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Analysis of major defects and finding their root causes in a sewing section of a selected Garments factory in Bangladesh

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Author Affiliations

  • 1Department of Industrial and Production Engineering, Shahjalal University of Science and Technology, Sylhet, Bangladesh
  • 2Department of Industrial and Production Engineering, Shahjalal University of Science and Technology, Sylhet, Bangladesh
  • 3Department of Industrial and Production Engineering, Shahjalal University of Science and Technology, Sylhet, Bangladesh
  • 4Department of Industrial and Production Engineering, Shahjalal University of Science and Technology, Sylhet, Bangladesh

Res. J. Engineering Sci., Volume 10, Issue (1), Pages 31-43, January,26 (2021)

Abstract

Bangladesh is in lead position in RMG industries. To ensure sustainable economic growth and compete in the global market, the industries should utilize their resources properly and minimize the defects rate to secure maximum defect free production. In this research, the defects in the sewing section of a RMG factory were identified and studied. Various lean and quality control tools such as Pareto analysis, 5 whys, check sheet etc. were used to find out the significant defect types among the many defect types and the root causes behind these defects. By performing Pareto analysis it was found that the 79% of total defects were happening due to 8 frequent defect types. The reasons that reduce productivity were isolated using cause and effect diagram and 5 whys. Questionnaires and observations were used in this research based upon brainstorming with the workers as well as management. This research recommended that workers efficiency was associated with proper workstation, supervision and training. Based on that, the recommendations for reducing defects were formed. For proposing the ergonomic workstation, necessary data were collected from the workers using anthropometric measurements. Findings of this research can be useful for the RMG factories upon future implementation.

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