Pdca Cycle: Plan-Do-Check-Act

PDCA CYCLE
A Case Study on the Application of

PDCA Cycle in Apparel Manufacturing
Plan-Do-
Check-Act PRESENTATION BY: NIKHIL,

DEVANSH AND KINJAL

CASE STUDY
Minimization of Sewing
Defects of an Apparel
Industry in Bangladesh
with 5S & PDCA
American Journal of Industrial Engineering, 2018, Vol. 5, No. 1, 17-24 Available online at
http://pubs.sciepub.com/ajie/5/1/3 ©Science and Education Publishing DOI:10.12691/ajie-5-1-3
The PDCA cycle and 5S was used to perform the present project.
Only the advantages and application of PDCA cycle is being
discussed in the presentation. The area of the project is of of
reducing sewing defect by applying PDCA cycle.
The PDCA cycle comprises four phases:
(1) Plan,
(2) Do
(3) Check
(4) Act.
Following slides describe how each PDCA phase was applied in the
project.
Methodology
Research Methodology
Step 1: For factory selection a factory, which is situated in Kaliakoir, Gazipur, Dhaka.
Step 2: The research work for the case study was done in a particular garment factory
named “Interstoff Apparels Limited”.
Step 3: In this step, the information was gathered from the sewing defects section of the
selected garment factory. The collected data on various sewing defects provided by the
management, was used for the Analysis purpose of the study.
Step 4: After analysis they found that the mistakes were more common than requires in
sewing , which was a mattern of concern,
DEFECT
CHART
5 WH Questions:
Q (1): What is needed to be done?
Q (2): How much is needed to be done?
Q (3): Where it is needed to be done?
Q (4): Who should do it?
Q (5): When it is needed to be done?
PLAN Answers of the 5 WH Questions:

A (1): Perfect stitching is needed.
A (2): Goal is to reach zero defects.
A (3): In every stitch on seam line.
A (4): The Operator should do it.
A (5): It is needed to be done during Sewing.
Process implementation according to PLAN:
Install, set up, and operate the machine
DO
correctly.
Using a good needle, high-quality sewing
thread, and other necessary tools.
Recruit a seasoned operator.
Give each operation the attention it deserves..
Inspection of the Process:
The procedure and the products should be

monitored and measured on a regular basis.
CHECK
Check to see if the defects have decreased.
If defects are not appearing or decreasing, the
procedure should be continued successfully.
If defects persist, return to the PLAN stage
and generate new ideas for resolving and
lowering defects before repeating the cycle.
Take action on the accurate process for
ACT continually improving process performance.

If any defects are found, then start the PLAN
stage for solving it.
Statistics of inspection checklists for accessories and packing cloth, data
of accessory swatch cards, data of manufacturing swatch, statistics of
daily quality control document, facts of slicing hassle record, records of
inspection file throughout embroidery, and other data must all be well
accompanied.
Recommended Measure all applicable seam houses, such as stitches according to cm,
Suggestions to extensibility, and seam electricity, to record seams and stitches for
garment assembly. Determine the assembly activities to be collected, the
Reduce Defects seams and threads to be used, and test system availability, keeping in
mind alternatives if machines are not available. Take a look at the finished
and Reworks in product.
Sewing Section
Take a look at the foreground and compare it to the image. Examine the
technical aspects of any material flaws, sewing thread, seaming flaws,
and a variety of other issues. All problems detected during final
inspection should be filed for quick rectification and to identify the need
for preventative action at a precise production level.
Conclusion
This paper has analyzed the garment sewing defects using lean tools:
Pareto chart, cause-effect diagram, 5S implementation, PDCA cycle for minimizing
defects and resulting increasing quality and making more profit.
The Pareto chart shows that the major cumulative defects are others (19%), broken
stitch (36%), slip stitch (48%), the open seam (59%) etc. From this chart, we can
easily find the most important defects and then we can use the cause-effect diagram
for finding the major causes for that defect.
The PDCA cycle helps to plan for continuously improving the quality by removing
defects, perform on the process based on the plan and next checking and monitoring
the process that it is going through the right procedures.
Finally, corrective is taken for further improvement. This study helps to minimize the
defects of sewing for any apparel industries.
Thank You
By:
Devansh Kain, Kinjal Das & Nikhil Kumar
B.F.Tech, NIFT, New Delhi

Pdca Cycle: Plan-Do-Check-Act

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Pdca Cycle: Plan-Do-Check-Act

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PDCA CYCLE

A Case Study on the Application of

DEVANSH AND KINJAL

PLAN Answers of the 5 WH Questions:

Install, set up, and operate the machine

The procedure and the products should be

ACT continually improving process performance.

Devansh Kain, Kinjal Das & Nikhil Kumar

B.F.Tech, NIFT, New Delhi

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