In apparel manufacturing, it'll not be a surprising thing if we found few rejected garments after shipment. Reason, most of the manufacturers believe that garments are dry goods and non-repairable defect may occur thanks to inferiority raw materials or faulty process or employee casual behavior. However factory must have check points to regulate over this issue.
There is no ready-made solution which will reduce rejection percentage overnight. Each order is exclusive . But I can suggest you ways to handle this issue and convey down rejection rate. Do i want to elucidate the way to calculate rejection percentage of an order? it's adequate to Total rejected garments *100/ Total cut quantity.
You got lot of rejected garment after shipment. You termed as rejected because those garments can’t be repaired by any means. you would like to scale back the share of rejections in your future shipment. to succeed in your goal, follow my recipe: you would like to read and act as you read to urge result.
Collect all rejected pieces. All means all pieces those weren't shipped which is adequate to cut quantity minus shipped quantity.
Call your garment checkers who understand what are defects and may find why those garments are rejected.
Ask them to diagnosis all rejected garments or defective garments. Defect analysis are often done to ways – one: you a have quality system in situ where checkers check garments and make report during checking, two: after getting rejected pieces rejected by final checker (who don’t made report) do fault finding in those rejected garments.
From your diagnosis, pick highest occurring defects (top 5 defects) and do exercise on finding root causes of these defect generations. Bring your quality personnel, production and technical personnel during this exercise.
Once you found the list of root causes for every defects, your next task is to seek out the way the way to stop making those defects again by eliminating root causes. i feel this task won't be very difficult to you as you're during this business and understand how error occurred. In case, you don’t find the thanks to cure root causes you would like to hunt for help from your colleagues or experts.
You found some solutions. Great! Make standard procedures to prevent generating same defects during processing in future. Implement it. See the result's your next shipment.
This is the thanks to improve move ship ratio and reduce rejection percentage rate. i think - corrective action is that the only remedy for stopping further defect generation
Once you found the list of root causes for every defects, your next task is to seek out the way the way to stop making those defects again by eliminating root causes. i feel this task won't be very difficult to you as you're during this business and understand how error occurred. In case, you don’t find the thanks to cure root causes you would like to hunt for help from your colleagues or experts.
You found some solutions. Great! Make standard procedures to prevent generating same defects during processing in future. Implement it. See the result's your next shipment.
This is the thanks to improve move ship ratio and reduce rejection percentage rate. i think - corrective action is that the only remedy for stopping further defect generation
Good practices to regulate defect generation within your factory
Make the workplace clean – From fabric store to cutting to sewing to washing and finishing.
Place internal control system in situ . I mean sufficient no. of checkers, trained checkers, checkers making report while checking, analysis of reports and take action supported the standard check reports.
Conduct educational program for the checkers on the way to check piece correctly to capture defective pieces. Train them to form garment checking reports.
Run quality awareness program for your employees.
Quality standard must be understood by each employee and everybody need to work to satisfy quality goal.
No low standard work should be accepted by the subsequent department.
In sewing line don’t allow operators to stay bundles open and every bundle must be completed before forwarding to subsequent . it'll assist you track missing pieces. As per my experience, operators throw pieces under tables once they make mistake or receive defective (incomplete) garments from previous operator. Nobody keeps track of those missing pieces until you found shortage of clothes in finishing.
Set standard operating procedures (SOP) for every task performed by your employees. SOP for internal control system for every department.
Set audit team to audit your quality system during a regular interval.
Implement 5S in your factory.
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