Quality improvement in readymade garments industry by traffic light system

Abstract

Consumers, manufacturers, and retailers worldwide are becoming conscious about high quality products at minimum cost. But plenty of apparels are becoming waste which increases the cost of production. As resources are decreasing but increasing costs of the products. Effective apparel waste management is needed to ensure the profit. Reducing such waste can be profitable options for the manufacturers as well as the buyers. Considering this matter, a project work is done in a ready-made garment manufacturing industry to improve the quality of the products through using a traffic light system. A traffic light system was implemented to minimize the defect rates of production. The study shows that the average defect rates were dropped from 4.13 to 1.25 pieces of a line for daily eight hours of production. By implementing this system, the defect rates are minimized and the monthly production is also increased and it clearly depicts that the monthly capacity before implementing the traffic light system was equivalent but the defective production was more whereas, after implementation, the defective production was negligible.