01 reduce reuse and rejection of orders of apparel industry.
- 1. Reduce Rework & Rejection Apparel Merchandising Review 1
- 2. Rework & Rejection ORework is done when the errors are small and can be rectified when worked upon. ORejection is the final decision taken when the errors or damage is in large scale and nothing can be done to correct it.
- 3. Why this happens??! O The main reason to this is DEFECT. O Rework and rejection happens when the garment gets deviated from its ‘perfect state’ and gets occupied by defects. O Defects are of two types: 1. Sewing defects 2. Non-sewing defects
- 4. Reasons for Rejection O During inspection and packing garments are rejected due to certain faults. O Defects are due to two main categories. 1. Material defects (50% responsibility) a) Fabric defects b) Trims & Accessories defects 2. Process defects (50% responsibility) a) Cutting b) Stitching c) Finishing d) Packing
- 5. Reducing Rework & Rejection O There is no readymade solution for reducing rejection percentage. Each order is different. O But different solutions can be given on how to handle this. O Rejection percentage of an order= (Total Rejected Garments*100)/(Total cut quantity)
- 6. Reducing Reworks O UNCUT THREAD Under bed trimmers are used and good quality thread cutters are used. O OPEN SEAM Proper threading, maintain tension, use quality thread O PUCKERING Operator training, Using apt fabric and thread. O BROKEN STITCHES Use quality thread and needle and proper alignment of needle
- 7. CONTN.. O IMPROPER FOLDER SETTING IN MACHINE Adjust folder guide, Improper material handling is avoided O MARGIN NOT FOLLOWED WHILE ATTATCHING WAIST BAND Operator instructed to be careful while feeding the fabric O POOR QUALITY FUSING Use quality fusing, use skilled operators O IMPROPER NOTCHES WHILE PLEATING Misalignment during cutting is avoided
- 8. CONTN.. O OILSPOTS Applying a scrap paper under the presser feet of the machine after day’s work so that the machine leaks can be tracked. O INK/CHALK MARKS Use good quality markers, markers which are washable. O SOIL & DUST Use plastic bags for storing and transporting
- 9. Reducing Rejection O Reducing rejection is a two-step process O The first step is to prepare a rejection analysis report, from which the reasons of rejection can be sorted out. O And the next step is to give a critical analysis of the rejection analysis report, containing the solution.
- 10. Step-1 Rejection Analysis Report O The main purpose of this report is IMPROVEMENT. O Getting improvements done in garments. O To do this the first step is to identify the reason for poor performance. O This is done by analyzing all the rejected pieces. O A clear report is produced by calculating the percentage of each occurred error and their reoccurrence.
- 11. Step-2 Critical Analysis of rejection analysis report. O Depending on the results of the rejection analysis report, the reasons for rejection are sorted out. O Now depending on majority and minority of reoccurrences the list is prepared. O Now measures are taken based on priority of the top most defect.
- 12. In review 2 O So far the steps to rework and rejection is studied based on theories of other people. O For the next review through personal experience the ways to reduce rework and rejection will be taken note of.