ANALYSIS OF SEWING DEFECTS THROUGH AN INTEGRATED APPROACH OF 5S AND PDCA CYCLE

Due to a large number of defects, which results in high rework and scrap rates in the sewing production line, around 3784 rework rates have been recorded in the last 3 three months, the objective of this research is Analysis of Sewing Defects and Suggesting Improvement mechanism through 5S & PDCA.To assess the quality-related problems of the company, primary and secondary data were collected using interviews, personal observations, and review of companies' daily production records, to analyze the collected data, the mathematical tools and techniques employed in statistical quality control are used.Excel spreadsheet, QM for Windows software, Pareto chart, cause and effect diagram, and control chart are used.After finding the major defects, a brainstorming tool was used to identify the probable causes and then potential root causes were identified by online inspections and root cause analysis.This method is very effective in the minimization of defects.The result indicates that the major problem of the company is stain, skip stitch and seam broken are the major problem.If the company implements in minimization of the suggested problem of defects and gives the same corrective action for the suggested problem, productivity will be increased and high customer satisfaction will be created.The company needs to analyze the daily recording defects data and interpret it to identify the root causes of the problem.Most of the time the company uses two main types of SQC Tools need to use another tool.Need Implementation of SQC tools in the company.