CHAPTER ONE

OVERVIEW OF THE INDUSTRY

1
BACKGROUND OF THE INDUSTRY

1. Company name: Starlight Sweaters Ltd.

2. Status: Private Ltd. Company.

3. Type: 100% Export oriented composite sweater

knitting industry.

4. Location:

Factory & Corporate Office for Sweater: Vogra, GazipurSadar

Gazipur, Bangladesh.

Tel: 880-2-9293125-6, 880-2-9293129

Fax: 880-2-9291429

5. Chairman: Salahuddin Alamgir

6. Factory details:

Established: 1999.

Annual Capacity: +/- 6 Million PCs per year.

Annual Turnover: U$ 30 million ~ U$35 million.

Item: Ladies’, Men’s, Children, Babies’

2
Product Line: Pullover, Cardigan in Strip, Jersey-

reverse ,Jersey, Shaker, Rib, Cables,

Pointelle, Busket stitch,Moss stitch, Plated

and Fancier stitches knitted in manual flat

knit machines.

Lead Time: 90 days (local yarn), 120 days (imported).

Repeat: 45 Days (for local yarn)

Minimum order: 5000 PCs/ Style & 1000 PCs / Color

Payment Term: Irrevocable and transferable Letter of Credit

at sight.

No. of worker: 7,500 Employees

Floor Space: 350,000 square feet.

Equipment: Knitting Machines:

: 3 GG 900Sets

: 5 GG 600 Sets

: 7 GG 500 Sets

: 12 GG 3000 Sets

Total 5000 Sets

3
 Dial Linking Machines:

: 14 GG 1200 Sets

: 8 GG 850 Sets

: 5/6GG 250 Sets

Total 2300 Sets

: Super Dial Linking Machines 15 Sets

: Winding machines 112 Sets

: Over Lock Machines 50 Sets

: Flat lock Machines 10 Sets

: Bar-Tack Machines 12 Sets

: Plain Machines (Sewing) 100 Sets

: Auto placket Machines 25 Sets

: Zipper attaching Machines 70 Sets

: Snap button attaching Machines 8 Sets

: Button Hole Machines 8 Sets

: Button Stitching Machines 7 Sets

: Steam Iron 200 Sets

4
 : Washing Machines 10 Sets

: Hydro Extractor 15 Sets

: Automatic Drying Tumbler (Double chamber) 10 Sets

: Boiler (470 Kg) Fulton 8 Sets

: Stand by Generator 4 Sets

: Metal Detector Machine 3 Set

Production Capacity : : 3 gg 150,000 PCs/Month

: 5 gg 100,000 PCs/Month

: 7 gg 100,000 PCs/Month

: 12 gg 300,000 PCs/Month

Total: 650,000 PCs/Month

Yarn used: 100% Acrylic, 100% Cotton, Acrylic/Cotton,

Acrylic/Wool, Acrylic/Elasthene, Viscose/ stretch

Nylon, Acrylic/Polyester/Nylon etc. blends in

regular, high bulky, Chenille, Boucle, Loop,

Rainbow, Slub etc. Different yarn mixing with

Lycra or Spandex. 100% Shetland or Lamb’s wool,

Merino wool, Tape yarn in polyester and acrylic.

Mohair and Cashmere like soft yarns.

5
Major Customers : BEST SELLER (DENMARK)

: CARREFOUR (FRANCE, SPAIN…)

: LA REDOUTE (FRANCE & USA)

: NEW LOOK (UK)

: MACKAYS (UK)

: GRUPO COIN / OBS (ITALY)

: LERROS (GERMANY)

: ALDI / LIDL (GERMANY)

: VERTBAUDET (FRANCE)

: DAXON (FRANCE)

: 3 SUISSES (FRANCE)

: ELLOS (SWEDEN)

: OBAIBI (FRANCE)

: TAKKO (GERMANY)

: BON-PRIX (GERMANY)

: NYGARD (CANADA)

6
Backward Linkage:

LABIB DYEING MILLS LTD

Established : 21 May, 2001

Capacity : 150,000 Lbs Acrylic per day

: 30,000 lbs Cotton per day

Dyeing Range : 100% Acrylic 2/32

: 100% Acrylic 2/36

: 100% Acrylic 1/36

: 100% Acrylic Mélange 2/32

: 100% Acrylic Smiling 1/9 (both dull & bright)

: 100% Acrylic Cashmere like 2/36, 2/32 & 3/28

: 100% Acrylic Cotton Like 2/27

: 100% Acrylic Bright 2/40

: 100% Cotton 2/20 & 2/32

: 50% Acrylic 50% Cotton 2/20 & 2/32

: 60% Cotton 40% Acrylic 2/16

: 70% Acrylic 30% Wool 2/32

7
 : 50% Acrylic 50% Wool 2/32

: 64% Viscose 36% Nylon 1/16

: 80% Viscose 18% Nylon 2% Elasthan 1/16

: 70% Acrylic 30% Nylon 1/16

: 100% Acrylic Mohair like 1/2.5

: 100% Acrylic Chenille

Location :Gazipur, Dhaka.

NICE COTTON LTD

Established : October, 2007

Capacity : 30,000 Lbs Cotton per day

Dyeing Range : 100% Cotton All Counts

JUTHI PACKAGING INDUSTRIES

Established : 15 January, 2001

Product : All kinds of cartons. Especially staple free and

best quality with imported papers.

Location :Gazipur, Dhaka.

8
 CHAPTER TWO

PRODUCTION PROCESS LAYOUT

AND

PRODUCT SELECTION

9
PRODUCTION PROCESS LAYOUT

The figure below shows floor plan of knitting and linking section of Starlight Sweater factory.

Note: This type of three floors is present in this factory, one is at 2 nd floor, and other two is in 4 th

and 6th.

10
The figure below shows the finishing section of Starlight Sweater factory.

11
Note: Two similar types of floor are present in the factory, one is at the 3 rd and the other is in 5 th

floor.

The figure below shows the warehouse and washing section of Starlight Sweater Ltd.

Note: This section is present at the ground floor of the factory.

12
PROCESS FLOW CHART

At the initial stage, different types of yarn have been brought from local and international yarn

manufacturer. At the next step, raw package of yarns are rolled up in winding section for giving

those suitable revolving shape and sent those to Yarn Distribution section, where every spin of

yarns has been properly weighted, and specific amount of spindled yarn has been allocated to the

Knitting section.

13
Every part of sweater is knitted in the knitting section and passed them off first inspection to get

those checked whether each part is properly knitted or not, and to get confirmed if any yarn is

wasted. After first inspection, each part of the sweaters is linked up in the linking section and

thoroughly checked in the second inspection. Accurate measurement is tested in the second

inspection; if it is found up to the standard, the sweaters are passed through trimming section and

then for mending loopholes. Another visual inspection is carried out before they are sent for

wash.

In the washing section the workers follow a particular chart mention the right temperature and

correct number of units to be washed and dried. After wash and dry each unit issent for another

inspection. The sweaters are hand checked and visually inspected for any kind of defects. Once

the products pass the standard they are sent for steam ironing and then passed through the

labeling section, where neck, care and size label are attached. Then depending on the style and

design buttons or zippers are attached to the sweaters.

Then the sweaters are sent in the quality control section (P.Q.C), where each part of sweater is

checked carefully. Also light test is carried out to find out problems and defects, thus if the

sweaters are found not up to the standard, they are sent back to the different sections for

alterations. Whole process of knitting is being examined at final inspection section, and passed

them for packing or folding. After packaging, the lots are transferred into the warehouse and kept

standby for shipping.

14
PRODUCT DESCRIPTION

As mentioned in the company description of Starlight Sweater Ltd. they are responsible for

making many different types of sweater garment. From those product lines we have selected a

particular consignment that Startlight Sweater Ltd. are recently fulfilling for a buyer. This buyer

is known as Carrefour, who has sent their choice of design, specification and specified the

required quantity. This product is described as L/S V-Neck PullBasicos Tricot, specifically a

woman’s wear for winter season 2012. A specification sheet has been added in the Appendix

section for more clarification.

PRODUCT QUALITY CHARACTERISTICS AND MANAGEMENT

The product we chose for this project (Basicos Tricot) has 18 different parts to work with for

which the buyer has specified measurement with acceptance level. Since there is a requirement

of the product to be within those specifications, quality controlling aspects come in concern.

Also during production procedure different types of quality management is also obligatory;

otherwise the company loses the standard of quality product.

Since quality is a great concern in the production procedure, quality control is carried at different

stages of production. Initially when the yarns are brought in the warehouse a yarn quality check

is carried out. Different inspections like Shading, Color tone, Yarn thickness/thinness, Yarn

contamination, knots, Puckering, Dyeing finish, etc are checked. Once it passes, it goes to

winding section and distributed to knitting section to make different parts of the sweater

15
garment. Before knitting is carried out each knitting machines are checked, oiled and greased for

proper functioning also needle detection test and tensile test is carried out. After machine check

different parts are made and then bundled according to the category and sizes. Then they are

passed off for inspection to get those checked whether each part is properly knitted or not. After

inspection is done, each part of the sweaters is linked up in the linking section and thoroughly

checked in the second inspection. Accurate measurement is tested and data is collected. After

that sweaters are taken for wash and dry and later another inspection is carried out. Shrinkage

test, oil, dirty spots and other types of defects are checked from those lots and data is collected in

sheets by QA inspector. After the products pass the standard they are sent for steam ironing and

then for labeling. Then the sweaters are sent in the quality control section (P.Q.C), where each

part of sweater is checked carefully. This inspection is reported as pre-final inspection where

knitting quality, broken stitches, open seams, broken buttons, misaligned buttons and holes,

loose zippers, Pulled / loose yarn, unfinished button holes, cracked stitches, soil defects and

many other faults are checked and defects are recorded. Light test is carried out to detect defects

likeknitted fabric defects, different shades within the same garment, Stain, Broken needle defect,

inappropriate trimmings, needle burns etc and thus if the sweaters are found not up to the

standard, they are sent back to the different sections for alterations. Whole process of knitting is

being examined at final inspection section, and passed them for packing or folding.

16
 CHAPTER THREE

QUALITY MANAGEMENT

AND PROBLEMS

17
QUALITY IN GARMENT MANUFACTURING

Quality means customer needs is to be satisfied. Failure to maintain an adequate quality standard

can therefore be unsuccessful. But maintaining an adequate standard of quality also costs effort.

From the first investigation to find out what the potential customer for a new product really

wants, through the processes of design, specification, controlled manufacture and sale. There are

a number of factors on which quality fitness of garment industry is based such as - performance,

reliability, durability, visual and perceived quality of the garment. Quality needs to be defined in

terms of a particular framework of cost. In the garment industry quality control is practiced right

from the initial stage of sourcing raw materials to the stage of final finished garment. For textile

and apparel industry product quality is calculated in terms of quality and standard of fibres,

yarns, fabric construction, color fastness, surface designs and the final finished garment products.

However quality expectations for export are related to the type of customer segments and the

retail outlets.

Starlight Sweater Ltd aims to maximize the production of goods within the specified tolerances

correctly the first time quality control is carried out. Also they aim to achieve a satisfactory

design of the fabric or garment in relation to the level of choice in design, styles, and colors,

suitability of components and fitness of product for the market and to provide customers with a

quality product, as per the standards required by them.

The basic Function is to source the facility/product, which fulfills the needs of the inquiry, sent

by the buyer and to place the orders on behalf of the buyer to coordinate between the buyer and

the manufacturer, at various stages of the production process, “ensuring that the end product

meets the basic standards required.

18
Random Sampling

Units from each lot are drawn at random so that each unit in the lot has an equal chance (without

regard to its quality) of being included in the sample. Random sampling inspection 15 a

prerequisite to ensure that the sample represents the quality of the lot to a high degree.

Depending on the size of the shipment and specified sampling quantity! The inspector selects a

cross section of cartons, from the packing list.

Inspection Levels

Sampling for inspection is performed in accordance with the AQL system, which is attached.

Starlight Sweater Ltd follows AQL 2.5. This is an acceptable quality level standard, however

each customer can specify the AQL that may conform to their quality.

Finished Measurement/Appearance

The measurement of finished garments shall conform to the measurement specifications chart

and established tolerances. A random check for appearance, shading within a garment,

materlainabric defects, ironing defects and other defects as mentioned in the defects

classification list, shall be performed.

Workmanship

Random checks of all seams, both from inside and outside for broken stitches, open seam,

puckering/pleating at seams and other stitching details is done. The defects found, are mark with

a sticker and the garments kept in a separate carton.

19
QUALITY PROBLEMS

The Quality Control Analysis is carried out in different stages of production. Since every aspect

of the quality analysis was not possible, we have selected three different section of production

process to work with. This is due to the fact that the company does not collect enough statistical

information to carry out in depth analysis of quality problems so we had our limitations.

The following analysis has been carried out to find out the cause of defects in linking section.

Data has been collected from the floor supervisor where a series of random sample of Linked

sweaters are checked for any kind of defect through eye inspection. A Binomial Process

Capability Analysis of the nonconforming is done to find the level of defects of one individual

process,

20
 Data collected on the causes or type of defects is given in Table

No. Defects Occurrence % Occurrence

1 Dimension out of tolerance 64 35.5

2 Reversed pieces 18 10

3 Skipped Stitches 11 6.11

4 Uneven edge 5 2.78

5 Broken stitches 8 4.44

6 Faulty Gauging 36 20.0

7 Pieces not aligned 13 7.22

8 Others 25 13.9

Total 180 100

The major causes or types of defects were identified through Pareto Chart

The major defects from Pareto Chart is considered for analysis and the defects are listed in Table

21
 Defects Occurrence

Dimension out of tolerance 64

Reversed pieces 18

Faulty Gauging 36

Through brainstorming and information provided by supervisor of the floor all potential causes

were identified. The identified causes are given in Cause & Effect diagram. Only the major types

of defects are considered for the cause and effect diagram.

22
Another important section of interest is required to be analyzed for source of defects which is

shrinking of sweaters after they are washed and dried. Data collection has be done like

previously and then analyzed. Statistical analysis suggests cause and effect diagram shown

below.

23
FORCE FIELD ANALYSIS

This tool is used, typically in a brainstorming session, to focus on the DRIVING FORCES in the

CURRENT SITUATION and the RESTRAINING FORCES that might get in the way of

attaining the DESIRED SITUATION. The DRIVING FORCES are all of the factors, pressures

and issues that exist in support of the change. DRIVING FORCES are identified by asking: What

is driving us to do something? The goal then would be to clarify and strengthen the DRIVING

FORCES. RESTRAINING FORCES are all of the factors, pressures and issues that can restrict

or prevent a change from a successful completion. RESTRAINING FORCES are the “speed

24
bump” that can slow us down or in fact grind us to a halt. Some are “show stoppers”; others can

be minimized

According to the information provided by the supervisors and management teams of different

area a force field analysis table has been drawn to show the Company’s driving forces and

retraining forces.

25
 CHAPTER FOUR

STATISTICAL DATA

REPRESENTATION

QUANTITATIVE DATA REPRESENTATION

LINKING SECTION

Since we are analyzing this section considering five important variables of the product,

statistical representation of these data points are processed.

26
 Linking Inspection - Measurement Check

Sweater size (M)

Variables Tolerance level Specification
Neck Width ± 0.5 19.50
Shoulder Width ± 0.5 9.50
Chest ± 1.0 48.00
Waist ± 1.0 44.00
Sleeve Length ± 1.0 64.00

The table below showing the processed form of Neck width measurement check data from
linking inspection section.

Cumulative
Neck Width Frequency Percent
Frequency
18.2 1 2.22 1
18.3 1 2.22 2
18.4 2 4.44 4
18.7 2 4.44 6
18.8 1 2.22 7
18.9 3 6.67 10
19.0 3 6.67 13
19.1 4 8.89 17
19.2 2 4.44 19
19.3 2 4.44 21
19.4 3 6.67 24
19.5 11 24.4 35
19.6 6 13.3 41
19.7 2 4.44 43
19.8 2 4.44 45
Figure showing Histogram of the above data from the table

27
The table below showing the processed form of Shoulder width measurement check data
from linking inspection section.

Cumulative
Shoulder Width Frequency Percent
Frequency
8.4 1 2.22 1
8.5 1 2.22 2
8.6 1 2.22 3
8.7 1 2.22 4
8.8 1 2.22 5
8.9 2 4.44 7
9.1 2 4.44 9
9.3 3 6.67 12
9.4 3 6.67 15
9.5 16 35.6 31
9.6 1 2.22 32
9.7 6 13.3 38
9.8 3 6.67 41
9.9 1 2.22 42
10.0 2 4.44 44
10.2 1 2.22 45

Figure showing Histogram of the above data from the table

28
The table below showing the processed form of Chest width measurement check data from
linking inspection section.

Cumulative
Chest Width Frequency Percent
Frequency
47.2 1 2.22 1
47.4 1 2.22 2
47.5 2 4.44 4
47.6 2 4.44 6
47.7 3 6.67 9
47.8 2 4.44 11
47.9 5 11.1 16
48.0 15 33.3 31
48.2 1 2.22 32
48.3 5 11.1 37
48.4 1 2.22 38
48.5 1 2.22 39
48.9 1 2.22 40
49.0 5 11.1 45

Figure showing Histogram of the above data from the table

29
The table below showing the processed form of Waist Length measurement check data
from linking inspection section.

Cumulative
Waist Length Frequency Percent
Frequency
43.5 1 2.22 1
43.6 2 4.44 3
43.7 2 4.44 5
43.8 2 4.44 7
43.9 5 11.11 12
44.0 5 11.11 17
44.1 4 8.89 21
44.2 2 4.44 23
44.3 2 4.44 25
44.4 3 6.67 28
44.5 2 4.44 30
44.6 1 2.22 31
44.7 2 4.44 33
45.0 6 13.33 39
45.5 1 2.22 40
45.6 2 4.44 42
45.8 2 4.44 44
46.0 1 2.22 45

Figure showing Histogram of the above data from the table

30
The table below showing the processed form of Sleeve Length measurement check data
from linking inspection section.

Cumulative
Sleeve Length Frequency Percent
Frequency
62.9 1 2.22 1
63.0 2 4.44 3
63.1 1 2.22 4
63.2 2 4.44 6
63.5 3 6.67 9
63.6 2 4.44 11
63.7 1 2.22 12
63.8 5 11.11 17
63.9 2 4.44 19
64.0 9 20.00 28
64.1 5 11.11 33
64.4 2 4.44 35
64.5 3 6.67 38
64.7 2 4.44 40
65.0 3 6.67 43
65.5 1 2.22 44
67.0 1 2.22 45

Figure showing Histogram of the above data from the table

31
P.Q.C SECTION

Since we are analyzing this section considering five important variables of the product,

statistical representation of these data points are processed.

P.Q.C Inspection - Measurement Check

Sweater size (M)

Variables Tolerance level Specification
Neck Width ± 0.5 19.50

32
 Shoulder Width ± 0.5 9.50
Chest ± 1.0 48.00
Waist ± 1.0 44.00
Sleeve Length ± 1.0 64.00

The table below showing the processed form of Neck width measurement check data from
P.Q.C inspection section.

Cumulative
Neck Width Frequency Percent
Frequency
19.0 2 4.44 2
19.2 1 2.22 3
19.3 4 8.89 7
19.4 7 15.56 14
19.5 19 42.22 33
19.6 8 17.78 41
19.7 2 4.44 43
19.8 1 2.22 44
20.0 1 2.22 45

Figure showing Histogram of the above data from the table

33
The table below showing the processed form of Shoulder width measurement check data
from P.Q.C inspection section.

Cumulative
Shoulder Width Frequency Percent
Frequency
9.0 1 2.22 1
9.2 1 2.22 2
9.3 1 2.22 3
9.4 7 15.56 10
9.5 18 40.00 28
9.6 6 13.33 34
9.7 6 13.33 40
9.8 3 6.67 43
9.9 1 2.22 44
10.0 1 2.22 45

Figure showing Histogram of the above data from the table

34
The table below showing the processed form of Chest width measurement check data from
P.Q.C inspection section.

Cumulative
Chest Width Frequency Percent
Frequency
47.1 1 2.22 1
47.2 1 2.22 2
47.4 2 4.44 4
47.6 1 2.22 5
47.7 2 4.44 7
47.8 2 4.44 9
47.9 6 13.33 15
48.0 17 37.78 32
48.2 1 2.22 33
48.3 5 11.11 38
48.5 3 6.67 41
48.7 2 4.44 43
49.0 2 4.44 45

Figure showing Histogram of the above data from the table

35
The table below showing the processed form of Waist Length measurement check data
from P.Q.C inspection section.

Cumulative
Waist Length Frequency Percent
Frequency
43.9 5 11.11 5
44.0 30 66.67 35
44.1 9 20.00 44
44.2 1 2.22 45

Figure showing Histogram of the above data from the table

36
The table below showing the processed form of Waist Length measurement check data
from P.Q.C inspection section.

Cumulative
Sleeve Length Frequency Percent
Frequency
63.1 1 2.22 1
63.2 1 2.22 2
63.5 1 2.22 3
63.6 3 6.67 6
63.8 4 8.89 10
63.9 1 2.22 11
64.0 16 35.56 27
64.1 8 17.78 35
64.2 3 6.67 38
64.4 1 2.22 39
64.5 2 4.44 41
64.6 3 6.67 44
65.8 1 2.22 45

Figure showing Histogram of the above data from the table

37
38
 CHAPTER FIVE

QUALITY CONTROL ANALYSIS

QUANTITATIVE QUALITY CONTROL ANALYSIS

LINKING SECTION

In the linking section measurements are taken and recorded in the data sheet. A minimum of 15

subgroups of sample size n=3 is taken to create control charts in Minitab software.

NECK WIDTH

39
The X-bar chart shows how the mean or average changes over time and the R chart shows how

the range of the subgroups changes over time. It is observed that the variation of the process is

within the control limits. So the process is under control.

X-BAR-S CHART

40
S- Chart is used to determine if the distribution of the process characteristic is stable. This pair

chart is used to show both the center of the process measurements and the spread of the data. It

shows the central tendency and the dispersion of the data. Result shows that the process is under

control since all the data points are within the control limits.

RUN CHART

41
Run charts are used to monitor process changes associated with particular characteristics over

time. After calculation of median test and up/down test it is observed that there is no nonrandom

variation present in the data. So the process is in control.

MOVING AVERAGE AND MOVING RANGE CHART

This chart is particularly useful when there is only one observation in each time period. The

purpose of constructing moving average and moving range chart is to see if the variation is due

to chance or to changes in the process. Every process exhibits some variation in outcomes of

care. Controlled variation is stable and consistent over time. This variation is due to chance or

inherent features of the process of care. Uncontrolled variations are points outside the limits and

these observations cannot be due to chance. They represent a change in the process of care that is

affecting outcomes.

42
Results show that two points are outside the control limits of the Chart. So it can be said that the
process is out of control.

43
From the above moving average chart it is observed that the process is in control since none of

the data points is outside the control limits. So the process is under control.

NOMINAL X-BAR AND R-CHART

This kind of chart is similar to x-bar chart and range chart except the nominal X-bar chart and R

chart uses coded measurements based on the nominal print dimension.

44
Construction of nominal X-bar chart and R chart shows that the data points are within the control

limits indicating that the process is under control.

MEDIAN-RANGE CHARTS

45
A median chart is a special purpose variation of the X-bar chart. This chart uses the median

instead of the subgroup average to show the system’s central location. The median is the middle

point when data points are arranged from high to low. The chart shows all the individual

readings. Although median charts show both central location and spread, they are often paired

with range charts. Results show that the data points are within the control limits indicating that

the process is under control.

SHOULDER WIDTH

46
X-BAR AND R-CHART

.It is observed that the variation of the process is within the control limits. So the process is under

control.

X-BAR-S CHART

47
Result shows that the process is under control since all the data points are within the control

limits.

RUN CHART

48
Calculation of median test and up/down test it is observed that there is no nonrandom variation

present in the data. So the process is in control.

MOVING AVERAGE AND MOVING RANGE CHART

49
Results show that all the data points are inside the control limits of the Chart. So it can be said
that the process is in control.

From the above moving average chart it is observed that the process is in control since none of

the data points is outside the control limits. So the process is under control.

50
NOMINAL X-BAR AND R-CHART

Construction of nominal X-bar chart and R chart shows that the data points are within the control

limits indicating that the process is under control.

51
MEDIAN-RANGE CHARTS

Results show that one point is outside the control limits indicating that the process is out of

control.

52
CHEST WIDTH

X-BAR-R CHART

.It is observed that the variation of the process is within the control limits. So the process is under

control.

53
X-BAR-S CHART

Result shows that the process is under control since all the data points are within the control

limits.

54
RUN CHART

Calculation of median test and up/down test it is observed that there is no nonrandom variation

present in the data. So the process is in control.

55
MOVING AVERAGE AND MOVING RANGE CHART

Results show that all the data points are inside the control limits of the Chart. So it can be said
that the process is in control.

From the above moving average chart it is observed that the process is in control since none of

the data points is outside the control limits. So the process is under control.

56
NOMINAL X-BAR AND R-CHART

Construction of nominal X-bar chart and R chart shows that the data points are within the control

limits indicating that the process is under control.

57
MEDIAN-RANGE CHARTS

Results show that none of the points is outside the control limits indicating that the process is in

control.

58
X-BAR-R CHART OF WAIST LENGTH

.It is observed that the variation of the process is within the control limits. So the process is under

control.

59
X-BAR-S CHART

Result shows that the process is under control since all the data points are within the control

limits.

60
RUN CHART

Calculation of median test and up/down test it is observed that there is no nonrandom variation

present in the data. So the process is in control.

61
MOVING AVERAGE AND MOVING RANGE CHART

Results show that all the data points are inside the control limits of the Chart. So it can be said
that the process is in control.

62
From the above moving average chart it is observed that the process is in control since none of

the data points is outside the control limits. So the process is under control.

NOMINAL X-BAR AND R-CHART

Construction of nominal X-bar chart and R chart shows that the data points are within the control

limits indicating that the process is under control.

63
MEDIAN-RANGE CHARTS

Since all the data points are within the control limits. Results show that the process is in control.

64
X-BAR-R CHART OF SLEEVE LENGTH

.It is observed that the variation of the process is within the control limits. So the process is under

control.

65
X-BAR-S CHART

Result shows that the process is under control since all the data points are within the control

limits.

66
RUN CHART

Calculation of median test gives a Z test value of greater than 2 and up/down test give result with

the range of less than 2 so it is observed that there is nonrandom variation present in the data. So

the process is out of control.

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MOVING AVERAGE AND MOVING RANGE CHART

Results show that some data points are outside the control limits of the Chart. So it can be said
that the process is out of control.

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From the above moving average chart it is observed that the process is in control since none of

the data points is outside the control limits. So the process is under control.

NOMINAL X-BAR AND R-CHART

Construction of nominal X-bar chart and R chart shows that the data points are within the control

limits indicating that the process is under control.

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MEDIAN-RANGE CHARTS

Since all the data points are within the control limits. Results show that the process is in control.

70
QUALITATIVE QUALITY CONTROL ANALYSIS

LINKING SECTION

Different types of defects occur when linking different parts of sweater. So it is required to

collect defects data so that the problem can be identified and defects can be minimized. From

variable sample size data is being collected and control charts have been carried out in Minitab

software.

71
From the above chart it can be observed that all data points are within the limits. This result

indicate that the process is stable.

Results indicate that the process is in control since all the data points are within the control

limits.

72
Results indicate that the process is in control, since all the data points are within the control

limits.

Result shows that one point is outside the control limits, so the process is out of control.

73
QUALITATIVE CONTROL ANALYSIS

AFTER WASH

After the sweaters are washed and dried they are inspected for any kind of defects. A sample size

of n=20 is collected at every interval and if defects are found data is collected in data sheets.

Those data are studied to take immediate action for quality improvement. From those data sheets

we have collected information and using those we have plotted control charts for nonconforming

units.

74
Results show that the data points are within the control limits indicating the process to be stable.

The above diagram shows that the process is in control as we can see the data points are within

the control limits.

75
Since the data points are within the boundary of control limits it can be said that the process is

under control.

The above diagram shows that the process is in control as we can see the data points are within

the control limits.

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QUANTITATIVE QUALITY CONTROL ANALYSIS

P.Q.C SECTION

In this section the products are inspected for any kind of faults. As it is necessary to maintain

quality standard of the product, quality control is carried too and the data of different faulty

products is recorded in data sheets. A minimum of 15 subgroups of sample size n=3 is taken to

create control charts in Minitab software.

X-BAR-R CHART OF NECK WIDTH

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It is observed that the variation of the process is within the control limits. So the process is under

control.

X-BAR-S CHART

Result shows that the process is under control since all the data points are within the control

limits.

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RUN CHART

After calculation of median test and up/down test it is observed that there is no nonrandom

variation present in the data. So the process is in control.

79
MOVING AVERAGE AND MOVING RANGE CHART

Results show that all points are inside the control limits of the Chart. So it can be said that the
process is in control.

80
From the above moving average chart it is observed that the process is in control since none of

the data points is outside the control limits. So the process is under control.

NOMINAL X-BAR AND R-CHART

This kind of chart is similar to x-bar chart and range chart except the nominal X-bar chart and R

chart uses coded measurements based on the nominal print dimension.

Construction of nominal X-bar chart and R chart shows that the data points are within the control

limits indicating that the process is under control.

81
MEDIAN-RANGE CHARTS

Results show that the data points are within the control limits indicating that the process is under

control.

82
X-BAR-S CHART OF SHOULDER WIDTH

.It is observed that the variation of the process is within the control limits. So the process is under

control.

83
X-BAR-S CHART

84
Result shows that the process is under control since all the data points are within the control

limits.

RUN CHART

85
Calculation of median test and up/down test it is observed that there is no nonrandom variation

present in the data. So the process is in control.

MOVING AVERAGE AND MOVING RANGE CHART

Results show that one data point is outside the control limits of the Chart. So it can be said that
the process is not in control.

86
From the above moving average chart it is observed that the process is in control since none of

the data points is outside the control limits. So the process is under control.

NOMINAL X-BAR AND R-CHART

87
Construction of nominal X-bar chart and R chart shows that the data points are within the control

limits indicating that the process is under control.

MEDIAN-RANGE CHARTS

88
Results show that all the points are inside the control limits indicating that the process is stable

and in control.

X-BAR-R CHART CHEST WIDTH

89
.It is observed that the variation of the process is within the control limits. So the process is under

control.

X-BAR-S CHART

90
Result shows that the process is under control since all the data points are within the control

limits.

RUN CHART

91
Calculation of median test and up/down test it is observed that there is no nonrandom variation

present in the data. So the process is in control.

MOVING AVERAGE AND MOVING RANGE CHART

92
Results show that none of the data points is outside the control limits of the Chart. So it can be
said that the process is in control.

From the above moving average chart it is observed that the process is in control since none of

the data points is outside the control limits. So the process is under control.

NOMINAL X-BAR AND R-CHART

93
Construction of nominal X-bar chart and R chart shows that the data points are within the control

limits indicating that the process is under control.

MEDIAN-RANGE CHARTS

94
Results show that all the points are inside the control limits indicating that the process is stable

and in control.

X-BAR-R CHART OF WAIST LENGTH

95
.It is observed that the variation of the process is within the control limits. So the process is under

control.

X-BAR-S CHART

96
Result shows that the process is under control since all the data points are within the control

limits.

RUN CHART

97
Calculation of median test and up/down test it is observed that there is no nonrandom variation

present in the data. So the process is in control.

MOVING AVERAGE AND MOVING RANGE CHART

98
Results show that all the data points are inside the control limits of the Chart. So it can be said
that the process is in control.

From the above moving average chart it is observed that the process is in control since none of

the data points is outside the control limits. So the process is under control.

NOMINAL X-BAR AND R-CHART

99
Construction of nominal X-bar chart and R chart shows that the data points are within the control

limits indicating that the process is under control.

MEDIAN-RANGE CHARTS

100
Results show that all the data points are intside the control limits indicating that the process is in

control.

SLEEVE ENGTH

X-BAR CHART AND R-CHART

101
.It is observed that the variation of the process is within the control limits. So the process is under

control.

X-BAR-S CHART

102
Result shows that the process is under control since all the data points are within the control

limits.

RUN CHART

103
Calculation of median test and up/down test it is observed that there is no nonrandom variation

present in the data. So the process is in control.

MOVING AVERAGE AND MOVING RANGE CHART

104
Results show that all the data points are inside the control limits of the Chart. So it can be said
that the process is in control.

From the above moving average chart it is observed that the process is in control since none of
the data points is outside the control limits. So the process is under control.

NOMINAL X-BAR AND R-CHART

105
Construction of nominal X-bar chart and R chart shows that the data points are within the control

limits indicating that the process is under control.

MEDIAN-RANGE CHARTS

106
Results show that one point is outside the control limits indicating that the process is out of

control.

QUALITATIVE CONTROL ANALYSIS

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P.Q.C SECTION

After data collection it is processed using p-cart with variable sample size. The Charts for non-

confirming and conformities has been calculated,

P-CHART

This graph shows that the data points are within their specification limits and so quality control is
necessary. Result significantly shows the process is under Control.

NP-CHART

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The following chart shows that the data is within the limits. So process is under control.

C-CHART

U- CHART

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Results show that the process is out of control since 2 points are out of control limits.

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 CHAPTER SIX

PROCESS CAPABILITY

PROCESS CAPABILITY AT LINKING SECTION

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Process capability is an important quality control tool, since it is important to understand that a

process is capable of doing a particular work or not. To check whether the process of linking a

particular part of sweater is capable or not capable we are going to process the data collected

from linking inspection sheet.

The figure below shows the process capability

From calculation of CPK it is observed that this process is not capable because the value is less

than 1.

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From calculation of CPK it is observed that this process is not capable because the value is less

than 1.

113
From calculation of CPK it is observed that this process is not capable because the value is less

than 1.

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The process is not capable, since the CPK value is not more than 1

115
 The process is not capable since CPK is not greater than 1.

P.Q.C PROCESS CAPABILITY ANALYSIS

116
 From the calculation, it is observed that the process is not in control.

From the result and analysis it is observed that still the process is not capable.

117
 Result shows that process is not capable.

From the previous diagram it is observed that the process is very much of capable.. As CPK is
greater than 1.

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Result shows that the process is not capable because it has CPK values which is less than 1.

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 CHAPTER SEVEN

TEST OF HYPOTHESIS

In this section we are willing to test whether the mean of the variables we have taken from the

buyer specification exceeds the expected mean of the sample

For the variable ‘Neck Width ‘I want to see whether the sample mean exceeds a specified mean

of 19.5. The hypothesis test is set like this way and results are calculated in Minitab.

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 HO: μ = 19.5

H1: μ ≠ 19.5

Variable N Mean StDev SE Mean 95% CI z p

Neck Width 45 19.242 0.410 0.149 (18.950, 19,534) -1.73 0.084

Since P value is greater than alpha then there is insufficient evidence to reject null hypothesis

For the variable ‘Shoulder Width ‘we want to see whether the sample mean exceeds a specified

mean of 9.5. The hypothesis test is set like this way and results are calculated in Minitab.

HO: μ = 9.5

H1: μ ≠ 9.5

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 Variable N Mean StDev SE Mean 95% CI z p

Shoulder 45 9.431 0.393 0.149 (9.139, 9.723) -0.46 0.644

Width

Since P value is greater than alpha then there is insufficient evidence to reject null hypothesis

For the variable ‘Chest Width ‘we want to see whether the sample mean exceeds a specified

mean of 48. The hypothesis test is set like this way and results are calculated in Minitab.

HO: μ = 48

H1: μ ≠ 48

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 Variable N Mean StDev SE Mean 95% CI z p

Chest 45 48.078 0.444 0.298 (47.493, 48.662) 0.26 0.794

Since P value is greater than alpha then there is insufficient evidence to reject null hypothesis

For the variable ‘Waist Length‘we want to see whether the sample mean exceeds a specified

mean of 44. The hypothesis test is set like this way and results are calculated in Minitab.

HO: μ = 44

H1: μ ≠ 44

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 Variable N Mean StDev SE Mean 95% CI z p

Waist 45 44.424 0.661 0.298 (43.840, 45.009) 1.42 0.155

Since P value is greater than alpha then there is insufficient evidence to reject null hypothesis

For the variable ‘Sleeve Length ‘we want to see whether the sample mean exceeds a specified

mean of 64. The hypothesis test is set like this way and results are calculated in Minitab.

HO: μ = 64

H1: μ ≠ 64

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 Variable N Mean StDev SE Mean 95% CI z p

Waist 45 64.051 0.722 0.298 (63.467, 64.635) 0.17 0.864

Since P value is greater than alpha then there is insufficient evidence to reject null hypothesis

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 CHAPTER EIGHT

CONCLUSION

Quality is a great asset to a Manufacturing company as it adds value to the product for which a

buyer is willing to pay the price. Since quality has become an important aspect and quality

maintenance and retaining every time has become challenge for most of the companies. Starlight

Sweaters Ltd has established in 1999 as a sweaters manufacturer and since then they are

performing the sweaters program for different buyers. Today, it is on the verge of becoming an

integrated and vertical operation, depending on its own resources, to streamline production from

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dyeing of yarn and manufacturing of accessories to export of sweaters. This effort, in such a

short time, is their reaction to the rapidly changing market requirement of quality garments in

shorter lead-time. The company’s growth, and expansion, is not only limited to products. They

follow training schemes to keep their merchandising and QA teams up to date with client

requirements. Also they regularly collect information from Italy and Taiwan regarding new yarn

developments, and fashion trend. This contributes greatly towards product development of their

customers.

If we summarize our project work in this section for discussion we can say that Starlight Sweater

Ltd maintains good quality control procedures throughout their production process. Starting from

Raw materials to finished goods they do not compromise for any kind of negligence towards

their work. They have maintained their Quality Assurance promise towards all of their clients

and customers. If we discuss our findings from this project then we can say that from the sections

of our research work we found that Starlight Sweaters take quality controlling a priority against

any other decisions or changes. In every section they have prioritized the need of quality check

and set standards of the products. At first we considered linking section where we found that

there is minimal rate of mismanagement and improper bundling of sweater parts. This was just

human error not just the fault of production process. Once the sweater production leaves the

section of linking it goes for another purpose which is Wash and Dry. Correct temperature

control is required to be maintained for wash and dry. Next a good inspection results with

different test results and patience. Then production goes to different section for sewing, labeling

mending etc. at every point quality check is must. Later a special quality controlling section

checks each and every product carefully till they are ready for shipments to different clients.

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When any operation is found to be giving to many defective products the processing and

progression of that operation is stopped until and unless it is in accepted level of working

condition. Every product is inspected and hand checked carefully and Q.C inspectors maintain

data sheets of information and regularly checking for any kind of faulty operation.

Reference

1. “Quality”, Third Edition-Donna C.S. Summers- 2003

2. George, M., (2002) “Lean Six Sigma, Combining Six Sigma Quality with Lean speed”,
McGraw-Hill.

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3. Chethan Kumar C S, Dr. N V R Naidu, Dr. K Ravindranath, (2007) “ Performance

improvement of manufacturing industry by reducing the Defectives using Six Sigma

Methodologies”, Vol. 1, Issue 1, pp. 001-009

4. “Successful Strategies for Teams”, Team Member Handbook by Frances A. Kennedy,

Ph.D.

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