed or the reason for
error is analyzed.

10. Theory
• Correct it after it occurred.
• Take analysis report and
then do it.
Practical
• Analysis report is also
taken, but the best way is
to prevent it.
• In that way, they follow the
5S method that prevents
errors in most of the
cases.

11. Theory
• Just free of errors.
• No damage.
• As expected output.
Practical
• Consistency
• Uniformity
• Low Tension
• Penetration

12. Theory
• Being careful
• By reducing errors
• Working even more
careful
Practical
• 5S method
• Seiri
• Seiton
• Seisto
• Seiketso
• Shitsuke

13. Theory
• Though you refer lots of
websites or read a lot,
lessons via you get only a
minimal quantity.
• Even when you are
whole-ly prepared, there
are many more inside the
industry.
Practical
• When you see through
real eyes instead of virtual
reality, you get to know
more and discover more.

14. Theory
• Experienced reports are
available in internet which
may provide real-life facts,
but the thing is that they
come for a single-user
payment of $ 3,000 which
equals INR 1.92Lacs.
• It would be more helpful if
people in industry come
forward and publish it as
free or low cost articles.
Practicals
• Employees must be even
more motivated and made
to feel free so that they
feel free to admit their
errors and correct them
rather than them, hiding or
throwing off their pieces
which may cause a huge
confusion.

15. 16BFT1006