The objective of this research is to implement Plan-Do-Check-Act (PDCA) cycle to reduce common sewing defects found in 14 days timeframe. The common sewing defects were found through the pareto chart, which include broken stitches, raw edges, and uncut threads, which harms the production quality and costs. Fishbone diagram is used to search for the root causes. The 5WH (who, what, when, where, why, and how) technique helps develop practical solutions, thus completing the planning stage. After the application of PDCA, an audit was done, that shows the average defective production drop went from 12.61% to 8.09% as well as the average number of defects per hundred units (DHU%) decreased from 14.66% to 9.00%. These results prove that PDCA is useful for reducing defects. In conclusion, this study is done to highlight the wider range of the use case of PDCA cycle in garments industries.
Reducing Sewing Defects in RMG Manufacturing for Continuous Improvement: A PDCA Framework Approach
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