QMS Standardization project for apparel manufacturing.pdf

This project created by
Mustafijur Rahman
A way for QMS Improvements
QMS Standardization Project
for Apparel Manufacturing
Project Created and Designed By
Mustafijur Rahman
QA & QMS Professional, CLSSBB, ISO 9001 QMS LA, LSSGB, TQM, Advance TOT
Contact: 01775535548 (WhatsApp)
Mail: m.Rahman.qatss@gmail.com
LinkedIn: https://www.linkedin.com/in/mustafijur-rahman-qa-tss

Mustafijur Rahman
The purpose of this project is to standardize the Quality Management System (QMS) in the Apparel to ensure
consistency, and compliance with industry standards, and to enhance product and process control. The project
will focus on implementing Good Manufacturing Practices (GMP) and establishing a robust system for quality
assurance and quality control.
The main objective of this project is to make Apparel as a standard to meet all Customers
QMS, GMP, As well as Product and Process control procedures by focusing on TQM and
Continuous Improvements.
By this project will :
1. Archive Zero Inspection Failure rate
2. Get Good and low OQL Rates from Inspections
3. Archive High scores in any Audit
4. Be free from any customer & product complaints
5. Get customer satisfaction and good feedback.
6. Establish 7 Quality Management Principles & TQM.
Project Timeline: 2 Months
Project Owner & Leader : Mustafijur Rahman
A project for Establishing an Effective QMS & GMP

Mustafijur Rahman
Effective QMS & GMP Establishment in Apparel Manufacturing
Content of QMS Standardization
1. Set Goals and KPI
2. Develop & Communicate SOP, JD & Work Instruction
3. GAP Analysis & Measurement System Analysis
4. Section-wise QMS Process Standardization
5. Established 7 QMP (Quality Management Principle )
6. Batch Tracking, Real-Time Inventory & First In And First Out (FIFO)
7. RCA, CAP, PAP & Investigation Report
8. RCA & 8 Wastage (DOWN TIME) Analysis
9. Hourly TOP Defects analysis, CAP & PAP
10.RFT and FTY Projects
11.Sewing Quality Parameter Testing Report
12.Quick Response Process
13.Build up the QCC Team
14.Install traceability and mold prevention procedures.
15.Implement 6S System for better housekeeping
16.Kaizen for Continuous Improvement
17.Visual Management System- Sharp tools Bord, Broken Needle Procedure flow Bord, 5S & 8 Wastage Bord
posted on the key place of the wall for standardized visual management system .

Mustafijur Rahman
Business without Goals, and Plans to reach them, we are like a ship that has set sail with no Destination
If we can’t Measure it, we can’t manage it.
Step-01: Set Goal and KPI
Purpose: The purpose of this setting Goal and KPI is to measure employees’ performance and skills.
Scope: This KPI and goals will apply to all employees in all units.
Objective: The main objective of this step:
1. Setting goals and KPIs ensures that the unit's activities and efforts align with the
organization's overall strategic objectives.
2. By tracking KPIs, the organization can assess the unit's productivity, efficiency, quality,
and effectiveness, allowing for the measurement of progress towards specific targets.
3. Clear and measurable goals combined with KPIs can motivate employees within the
unit, providing them with a sense of purpose and direction
4. Goals and KPIs provide a framework for holding the unit accountable for its
performance.
5. KPIs provide valuable data and insights that support informed decision-making within
the unit.

Mustafijur Rahman
Without a defined course and purpose, we risk drifting aimlessly, lacking direction and coherence in our efforts
Without knowing JD & WI, No can perform better
Step-02: Develop & Communicate JD & Work Instruction
Purpose: The purpose of this implementation JD & WI for understand employees’ rules, responsibilities, and
tasks leading to improved productivity, streamlining processes, and enhanced performance across the
organization.
Scope: This JD was developed for all positions within Apparel including Quality, Operational, etc., and developed
work instructions for critical processes.
1. Develop detailed job descriptions for all positions within the
organization.
2. Create comprehensive work instructions for key processes and tasks.
3. Ensure alignment between job descriptions, work instructions, and
organizational goals.
4. Train employees on the use and importance of job descriptions and
work instructions.

Mustafijur Rahman
Without measuring and delegating responsibilities, we can not achieve our Goals and Objectives.
If we can’t Measure it, we can’t manage it.
Step-03: GAP Analysis & MSA
Purpose: The purpose of this step is to identify the GAP of Employees, and train Coach them to overcome
Scope: This GAP Analysis MSA will be applied to all section employees of Apparel.
1. Identify employee’s knowledge GAP and do Training Need Analysis.
2. Measure employee performance and take preventive action plan.
3. Empower employees by guiding and instructing.
4. Trains employees based on their knowledge GAP.

Mustafijur Rahman
The importance of QMS standardization lies in its capacity to establish consistent, documented procedures
and practices across an organization, ensuring regulatory compliance, improving efficiency, and fostering a
culture of quality.
Step-04: QMS Standardization
Purpose: The purpose of this QMS Standardization process, is to make Apparel a standard to meet all customer’s
requirements, process and product quality and a good manufacturing process.
Scope: This process will implemented in all manufacturing units and sections in Apparel.
1. Ensure compliance with relevant regulatory requirements, industry standards, and
customer specifications.
2. Enhance product or service quality by implementing best practices and continuous
improvement methodologies.
3. Trains and guides employees about customer standards and requirements to meet.
4. Enhance customer satisfaction by delivering products or services that meet or exceed
their expectations.
5. Foster a culture of quality, accountability, and responsibility throughout the
organization.
6. Continuously improve organizational performance and achieve strategic objectives
through systematic management of quality processes

Mustafijur Rahman
Step-05: Established 7 QMP (Quality Management Principle)
Purpose: The purpose of this established 7 QMP (Quality Management Principle) for standardized organizations
QMS System aligns with ISO QMS System
Scope: This process will implemented in all manufacturing units and sections in Apparel.
1. To provide a framework for organizations to enhance their performance,
customer satisfaction, and overall success through effective quality
management practices.
2. These principles are guiding values underpinning quality management
systems and help organizations achieve their quality-related goals.
By adhering to these principles, organizations can foster a culture of quality,
continuous improvement, and customer focus, thereby driving organizational
excellence and sustained success.

Mustafijur Rahman
Effective inventory management is the silent guardian of business success, ensuring every product finds its
purpose, every resource is maximized, and every opportunity is seized
Step-06: Batch Track, Real-Time Inventory, and FIFO
Purpose: The purpose of this process is to track inventory and control for saving cost.
Scope: This process will be applicable in all inventory process in all section
1. Batch Track: To accurately trace and monitor the production, distribution, and
utilization of batches or lots of products, ensuring accountability, quality control, and
regulatory compliance throughout the supply chain.
2. Real-Time Inventory: To maintain up-to-date and accurate records of inventory levels,
locations, and movements, enabling efficient inventory management, timely order
fulfillment, and avoidance of stockouts or overstock situations.
3. FIFO (First-In, First-Out) Process: To ensure that inventory is used in the order it was
received, minimizing the risk of product expiration, obsolescence, or deterioration,
and optimizing product quality and shelf life while reducing waste and costs.

Mustafijur Rahman
Step-07: RCA, CAP, PAP & Investigation Report
Purpose: The purpose of this process is to find out the actual cause of any NC/Defect/Mistake and to take
preventive action to solve those permanently.
Scope: This RCA, CAP, PAP, and investigation report will apply to Hourly Top Defect Analysis, Any Mistake,
Inspection failure, Customer claim, any Defective/Non-Conforming, Rejection Cause Analysis, and taking
preventing action plan.
1. Prevent any defect, non-conforming, mistake, etc. permanently by finding out the actual cause.
2. Stop re-occurrence and rejection rate.
3. Identify hidden cause of continuous problem.
4. Analysis Rejection Root Cause and reduce rejection rate.

Mustafijur Rahman
Step-08: RCA & 8 Wastage (Down-Time) Analysis
Purpose: The purpose of this process to effective analysis for production hampering and bottleneck.
Scope: This process will be applicable in all manufacturing areas.
1. Trains production people about 8 wastage.
2. Implement and communicate downtime process.
3. Root Cause Analysis for production hampering and less production.
4. Take corrective action plan and preventive action plan for production reduce.
5. RCA to reduce employees absenteeism.

Mustafijur Rahman
Step-09: Hourly Top Defect Analysis.
Purpose: The purpose of this process to prevent top defect hourly basis purpose of DHU Reduce.
Scope: This process will applicable in cutting, sewing and finishing quality check point areas.
1. To prevent top defect top defect hourly basis.
2. To find out major defect and mistake hourly basis and minimize this in place.
3. Develop root cause analysis, corrective action and preventive action process
4. Reduce DHU Rate randomly by hourly top defect analysis.

Mustafijur Rahman
Step-10: RFT and FTY
Definition: Right First Time (RFT) is a concept from Total Quality Management (TQM) that is intended to
ensure that activities are performed correctly the first time so that no rework is necessary.
Purpose: The purpose of the RFT Project is to prevent Defects and Non-Value Added Activities by
ensuring RFT and continuous improvements.
Scope: The Scope of the RFT Project can be determined based on the specific needs and the goals of the
organization. It may include a specific process, a particular product or production line, or the entire
organization.
Objective: Build a Quality Mindset and quick response to prevent any defect from the source.
Goals: Prevent Defects, Eliminate Non-Value Added Activities, and ensure the production of the product
right first time by the right decisions.
Responsibility: Management, Managers assigned staff, and leaders are responsible for their areas of RFT.
RFT Project Required for:
1. Operator to produce right 1st time product.
2. The Quality Checker to check and confirm the product by 1st time check.
3. Staff and Managers to make the right decision in 1st time.
4. Managements to utilize skills and delegate responsibility to the right Person.
5. Process Owner/ Operator to complete on the right first time.
6. Section-wise Suppliers to supply the items according to approved standards at the 1st time.

Mustafijur Rahman
Step-11: Sewing Quality Parameter Testing Report
Purpose: The purpose of this process ensure sewing line quality by testing line key point.
Scope: This process will be applicable for sewing line to ensure line quality.
1. By this process quality inspector will check key process sewing quality parameters.
2. Tack Sewing line by randomly follow up and take corrective action plan.
3. Take action plan to prevent any problem permanently.
4. Ensure hourly basis input trims & cut panel quality, pattern & marking process accuracy, edge cutting process,
Machine set up and process followed Mock-up, quality inspection process validation.

Mustafijur Rahman
Step-12: Quick Response process.
Purpose: The purpose of this process to fix any problem immediately.
Scope: This process will be applicable in all manufacturing areas.
1. Reduce Inventory time and lead time.
2. Reduce defect and mistake fixing time.
3. Minimize delayed response and lead time.
4. Eliminate Non Value added wastage in the organization.
5. Build a Strong communication system and supply chin.

Mustafijur Rahman
Step-13: QCC (Quality Control Cercle) Programs
Purpose: The purpose of This team A quality control circle (QCC) team of people usually coming from the
same work area who voluntarily meet regularly to identify, investigate, analyze, and solve their work-related
problems
Scope: These programs will be applicable in all manufacturing areas.
1. To identify current weaknesses in product packaging.
2. To develop strategies for improving product packaging quality.
3. To implement changes and monitor their effectiveness.
4. To ensure compliance with relevant quality standards and regulations.
Deliverables:
Assessment report detailing current packaging quality issues.
1. Proposal for improvement strategies.
2. Implementation plan outlining steps to enhance packaging quality.
3. Monitoring mechanisms to track the effectiveness of implemented changes.
4. Updated quality standards and procedures documentation.

Mustafijur Rahman
Step-14: Install Traceability and Mold Prevention Process.
Purpose: The purpose of this process to ensure Apparel all unites are easy to trace anything and mold free.
Scope: This process will be applicable in all manufacturing units.
1. Ensure all process and product are traceable and mold free.
2. Identify any equipment's easily to use.
3. All used tools and equipment's are free from mold and traceable
4. Track trackability and mold prevention procedure are implemented properly.
5. Standardize traceability and mold prevention process.

Mustafijur Rahman
Step-15: Implement 6S System.
Purpose: The purpose of this 6S Process Implementation to standardize Apparel Housekeeping.
Scope: This system will be applicable in Apparel manufacturing units.
1. Trains employees about 6S system to ensure better housekeeping.
2. Establish 6S Culture to organize and trace any thins easily.
3. Ensure proper cleaning system as per 3S- Shine.
4. Maintain 6S Auditing System to follow-up.
5. Make Apparel working environments as standards.

Mustafijur Rahman
Step-16: Kaizen for Continuous Improvement
Purpose: The purpose of this concepts to make a continuous improvement culture in Apparel.
Scope: This concept will be applicable in Apparel all manufacturing units.
1. Implement Kaizen in section wise to change for better
2. Implement kaizen event to show the progress of this Kaizen Projects.
3. Find out weak points and substandard to make it better.
4. Analyses process and find out better and make it as standards.
5. Follow-up Continuous improvement projects

Mustafijur Rahman
Step-17: Visual Management System- Sharp Tools Board, Broken Needle
Procedure flow Board, 5S & 8 Wastage Board.
Purpose: The purpose of this process to visualize and communicate Sharp tools, Broken Needle, 5S & 8 Wastage.
Scope: This Visual Management System will apply to all employees in all units.

Mustafijur Rahman
Next Project will be:
1.PDCA
2.TPM
3.Poka Yoke
4.DMAIC

THANK YOU
BY Mustafijur Rahman
QA & QMS Professional, CLSSBB, ISO 9001 QMS LA

QMS Standardization project for apparel manufacturing.pdf

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