Research Journal of Management Sciences ____________________________________________ ISSN 2319–1171 Vol. 2(8), 10-15, August (2013) Res. J. Management Sci. International Science Congress Association 10 Minimization of Defects in the Sewing Section of Apparel Industry Md. Mazedul Islam, Adnan Maroof Khan and Md. Mashiur Rahman Khan2 Department of Textile Engineering, Daffodil International University, Bangladesh, BANGLADESH Department of Apparel Manufacturing Engineering, Bangladesh University of textiles, BANGLADESHAvailable online at: www.isca.in Received 2nd May 2013, revised 9th June 2013, accepted 5th July 2013 AbstractThis article is inspired by many unavoidable issues in rejection of huge number of finished apparel products after shipment due to quality control failure in apparel manufacturing. The fast changing economic conditions, such as global competition, declining profit margin, customer demand for high quality product, product variety and reduced lead–time etc. play a major impact on apparel manufacturing industries. The demand for higher value at lower price is increasing and to survive, apparel manufacturers need to improve their operations through-producing right first time quality. This paper discusses the quality and productivity improvement in apparel manufacturing by minimizing reworks that usually occur in the production process. The application of this paper improves the process performance of the critical operational process, leading to better utilization of resources, decreases variations and maintains consistent quality of the process output. The outcome of this observation reflected that an industry may gain higher productivity and profitability with improved quality product by minimizing defects. It also minimizes cost and improves internal throughput time. A general overview over the development is given in this paper that suggests how to handle these issues and bring down rejection rate to minimum. Keywords: Apparel Defects, Cost reduction, Productivity, Profitability, Product Quality, Reworks. Introduction As the global economic condition changing in a rapid motion, generally in an industry more focus is given on profit margin, customer demand for high quality product and improved productivity. In garment manufacturing, it is usual that there will be few rejected garments after shipment. Reasons are most of the manufacturers believed that garments are soft goods and non-repairable defect may occur due to low quality raw materials or faulty process or employee casual behavior. However, factory must have check points to control over this issue. There is no ready-made solution that can reduce rejection percentage overnight. Each order is unique. But this paper work suggests how to handle such problems and bring down rejection rate to minimum with quality production. As we see a lot of rejected garment after shipment, most of the organization termed these garments as rejected because those garments can’t be repaired by any means. Reworks in the garments industry is a common works that hampers the smooth production rate and focus poor quality products having an impact on overall factory economy. Minimization of reworks is a must in quality and productivity improvement. Reworks are a vital issue for poor quality product and low production rate. Reworks are the non productive activities focusing on any activity that customer are not willing to pay for. Non productive activities describe that the customer does not consider as adding value to his product. By reacting quicker in minimization of reworks to make a product as per customer demand with expected quality, the company can invest less money and more costs savings. Therefore, a study was carried out in the garment industry named Opex and Sinha Textile Group located at Mirpur, Dhaka, Bangladesh at sewing section to identify reworks so as to eliminate them for saving time, cost and improved product quality. Problem Statement and Methodology To be effective in defects and rejection reduction, it is essential to establish and maintain clear, complete and current written records of inspection and test procedures for each operation. These records should identify criteria for acceptance/rejection. In the Apparel Manufacturing Industry, main raw material is fabric; others are different types of trimming and accessories. Operational wastages in the Apparel manufacturing process are- top surface rework, printed label rework, sewing defects, pinhole rework, fabric defects, improper fly shape, and other reworks. To achieve the overall objective in minimizing defects and rejection of finished products it is needed to establish document and maintain a system capable of ensuring that products conform in total to standards specifications. This will be required at every stage of manufacture. Records must be maintained to give objective evidence that the specified requirements have been met. Also need to appoint a management representative preferably independent of other functions to be responsible to oversee the total control system and inspection at each stage of manufacture. The person appointed should have the necessary authority to execute any action related to achieving the desired standard of product. To be effective the system requires planned periodic review by senior management to ensure that its effectiveness is maintained. The general methodology followed to minimize defects rate is given in figure 1.