Errors in Finishing Process

8/11/2019 Errors in Finishing Process

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ERRORS IN FINISHING PROCESS

LIST OF ABBREVIATIONS USED

QC : Quality Checker

QA : Quality Auditor

PO : Purchase Order

EDI : Electronic Data Interface

DC : Delivery Chain

NQA : Nominated Quality Auditor

AQL : Accepted Quality Level

UPC : Unique Product CodeGOH : Garment on Hangers

METHODOLOGY

The work methodology of the project is carried out by following steps:

1. Selection of Buyers2. In depth study of packing processes of respective buyers3. Value Stream Mapping4. List out the packing errors accounting for the major part of the claim5. Making cause and effect diagram for each problem6. Pareto chart7. SIPOC (Supplier Input Process Output Customer)8. Data collection plan9. Data action plan10. VSM of solutions (Value Stream Mapping)

Detailed Methodology:

Selection of Buyers:

Our main focus was on Eddie Bauer and Ralph Lauren. The selection was madebased on the amount of claims received from the Buyers in the last 6 months i.e.November 2013 to March 2014.


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In depth study of packing processes of respective buyers:

1. The process flow of Tommy-Hilfiger:

tommycopy.xlsx

2. The process flow of Kohls:

kohls.xlsx

3. The overall packing process:

PROCESS FLOW OFPACKING copy.xlsx

4. The process flow of wash-care label:

wash care and sizelabel process.xlsx

Value Stream Mapping:

With the help of VSM we have shown the flow of material as well as information inthe whole process of packing.


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List out the packing errors accounting for the major part of the claim:

The below shown table contains the total percentage of the individual error for whichclaims have been received by Karle International in the last six months.

Errors of packing process in Kohls:

Shipment Month Buyer Ship QuantityWrong/Missing

Packing List Wrong RatioWrong /Missing

UPCDuplicate

Carton LabelWrong Type of

Pack

WrongCartonLabel

December'11 Kohls $ 9,43,611.6 18.18% 0.49% 0.42% 3.55%January'12 Kohls $ 2,32,796.9 27.92% 4.55% 100% 1.40%February'12 Kohls $ 6,52,130.11 9.21% 3.47% 0.19% 0.95%August'11 Tommy $ 3,895 1.91%September'11 Tommy $ 2,887.5 0.20%October'11 Tommy $ 3,95,198.51 75% 1.23% 0.89% 1.11%December'11 Tommy 0.73% 0.72%November'11 Tommy $ 9,48,327.08 1.19% 0.43%January'12 Tommy $ 2,81,904.65 0.56% 0.86%February'12 Tommy $ 1,29,024.8 0.08% 0.23% 0.16% 0.07%March'12 Tommy $ 1,296 21.15% 0.05% 0.09%April'12 Tommy 0.31%


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The table is given below in which all the Kohls errors are mentioned:

Errors of Kohls Frequency % of error found Cumulative %Wrong Ratio 4356 79.8 79.809

Wrong Packing 459 8.4 88.218Wrong/Missing UPC 312 5.7 93.934

Wrong wash carelabel 288 5.3 99.21

Wrong carton labels 39 0.7 99.924Duplicate carton

labels 4 0.1 100

Errors of packing process in Tommy-Hilfiger:

The table is given below in which all the Tommy- Hilfigers error of packing ismentioned:

Errors of Tommy Frequency % of error found Cumulative %

Wrong Ratio 2307 94.05% 94.05%

Wrong/Missing Poly-bagSticker 53 2.16% 96.21%

Wrong/Missing UPC 38 1.55% 97.76%

Duplicate Carton labels 30 1.22% 98.98%

Wrong Packing List 15 0.61% 99.59%

Packing list not sent 10 0.41% 100%

79.8

8.4 5.7 5.30.7 0.1

0.0

20.0

40.0

60.0

80.0

100.0

120.0

% of error found

Cumulative %


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So, from the above tables we have listed down the below mentioned errors of whichwe have carried out a detailed study and made cause and effect diagram -

Cause and Effect diagram of packing errors:

SIPOC:

We used this method to find the answers of some questions like-

1. Where does the process start and end?2. What are the major steps in the process?3. What are the primary process of inputs and outputs?4. Who are the key customers of the process (both internal and external)?5. Who are the key suppliers of the process (both internal and external)?6. What are the requirements of the customers?7. Where do the errors occur (in which steps)?8. At which stage errors can be rectified?9. At which stage errors can be detected?

This method is used for each and every step of the packing procedures which isgiven below:

Cause and EffectDiagram(1).vsd


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SIPOC OF KOHLS

1. Pick garment pi ece from the tabl e Garment picked

2. Lay the garment on the table Garment laid on its back

Ironing operator and endlineinspector

Iron and endline inspectedgarment

3. Iron the sle eves and front Sl eeves and front irone d

Sub-store Hanger 4. Pick up a hanger kept on the table Hanger picked

Sub-store and ironingoperator

Hanger and half ironedgarment piece

5. Put the hanger inside the garment Hange r inserted

Half ironed garment withhanger inserted

6. Lay the garment again on the table Garment laid on its front

Iron and Half ironed garmentwith hanger inserted

7. Iron the back of the garment and backsleeve

Back and back sleeves ironed

Ironed garment with hanger

inserted in it

8. Keep the ironed garment on the side of the

table

Garment ironed and hanger

inserted

Ironing operator

End l ine inspector End l ine inspected garment

Size crown attaching operator

IRONING AND PUTTING HANGERSSUPPLIER INPUT PROCESS OUTPUT CUSTOMER


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1. Pick ironed garments from the ironingtable

Ironed garment picked fromironing table

2. Keep the garments on the size crown

attaching table

Ironed garment kept on the

table

3. Pick one ironed garment One garment picked

4. See the size on the garment from the sizelabel

Size seen

Sub-store Size crowns5. Pick appropriate size crown from the size

crown containerSize crown picked

Sub-store and ironingoperator

Size crown and ironedgarment

6. Put the size crown on the hangerSize crown attached to the

hanger

Size crown attaching operatorSize crown attached ironed

garment7. Hang the garment on the hanging rack

Size crown attached garmentshanged

SUPPLIER INPUT PROCESS OUTPUT CUSTOMER

Tagging Operator

Ironing operator Ironed garments

PUTTING SIZE CROWNS ON HANGERS

Size crown attaching operatorSize crown attached hanged

garment1. See the size crown of the hanged garments

on the hanging rackSize crown seen

Tagging operator Kimble gun 2. Holds the kimble gun on one hand Kimble gun held

Sub-store Tags3. Picks up the appropriate tags from the

containerTag picked

Sub-store, tagging operatorand size crown attaching

operator

Tag, kimble gun and sizecrown attached hanged

garments

4. Tags the hanged garment with the kimblegun

Garment tagged

Tagging operator Tagged garments5. Keep the tagged garment hanging there

onlyTagged garment kept

Checking Operator

TAGGINGSUPPLIER INPUT PROCESS OUTPUT CUSTOMER

1. Pick tagged hanged garments from thehanging rack

Garments hanged

2. Keep the garments on the checking tableGarments kept on checking

table

3. Lay the garment on the checking tab le Garmen t l aid

4. Check the stiches, embroidery and thematches the tags and the upc number

Garment checked

Sub-store and taggingoperator

Arrow sticker and defectedpiece

5. Put the arrow sticker where defects occur Sticked attached

Tagging Operator Defected garments 6. Keep the defected pieces aside Defected pieces kept aside

Tagging OperatorChecked and approved

garments7. Keep the checked and approved garments

back on the hanging rackChecked and approved

garments kept on hanging rack

Tagged hanged garmentsTagging Operator

CHECKINGSUPPLIER INPUT PROCESS OUTPUT CUSTOMER


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1. Take the hanging racks loaded with hangedgarments to the packaging area

Hanging racks sent to packingarea

2. Check and match the size crowns of thehanged garments with the size label (auditor) Checked hanged garments

3. Enter the packing area Packing area entered

2. Keep the garments from the hanging rackson the storage racks

Unloaded hanging racks broughtback

Empty hanging racks3. Take the unloaded hanging racks back to

the production floorUnloaded hanging racks brought

back

Hanging racks with hangedchecked garments

Ratio makerTransporter

TRANSPORTATIONSUPPLIER INPUT PROCESS OUTPUT CUSTOMER

Supervisor Ratio details 1. See the ratio details Details seen

2. Picks hanged garment from the storageracks

Hanged garments picked

3. Keep it on the same storage rack onanother end

Hanged garment kept

4. Make app ro pri at e rat io of hange d garmen ts R at io made

Ratio makerBunch of hanged garments in

ratio5. Keep the bunch of arranged hanged

garments in ratio on the adjacen t storage rackBunch pf arranged hanged

garments in ratio kept

Hanged garmentsTransporter Poly-bag Packer

RATIO-MAKINGSUPPLIER INPUT PROCESS OUTPUT CUSTOMER

Sub-store Poly-bag 1. Pick A poly-bag Poly-bnag picked

Ratio-maker Hanged garments in ratio2. Pick the Hanged garments in ratio f rom the

storage rackHanged garments picked

3. Put the hanger ends in the hole of the poly-bag

Hanger end put in the hole ofPoly-bag

4. Insert the poly-bag over the garments onhangers

Poly-bagged garments

Poly-bag packing operatorPoly-bagged ratio packed

garments5. Put the poly-baged garments on the same

storage rack at another end of the rackPoly-bagged garments stored at

the end of the rack

Poly-bag and Hangedgarments

carton packerSub-store and Ratio-maker

POLY BAG PACKING



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Flat carton 1. Pick flat carton Flat carton picked

Flat carton and tape 2. Prepare the final carton Final carton prepared

Ratio maker Ratio packed polybag3. Pick ratio packed poly-bags from the

storage racks as per packing detailsRatio-packed polybags pikced

Ratio maker and carton makerRatio packed polybag and final

carton

4. Put the appropriate ratio-packed polybagsin the final carton and lock hangers' end with

the thread loopRatio-packed polybags kept

5. Close the final carton Final carton closed

6. Store the final carton in the adjacent areaas per PO number in the form of a stack

Final carton stored

Carton packer and productionfloor

Stack of packed cartons andtrolley

1. Put the stack of the packed cartons on thetrolley

Cartons kept on trolley

Loaded trolley with packedfinal cartons

2. Move the trolley from the packing area tothe scanning area

Trolley moved

Loaded trolley with packedfinal cartons

3. Unload the final cartons on the scanningarea

Cartons unloaded

Empty trolle y 4. Take the troll ey back to the packing are a Troll ey sent back

1. Pick a packed carton Carton picked

2. Keep the carton on the table Carton kept

Printer Sticker 3. Scans a sticker Sticker scanned

Printer and transporter Sticker and carton 4. Put the sticker on the carton Stickered carton

Carton 5. Open the carton carton opened

Han ge r packs 6. Tak e o ut th e rati o p ack ed han ge r p ack sratio packed hanger packs

takenb out

Hanging rack and hanger pack 7. Hang the hanger packs on the hanging rackHanger packs kept on hanging

rack

scanner and tagged garments 8. Scan the tag of each garment of the h anger

packtags scanned

9. Moves the scanned hange r packs to theother end

hanger packs moved

10. Pick the scanned hanger packs from thehanging rack

scanned hanger packs picked

Scanner hanger packs andsame carton

11. Keep the scanned hanger packs in thesame carton

scanned hanger packs kept incarton

Packing operator and sub-store

Packed carton and tape 12. Seal the carton with tape carton sealed

Sub-store and packingoperator

Token no. sticker and tapedcarton pack

13. Put the token no. of the scanningoperator on the tape

token no. put on carton seal


Sea led car tons 14 . Keep the ca rton as ide in the fo rm of st ack sea led cartons kep t a side

Transporter

Packed carton

Scanning operator andtransporter

Transporter

Transporter

Scanned hanger packedgarments and hanging rack

Scanning operator

Transporter

Scanner

SCANNING


Transporter

Packed final carton

Store

Carton packer

TRANSPORTATION TO SCANN ING AREA


CARTON PACKING


Pack ing operato r Seal ed cartons and t ro ll ey 1. Load the s eal ed carton on the Trol ley Seal ed cartons l oaded

2. Bring loaded Trolley to the CTPAT area Trolley brought to CTPAT area

3. Unload the Sealed cartons from the TrolleySealed Cartons unloaded from

the trolley

Sealed cartons4. Keep the sealed cartons arranged as per PO

in CTPAT areaSealed cartons properly

arranged as per PO

Buyer QALoaded trolleyTransporter

TRANSPORTING OF SEALED AND SCANNED TO CTPAT AREASUPPLIER INPUT PROCESS OUTPUT CUSTOMER


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SIPOC OF TOMMY-HILFIGER

6. Finding the location for the tagging inthe garment

Tagged Garments

Tagged Garment

3. Segregate the ironed garmentsaccording to sizes and keep aside on

table as a bundle

Size segregated ironed-folded garments

Size segregated ironed-foldedgarments

Iron and Folding Operator

4. take the particular bundle from thetable

bundle picked

Sub-Store

Next packing operator

Laid Garments

Ironed picked

Ironed Sleeve

Sleeve Balancing Checked

Ironed Garment

Garments kept on the tagging table

Tag Picked by the operator

TAGGINGPROCESS OUTPUT CUSTOMERINPUTSUPPLIER

Bundle of folded garments ofdifferent sizes

Tags

1.pick ironed and folded garment fromironing table

2. Keep garments on the Tagging Table

5. Picks Tags from tag container based onthe size of the garment checked last

7.Tag the garment with the Kimble Gun

8.Keep the bundle aside after tagging

Kimble Gun, tags, iron andfolded garments

Tagging Operator

Iron Operator

Folded garments

Measured & Ironed garment

Folded garment

Final Ironed & Folded garmentat side of the Table

2. Laying the garment on the table

3. Picking the iron

4. Iron the sleeve

5. Check the balancing of the sleeve

Ironed garments &Measurement scale

Folding pattern & Ironedgarment

IRONING AND FOLDINGSUPPLIER INPUT PROCESS OUTPUT CUSTOMER

End line inspectedgarments

Iron

Iron and End lineinspected garments

End line inspector

Iron Operator

End line inspector

Tagging Operator6. Iron the front and back

7. Measure the garment with the help ofmeasurement scale

8. Keep the folding pattern on thebackside of the garment

9. Fold the garment

10. Pick the garment and keep it aside

1. Picking the garment from the table


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Polypacking operator Size sticker applying Pattern Pattern Picked5. Pick the size sticker applying pattern (L-

shaped)

6. Keep pattern on poly-packed garment

9. Put the size sticker on the polybag


Tagging Operator

Sub-store

Kanban Auditor

1. Picks up each Tagged garment

2. Remove Size and Sleeve descriptivesticker

3. Picks up one Poly-bag

4. Put the garment in Poly-bag

10. put the Poly-packed garment on tableor in storage bin/sample carton

Tagged Garments

Poly-bag

Tagged Garments and polybag

CartonsStore

Tagged Garments Picked

Stickers removed

Poly-bag Picked

Poly-packed Garments

Poly-packed Garments kept ontable/bin

7. Pick the Size Sticker

PUTTING SIZE STRIPE ON THE TAGGED GARMENT

Pattern and Polypackedgarment

Size stripe sticker

Size stripe sticker and polybag

Sub-store

Sub-store and TaggingOperator

Sticker Applying Operator

1. Pick the tagged folded garment

2. Pick the size stripe from the container

3. Remove the size stripe from the cover

4. Put the size stripe on the garment at aspecified position

5. Keep the size striped garment aside

Pattern Kept on polybag

Size Sticker picked

Bare size-sticker

Size Stickered polybag

Poly-packer

Tagged folded garment

Size sticker

Size sticker and TaggedFolded Garment

Stickered Tagged FoldedGarment

Garment Kept on table

Sticker picked

Bare size stripe

Size-striped tagged garment

Size-striped garment kept aside

Putting garment in poly-bag(Solid Packing)SUPPLIER INPUT PROCESS OUTPUT CUSTOMER

Tagging Operator and Sub-store

Polypacking operator

Sub-store

Tagging Operator

Sub-store and PolypackingOperator

8. Remove the size sticker from its cover

Ratio-bundle made

Bundle kept on packing pattern

Tagged Garments and ratiodetails

Putting garment in poly-bag(Ratio Packing)SUPPLIER INPUT PROCESS OUTPUT CUSTOMER

1. Take garment pieces from sizesegregated bundles

3. Make a ratio bundle as per ratio detail s

Bundle and Packing Pattern

Poly-bag

Stack , Packing pattern andPoly-bag

Blister Packed Garments

Tagging Operator

Tagging Operator and PackingSupervisor

Packing operator

Sub-store


Packing operator

Tagged Garments

Poly-bag pickedScanning operator

Garments picked

4. Keep the ratio arranged Bundle onpacking pattern

5. Pick the Poly-bag

6. Insert bundle in a poly-bag with thehelp of packing pattern

7. Remove the packing pattern

8. Seal the Poly-bag

9. Keep sealed blister in storage bin

Garments inserted in the poly-bag

Packing pattern removed

Poly-bag sealed

Sealed blister kept in storage bin


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Packing operator2. keep those garments/pieces a t a

specified cartons as per item no.

3. Send the empty unloaded cartonsback to the production floor

garments picked

garments kept in the specifiedcartons

Empty unloaded cartons sent

Loaded Cartons from

production floorGarment pieces from

unloaded cartons

Empty unloaded cartons

6. keep the final cartons in the scanningarea

CartonsStore

Poly-packed garments

card-board, Poly-packedgarments

Ratio-packed cartons

Production floor

Store, Production floor

Ratio-packer

1. See the details on the cartons

3. picks the Poly-packed garments from

the stored cartons

2. Prepare cartons

4. put garments into the final carton asper packing details5. Put the card-board on top of the poly -packed garments

Details Observed

Prepared cartons

Poly-packed garments picked andkept in final carton as per details


1. Brings the Trolley to the particularTable

2. Load Cartons on the Trolley

3. Send loaded Trolley to Holding area

4. Unload the Cartons in Holding Area

Trolley

Approved Poly-packedgarments

Trolley loaded wi th cartons

Cartons received at CPTAT area

Stores

Stacked/stored cartons which mayor may not be in ratio


1. Take out garment/pieces from the

unloaded cartons

Packer on the production

floorTransporter

Holding area

CUSTOMER

1. Pick up any polypack from carton orfrom table

2. Open the polybag

3. Keep the garment on the table

SUPPLIER INPUT PROCESS OUTPUT

Poly opened

Garment laidPoly-packerTransporter

6. Put signature on the sticker of thepolypack

poly-packed garments

stickers, Poly-packed garment

Carton packing done

Final packed cartons kept

HOLDING AREA

Scanner

Packing AreaLine QA

Solid Packing Final Cartons

Kanban Auditor

4. Check sewing and balancing

5. Put rejected garment pieces back toend line inspection

Sewing and balancing checked

Rejected garments sent back

Approved garmentsSub-store, Poly-packer


TRANSPORTATION OF CARTONS/PIECES TO CTPAT AREA


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Prepared cartons

Details verified

Final packed carton

1. Prepare the final cartons

2. verify the details of the final cartons

3. keep the Blister packed garment in thefinal carton

4. put the card-board on top of the blister

5. keep the final carton in the scanningarea

Final Cartons

Final Cartons and Blisterpacked garment

Card-board and final carton

Store

Store & Production floor

Store

Packing operator

Bundle/Blister Packing Final CartonsSUPPLIER INPUT PROCESS OUTPUT CUSTOMER

Final packed cartons kept

ScannerBlister packed garments kept in

final cartons

Card-board kept

INPUT PROCESS OUTPUT CUSTOMER

SCANNING of SOLID PACKING

Manual Counting

1. Picks carton near the scanning table

2. open the carton

3. Unload cartons contents on thescanning table

4. Scan the tag/polybag stickers of theindividual garments

5. Put the garments in same Poly-bag

6. put the poly-packed garments in thesame final carton

8. Put the carton sticker on the specifiedposition on the carton

9. Tapes the carton

Arranged sealed cartons

Poly-packed garments kept in thecartons

Stickered Cartons

Ratio packer

Scanning Operator and Poly-packer

Tagging Operator

Scanning Operator and Ratiopacker

Printer, scanner and ratiopacker

Sub-store and Scanningoperator

Scanning Operator

Taped Cartons

Poly-packed ScannedGarment and carton

Carton sticker,printer andfinal carton

Scanned garment & blister

Blister & final carton

2. Open the Carton

3. Unload carton contents

4. Open Blister

5. Take out garments

6. Scan tag of each garment

8. Put Blister in carton after scanning thewhole stack of garment

Packed final carton

Blister

Scanner & Tagged garment

Tape and stickered carton

scanned and sealed cartons10. keep the scanned cartons according toPO

Final Packed Cartons

Scanner and Poly-packedGarments

Tagged Garments and Polybag

Cartons Brought

Cartons opened

Carton Unloaded

Tagged Scanned

Re-polypacked garments

SUPPLIER

Carton sticker & final carton

CUSTOMER

1. Picks carton near the scanning table

7. put the stack of garments in Blister

12. Keep cartons as per PO

Cartons picked

Carton opened

Carton contents unloaded

Blister opened

Garments taken out

Scanned tags

Re-packed Blister

Blister kept in carton

Stickered carton

Taped carton

Arranged carton

9. Take print out of carton sticker & tearthe sticker from printer

10. Paste the carton sticker on the carton

11. Tape carton

Printer Sticker generatedStore

Store Printer7. Take print out of carton sticker & tear

the sticker from printerSticker generated

Tape and final carton

Final carton

Packing area

Production floor

Packing area & Productionfloor

Scanning operator &production floor

Production floor & Packingarea

Printer & Packing area

Sub-store & Packing area

Packing area

SCANNING of BLISTER PACKING

SUPPLIER INPUT PROCESS OUTPUT

Buyer QA


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7. Keep the cartons at the specifi cposition according to PO number

Buyer QA

CUSTOMER

1. Pick the scanned cartons from thestored area

2. Unload the scanned carton on the table

3. Count manually

4. Check the garment's tags

5. After 100% counting, keep thegarments in the cartons

Cartons picked and unloaded

Counted & checked Garments

Garments kept in cartons

Taped cartons6. Tapes the carton

OUTPUT

MANUAL COUNTING

Counting operator, Sub-store& Scanning operator

Counted & checked garments

Counted Garments, Tape &cartons

SUPPLIER

Scanning Operator

Counting operator

Arranged Taped CartonsCounting operator

INPUT PROCESS

Taped cartons

Scanned Cartons

Poly-packed scannedgarments

7. send cartons to the specified location

Buyer

Approved garments brought

Re-packed garments

Counted garments

Verified

Final cartons re-packed

Cartons sealed

Cartons sent

1. Bring Buyer QA Approved garments forrepacking

2. Repacks the garments in poly bag

3. Manual counting

4. Verify with the packing list

5. Put garments in the same final cartons

Sealed cartons

Buyer QA

Supervisor

Buyer QA

Re-packing Operator and sub-store

Re-packing Operator

Approved garments

6. Seal cartons with Buyer tapePacked cartons and buyer

tape

Approved garments andpolybag

Packing list

Verified garments and finalcartons

REPACKINGSUPPLIER INPUT PROCESS OUTPUT CUSTOMER

RE-PRINTSUPPLIER INPUT PROCESS OUTPUT CUSTOMER

1. Check carton sticker

2. Make note of damaged stickers

3. Select the serial no. of cartons fromthe software

4. generate stickers for those serial nos.

Audited cartonsManual counter

Buyer

Store

Printer5. Paste re-printed stickers on respective

cartons

Note made

Serial no. of damaged stickersselected

Sticker re-printed

Re-printed stickers pasted

Buyer QA

Stored cartons

Damaged cartons

Software & Serial no.

Printer

Re-printed Sticker & cartons


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Data Collection Plan:

The below mentioned formats have been generated to collect data about day to dayerrors occurring in the packing process of Tommy and Kohls. With the help of thesewe can also come to know that where the errors are being detected and how muchof each error is occurring on daily basis.

data collection.xlsx

Data Detection Plan:

In this plan, we have made random visits to each floor to check at which point theoperators are deviating from the SOPs (Standard Operating Procedures) of eachprocess of the respective buyers. We have visited all floor i.e. from 12A, 12B, 12C,12D, 12E and 12F from 23 rd June, 2012 to 30 th June, 2012.

data detection

plan.xlsx After making the random samples, we have calculated the percentage of deviatingprocedures in each packing process.


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40 - 75 BETWEEN 40 TO 75 PERCENT>75 GREATER THAN 75 PERCENT


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After this, we have made a table where we put together the deviating points and theirdetection points as well as their percentage occurrence of each error (floor wise).

ERRORS DETECTION POINTS OBSERVATION POINT % ERROR

No size segregation of garments before tagging71.43%More than one tag container at one table 57.14%

Tag container without cover 14.29%No size/colour marking on tag container 85.71%

No divisions made for keeping the size segregated garments onthe table

14.29%

No checking of garments size label before tagging0.00%

Doing job with carelessness and insincerely 0.00%

No display of sample of tags of running item no. on table85.71%

Carton packing No tagging details displayed on the table71.43%Each piece is scanned against a fixed ratio based onthe software being used

No round container 14.29%

FS Audit Tags kept on table instead of tag container0.00%Final Carton AuditBuyer QA Audit

At the time of ironing and folding (in some cases)Doing job with carelessness and insincerely 0.00%

No immediate packing of ratio bundleNo complete scanning of garment pieces in a carton0.00%

At the time of packing in poly-bag

At the time of ScanningAt the time of FS Audit/ Carton Audit

Buyer QA AuditFS Audit Doing job with carelessness and insincerely @ scanning0.00%

Final Carton Audit

DETECTION POINT OF 12-A

The operator looks at the tag of the garment(inmaximum cases) and based on the information, picksup the size stripe of the same size from the bunch of

the stripes kept on the table

Takes out the required sizes' pieces from the stack ofthe garment(containing pieces of all the sizes in

disorgarnized order) by looking at size label/pricelabel OR Size tag at the time of packing

WRONG CARTONLABEL

Buyer QA AuditMix up of two or more carton stickers on the scanning table0.00%

DUPLICATE CARTONLABELS

Final Carton Audit



WRONG TAG

MISSING TAGS


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Tag container without cover 86.67%

No size/colour marking on tag container 93.33%No divisions made for keeping the size segregated garments on

the table100.00%

No checking of garments size label before tagging 0.00%

Doing job with carelessness and insincerely 13.33%


Carton packing No tagging details displayed on the table100.00%Each piece is scanned against a fixed ratio based on

the software being used No round container 80.00%FS Audit

Final Carton AuditBuyer QA Audit

At the time of ironing and folding (in some cases) Doing job with carelessness and insincerely @ tagging13.33%No immediate packing of ratio bundle 31.25%

No complete scanning of garment pieces in a carton0.00%

At the time of solid-packingAt the time of Scanning

At the time of FS Audit/ Carton AuditBuyer QA Audit

At the time of scanning No ratio details displayed on the table 68.75%Buyer QA Audit No size segregated tagged garments on the table18.75%

No checking of size of garments before making ratio0.00%No immediate packing of ratio bundle 31.25%

No details of the current style no. 68.75%No divisions made for keeping the size segregated garments on

the table100.00%

Not making ratio packs in the area allotted for the operation0.00%Doing job with carelessness and insincerely 25.00%

No cartons to put the garments 43.75%No complete scanning of garment pieces in a carton0.00%

Forgetting to replace rejected garments 0.00%FS Audit Doing job with carelessness and insincerely @ scanning0.00%Final Carton AuditBuyer QA AuditFinal Carton AuditBuyer QA AuditFS Audit

DETECTION POINT OF 12-B




disorgarnized order) by looking at size label /pricelabel OR Size tag at the time of packing (ratio packing

or solid packing)

WRONG TAGS

Tags kept on table instead of tag container 6.67%

WRONG CARTONLABEL Mix up of two or more carton stickers on the scanning table 0.00%

DUPLICATE CARTONLABEL

0.00%

Doing job carelessly @ scanning 0.00%

WRONG RATIO



At the time of ratio packing

MISSING TAGSDoing job carelessly @ scanning


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Tag container without cover 100.00%

No size/colour marking on tag container 100.00%No divisions made for keeping the size segregated garments on

the table100.00%

No checking of garments size label before tagging 7.14%Doing job with carelessness and insincerely 14.29%


Carton packing No tagging details displayed on the table100.00%

Each piece is scanned against a fixed ratio based onthe software being used No round container 92.86%

FS Audit

Final Carton Audit

Buyer QA AuditAt the time of ironing and folding (in some cases) Doing job with carelessness and insincerely @ tagging14.29%

No immediate packing of ratio bundle 100.00%No complete scanning of garment pieces in a carton0.00%






the table100.00%



Forgetting to replace rejected garments 0.00%FS Audit Doing job with carelessness and insincerely @ scanning16.67%Final Carton AuditBuyer QA AuditFinal Carton Audit

Buyer QA AuditFS Audit

DETECTION POINT OF 12-C

0.00%

MISSING TAGS

The operator looks at the tag of the garment(inmaximum cases) and based on the information, picksup the size stripe of the same size from the bunch of Doing job carelessly @ scanning


16.67%

WRONG TAGS




disorgarnized order) by looking at size label/pricelabel OR Size tag at the time of packing (ratio packing

or solid packing)

Tags kept on table instead of tag container

WRONG RATIO

Doing job carelessly @ scanning 16.67%

WRONG CARTONLABEL Mix up of two or more carton stickers on the scanning table


0.00%


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100.00%


No display of sample of tags of running item no. on table88.89%Carton packing No tagging details displayed on the table88.89%

Each piece is scanned against a fixed ratio based onthe software being used


FS Audit

Final Carton AuditBuyer QA Audit





At the time of scanning No ratio details displayed on the table0.00%Buyer QA Audit No size segregated tagged garments on the table0.00%



the table100.00%




DETECTION POINT OF 12-D

WRONG TAGS

The operator looks at the tag of the garment(in

maximum cases) and based on the information, picksup the size stripe of the same size from the bunch of



Tags kept on table instead of tag container 0.00%


DUPLICATE CARTON

LABEL

0.00%

0.00%

0.00%

MISSING TAGS


Doing job carelessly @ scanning


WRONG RATIO



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100.00%

No checking of garments size label before tagging0.00%Doing job with carelessness and insincerely 0.00%


Each piece is scanned against a fixed ratio based onthe software being used


FS AuditFinal Carton AuditBuyer QA Audit





At the time of scanning No ratio details displayed on the table33.33%Buyer QA Audit No size segregated tagged garments on the table33.33%



the table33.33%

Not making ratio packs in the area allotted for the operation0.00%

Doing job with carelessness and insincerely33.33%No cartons to put the garments 0.00%


Forgetting to replace rejected garments 0.00%FS Audit Doing job with carelessness and insincerely @ scanning0.00%Final Carton AuditBuyer QA AuditFinal Carton Audit

Buyer QA AuditFS Audit

DETECTION POINT OF 12-E

WRONG TAGS

The operator looks at the tag of the garment(in

maximum cases) and based on the information, picksup the size stripe of the same size from the bunch of




MISSING TAGS




WRONG RATIO




20.00%

0.00%

0.00%

0.00%


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100.00%



Each piece is scanned against a fixed ratio based on

the software being usedNo round container 90.00%

FS AuditFinal Carton AuditBuyer QA Audit








the table100.00%

Not making ratio packs in the area allotted for the operation0.00%Doing job with carelessness and insincerely 0.00%No cartons to put the garments 50.00%



DETECTION POINT OF 12-F

WRONG TAGS





MISSING TAGS




WRONG RATIO




0.00%

0.00%

0.00%

0.00%


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VSM Solutions:

Through VSM, we have shown that in a particular process, what things may gowrong and whether it can be rectified or not. There are some solutions which wehave suggested through VSM.


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CONCLUSION

Findings:

We have seen that, the main problem is that the information is not properly

communicated to the operators Second point is that, even if the operator has been given information about

how to do the process, then also he/she will perform the work according totheir own ease, thus creating errors

At vital points in the whole process, there is lack of proper accountability

Some of the processes are as such, which are not easy to follow from theoperators point of view for example, picking the tag from the tag container. Asa result they invent their own kind of tag container, which is inappropriate

The operators do not follow the SOPs (Standard Operating Procedures) Mostly the errors occur due to human errors, and the thinking of the operators

goes as such that, even if one mistake occurs that is justifiable. But theoperators are not given proper information about the consequences about theerrors.

We have found out the top five errors having maximum claims are Wrong Ratio Wrong Carton Label

Duplicate Carton Label Missing UPC Wrong UPC Wrong Wash Care Label

We have also found the reasons behind each problem. It is given below in a tabularform:


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PROBLEM: WRONG RATIO

REASONS: No ratio details Wrong size tags on garment pieces

Garment pieces of multiple countries at one table Multiple ratio packs in one style No or improper size segregated garments No ratio details on the table Hurry, carelessness and lethargy of the operator Ineffective checkpoints such as scanning In re-packing, sometimes failing to replace the rejected garments causes wrong ratio Poor work-place No proper checking and matching of tags during ratio-packing

CHANGES TO BE MADE: Scanning after re-packing For proper scanning, the system can be fixed in the center of the table.

SOLUTION: The computer system can be fixed at the center of the table, so that the scanning operator can only unload thscanned garment pieces on one side, and after scanning the garments to be kept on the other side of the table, so that no munscanned and scanned pieces occur.

PROBLEM:WRONG CARTON LABELS

REASONS: Scanning second carton before the first is sealed Putting stickers in a hurried and careless manner Not putting carton stickers immediately after scanning Keeping multiple cartons open after scanning More than one type of stickers kept on tagging table Not changing carton sticker and packing list in case of change in quantity Changing pieces from one carton to another

Applying carton labels at the last moment all at once Ineffective checking of the operator Picking up of cartons of a different PO


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PROBLEM: DUPLICATE CARTON LABELS

REASONS: Same sticker generated multiple times

Re-print not done for exact replacement quantity No written request for replacement of stickers Ineffective monitoring Hurry and carelessness of operator Damaged labels due to improper storage and poor storage space Damaged labels due to improper printing (printing head, wrinkling of ribbon, electricity fluctuation) Operator's unawareness of the consequences of wrong carton stickers leading to carelessness

CHANGES TO BE MADE: Make accountability

SOLUTION: There should be a written request or receipt for the carton stickers that should be re-printed and signature of thecarton

sticker printer should be there on the receipt, so that he will be accountable for the stickers that are re-pri

PROBLEM: MISSING TAGS

REASONS: Improper way of tagging, for example faulty shot of kimble gun causes missing tags if the operator dowhether the tag has been attached to the garment or not after a shot.

Tag handling at various operation may cause the tags to fall and thus cause missing tags Tagging in one or two stitches instead of four or five, thus causing the possibility of the tags falling d

breakage of stitch. Loose stiches Tagging in a hurried and careless manner

Unskilled manpower

Movement of tags in hanger packs during transportation No checking of stitch strength while tagging

No chekcing of tags immediately after tagging and ineffective checking Faulty kimble with thinner end Tags having bigger holes than required

Heavier tags in hanger packs


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SOLUTION: The attaching of the wash-care labels should be carried out in the cutting section only, instead of attaching thsewing

line. After the ticketing process, there should be a sewing machine, where the attachment of the wash-care place, sothat there would not be any missing / wrong wash-care label.

PROBLEM: WRONG WASH-CARE LABELS

REASONS: Loading of non-ratio pieces due to recutting causes in wrong attachment of wash-care labels Lack of correct information from the feeding helper during the loading of re-cut pieces

Mix up of different types of wash-care label on the operation table due to poor storage of washcare labels Carelessness and hurry of the operator Ineffective super-vision Improper segregation of the wash-care labels

CHANGES TO BE MADE: Attaching of wash-care label should be in cutting only instead of occuring in the sewing line.

Documents

Errors in Finishing Process