Garment Manufacturing Defects: A Case Study

2.4 Garment Manufacturing Defects

Defects play a great negative impact on the productivity of the garments manufacturing. If a defect was detected in the final inspection, the defective piece has gone a long way before the defect was detected. The consumption time and cost of the production process for a defective garment are totally wasted as the product cannot reach on time (Uddin and Rahman 2014).

In addition (Uddin and Rahman 2014) Speaks, defects usually arise from different garment areas of fabric sections, sewing sections, or finishing sections and they studied a primary investigation on these different sections in order to identify the area where most defects were occurred. Finally through DMIAC methodology of six sigma they conducted

1. Probability of failure occurrence (O)

This factor determines the possibility of occurrence of a potential cause or mechanism of failure.

Or, the probability of occurrence specifies that a potential error happens with a specified frequency. The probability of occurrence is evaluated on the basis of a range of 1–10.

Now it is essential to examine the cause of a failure mode and its probability of occurrence. All the possible causes for a failure mode should be identified and documented. Causes can be human faults, manufacturing errors, and so on. Therefore, only through the elimination or reduction of the causes or mechanisms of each failure, it would still be possible to reduce the number of different failures, possible values.

2. Severity of failure (S)

Severity is the intensity of the effect of failure on the product or end-user’s experience.

Severity of failures is expressed on a scale from 1 to 10, ranging from “none” to “dangerously high”

3. Detectability of failure

RPN evaluation

After achieving Severity (S), Occurrence (O) and Detect (D), these values should be multiplied, to calculate the RPN number as RPN=(S)*(O)*(D)

In addition RPN value lies in a range of 1 and 1,000 and failures will be ranked with regard to their numbers. Failures of high risk priority are preferred to be examined more carefully, and operators should concentrate on errors owning a higher RPN value and RPN is a measure for separating tolerable and intolerable risks in the mentioned system (Pazireh et al 2017).

(Yucel 2007) carried out an application of FMEA for defining the potential fault types and decreasing the negative effect on production systems in a clothing factory. A team was set up to find the causes of the faults. Finally, it was obtained 4.1% decrease of seam fault in the trouser production line and 5.2% in the shirt production line. Additionally, 966.3 minutes reduction time was achieved in the fault correction.

In addition to different researchers (Rohit S. 2015) says application of FMEA helps:

• To expand the quality, reliability and safety of a product/process

• Improve company image and competitiveness

• upgrade users satisfaction

• Reduce system development time and