Problem Recognition:

1st hour production=5Pcs

2nd hour production=15Pcs

 Objective: To improve 1st hour production

 Findings:
◦ No feeding of garment, sand paper and double
sided tape to operator at 09:00am.
 0.5
1
1.5
2
2.5

0
THREAD MARK

0.562
FOLDING MARK

2.096
SCRAPPING LESS

.062
THREAD CUT

.124
WHISKER LESS

1.252
WHISKER HEAVY

.114
WHISKER UNEVEN

1.508
TACKING DAMAGE

.062
FRONT DAMAGE

TACKING LESS

LOOP DAMAGE

.044 .006
BOTTOM DAMAGE

SIDE SEMI LESS

.146

ZIP DAMAGE

LOOSE THREAD
.104

BACK SIDE HEAVY

.01

BACK MERGING
.014

DARK LINE
AVERAGE DEFECT

.008

BACK SIDE UNEVEN

LESS CHEVRON

PANEL TO PANEL

BACK POCKET DAMAGE

.086

WHISKER MISS

FRONT RISE DAMAGE

.018
AVERAGE DEFECT

TOTAL-6.292%
2.5

2.05
2 1.85
1.8

1.5 1.35

1 DEFECT%

0.46
0.5
0.31
0.21
0.05
0.18 TOTAL-8.26%

0
1.8 1.71

1.6
1.37
1.4

1.2 1.07
1.01
1

0.8
DEFECT%
0.6
TOTAL-5.81%
0.4 0.31

0.2 0.08 0.03 0.04 0.07

0.04 0.02 0.01 0.05
0
 DEFECT%
1.16
1.2 1.05 1.06

0.8

0.6

0.4 0.31 DEFECT%

0.27
0.2 0.14
0.06 TOTAL-4.16 %
0.04 0.01 0.04 0.01
0.01
0
 DEFECT%

3
2.6
2.5

2 1.67

1.5 1.36

1
0.69 DEFECT%
0.43
0.5
0.23
0.04 0.01 0.04 0.01 0.09
TOTAL-7.17 %
0
 DEFECT%

3.5
3.07
3

2.5

2 1.59
1.32
1.5

1 DEFECT%

0.5 0.03 0.01 0.04

0
TOTAL-6.06 %
 Cause – Unwanted thread of row garment
 Effect – Appear thread like mark in surface of
the garment & it will appear more dense
when garment in final wash.
 Remedy – Clean all unwanted thread from
garment before it is send for dry process
from sewing .
 Cause – Uneven pressure in hand sanding
mannequin
 Effect – Appear mark in surface of the
garment .
 Remedy – Maintain appropriate air pressure in
each mannequin depending upon the size of
garment .
 Cause – It is occurred due to some wrong
assumption of whisker intensity.
 Effect – After wash it appear less as compare
to the standards .
 Remedy – Proper assumption of whisker
intensity before starting the whiskering
process .
 Cause – It is occurred due to unequal
intensity of whisker done by both operator( in
a garment every leg of whisker doing by
individual operator).
 Effect – After wash both leg appear unequal
whisker intensity.
 Remedy – Both operator should be doing
same intensity in every garment.
 Cause – It is occurred due to less scrapping
intensity done by some operator.
 Effect – After wash it appear less as compare
to the standards .
 Remedy – Proper monitoring & proper
checking of each & every operator.
 Cause – It is occurred in both hand sanding &
whisker due to unappropriated operation in
hand sanding & whisker, when operator by
mistakenly doing wronged scraping in
unwanted area where some embroidery
thread is there .
 Effect – Garment are treated as red tag, & it is
counted as a rejection garment.
 Remedy – Proper monitoring & proper
checking of each & every operator .
 Cause – tacking damage occur in washing
when tack is not removed before hydro then
some short of damage is occurred.
 Effect – Garment are treated as red tag, & it is
counted as a rejection garment.
 Remedy – Proper monitoring & proper
checking of each & every stage of operation .
 Cause – It is occurred due to some short of
missing tag.
 Effect –The garment appears tag less .
 Remedy – Proper monitoring & proper
checking in tagging operation .
 Cause – It is occurred in hand sanding , when
excess pressure is inserted in mannequin .
 Effect –The loop/front/back of garment is
damaged & it is treated as rejected garment .
 Remedy – Maintain proper air pressure in
every mannequin.
 Cause – It is occurred when side seam iron is
missing .
 Effect –Garment looks .
 Remedy – Maintain proper air pressure in
every mannequin