Sammarth Tuli

Registration Number:

MFM/16/41

STATISTICS
PROJECT
Assignment 1: The Scope Of Statistics in the
Fashion Industry
Ms. Gulnaz Banu P

Statistics: An industry Overview

Statistics in a broader sense is quite a vast subject and in todays world
has been quite influential in business across various industries . its
applications range from simple data analysis in a classroom to even
constructing something as complex as a rocket. The garments industry too
has certain applications because, lets face it; it is near impossible to
discover two pieces of of yarn that have the very same count, quality,
equality, length etc. And this stems from the fact that the raw material
used to produce any kind of finished article, whether a t-shirt or a simple
undergarment differs from fiber to fiber, parcel to bundle, and season to
season. The nature of the item in every procedure, in this manner,
fluctuates as per the variety in the raw material utilized as well as the
labours ability to refine and prepare the garment at hand.
The capital too, i.e. the machines that are used to produce the garment
are often subjected to wear and tear over time depending on their usage
and long utilization and can often result in further fluctuations, and unless
the owner is continuously earning massive profits, replacing the machines
on a periodical places is although recommended, not entirely feasible.
Superimposed on this is the variety emerging from absence of fiber
control amid drafting. Further, it is difficult to wipe out the impact of
human errors. Changes in atmosphere too contribute towards alteration in
a standardized batch of batch even though it is mass produced . These
differences mainly happen due to various segregations in the materials.
Utilizing different numerical computations can explain these varieties
however, to get an insight, various statistical tools can be used to explain
the variations caused in these situations.
The scope of statistics in fashion can be utilized both in qualitative as well
as quantitative form, however this study will focus on the techniques used
in the production side, some of which are highlighted below.

Statistics: A Basic Concept

The modern textile industry is a complex, high technology industry facing
numerous competitive challenges. Markets are becoming more complex.
Short life cycles are common, and demands for rapid response and just intime delivery are growing. As competition continues to increase, textile
companies must rely more on superior quality, innovative products and
rapid response to customer needs, to secure markets and continue to
grow. To cope with these challenges, many textile companies have
implemented quality management initiatives, to reduce costs and
increase both product quality and customer satisfaction.
One of the most recent trends in automation is the use of continuous
monitoring systems for recording defects. The continuous monitoring of a
process often produces more data than manufacturers are equipped to
use profitably, and continuous correction of a process based on a data
stream may actually decrease product quality or hide problems needing
attention.
Statistical quality control (SQC) is designed to sample a large population
on an infrequent basis. Quality assessment therefore only takes place on a
small portion of the total product. In recent years, those SQC techniques
that worked well for final product quality control have been applied to
both the materials being processed and to process conditions. This
procedure is now known as statistical process control (SPC). However,
some SPC techniques that work with infrequent sampling may not be
useful when very frequent or continuous sampling is necessary.
Nevertheless, SPC is currently widely used in the textile industry.
SQC:
SQC comprises the set of statistical tools used by quality control
professionals. It can be divided into three broad categories:
-

Descriptive statistics: These are used to describe quality

characteristics and relationships. This group includes the mean,
standard deviation, range and distribution of data.
SPC: This involves inspecting a random sample of the output from a
process and deciding whether the characteristics of the products in
the sample fall within a predetermined range. SPC is used to
determine whether the process is functioning properly or not.
Acceptance sampling: This involves random inspection of a sample
of goods. Based on the results of the sample, a decision is made as
to whether a batch of goods should be accepted or rejected.

The tools in each of these categories provide different types of information

for use in quality analysis. Descriptive statistics are used to describe

certain quality characteristics, such as the central tendency and variability

of observed data. Although descriptions of specific characteristics are
helpful, they are not enough to identify whether there is a problem with
quality. Acceptance sampling however helps to solve this problem.
However, although acceptance sampling is helpful in deciding on
acceptability after the product has been produced, it does not aid in
identifying a quality problem during the production process. To do this it is
necessary to use tools from the SPC category.
Variation in the quality of manufactured textiles is inevitable. The
manufacturing processes currently in use are not capable of producing
completely identical products. However, inspection of all of the raw
materials and finished goods is impossible, because:
i)

The standard test is destructive in nature- For example, a

fabric manufacturer buys yarn from a spinning mill. It has been
settled between the two parties that each consignment of yarn
delivered to the fabric manufacturer should have an average
linear density inside the tolerance range 40 1 Tex. When the
batch of yarn is delivered, it would be impractical to test the
whole consignment for whether or not the average linear density
lies within the tolerances, as the standard test for linear density
is destructive. There would therefore be no product left to work
with.

ii)

The population size is too large- For example, a menswear

manufacturer marks the size of the trousers he produces
according to the waist size. In order to design the trousers,
therefore, he must know the average waist size of the men in the
population to whom he is hoping to sell the trousers. To
determine this average exactly, the waist size of every man in
the population would have to be measured, which would of
course be prohibitively expensive and time-consuming.

iii)

The rate of production is too high to examine every

product: For example, a garment manufacturer knows from past
experience that usually 2% of the garment blanks he produces
are defective. He is content with this level of defective items but
he does not want it to increase, so he aims to control the level,
that is, to detect quickly any increase in the number of defective
items being produced so that remedial action can be taken. To do
this, garment blanks must be inspected, but the rate of
production is too high to examine every single blank.

The only reasonable method of addressing the above problems is to

examine a small fraction of the population or output, on the assumption
that the results of the sample are representative of the untested
population or output.

However, there are still some questions that arise, for example:
Using sample data, what can be said about the average value of the
population from which the sample was drawn?
How many standard tests should be carried out?
How should the test results be used to describe whether or not the
population meets the required specifications?
How should these results be used to detect a change in the preset
levels?
When there is variation within a population and only a sample has been
examined, our knowledge of the population is incomplete and uncertain.
Statistical methods deal with this by also measuring the degree of
uncertainty.
The statistics can be summarised according to the data:
Measures of central tendency
Measures of variability
Both of which will be explained below along with illustrated examples:

Measures of Central tendency:

Measures of central tendency like process average gives an idea about
average staple length of fibre produced in a continuous or batch wise
process This represents the average of set of values or data. The average
is the general term which can be specifically defined by three different
terminologies namely, mean, median and mode.
Arithmetic mean
This is a commonly used term in the industry that has the advantages of
(1) being simple to understand, (2) being easy to calculate, and (3) using
all the measurements. It is therefore the most popular method used to
locate a distribution.
-

Sample mean

Population mean

where Xi = observed value, n = sample size, N = population size.

Median
This is the middle value when the data are arranged in increasing or
decreasing order. The median divides the area under the frequency curve
into two equal parts.

where L is the lower limit of the median class, f is the frequency of the
median class, h is the class interval, C is the cumulative frequency of class
preceding the median class.

For Example:
Question: Suppose 15 threads have been tested for single thread
strength in grams and the values have been noted down in order of
increasing strength: 174, 178, 180, 181, 184, 186, 186, 187, 189, 191,
191, 193 ,195, 196, 196
Answer: The median is the eighth value, that is, 187 g.
Should there be an even number of values, then the mean of the two
middle values is taken to determine the median: 147, 149, 151, 151, 152.
153. 153, 154, 155, 156
The median is the sum of the fifth and sixth values divided by 2,
that is (152 + 153) 2 = 152.5 g.
Mode
The mode is the value occurring most frequently in the data.

where, L is the lower limit of the modal class,

f1 is the frequency of the modal class,
f0 is the frequency of class preceding the modal class,
f2 is the frequency of class preceding the modal class,
h is the class interval.
The median and the mode are not usually used in the textile industry. If
the frequency curve is symmetrical the mean, median and mode will
coincide. Where the curve is moderately asymmetrical, there is an
interesting approximate relationship between the three values ( Show in
fig 1.1)

Measures of Variation:
Moving on, the second application of central tendency utilizes the
measures of variation, which is simply defined as the difference between
the largest and the smallest observations in the sample:
A) With Range being measured with:

B) Variance being measured with:

As an example, the deviations for the sample of garment blank lengths

are given in A (Deviations in Garments length) shown below:

Table A: Deviations in Garments Length

From A , sample variance for the garment blank length is found

as S2 = 10.62/(61) = 2.124 cm2
C) Standard deviation (SD): Sample standard deviation is found using
the following formula:

Population standard deviation is found using:

Since S2 = 2.124 cm2, we find that the standard deviation of the garment
blank length data isS = (2.124)1/2 = 1.46.
-

Coefficient of variation uses the following formula:

For the garment length data, mean is 53.6 cm and s = 1.46 cm, so the
coefficient of variation is C = 100 1.46/53.6 = 2.72%
As seen above, Statistical techniques are important tools for effective
process control and innovative solutions to problems. The main focus of
statistical techniques is to avoid defects that are produced in the
manufacturing process. Experiments designed to assess the advantages
of novel types of processing or to determine optimal conditions also fall
into the category of SQC. Statistical techniques are also very useful in
determining sample size, deciding rate of recurrence of inspection,
deciding natural limits of variation of the process, testing conformity of
sample to specification provided and so on.
In any product line, no two articles are perfectly identical. For example, it
is impossible to find two bundles of yarn with exactly the same count,
strength, evenness, length, etc. This is due to raw material variation. The
product quality depends on the raw materials used in the process and the
level of technical enhancement attained during manufacturing. Machines
and tools will sustain wear and tear through use and it is neither practical
nor cost-effective to remove or repair the machines after every small
occurrence. Therefore, a certain margin for error must be built into the
manufacturing process.

Significance tests
Post the numerical analysis, A software such as SPSS or Strata10 can be
used to for the application of the numerical data gathered investigate
whether differences exists between the batches for means or standard.
Overall a brief overview of the tests listed above, allow us to take
remedial and preventive measures if at all there is a major difference in
the sample. Some of theses techniques include:
-

Chi-square Test: This method is used when there is no prior

knowledge of the distribution of test values. And for any given
sample irrespective of what it maybe, it is used to identify the
goodness of the fit. End breakages in spinning, roving, carding, nep
generation in blow rooms and carding are all assessed using this
test. And the results are then compared with the confidence limits,
with the performances within the sample then being analysed.
It is given by the

formula:

'F' Test: This distribution is used to test the equality of variance of

the populations from which two small samples have been drawn.
Auto-leveller performance and twist variability are determined using
this test.

It is given by the formula:

T' Test: This is used to assess the

performance of the same specimen
produced from different sectors having the same type of machines
and then comparing the result to find if any significant differences
are present in the performances. E.g. comparing hardness of a
denim between two samples produced from different machines.

Graphical Analysis
And finally post the analysis described above, data maybe presented in
graphical analysis. While numerical values may give a thorough idea on
may provide Charts are used represent the data that may be gathered
from the above analysis in graphical form so that relative variations
between two or more variables can be analysed. Some of the various
graphical representations are:
-

Control Chart: It shows whether or not the job is running with

satisfaction over a period of time, showing a need for corrective
action if something goes wrong and provides a measure for
improving the process. It as a powerful tool for monitoring variations
in process. It is applicable mainly in spinning wherein control over
the various process and variables such as hank, degree of opening
and cleaning is a must. Variations in production and quality in
various sectors like spinning, weaving, knitting, etc. can be also be
analysed. It is illustrated by the following figure:

Figure 1.1: Control Chart

-

Histogram: Histogram is a simple graph compiling measured data

such as GSM, Garment measurement, etc. It serves to estimate the
extent of variation in the group and to determine whether the nonconformance is due to setting or variability. It is illustrated by the
following figure:

Figure 1.2: Histogram

-

Nomogram: The variables of the calculation are indicated on scales

of separate graphs and the answer is arrived at with the aid of a
straight edge. Nomograms are used in ring frame production,
spindle speed calculation, twist/cm, yarn delivery, etc. A Nomogram,
for example is illustrated below for Ring Frame Production.

Figure 1.3: Nomogram

To conclude, The scope of statistics is nearly unlimited. In textile from very

process oriented function to apparel manufacturing are almost all
certainly carried out by calculations. In order to get the required quality
and production mathematical knowledge, it is essential especially in the
fashion production side. Instead of going for testing the samples for
identifying many numbers of variables to arrive at the result,
mathematical conversions and formulas are used for easy calculations and
time saving. These mathematical formulas are mostly applied in textile
sampling and testing.

For example, the effect of n number washes (identical conditions) on m

fabrics on a particular fabric property can easily be found by either tests
of significance or analysis of variance. Similarly the effect of different
detergents on fabric types can be investigated by two-way analysis of
variance. Similarly different types of fabrics and the effect of sewing
conditions can be studied by ANOVA. In garment production the control of
measurements and its distribution can be well understood by control and
polar charts.

Works Cited

N. Karthikeyan, J. J. (2014). Mathematical Application in Textile. Retrieved

August 13th, 2016, from Fibre2Fashion:
http://www.fibre2fashion.com/industry-article/3671/mathematicalapplication-in-textiles?page=5
TEXT-TEAM. (2015). Textlnfo.Wordpress. Retrieved August 13th, 2016, from
Applications of statistical tools in various processing stages of textile
production: https://textlnfo.wordpress.com/2014/06/25/applications-ofstatistical-tools-in-various-processing-stages-of-textile-production/
Hayavadana, J. Statistics For Textile and Apparel Management.