Investigating Root Causes of Sewing Defects Using TQM Tools for Quality Improvement in the Knit Garment Industry

Chowdhury Jony Moin , Kazi Rezwan Hossain, Lal Mohan Baral

2023 / Volume 6 / Pages 417-433
Received 10 July 2023; Accepted 28 August 2023; Published 6 September 2023

To increase customer satisfaction in the highly dynamic and competitive apparel industry, it is essential to manufacture garments of superior quality. The study aimed to investigate the underlying causes of sewing faults and offer solutions for enhancing quality to a 100% export-oriented knit garment industry in Bangladesh. The study employed a comprehensive approach using quantitative and qualitative research methods to evaluate garment faults systematically. The whole garment inspection procedure was done on five common garment styles to collect the quantitative data. Some novel TQM (Total Quality Management) tools, Pareto analysis, WH questionnaire, cause-effect diagram, and a highly potential focus group panel were employed. The findings indicate the most prevalent faults like an open seam, skip stitch, and label mistake, accounting for 50 per cent, 29 per cent, and 7 per cent of all observed defects, respectively, and their remedies. The research’s significance lies in its holistic approach to quality improvement in the knit garment manufacturing industries. This study provides a valuable framework for enhancing product quality and reducing rejection rates by pinpointing crucial defects, their origins, and effective remedies.

sewing defects, knit garment industry, quality control, Total Quality Management