The Use and Implementation of Pareto and Ishikawa Diagram for defect minimization in manufacturing firms
Dereje Geleta Oljira & MisganaLamessa DinsaMany unavoidable challenges in the rejection of a large percentage of finished garment products after shipment owing to quality control failures in garment manufacturing motivated this article. Global competition, diminishing profit margins, customer need for products, product variety, and shorter lead times, among other factors, have a significant impact on the garment manufacturing industry. The need for higher quality products at a lower price is growing, and clothing manufacturers must enhance their operations by manufacturing right the first time. This paper examines how to enhance garment manufacturing quality and productivity by reducing the number of reworks that occur during the manufacturing process. Using Pareto analysis and the Ishikawa diagram effectively, this study enhances the process performance of a major operational process, resulting in higher resource utilization, less variances, and consistent quality of the process output. According to the Pareto principal of 80/20 of 80/20 rule, the up and down sections are rated top in the sewing process area, followed by broken stitch 27.20 percent, uneven stitch 9.44 percent, twisting 6.94 percent, and slip stitch 5.28 percent of defects. After identifying and ranking the primary causes based on the 80/20 principle, viable solutions were presented on how to tackle these issues and reduce the rejection rate to a minimum, as well as minimize costs and increase internal throughput time. This study provides a general summary of the development, stating that by decreasing faults, an industry can earn higher production and profitability.