Approaching Zero Defect in

manufacture of ready made garments

Make in India
Textiles Committee & FICCI Strategy Seminar
New Delhi
Presentation by Gokaldas Exports
7th April 2015
 What is Zero Defect ?
It is not about being perfect, it is about changing our
mindset …..
It does this by demanding that we ….

• Meet or exceed customer expectation

• Recognize the high cost of poor quality
• Continuously think of the areas where flaws can be
introduced in the production process.
• Work proactively to address vulnerabilities in our systems
and processes, which allow defects to occur
• Continuously measure performance against standards
• Seek continuous improvement in standards itself.
 What is Zero Defect …?

“Zero defects” is a standard.

It is a measure against which any system, process, action, or
outcome can be analyzed

When zero defects becomes the goal, every aspect of the

business is subject to scrutiny in terms of whether it is
measurable or not ….. And
What cannot be measured cannot be improved !!
 Approach to move towards
Zero defect .
Establish norms for each stage of the process ;
Ensure processes are performed as per the norms,
Measure and evaluate the results consistently against the
standards … and
Take corrective action to eliminate the root cause of the
deviations
Upgrade standards as we go along the path of improvement

3rd Party evaluation & certification needed to verify the process

being followed as a zero defect manufacturer ….
Objective Validation essential to be accepted by all customers
Technology for Achieving Zero Defect

Do We have Technology ?
Benefits of Adopting Technology
Challenges
 Do we have the Technology ?

Most Indian manufacturing unit perceive that

they have modern technology but probably
none of us have a world class plant.

Indian garments industry needs Technology

Upgradation urgently to be globally
competitive.
Benefits of Adopting Technology For
Zero defect

Minimizing
• Improving percentage of First
human time right in process(FTR)
interface with • Quality Consistency .
• Error proofing in
automation manufacturing process.
and specialized • Reduction of re-work rate
• Indirectly it helps On-time
tools helps in delivery and order fulfillment
………
 Challenges
Buying technology is expensive and can be justified only with the
economies of scale.

Information about technology does not reach manufacturers on a

periodic basis and it is dependent on the machinery suppliers

Most of the time Technology is developed for a specialized operation

and not for a standard operation.

Life cycle of tools & equipment's used in manufacturing process is

extended due to low profitability.

Inadequate competence within individual companies to evaluate the

technology.
STANDARDIZATION OF THE
PROCESSES
 Standardization

Standardization is required as a part of

manufacturing excellence and has to
be followed from yarn to end product.

Everyone in Supply Chain need to

follow Operational Excellence driven
management systems
 PROCESS FOLLOWED…..
Fabric geometry and inter relationship of yarn count, loop length, pick count, relaxation
& fabric properties toward achieving defect free product.

Process variations : identify, measure & monitor key performance indicators.

Systematic Process improvement program.

Process optimization.

Error proofing system in manufacturing.

Technical understanding and fault rate recording system.

Causes & Prevention of process break down.

Skill development : The Key to
achieve Zero defect
 Importance of Skilled Workforce

• Apparel manufacturing industry handles wide range of

products…….
• This requires a trained work force and …… they become a
crucial strategic resource to any organization’s success
• Success in any field depends on educating and training people ….
which should be a continuous process .
• Technology up-gradation alone will not bring the desired results
• Training and learning skills is vital to compete in the global
market through improved quality and productivity
 Limitations along this dimension...
• Massive gap in terms of availability of skilled workforce across the
industry ;
• To support large expansion of capacity, modern training institutions
particularly for the supervisory level, are crucial
• Most firms are reluctant to invest in training and those who do provide on-
job-training forget to make it a continuing process.
• Training must be practical and directly related to the needs of the enterprise
which is missing at present .
• It should also result in a change of behavior so that job is better performed.
• Government supported training crucial for Textile and Apparel Industry
….. Supervisors, Pattern makers, Industrial Engineers, Maintenance
personnel for handling specialized machines.
 Skill development

However
companies • Certified training on special jobs
find their • On job Training for regular
work
own way • Creating awareness of
of company’s goal by conducting
frequent meetings
developing • Do Video presentation on best
skilled practices followed in the
workforce Industry
by giving
 What is needed …..
Gather Information of Existing Skills Sets in
the various Functions in the Manufacturing
Units

Study Required Skills Sets needed by

Benchmarking to National and International
Manufacturing standards

Reduce gap in the Existing Skill Sets by giving

adequate and continuous training
BEST MANAGEMENT
PRACTICES
 Best Practices ….
• Waste Management.
• Visual Management.
• Product Risk analysis
• Quality Audit Analysis.
• Periodic QMS audit in plants.
• Traffic Light System & AQL1 process
• Early alert mechanism for abnormalities in the
process with immediate response for closure.
• Process ownership with KRA
 Focus areas to bring down defect rate
• Fabric inspection
• Cut panel precision
• Appropriate Machinery and Automation
• Adherence to Process standards
• Quality check points
• Washing parameters
• Presentation checking
 BENCHMARKS
Zero defect must be integrated as a part of company culture.

Understand the expectation of the customer in terms of Quality &

Product safety.

Achieving FTR 95 % & above

Zero external re-screen

Achieving QMS audit score 95 & above

Build Quality into your performance expectation

 Value of Zero Defect …..
• Indian apparel exports are valued at USD 16Bn
• 1% reduction in rejection rates would add
– USD 160Mn to the sales turnover and the bottom line
– A mind boggling Rs.990crs !!
• 1% reduction in rejection rates would reduce rework
– Savings in labour cost : Rs.250crs
• Additional Drawback : Rs.70crs
• Total Impact Rs.1310crs …. USD 210Mn
• Besides it will
– Add value to the product from the Customers’ perspective
– Strengthen our competitive advantage !!
 We have to do it together …
• Quality comes in cans …….
– I can
– YOU can
– WE can
• All stakeholders have to resolve to work together
– Fabric manufacturers, Accessories manufacturers
– Garment manufacturers
– Labour and Management
– The Government agencies
 ……….TO CONCLUDE

ZERO DEFECT ADDS VALUE TO THE

PRODUCT, IMPROVES PROFITABILITY AND
REINFORCES COMPETITIVE ADVANTAGE
…….

THEN WHAT ARE WE WAITING FOR ?

LET’s DO IT !!!