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Quality in Decentralised Mfg.
Transcript of Quality in Decentralised Mfg.
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7/29/2019 Quality in Decentralised Mfg.
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'Doorsamvad', presentation by
Professor Rajesh Bheda , GMTDeptt, NIFT 2/5/2000
Managing Quality in
Decentralised Manufacturing
Presentation Coverage:Indian apparel manufacturing: Few Facts
Can quality be assured in decentralised
manufacturing?Product Vs. Process approach to QA
Process Capability Model
Application of process model to apparelindustry
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'Doorsamvad', presentation by
Professor Rajesh Bheda , GMTDeptt, NIFT 2/5/2000
Q: Why do you face quality
problems?
A: We have no problems
at our end but oursuppliers dont
understand quality /
sub-contractors are not
bothered about quality
and so on.
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'Doorsamvad', presentation by
Professor Rajesh Bheda , GMTDeptt, NIFT 2/5/2000
We must answer following
questions before goingahead
Can we afford to sit back and give
excuses for our quality problems?Can quality apparel be produced by
fabricators?
Ultimately who is answerable to buyersabout the product quality?
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'Doorsamvad', presentation by
Professor Rajesh Bheda , GMT
Deptt, NIFT 2/5/2000
Apparel Industry: Few Facts
Order quantities are reducing continuallyLabor controlled, not machine controlled
processes
Varied raw material
Seasonal products with low shelf life
Largely decentralized manufacturing
Buyers are asking for in-house factories
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'Doorsamvad', presentation by
Professor Rajesh Bheda , GMT
Deptt, NIFT 2/5/2000
Role of Fabricators
Flexible manufacturing capacity
Good at manual value addition
Accept low volume complex styles
Backbone of Delhi fashion apparelexporting industry
Italian textile & apparel industry usesdecentralised manufacturing effectively
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'Doorsamvad', presentation by
Professor Rajesh Bheda , GMT
Deptt, NIFT 2/5/2000
Quality Assurance for
Standard Product
Dedicated facility for a product is must.Can plan detailed QA procedures and train
people in specialist jobs.Processes are well planned in advance
with control parameters in place
Random sampling inspection at the endcan be used to assess product quality
Planners are different from implementers
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'Doorsamvad', presentation by
Professor Rajesh Bheda , GMT
Deptt, NIFT 2/5/2000
Key to Quality in Fashion
Apparel Mfg. :Process
Capability
Without Process capability Quality can notbe expected
It is the responsibility of top managementto ensure the process capability ofdifferent process groups
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'Doorsamvad', presentation by
Professor Rajesh Bheda , GMT
Deptt, NIFT 2/5/2000
PLANT & MACHINERY
TRAINING
MOTIVATED PEOPLE
KNOW-HOW
SKILLS
QUALITY
INPUT
=
RAW MATERIAL
+SPECIFICATIONS
QUALITY
OUTPUT
=
PROCESSED
COMPONENT
OR
GARMENTS
PROCESS MODEL FOR SEWING
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'Doorsamvad', presentation by
Professor Rajesh Bheda , GMT
Deptt, NIFT 2/5/2000
INPUT
PROCESS CHAIN
OUTPUT
=
PROCESS A PROCESS B
Three Golden Rules
Output of previous process becomes input to next process.
No substandard input to be given to any process.
No process shall allow sub standard output to come out.
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'Doorsamvad', presentation by
Professor Rajesh Bheda , GMT
Deptt, NIFT 2/5/2000
Is average fabricator
process capable?
No, but they can be made process capable
We need to find out the deficiency
To get the solutions we need to think non-traditionally
Also check the quality of inputs to
fabricators
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'Doorsamvad', presentation by
Professor Rajesh Bheda , GMT
Deptt, NIFT 2/5/2000
Suggestions for improving
inputs
Start in-house cutting, dont issue fabric
Cut interlining with die or band knife
Carry out in-house fusing
Provide right needles, thread etc.
Graphic specifications in local language
Multiple templates for pocket, collar etc.Set up special operation cell
Enclosed transport for Cut parts
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'Doorsamvad', presentation by
Professor Rajesh Bheda , GMT
Deptt, NIFT 2/5/2000
Helping Achieve Process
Capability
Provide machine maintenance supportNeed based technical support & training
by master or outside expert
Improve illumination level ( use ofinverters, for lights and fans)
Encourage cleanliness to avoid stains
Provide attachments & lease specialmachines
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'Doorsamvad', presentation by
Professor Rajesh Bheda , GMT
Deptt, NIFT 2/5/2000
The Benefits
Promotes Knowledge Workers
Right first time
Reduced Inspection
Increased Flexibility
Minimum Repairs and Rejects
Increased Productivity
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'Doorsamvad', presentation by
Professor Rajesh Bheda , GMT
Deptt, NIFT 2/5/2000
Reasons for Failure
Do not have a clear quality policy nor do they
demonstrate commitment to quality
Employees of these organizations are well awareof the Chalta Hai approach of the management
To the extent possible they would like to blame
others for the quality problems of their merchandise
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'Doorsamvad', presentation by
Professor Rajesh Bheda , GMT
Deptt, NIFT 2/5/2000
Reasons for Failure
Belief that Quality starts with inspection and ends
with inspection
Mainly quantity driven targets for the departments
Departmental goals may not synergise with
organizational goal
Have no idea about the Cost of Quality in their
organization