Reduce Rework & Rejection

Reduce Rework & Rejection

Rework & Rejection

       Review 1

o   Rework is done when the errors are small and can be rectified when worked upon.

o   Rejection is the final decision taken when the errors or damage is in large scale and nothing can be done to correct it.

Why this happens??!

The main reason to this is a DEFECT.

o   Rework and rejection happen when the garment gets deviated from its ‘perfect state’ and gets occupied by defects.

o   Defects are of two types:

1.     Sewing defects

2.     Non-sewing defects

Reasons for Rejection

o   During inspection and packing garments are rejected due to certain faults.

o   Defects are due to two main categories.

1.     Material defects (50% responsibility)

a)     Yarn defects

b)     Trims & Accessories defects

2.     Process defects (50% responsibility)

a)     Knitting

b)     Linking

c)     Trimming

e)     Finishing

Reducing Rework & Rejection

o   There is no readymade solution for reducing rejection percentage. Each order is different.

o   But different solutions can be given on how to handle this.

o   Rejection percentage of an order=

(Total Rejected Garments*100)/(Total cut quantity)

Reducing Reworks eg..

o   UNCUT THREAD

Under bed trimmers are used and good quality thread cutters are used.

o   OPEN SEAM

Proper threading, maintain tension, use quality thread

o   PUCKERING

Operator training, Using apt yarn/thread.

o   BROKEN STITCHES

Use quality thread and needle and proper alignment of needle

Reducing Rejection

o   Reducing rejection is a two-step process

o   The first step is to prepare a rejection analysis report, from which the reasons of rejection can be sorted out.

o   And the next step is to give a critical analysis of the rejection analysis report, containing the solution.

Step-1

Rejection Analysis Report

o   The main purpose of this report is

IMPROVEMENT.

o   Getting improvements done in garments.

o   To do this the first step is to identify the reason for poor performance.

o   This is done by analyzing all the rejected pieces.

o   A clear report is produced by calculating the percentage of each occurred error and their reoccurrence.

Step-1

Critical Analysis of rejection analysis report.

o   Depending on the results of the rejection analysis report, the reasons for rejection are sorted out.

o   Now depending on majority and minority of reoccurrences the list is prepared.

o   Now measures are taken based on priority of the top most defect.

In review 2

o   So far the steps to rework and rejection is studied based on theories of other people.

o   For the next review through personal experience the ways to reduce rework and rejection will be taken note of.