Introduction


The domestic apparel industry in India showed a growth of Rs. 2026 billion in the financial year (2012-2013) from Rs. 1260 billion in the financial year (2007-08) and with the resumption of zero exercise duty on readymade garments and made ups announced in the union budget of 2013-14, the industry is eyeing more heights to achieve in the next five years. The main reason of growth of apparel industry in spite of country being hit by recession are changing of fashion trends , rise of urbanization , growth of consumer class who understands fashion etc.


But the reverse side of the coin shows the big apparel manufacturing running to the extremes to meet the production targets. The fast changing economic conditions such as global competition, declining profit margin, customer demand for high quality product, product variety, change of customer taste from seasons to seasons and reduced leadtime etc. had a major impact on the apparel manufacturing industries. The demand for higher value at lower price is increasing and to survive, apparel manufacturers need to improve their operations through producing right first time quality and waste reduction are the only tools of not only surviving in the market but also help in having a steady growth pace within the competitors.


The only point that speaks in favour of the manufacturer is the quality of the garment. The garment quality is inversely proportional to the no. of defects occurred during the manufacturing process. To have a control over the defects every manufacturing organization tried to implement a whole lot of things like 5s, six sigma, kanban principles, poka-yoke, traffic light system, kaizen principles, lean manufacturing process etc. but still defects happen during the manufacturing process.


The defects occurring in the manufacturing process can be classified under five major categories:-


1.      Fabric Defects

2.      Machine defects

v     Broken Stitches

v     Skip Stitches

v     Uneven spi( stitch per inch)

v     Puckering formation

v     Loose tension

v     Unsecure button/snaps