Enhancement quality level of processes in an apparel manufacturing company via value stream mapping

Abstract

‘Ensure Quality’ is an indispensable facet in any manufacturing industry, which is essential to sustain in volatile markets. This has become a widely spoken, an important topic in the arena. ‘Apparel ‘the highest income gainer of Sri Lankan Economy is in a gloomy situation, struggling with immense challenges prevailing. Favorable acknowledgement about the quality of Sri Lankan produced garments stow a hope in our hearts, where a study about the matter is undoubtedly escort benefits for the industry. This study is undertaken with a view to enhance process quality of Value Streams of main customers in a leading apparel manufacturing company in Sri Lanka. In order to identify quality improvement opportunities, VSM’s were developed for selected customers and identified most crucial processes needs to study on. It was able to distinguish cutting/molding, production and AQL processes are pivotal processes which contribute in generating of VSM’s . It studied process wise types of defects occurred as well as causes for such occurrences. It emphasized production process consists higher defect percentage than the other processes. The study elaborated to check whether the quality level of production processes of all customers lies within the statistically in control levels. The study revealed that all processes are within the control limits.. With the aid of statistics and Lean Manufacturing tools production processes deeply studied. Actions were taken for identified improvement opportunities and re-checked the quality levels. Results stipulated that the quality level of production processes is being improved. Similarly, its consequences the production processes are statistically capable. Study further elaborated to check the capability of the plant quality process and sample size daily examined. The study reveals that the plant quality process and daily examining sample size are inadequate. It is recommended to improve the plant quality process and to increase daily auditing sample size.