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Managing Quality in Decentralised Manufacturing' Presentation

The document summarizes a presentation on managing quality in decentralized apparel manufacturing. It discusses that quality can be assured even in decentralized manufacturing by focusing on process capability. The presentation suggests that fabricators can produce quality apparel if their processes are made capable through improvements like providing the right equipment, training, specifications and quality inputs. It also identifies reasons for quality failures like the lack of a clear quality policy and cost of quality awareness.

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sakshi ranade
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102 views15 pages

Managing Quality in Decentralised Manufacturing' Presentation

The document summarizes a presentation on managing quality in decentralized apparel manufacturing. It discusses that quality can be assured even in decentralized manufacturing by focusing on process capability. The presentation suggests that fabricators can produce quality apparel if their processes are made capable through improvements like providing the right equipment, training, specifications and quality inputs. It also identifies reasons for quality failures like the lack of a clear quality policy and cost of quality awareness.

Uploaded by

sakshi ranade
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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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 apparel
industry
'Doorsamvad', presentation by
Professor Rajesh Bheda , GMT
Deptt, NIFT 2/5/2000
Q: Why do you face quality
problems?
A: We have no problems
at our end but our
suppliers dont
understand quality /
sub-contractors are not
bothered about quality
and so on.
'Doorsamvad', presentation by
Professor Rajesh Bheda , GMT
Deptt, NIFT 2/5/2000
We must answer following
questions before going
ahead
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 buyers
about the product quality?
'Doorsamvad', presentation by
Professor Rajesh Bheda , GMT
Deptt, NIFT 2/5/2000
Apparel Industry: Few Facts
Order quantities are reducing continually
Labor controlled, not machine controlled
processes
Varied raw material
Seasonal products with low shelf life
Largely decentralized manufacturing
Buyers are asking for in-house factories

'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 apparel
exporting industry
Italian textile & apparel industry uses
decentralised manufacturing effectively
'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 end
can be used to assess product quality
Planners are different from implementers
'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 not


be expected
It is the responsibility of top management
to ensure the process capability of
different process groups

'Doorsamvad', presentation by
Professor Rajesh Bheda , GMT
Deptt, NIFT 2/5/2000
PROCESS MODEL FOR SEWING

MOTIVATED PEOPLE
QUALITY QUALITY
INPUT OUTPUT
KNOW-HOW

= SKILLS =
RAW MATERIAL TRAINING PROCESSED
COMPONENT
+ PLANT & MACHINERY OR
SPECIFICATIONS GARMENTS

'Doorsamvad', presentation by
Professor Rajesh Bheda , GMT
Deptt, NIFT 2/5/2000
PROCESS CHAIN

OUTPUT

INPUT

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.

'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

'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
'Doorsamvad', presentation by
Professor Rajesh Bheda , GMT
Deptt, NIFT 2/5/2000
Helping Achieve Process
Capability
Provide machine maintenance support
Need based technical support & training
by master or outside expert
Improve illumination level ( use of
inverters, for lights and fans)
Encourage cleanliness to avoid stains
Provide attachments & lease special
machines
'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

'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 aware
of the Chalta Hai approach of the management
To the extent possible they would like to blame
others for the quality problems of their merchandise

'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
'Doorsamvad', presentation by
Professor Rajesh Bheda , GMT
Deptt, NIFT 2/5/2000

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