IQC Body

Westmead International School
College of Engineering
Chapter 1
INTRODUCTION
Six Sigma is a comprehensive and flexible system for achieving,
sustaining and maximizing business success. It is uniquely driven by close
understanding of customer needs, disciplined use of facts, data, and statistical
analysis, and diligent attention to managing, improving, and reinventing
business processes. The types of “business success” you may achieve are
broad because the proven benefits of the Six Sigma “system” are diverse,
including; Cost reduction, Productivity improvement, Market-share growth,
Customer retention, Cycle-time reduction, Defect reduction , Culture change,
Product/service development [10].
In Addition, Another definition of Six Sigma is that it’s aim of near-
perfection in meeting customer requirements. This also truthful; in fact, the term
“Six Sigma” itself refers to a statistically resulting performance target of
operating with only 3.4 defects for every million activities or “opportunities.” It’s a
goal of few companies or processes can claim to have achieved.
However, understanding the key features, complications, and deficiencies
of the six sigma method allows organizations to better support their tactical
directions, and increasing needs for coaching, mentoring, and training. It also
provides opportunities to better appliance six sigma projects. Meanwhile, the
force from globalization has made manufacturing organizations moving towards
three major competitive fields: quality, cost, and awareness. Quality is a

Reduction of Dropped/Skipped Stitches through Implementation of Six Sigma in Vesja
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universal value and has become a global issue. In order to survive and be able
to provide customers with good products, manufacturing organizations are
required to guarantee that their processes are constantly supervised and
product quality is improved.
Nevertheless, quality can be defined as fulfilling specification or customer
requirement, without any defect. It refers to activities to ensure that produced
items are fulfilling the highest possible quality. Most of tools and techniques to
control quality are statistical techniques. Quality control techniques can be
classified into basic, intermediate and advance level, but there is no consensus
among researchers in the classification [1].
However, defects in product have been and continue to be a major
source of seconds in finished garments. These defects continue despite several
visual inspections and severe efforts to remove defective parts during sewing
operations. Some defects usually occur in the garment industries are broken
buttons, broken seams, broken stitches, dropped stitches, untrimmed thread
ends and so on .The imperfection is the basic term in the article of clothing
industry. Article of clothing escapes are likewise notable as reject the thing.
Various kinds of imperfections are found in the article of clothing industry. In
pieces of clothing industry, these imperfections are dependent upon the
arrangement of defects and a supervisor’s capacity to decide.

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Vesja Sub.Con Garments is a one of the newly-formed garments
organization in CALABARZON. This garment is one of the sub contracts of Jag
and Dickies producing pants and shorts. They are currently experiencing defects
during their process that causes reworks, delays and less productivity in their
industry. Base on the weekly records, there are ten (10) defects typically
encountered. The broken buttons, broken seams, broken stitches, untrimmed
thread ends, inoperative zipper, unfinished buttonholes, incorrect labels,
uncut/loose threads, dropped/skipped stitches and lastly the wavy stitches.
The purpose of the study is to specifically identify the defects and the
most or top defects that the sewers usually encountered in the garments. This
study also aims to reduce and control the defect through the implementation of
Six Sigma.

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Review of Related Literature
Quality can be defined as fulfilling specification or customer requirement,
without any defect. A product is said to be high in quality if it is functioning as
expected and reliable. Quality control refers to activities to ensure that produced
items are fulfilling the highest possible quality. Most of tools and techniques to
control quality are statistical techniques. Quality control techniques can be
classified into basic, intermediate, and advance level, but there is no consensus
among researchers in the classification [1].
The basic idea of control charts is to test the hypothesis that there are
only common causes of variability versus the alternative that there are special
causes By continuously monitoring the process, the manufacturing organization
could prevent defect items to be processed in the next stage and to take
immediate corrective action once a process is found to be out of control [2].
DoE and Taguchi methods are powerful tools for product and process
development. Taguchi methods, for instance, aim at making product or process
that robust to undesirable disturbances such as environmental and
manufacturing variations. However, the application of these two methods by
industries is limited [3].
Explore the difficulties in the application including improper understanding
and fear of statistical concepts in the methods, thus propose a methodology for

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the implementation. Process capability study is an efficient method to examine
the capability of a process to produce items that meet specifications [4].
Capability studies show that the machine tool and process capability and
production stability was evaluated and necessary steps to reduce poor quality
production was carried out using other statistical techniques [5].
Six sigma is also a statistical tool for ensuring defect free products
through process continuous improvement. The term six sigma originated at
Motorola and many inspired worldwide organizations have set goal towards a six
sigma level of performance [6].
The application of six sigma has been mainly used in manufacturing
industry. An example of the use of six sigma in nonmanufacturing industry is in
software development [7].
Acceptance sampling is another statistical technique to make a decision
whether to accept or reject a lot based on the information from sample. The
application of acceptance sampling allows industries to minimize product
destruction during inspection and testing, and to increase the inspection quantity
and effectiveness [8].
The application of acceptance sampling has been mainly used in
manufacturing industry. Similarly, its application in nonmanufacturing industry is
widely reported [9].

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A comprehensive and flexible system for achieving, sustaining and
maximizing business success. Six Sigma is uniquely driven by close
understanding of customer needs, disciplined use of facts, data, and statistical
analysis, and diligent attention to managing, improving, and reinventing
business processes. This is the definition that will provide the foundation for our
efforts to unlock the potential of Six Sigma for your organization [10].
The strong understanding of Six Sigma management philosophy,
concepts, and practices and to apply this knowledge to creating a Six Sigma
academic course or training program. This was done through three main
methods: preliminary research and data collection, the creation of a design
model for Six Sigma academic course/training program establishment, and the
creation of a Six Sigma academic course/training program syllabus [11].
It focuses on the joint use of two popular improvement initiatives:
Capability Maturity Model Integration (CMMI®) and Six Sigma. This report
contains a brief summary of each initiative and then outlines the connections
between frameworks commonly used in Six Sigma and the CMMI process areas
has make recommendations that would improve the performance of six sigma
within the ford motor company [12].
A longitudinal case study describing the evolution of ‘Six Sigma
Management’ at Siemens in Sweden. The success of the programmer was to a
large degree built on previous failures, confirming Juran’s old saying ‘Failure is a

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gold mine’. From the case study, success factors for implementing Six Sigma at
Siemens are identified and compared to those given in the literature. The
evaluation of sewing threads consumption in jeans and classic pants clothingsix
different input parameters are chosen and used for investigation. To objectively
evaluate their contributions, a Taguchi design analysis was applied [13].
The research methodology concentrates the implementation of DMAIC
and cause and effective diagram are used for eliminating garment defectives
and 5S Concepts for reducing defects and motion [14].
Quality Improvement can play a vital role for improving productivity as
well as economic development for the country. They have used the tools of TQM
such as Flow chart, Check sheet, and Histogram, Pareto Chart, Scatter
Diagram, Control Chart, Cause and effect diagram in a garment industry of
Bangladesh and it is found that a significant amount of rework and scrap per
style, per month has minimized by applying this method [15].
Conducted to improve efficiency of the sewing process in apparel industry
through the reduction of defectives. This study is focused in three major defect
types; run off stitches, dropped/skipped stitches and wavy seams. They have
developed generalized linear models for each defect type to find the significant
factors affecting on the proportion of occurrence of defects the pros of
implementing the quality tools; review the issues related to the implementation

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of such tools and finally understand the role of such tools in the framework of
TQM [16].
Detail investigation on quality improvement of a garment factory by
applying Pareto Analysis and Cause-Effect Diagram, the aim of the study was to
minimize defects that will reduce rework and rejection rate [17].
The SPC methods such as check list, Pareto analysis, cause-effect
diagram and P control chart were used. The frequencies of sewing defects in the
operations at the sewing department are determined by check list. The
operations which have highest sewing defect rates and the effects of these
operations to the defect rate are examined by using the Pareto analysis [18].
The reasons of the defects are analyzed with the cause-effect diagram for
the operation which has the highest sewing defect rate. The rate of defect in the
sewing department is examined statistically by p control chart whether it’s under
control or not. Sampling based statistical quality control system is proposed in
finishing section to eliminate 100% inspection by sampling based inspection [19].
Provide an easy introduction of 7 QC tools and to improve the quality
level of manufacturing processes by applying it. An application of methodology
in an industry which provides a framework to identify quantify and eliminate
sources of variation in an operational process, to optimize the operation
variables, improve and sustain process performance with well-executed control
plans [20].

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Empirical evidence on Six Sigma implementation in service industries in
Singapore, Six Sigma case study analysis involving three service organizations
of Singapore the organizations are a local hospital, a construction and related
engineering service, and a consultancy service [21].
It designed to test the application of a novel Six Sigma deployment
programme specifically for SMEs. Introduction a new notion, which we call six
sigma supply chains to describe and quantify supply chains with sharp and
timely deliveries, and develop an innovative approach for designing such
networks [22].
Both total productive maintenance (TPM) and Six Sigma are key
business process strategies, which are employed by companies to enhance
their manufacturing performance. Therefore, will be to develop and implement
an integrated Six Sigma Maintenance (SSM) model for manufacturing industry

[23].
Garment industries in developing countries are more focused on sourcing
of raw material and minimizing delivery cost than labor productivity because of
the availability of cheap labor. Due to this, labor productivity is lower in
developing countries than in the developed ones. For example, labour is very
cheap in Bangladesh but the productivity is poor among other developing
countries [24].

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In some cases it has been observed that, in developing countries the
garment industries are run as family business lacking skilled personnel as well
as capital to implement new technologies for improving productivity and
flexibility. Because of this, industries have been running in a traditional way for
years and are rigid to change. They are happy as long as they are sustaining
their business. They don’t have much confidence and will towards innovation
over old processes. Now the time has come to struggle with global market
demand and niche market in garment industries if they want to run it further [25].
The popular definition of Lean Manufacturing and the Toyota Production
System usually consists of the following (Wilson, 2009, p. 29-30). It is a
comprehensive set of techniques which when combined allows you to reduce
and eliminate the wastes. This will make the company leaner, more flexible and
more responsive by reducing waste. Lean is the systematic approach to
identifying and eliminating waste through continuous improvement by flowing the
product or service at the pull of your customer in pursuit of perfection [26].
The shortage of raw materials, absenteeism, machine malfunction,
unexpected WIP, defective products, frequent changeover in production
schedule production shutdown caused by political action and power supply
problem are contributor to low productivity [27].
A large number of studies have determined major quality improvement
tools their paper discusses the quality and productivity improvement in a

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manufacturing enterprise through practical study. This paper deals with an
application of methodology in an industry which provides a framework to identify
quantify and eliminate sources of variation in an operational process, to optimize
the operation variables, improve and sustain process performance with well-
executed control plans. The application of the paper also improves the process
performance of the critical operational process, leading to better utilization of
resources, decreases variations & maintains consistent quality of the process
output. The outcome of this observation reflected that an industry may gain
higher productivity and profitability with improved quality product by minimizing
reworks activities. It also minimizes cost and improves internal throughput time.
Finally a general overview over this development is given [27].

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Conceptual Framework
INPUT PROCESS OUTPUT

 Definition of  Collection of
current Defect data through
condition of Quality  Reducing of
dropped/skippe Control defects
d stitches. schedule through
 Root cause implementati
analysis  Presentation
of Check on of six
 Why-why
Sheet sigma of
analysis
 Vesja
Workers before  Presentation
and after of chart: Subcon.
efficiency/ Garments
productivity  Analysis of
chart
 Interpretation
of Result
Feedback
Figure 1: Research Paradigm
Figure 1 shows the sequential process that the researchers used in the
study. The input was to gather the data of their defects for several months. After
gathering the data, each defect was analyzed and recognized as the greatest
number of defects in the garments. Throughout the study, researchers were able
to reduce or eliminate the defects and implement changes in the system. Lastly,
they developed a uniform procedure in each process.

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Objectives of the Study
The main objective of the study was to reduce the Dropped/ Skipped
Stitches in the garments. Specifically, sought to answer the following objectives:
1. To define the current defect condition of dropped stitches.
2. To measure the current defects data.
3. To analyze the root cause of dropped stitches.
4. To improve or reduce the root cause of dropped stitches in the garments.
5. To control the causes of dropped stitches in the garments.

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Chapter 2
METHODOLOGY
This chapter portrays diverse exploration techniques and methodologies
used as a part of this research study. Throughout the chapter, the researchers
attempted to justify the reasons for using such method, approach, strategy and
instrument. Lastly, it presented how this research was conducted, with respect
to the said strategies and methodologies.
Research design
The research design used in this study was an applied research type
which aimed to find out the effective solution on the problems that the company
is facing. Improvement research is a unique work that attempted to obtain new
information with a particular application in perspective. It is attempted either to
determine possible utilization for the result that has been undertaken or to
determine better approaches for accomplishing some goals. Also, it focuses on
the taking of such result of a scientific research and utilizing it directly. This
study is an applied research since further improvements will be implemented on
the company. Also this study will develop a proposed operating procedure in
each process.
Research Locale
Vesja SubCon. Garments is a newly-formed garment industry located at
Lapu-Lapu 2, SanJose Batangas. It was owned by Mrs. Evelinda Briones. The
researchers focused their study in the quality control, and the defects in whole
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product schedule. The specific defect that they improved was the dropped or
skipped stitches of the workers in the garments.
Participants of the study
The participants of the study were the collaborative team from the
company. It is consisted of the General Manager, Mrs Evelinda Briones,
Supervisor, Mr. Andey Contante and Mrs. Flordeliza Villvar, the Assistant
Supervisor of Vesja SubCon. Garments.
The researchers interviewed the operators about the working system. A
supervisor was asked about the targeted output. The researchers observed
different sewing line and asked questions to the operators especially to the
workers assigned in the quality control.
Mr. Andey Contante oriented and guided the workers during their first time
in the company, showed how the production flows and how the processes were
done and also gave data about their current process and their outputs each
month.
Research Instrument
The researchers used different instruments in order to determine the
cause of this problem. This instrument helped the researchers to analyze the
problem and find an immediate solution.

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Data gathering were used by the researchers to identify the specific defect
in the process system. Each operation was gathered by the quality controller in 3
times to easily identify the defects and bottleneck that affects the production.
Check sheet was used by the researchers in recording data for a given
nonconforming. A certain system was observed by the researchers to know the
constraints that affect the production line. By the use of check sheet, researchers
can easily identify the highest number of defects.
Pareto Chart was also used by the researchers to easy identify the highest
percent of defects in the system which is used based on the data gathered.
Ishikawa or the fish bone diagram or the Ishikawa diagram is a tool used
to identify the root cause of poor process sequence.
Stop watch was used by the researchers to identify the cycle time of each
operation. Each operation was observed 10 times to easily identify the main
cause of the problems.
P Control Chart was also used in the study to control one quality
characteristic, as done with the chart; to control a group of quality characteristics
of the same type or of the same part, or to control the entire product.
Six Sigma tool was also used in this study as a guide or pattern to help the
researchers in the reduction of dropped or skipped stitches and other defects in
the garments.

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Why-why Analysis, an important component of root cause analysis is a
thorough understanding of “what happened”. The information-gathering process
includes interviews with staffs and workers who were directly and indirectly
involved with the physical environment where the event and other relevant
processes took place along with observation of usual work processes. This
information is synthesized into a “final understanding”, which was further used by
the team to begin the “why” portion of the analysis in a logical sequence to find a
logical solution to the problem. It is one of the many brainstorming methodology
of asking “why” five times repeatedly to help in identifying the root cause of a
problem.
Data Gathering Procedure
The researchers submitted a request letter to conduct a study to Vesja
SubCon. Garments. After the approval of the owner of the company, the
supervisor oriented the researchers about the over-all production and different
types of the product they produced. The supervisor also introduced the
researchers to the production supervisor and area leader. The data gathering
started last October 16, 2017.
The researchers conducted interviews to the operators, line leaders,
different area supervisors and quality control workers about the current process
and how they sustain the quality of their products. They also gathered data,
specifically the number of defects in different products in the sewing line.

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In this study, the researchers identified the most common problem that
each garment industry still encounters, and that contributes low efficiency. To
make some solutions, they brainstormed about different techniques used to
make the study possible.
Eliminating the non-value added motion and rushed undertaking actions
are some factors or tools that can help surpass the problem. By evaluating the
products repeatedly, the researchers determined the non-value added motions
and the avoidable performance of the operators. After the researchers identified
the defects, they analyzed it and improved the system.
After the researchers identified the defects, the researchers identified the
waste; they used Root - Cause Analysis to identify the causes of the problem or
events and an approach for responding to them. This method is often used to
help people understands why it occurs. Root cause analysis was used by the
researchers to determine the cause of the problem. This is to analyze what
happened, how it happened and why it happened. Also, the researchers were
able to analyze the variables affecting each process.
Data Analysis
The collected data were analyzed using Microsoft excel and Mini tab
software for forming Pareto diagram, Control chart, Cause and effect diagram.
Normal Time
It is the amount of time that a worker produces a certain product at a
normal pace.
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Normal Time = Observed Time x Performance Rating
100
Standard Time
It is the amount time that should be the average time a worker should
produce one unit.
Standard Time =Normal Time (1 + Allowance)

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Chapter 3
RESULT AND DISCUSSION
This chapter portrays diverse exploration techniques and methodologies
used as a part of this research study. Throughout the chapter, the researchers
attempted to justify the reasons for using such method, approach, strategy and
instrument. Lastly, the aim of the work is to reduce the dropped stitches and
other defects through implementation of Six Sigma.
1.0 Define Phase
Define is the first phase of the DMAIC methodology of Six Sigma. The
purpose of this phase is to define the problem, goal of the project and the
process needed to be improved to get higher sigma level. There are six different
sigma tools that are available for define phase SIPOC. This is a process map
which includes Suppliers, Inputs, Process, Outputs and Customers. Quality is
judged based on the output of a process and the following table shows the
SIPOC flow of the factory and also was used for understanding the clear
relationship between customer and supplier.
Table 1.0 SIPOC Suppliers-Input-Process-Outputs-Customers

Supplier Inputs Processes Outputs Customer
All of the sub
contractor of
Dickies / Jag Front and back Dickies and
Manufacturer Cut fabrics 1. Bearer Fabric Jag
Vesja SubCon Co
Back
Staff-Workers Back part Back pocket fab Sewing Prep 1
2. pocket
Vesja SubCon Co
Staff-Workers
Paneling Process Front and 3. Front/ Paneled front

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back Back
Step Staff- workers Fabric Panel and back pocket Sewing Prep 1
Vesja SubCon Co
Staff-Workers
Front and Back
Bearing
Front part
Process Step Staff Fabric Sewing Prep 2
panelled 4. Bearer
Vesja SubCon Co
Staff-Workers
Pocketing Process
Back
Step Staff Pockets Back Fabric Sewing Prep 2
5. Pocket
Vesja SubCon Co
Staff-Workers
Pocketing Process Outlined back
Step Staff Back Pockets 6. Outline Part Sewing Prep 2
Vesja SubCon Co
Staff-Workers
Pocketing Process Pointed Back
Back pocket Back
Step Staff pocket Sewing Prep 2
Part 7. Pkt. Pt
Vesja SubCon Co
Staff-Workers
Pocketing Process Combined Back
S
Step Staff Back Pocket FLY/D pocket Sewing Prep 2
8. FLY
Vesja SubCon Co
Staff-Workers
Close
Pocketing Process Finished back
9. pocket
Step Staff Bag pocket Bag pocket Sewing Prep 2
Vesja SubCon Co
Staff-Workers
Back
Pocketing Process Finished back
10. Pkt. Pt
Upper bag
Step Staff upper pocket Sewing Prep 2
pocket upper
Vesja SubCon Co
Staff-Workers
Upper bag
Pocketing Process Outlined upper
pocket
Prep D
Step Staff Lining bag pocket Sewing Prep 2
11. fly
Vesja SubCon Co
Staff-Workers
Small pocket
Pocketing Process Coined small
in front Hem
12. coin pkt
Step Staff Part pocket Sewing Prep 3
Vesja SubCon Co
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Staff-Workers
Attach
Zippering Process
13. zipper
Zipper and
Step Staff Zippered Front Sewing Prep 3
front part to fly
Sett lift
Vesja SubCon Co Front Part Settled front Sewing Prep 4
14. fly w/
Table shows that different suppliers may provide different raw material.
One may be a raw material with high quality and the other one might be poor
raw material which may cause high effect on the final product. For this reason,
the SIPOC will help us in differentiating the variability place whether it comes
from supplier, input, process, output or customer and also it will be very easy for
taking corrective action.
Figure 2: Value Stream Mapping
Value stream mapping is a lean manufacturing or lean enterprise
technique used to document, analyze and improve the flow of information or
materials required to produce a product or service for a customer.

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2.0 Measurement Phase

Table 2.0 Defects Condition
Table 2 shows the record of defects from January to May or eighteen (18)
weeks. Letter I, which is the dropped stitches, had the highest number of defects
with the total number of 1,227 units over 21,600 of maong pants. According to
Islam, Bagum and Rashed they found that shortage of raw materials,
absenteeism, machine malfunction, unexpected WIP, defective products,
frequent changeover in production. Schedule production shutdown caused by
political action and power supply problem are contributor to low productivity.
Table 3.0 Continuation

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This table shows the record of defects from the month of June to October
or in nineteen (19) weeks. This states that the letter I, which is the dropped
stitches, had the highest number of defects with the total number of 1,860 units
over 22,800 units of jeans.
The SPC methods such as check list, Pareto analysis, cause-effect
diagram and P control chart were used. The frequencies of sewing defects in the
operations at the sewing department are determined by check list [18]. The
reasons of the defects are analyzed with the cause-effect diagram for the
operation which has the highest sewing defect rate. The rate of defect in the
control or not. Sampling based statistical quality control system is proposed in
finishing section to eliminate 100% inspection by sampling based inspection [19].
Table 4.0 Total Defects

DEFECTS F P
A. Broken Buttons 1421 8%
B. Broken Seams 1561 9%
C. Broken Stitches 1875 11%
D. Untrimmed Thread Ends 1438 8%
E. Inoperative Zippers 1647 9%
F. Unfinished Buttonholes 1636 9%
G. Incorrect Labels 1406 8%
H. Uncut/Loose threads 1539 9%
I. Dropped/Skipped Stitches 3807 17%
J. Wavy Stitches 2057 12%
TOTAL 17667 100%
Table 4 shows that the letter I. “Dropped stitches” has the highest rate of
defects during the inspection that gathered 3,087 units of jeans or 17%.

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Figure 3: Pareto Chart

Ten Months Data
Pareto Chart shows the current measurement of defects in the garments.
This data proves that the “Dropped Stitches” have the highest number and
percentage of defects with the total of 3,087 or 17.5 % units of pants. It is
followed by the other defects like Wavy Stitches which had 2,057 or 29.1% units,
the Broken Stiches which had 1,875 or 10.6% units, Inoperative Zippers had
1,647 or 9.3% units, the Unfinished Buttonhole which had 1,636 or 9.3% units,
the Broken Seams which had 1,561 or 8.8% units, the Uncut/Loose Threads had
Untrimmed Thread Ends which had 1,438 or 8.1% units, the Broken Buttons
which had 1,421 or 8% of units and lastly is the Wavy Stitches which had 1,406
or 8% units of pants. The operations which have highest sewing defect rates and
the effects of these operations to the defect rate are examined by using the
Pareto analysis [18].

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3.0 Analyze Phase
The goal of the analyze phase is to go through the data to find out the root
causes of the problems and seek improvement opportunities. At the measure
phase, 3 major types of defects were identified and the target of this phase is to
find out all the potential causes of those defects. Four problems solving six
sigma tools were used at analyze phase and these were cause effect diagram,
Regression, Pareto, why-why. In order to identify the potential causes of the
defects and their respective solutions in the Brainstorming session, large
number of creative and useful ideas was generated and was arranged at the
selected session and carried out by the presence of the following members that
is shown in the appendix.
Figure 4: Cause of Dropped Stitches
Figure 4 shows all the defects that were coming from the material,
method, machine, and man are listed and prioritized and the Pareto indicates

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that the needle bent or dull plays significant role for the cause of
dropped/skipped stitch. The second one is the machine setting. The cause that
comes from the machine has also a great effect for the dropped/skipped stitch
and others can also contribute with the same case with the quality of the thread
and needle insertion. The only difference is the frequency of their occurrence.
For the top machine defect, needle bent or dull is the most frequent machine
defect. The machine setting is the second most frequent machine defect. Skill
problem, improper threading and worn defective thread guidelines are some of
the few vital machines defect that play great role for the occurrence of skip
stitch. Further, Pareto Analysis for the material defects can be seen on those
top defect positions to identify the few vital defect types that are responsible for
maximum amount of defect.
Figure 5: Cause and Effect Diagram

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Figure 5 shows the cause and effect diagram for drop/skip stitches and
then the potential causes were identified by inspections and root cause analysis
of defects from Pareto Analysis. The top defect types have been identified
which is Skipped Stitch. By our own observation and data provided by
supervisor from the production lines and interviews, the causes for specific
defect types had been identified. These causes are ordered according to the
frequency of the feedback provided by Quality Control supervisors. Out of all
causes, the critical root causes were Absence of scheduled maintenance, Spare
part shortage, Lack of skill, Machine adjustment, Low thread quality and Long-
time needle usage. The reasons of the defects are analyzed with the cause-
effect diagram for the operation which has the highest sewing defect rate [18].
Problem Statement: The cause of the dropped/skipped stitches is man power,
machines, method and materials.
Root Cause Definition: Dropped/Skipped Stitches
Problem Statement: Sewing machines are not in their proper control that
caused rework and delays in their production. The poor process system causes
a lot of time in operation.
Man:
Root Cause Definition 1: Qualification
Problem Statement: Some of the new workers are not oriented and just
learning on actual work. Some are incapable like poor eye-sight that affects

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their performance. Others have low awareness and skill that leads them to act
unnecessary like increasing speed while operating.
Machine:
Root Cause Definition 1: Machine Damage
Problem Statement: Poor machine that is still being used that can cause
constraints during the process.
Root Cause Definition 2: Long time usage of needle
Problem Statement: Long time usage of needle can cause unexpected
bending especially when the type of fabric is hard. It causes time to idle and
bottlenecks.
Materials:
Root Cause Definition 1: Quality of the thread
Problem Statement: Some materials in garments like thread are loosening up
to the needle that causes malfunction of the garments.
Root Cause Definition 1: Quality
Problem Statement: Bad quality of raw materials leads to bad quality of
output. The company’s reputation is built upon the quality of the product.

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Figure 6: Dropped/Skipped Stitch
Irregular stitching along the seam that appears due to improper handling
of cut pieces or machine usage. Improper threading, dirty machine, wrong
setting, long time needle usage needle bent or dull , incorrect needle insertion
skill problem, poor quality needle, poor quality thread, high speed and handling
problem.
Why- Why analysis
An important component of root cause analysis is a thorough
understanding of “what happened”. The information-gathering process includes
interviews with staffs and workers who were directly and indirectly involved with
the physical environment where the event and other relevant processes took
place, along with observation of usual work processes. This information is
synthesized into a “final understanding”, which is further used by the team to
begin the “why” portion of the analysis in a logical sequence to find a logical
solution to the problem. It is one of the brainstorming methodologies of asking
“why” five times repeatedly to help in identifying the root cause of a problem. If a
SubCon. Garments
30
problem is repeatedly questioned, each time an alternative solution comes out
which is linked to the root cause.
However, asking why may be continued till getting an agreeable solution.
Five is an arbitrary figure. The theory is that after asking “why” five times, one is
likely to arrive at the root cause and it was also employed in developing critical
thinking in identifying the root causes of the problem & recognizing the
relationship among them.
The process of asking questions was continued till the root cause of the
problem has been identified. (i) Why operators increase the speed? For
finishing the work fast. (ii) Why they want to finish the work fast? Due to not
known the effect and dissatisfaction by the set speed. (iii) Why dissatisfaction
by the set speeds and not knowing the effect? Due to lack in awareness of
problem and over confidence. Why over confidence and awareness problem
due to lack of continuous training and high experience (iv) why lack of
continuous training and high experience? Because they are only trained when
they are hired. (v) Why they are trained when they are hired? Due to there is
high cost for training.
According to the data, the “Needle Bent or Dull” have the highest number
of cause of dropped stitches. It is clear that the needle time, speed, needle
insertion and the thread quality are factors that affect the occurrence of
dropped/skip stitches. Each factor has levels to start from the needle time in the
first level it indicates the changing of needle. Since, Vesja Garments is a

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31
subcontracting firm of Dickies and Jug products, the contributors settled due
date or number of days they needed to finish the jeans and shorts.
Table 5.0 Time Study of Garments Process

ELEMENTS Average Time/Sec
1. Bearer 19.5
2. Back pocket 23.5
3. Front/Back panel 294
4. Bearer 92.3
5. Back Pocket 523
6. Outline 10.76
7. Back Pkt. Pt 15.26
8. S FLY/D FLY 16.74
9. Close pocket bag 74.42
10.Back Pkt. Pt upper 40.84
11. Prep Dfly 39.655
12. Hem coin pkt 10.268
13. Attach zipper to fly 41.54
14. Sett lift fly w/ tls 16.076
15.Design bk. Pkt 3 passes 2color thread 15.944
16. tls close pkt my corner 15.222
17. Stayknotch 14.395
18. Attach back pkt 131.568
19. Riser back seam 12.703
20. Attach w/ band contour 2pc w/ insert Loops 10.51
21. Bartack x2 16.64
22. Button hole 39.79
23. Closeband 82.822
24. Hemleg 63.14
25. Bearer to Lining 10.887
26. Side Close 6.355
27. Top side 13.46
28. Attach Care Labels 15.107
29. Combine 177.801
30. Attach with Bond label w/ plastic 12.445
31. Binding with Bias 58.311
32. Join Crotch 54.22
33. Outline 28.54
1997.719
Table 5 shows the process system of jeans operation. This states that
the total time for sewing one unit is 1997.719 seconds or 26.64 minutes per

SubCon. Garments
32
unit. It proves that the workers are taking or sewing the jeans fast which cause
the bending of the needles.
Needle Bending or Dull are due to the performance of the workers aiming
to finish their works in the given time. The workers are over confident of doing
their works and not aware for the results of their finished products.
Normal Time
It is the amount of time that a worker produces a certain product at a
normal pace.
Normal Time = Observed Time x Performance Rating

100
NT= 1997.7 x 80= 1,598.16 secs = 26.64 mins.
100
The computation shows that the normal time of the workers in the
garments are just 26.64 minutes in finishing the one whole jeans from the
beginning up to the end process. It states that the normal time for finishing one
jeans is too fast from the supposedly ordinary or regular machine speed that the
sewing machine have to run. The normal time is too fast for over 480 minutes per
day that is given to the workers to meet their average number of unit they have to
finish per day so they can follow and meet the due dates of submissions of the
finished product to the customers.

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33
4.0 Improve Phase
The purpose of the DMAIC Improve phase is to discover a solution to the
problem that the task aims to address. This involves brainstorming potential
solutions, selection of solutions to test and evaluating the results of the
implemented solutions.
Table 6.0 Normal Man-Machine Speed

ELEMENTS Average Time/Sec
1. Bearer 36.15
2. Back pocket 46.12
3. Front/Back panel 561
4. Bearer 182.4
5. Back Pocket 523
6. Outline 21.11
7. Back Pkt. Pt 30.21
8. S FLY/D FLY 12.15
9. Close pocket bag 140.64
10.Back Pkt. Pt upper 80.21
11. Prep Dfly 68.12
12. Hem coin pkt 20.12
13. Attach zipper to fly 52.62
14. Sett lift fly w/ tls 28.215
15.Design bk. Pkt 3 passes 2color thread 31.554
16. tls close pkt my corner 30.845
17. Stayknotch 28.154
18. Attach back pkt 230.21
19. Riser back seam 24.3125
20. Attach w/ band contour 2pc w/ insert Loops 21.01
21. Bartack x2 26.12
22. Button hole 38.24
23. Closeband 162.21
24. Hemleg 126.18
25. Bearer to Lining 20.88
26. Side Close 630.616
27. Top side 48.21
28. Attach Care Labels 41.48
29. Combine 195.15
30. Attach with Bond label w/ plastic 24.18
31. Binding with Bias 116.17
32. Join Crotch 108.32
33. Outline 52.69
1997.719
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34
The table shows the new applied time schedule of the workers having a
careful usage of machines and material. This table illustrates that the newly
revised time study is 3,155.33, which gives more time to the workers to be
careful for what they are doing and processing. The workers are applicable to
sew fast.
The sewing speed is normal, therefore there is no breakage of needle
happened during the process. The skipped or dropped stitches are avoided and
the number of defects decreased.
5.0 Control Phase
Attribute control chart-p-chart were used for non-conforming (defective
products) per day and a sample of ten month data has been taken periodically
from the production process, and the proportion of defective items in the sample
were determined to see the proportion falls within the control limits on the chart.
Figure 7: P Chart

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35
Figure 7 shows the process were below the upper and lower limit, the
process is out of control and the cause has been detected and there were
assignable cause of variation that affects the process. Since the process being
below the lower limit is good because reducing the rework rate is our target.
Process were above the upper control limit during 1, 2, 3, 5, 6, 7, 8, 9
and 10th month. It shows that something was wrong and from the inspection
results of the company, it shows that in day 9, a defective purchased from
supplier, in day 18, different operators problems, in day 20 improper needle
adjustment problem by the operator, in day 26, poor handling problem and in
day 28, there were spare part shortage. Already, the nature of the assignable
cause of variation has been identified and after this counter, measures should
be taken for making the process stable.
Figure 8: Revised P Chart

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36
Assuming that actions were taken so that the processes remain in control
after the improvement plans have been implemented, out of control state has
been quickly detected & associated special causes were determined so that
actions can be taken to correct the problem before non-conformities are
produced. Now, the process is in control and the company needs to sustain the
stable process and also control plans should be prepared for specifying
process, monitoring and corrective actions. To summarize, in define phase the
problem were identified, in measure phase, the current performance were
measured, in analyze phase, the root cause of the problem were analyzed, in
improve phase to eliminate the root causes. The processes were improved in
control to sustain the gains controlling the process. Due to this reason, the
methodology was effective.
P control chart were used. The frequencies of sewing defects in the
operations at the sewing department are determined by check list. The
operations which have the highest sewing defect rates and the effects of these
operations to the defect rate are examined by using the Pareto analysis. The
reasons of the defects are analyzed with the cause-effect diagram for the
operation which has the highest sewing defect rate. The rate of defect in the
control or not. Sampling based on statistical quality control system is proposed
in finishing section to eliminate 100% inspection by sampling based inspect [18].

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37
Chapter 4
CONCLUSION AND RECOMMENDATION
This chapter presents the conclusion based on the objectives of the study.
It also discusses the recommendations in the study that has been developed the
results.
CONCLUSIONS
1. The most difficult thing in manufacturing is producing right quality product
all the time. Still, it is important to work on improving product quality to
satisfy customers, to control production cost and to save energy.
Improving product quality is generally not difficult, but requires deliberate
and on-going attention which requires commitment of every individual
within the manufacturing company. Quality of product plays an important
role in any industry.
2. Manufacturing the quality product is required to sustain in global
competitive market. If a consumer does not like the quality of the product
then the chances of sales become very less. Today, clothes play a very
important role in the society. They helped in creating an impression and
define the human being in some aspects. Therefore it is very important to
see to it that garments are made of high quality. In garment and textile
factory, sewing is one of the major processes. It plays an important role
in maintaining the quality of clothes. Hence, it is important that all defects
have to be avoided during sewing any. In this paper, various faults or

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38
defects that can take place during sewing along with different remedies
or methods to solve these defects are discussed.
3. Minimizing defect is very important for ensuring the quality of products.
From the Pareto Chart, Dropped/Skipped stitches are defect
that were identified were responsible for more than 17.5% of total defects
occurring in the sewing section of the Vesja garment factory for the item of
jeans. After finding the highest number of defects, brainstorming tool was
used to identify the probable causes and then potential root causes were
identified by inspections and root cause analysis. This method is very
effective to the minimization of defects. Since minimization of defects is a
continuous process, further implementation of this methodology will help
the company enjoying more reduction on defect rate and improvement on
productivity.
4. This study is concentrated only in the sewing section, an integrated study
of other sections of the factory such as knitting, dying, cutting and finishing
can be more effective on the minimization of defects.

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39
Recommendation
Based on the findings and conclusions drawn from the study, the
researchers recommend the following:
Table 7.0 Action Plan for all major defects with corresponding causes
Areas Causes Suggested Solutions

Inadequate training and
Human Technical training for the operators
operator efficiency
Carelessness Improve supervision
Machine is threaded Rethread machine and maintain proper thread
Machine incorrectly or excessive tenson. Make sure the thread passes through
thread tension the tension discs.
Dull or bent sewing
Replace the needle and knife with a new one.
machine needle and knife
Excessive pressure on Lessen the pressure on the presser foot.
the presser foot. Slacken both tensions.
Machine dirty. Autonomous maintenance.
Wrong setting Proper setting.
Long-time needle usage Changing the needle frequently
Numbering stain Proper numbering
Uncleaned machine Cleaning the machine frequently
Insert the needle on correct position. Check
Incorrectly inserted
Method that the bobbin is wound correctly and no loose
needle
threads or loop sticking out.
Comparatively long stitch
Shorten the stitch length by means of the stirch
for the type of fabric in
regulator, especially when sewing fine fabrics.
work
Poor handling Proper handling fabric
Lack of SOP Structures SOP
Lack of Transportation Use appropriate transportation
Standardization Every work should standardize
Packing Use proper packaging material
Material Poor quality thread Use good quality thread.
Use high quality needles from another brand.
Poor quality needle Needles should have high heat resistance
capacity.
Poor quality scissor Good quality scissor.

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40
Table 7 shows that there can be many reasons behind the problems that
arise while sewing and knowing the cause of these problems and a solution for
each particular cause is essential. These problems can be minimized by
avoiding errors during handing of materials and machines by following the right
working methods. This research has been carried out on sewing section of
Vesja garment factory to improve its level of quality status. Currently, analyzed
data indicates that the rework rate is very high when it is evaluated with the
company‘s quality target.
To improve its quality of product, the study focused in reducing the
rework rate. The factory needs to address the critical causes of defects to
improve its quality based on the following recommendations. The factory needs
to focus on the critical identified fabric defects and their respective causes to
improve its quality. Preventing defects will be given more priority than correcting
defects. It is recommended that Standard Operating Procedure (SOP) must be
used since it is the best prevention tool to minimize defect rate while operating
production and also keeps machine healthy. The factory needs to monitor
machine operation, machine cleaning, replacement of dull or bent sewing
machine needles and knives with new ones , insert the needles to the correct
position, provide adequate training to the operator, improve supervision, change
faulty machine parts, develop a proper quality management system in order to
quick detection and solution of the quality problems.

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41
BIBLIOGRAPHY

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42
Bibliography
Journal:
[1] Xie and Goh (1999)

Retrieved by: http://ieomsociety.org/ieom2017/
Web:
[2] Six Sigma Way Hairulliza et al., 2005

[3] Antony and Kaye, 1995.

[4] Improving Ready-Made Garment Productivity by

Changing Worker Antony et al (1998)
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[5] Improving Ready-Made Garment Productivity by Changing Worker

by Motorcu and Gullu (2004) and Srikaeo et al (2005)
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[6] Breyfogle and Cupello, 2001 1857 – 7881 (Print) e - ISSN
[7] Mahanti and Antony, 2005

Thorpe et al. (1994), Gardiner and Mitra (1994) Bathika (2003)
and Slattery (2005)
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Attitude Thorpe et al. (1994), Gardiner and Mitra (1994) Bathika
(2003) and Slattery (2005)
Retrieved from: https://goo.gl/YVJIFQ
[10] Six Sigma Way

Hairulliza et al., 2005
Retrieved by: https://goo.gl/8TaWgz
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43
[11] (Case: MAA Garment and Textile Factory) Wong, Kwong, Mok, Ip,
and Chan (2005); . Matthew(2008)
Retrieved from: http://ieomsociety.org/ieom2014/pdfs/273.pdf
[12] (Case: MAA Garment and Textile Factory)

Jeannine(2005 Retrieved from
http://ieomsociety.org/ieom2017/papers/406.pdf
[13] (Case: MAA Garment and Textile Factory) Peter

2005 Retrieved from
http://pubsonline.informs.org/doi/abs/10.1287
[14] (B. Jaouachi1, F. Khedher , F. Mili (2012)” Consumption Of The

Sewing Thread Of Jean Pant Using Taguchi Design Analysis”
Autex Research Journal, Vol. 12, No 4,
Retrieved from http://ol.efficiency org/doi/abs/10
[15] M. M.Rahman And A.K.M. Masud(2011) “Quality Improvement In

garments `Industry Through TQM Approach” Proceedings Of The
International Conference On Mechanical Engineering (Icme2011)
18-20 , Dhaka, Banglades
[16] N.A.M.R.Senaviratna(2013),”Application Of Generalized Linear

Model To The Minimization Of Defectives In Sewing Process Of
Apparel Industry” International Journal Of Scientific And Research
Publications, Volume 3, Issue 7, Issn 2250-3153
[17] Hau L. Lee , Seungjin Whang(2005)”Higher Supply chain Security

with Lower Cost: Lessons From Total Quality Management” Int. J.
Production Economics 96 , 289–300
[18] InciDengizlerKayaalp ,Ege U. Emel Akın

MeslekYuksekokulu(2009)” Decreasing Sewing Defects By Using
Statistical Process Control Methods In The Apparel Factory”
TekstilVeKonfeksiyon
[19] Md. Mohibul Islam And Md. Mosharraf Hossain(2013), Statistical

Quality Control Approach Intypical Garments Manufacturing
Industry In Bangladesh: A Case Study” Proceedings Of 9th Asian
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44
Business Research Conference 20-21 , Biam Foundation, Dhaka,

Bangladesh
[20 Varsha Hemant Patil, Snehal M. Kamlapur, Manikrao L. Dhore

(2006)”Six Sigma In Education: To Achieve Overall Excellence
In The Field Of
Education” Proceedings Of The Third International Conference On
Information Technology: New Generations (Itng'06) 0-7695-2497-
4/06]
[21] ,Md.Mazedul Islam ,Adnan Maroof Khan, Md.Mashiur Rahman

Khan (2013)”Minimization Of Reworks In Quality And Productivity
Improvement In The Apparel Industry” International Journal Of
Engineering and Applied Sciences ,Vol. 1, No.4
[22] Pantano 2006

Retrieved from http://ieomsociety.org/ieom2017/
[23] Garg 2004

Retrieved from http://ieomsociety.org/ieom2017/
[24] (Shahidul and Syed Shazali,

Retrieved from http://www.garmentbusiness.biz/upload/lean.pdf
[25] (Gao, Norton, Zhang and Kin-man To, 2009).

Retrieved from http://www.garmentbusiness.biz/upload/lean.pdf
[26] (Nash, Poling and Ward, 2006, p. 17).

Retrieved from http: www.garmentbusiness.biz/upload/lean.pdf
[27] Sajid Ibrahim Hashmi And JongmoonBaik(2008)”Quantitative

Process Improvement In Xp Using Six Sigma Tools” Seventh
IeeeAcis International Conference On Computer And Information
Science
[28] Md. Mazedul Islam ,Adnan Maroof Khan ,Md.Mashiur Rahman

Khan( 2014)” Minimization Of Reworks In Quality And Productivity
Improvement In The Apparel Industry” International Journal Of
Engineering And Applied Sciences Vol. 1, No.4 Issn 2305-8269

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APPENDICES

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Appendix A
Letter for Company
Dear Sir/Ma’am,
Warm greetings of Peace!
We, the fourth year Industrial Engineering students of Westmead
International School are currently enrolled in Ergonomics, Operation Research 1,
and Industrial Quality Control/IE 411. As a part of the subject requirements, we
are asked to conduct a study.
In line with this, we are also asking for your permission to visit and
observe in your production area for the identification of potential improvement
project and study.
Rest assured that all information you will be entrusting to us will be
handled with strict confidentiality and shall be used for academic purpose only.
We are looking forward that this request will merit your favourable
consideration.
Thank you very much and God Bless!
Sincerely Yours,
Almarez, Kristian Rio M.
Bagon, Rachelle D.
Barte, Niña Vanessa C.
Consigo, Evangeline P.
Malibiran, Jasmin V.
Noted by:
Engr. Ryan Jeffrey P. Curbano
Subject Adviser

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Appendix B
Data and Result
DEFECTS F P
A. Broken Buttons 1421 8%
B. Broken Seams 1561 9%
C. Broken Stitches 1875 11%
D. Untrimmed Thread Ends 1438 8%
E. Inoperative Zippers 1647 9%
F. Unfinished Buttonholes 1636 9%
G. Incorrect Labels 1406 8%
H. Uncut/Loose threads 1539 9%
I. Dropped/Skipped Stitches 3807 17%
J. Wavy Stitches 2057 12%
TOTAL 17667 100%
FE
D JAN B MAR APR MAY JUN JUL AUG SP OCT T P
A 100 135 144 84 198 133 152 194 186 95 1421 8%
B 83 157 119 71 199 165 151 266 268 82 1561 9%
C 115 149 158 79 223 160 258 320 283 130 1875 11%
D 102 150 153 80 205 154 124 151 227 92 1438 8%
E 132 166 177 66 173 148 126 309 203 147 1647 9%
F 156 146 177 83 209 157 183 227 176 122 1636 9%
G 60 153 239 ### 150 125 89 203 150 85 1406 8%
H 123 147 161 77 205 165 147 220 184 110 1539 9%
I 215 259 267 ### 360 281 278 479 544 278 3087 17%
J 141 189 168 ### 258 232 222 366 263 108 2057 12%
### ###
#### #### #### ### #### #### # #### # #### ##### 100%

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Machine
1. Quality Thread 2 7 18
2. Machine Setting 2 5 20
3. Long time usage 5 5 2 15
4. Needed bent/ dull 12 2 13
5. Needle Insertion 18 5 4 0
6. Skill Problem 23 2 2 0
7. Improper threading 5 15 6 1
8. Worn defective thread guidelines 10 12 5 0
61 55 33 67
Man Power
1. Fatigue 12 8 5 2
2. Wrong Setting 2 5 2 18
3. Increase in Speed 8 4 7 8
22 17 7 28
Method
1. Improper threading 5 4 15 3
2. Operation Skill 7 9 8 3
3. Types of Operation 5 4 8 10
4. Improper feeding 12 3 5 7
5. Irregular thread tension 11 4 5 7
40 24 41
Material
1. Fabric Type 2 7 12 6
2. Types of thread 3 5 7 12
3. Thick or thin 5 12 5 5
4. Quality of the thread 1 4 3 19

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Appendix A
Grammarian Certificate

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50
CURRICULUM VITAE

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Almarez, Kristian Rio M.

Bolbok, Batangas City, Batangas
09983390690
kristian.almarez@yahoo.com
OBJECTIVE:
To obtain a teaching career where I can apply my learning experiences

and will utilize my skills and expertise in a well-established institution.
Educational TERTIARY
Qualification Westmead International School
Bachelor of Science in Industrial Engineering
Alangilan, Batangas City
2014– Present
SECONDARY
Batangas State University- Integrated School
2009 -2013
PRIMARY
Saint Mary Eufracia Montessori
2003 – 2009
Extra-Curricular Society of Future Engineers (SFE) Junior

Ativities Westmead International School
Member
2014-2016
Society of Future Engineers (SFE) Senior

Active Member
2016 – Present

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Junior Philippines Institute of Industrial Engineering

(JPIIE)
Active Member
2013 – 2014
Seminars National Service Training Program (NSTP)

Attended “NROTC Course”
June 2013- March 2014
5th Engineering Orientation Seminar

“ASEAN 2015: Its implications in the
Engineering and Architecture Professions”
Green Coral Resort, Gulod Labac, Batangas City
October 03- 04, 2014
CEA and CITCS Orientation Seminar in Engineering

and ICT Education
“Engineering and Information Technology Education
Opportunities and Challenges and the ASEAN 2015”
Teacher Conference Center, Batangas City
September 30- October 01, 2013
7th Southern Tagalog Industrial Engineering Seminar –

“Transcend: Appraising the Alternatives for Effective
Breakthroughs”
University of the Philippines Los Baños, D.L. Umali
Auditorium
(September 19, 2015)
7th Annual Business Forum 2017

“E-Business: Revolutionizing the Global Marketplace”
Provincial Auditorium Capitol Site, Batangas City
February 3, 2017

“Perceive: Industrial Engineer’s Roles in Service
Quality Management”

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University of the Philippines Los Banos, D.L. Umali

Auditorium
October 21, 2017
Personal Date of Birth : February 14, 1997

Backgorund Place of Birth : Maternity House, Batangas City
Language Spoken : English, Tagalog
Characteristic : Positive, Diligent, Active, Flexible
*References are Available upon Request*
KRISTIAN RIO M. ALMAREZ

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Rachelle D. Bagon
Purok 3, Dalig Kanluran, Batangas City
09551772471
Rachellebagon24@yahoo.com
OBJECTIVE:

2014– Present
SECONDARY
Batangas National High School
Rizal Avenue, Batangas City
2013-2014
PRIMARY
Melecio Arceo Memorial Elementary School
2009-2010

Member
2014-2016

Active Member
2016 – Present
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(JPIIE)
Active Member
2013 – 2014


Green Coral Resort, GulodLabac, Batangas City
October 03- 04, 2014

and ICT Education
Opportunities and Challanges and the ASEAN 2015”

Breakthroughs”
Auditorium

February 3, 2017

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56
Auditorium
October 21, 2017
Personal Date of Birth : October 24, 1997

Backgorund Place of Birth : Batangas Medical Center
Characteristics : Positive, Diligent, Active,
Flexible, Reliable, and
willing to learn.
RACHELLE D. BAGON

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BARTE, NINA VANESSA C.

Mahabang Parang, Batangas City
09057275973
Vanessabarte9@gmail.com
OBJECTIVE:

2014– Present
SECONDARY
Natalia V. Ramos Memorial National High School
Concepcion Batangas City
2013-2014
PRIMARY
Concepcion Elementary School
Concepcion Batangas City
2009-2010

Member
2014-2016


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Active Member
2016 – Present

(JPIIE)
Active Member
2013 – 2014


October 03- 04, 2014

and ICT Education

Breakthroughs”
Auditorium

February 3, 2017
SubCon. Garments
59

Auditorium
October 21, 2017

Backgorund Place of Birth : Batangas
willing to learn.
NINA VANESSA C. BARTE

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EVANGELINE P. CONSIGO
Santiago, Naujan Oriental Mindoro
09207960596
Evangeline.consigo@facebook.com
OBJECTIVE:

2014– Present
SECONDARY
Agustin Gutierrez Memorial Academy
Poblacion 1, Naujan Oriental Mindoro
2013-2014
PRIMARY
Jose L. Basa Memorial School
2009-2010

Member
2014-2016

Active Member
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2016 – Present

(JPIIE)
Active Member
2013 – 2014


October 03- 04, 2014

and ICT Education

Breakthroughs”
Auditorium

February 3, 2017

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62

Auditorium
October 21, 2017
IESHIEKAWA 12
“HIRAYA: Engineering the Backbone of the Nation”
University of the Philippines – Diliman, Quezon City
November 18, 2017
Personal Date of Birth : September 30, 1998

Backgorund Place of Birth : Naujan,Oriental Mindoro
Willing to learn.
EVANGELINE P. CONSIGO

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Jasmin V. Malibiran
Libjo Lamao, Batangas City
09107854988
Jasmine_malibiran@yahoo.com
OBJECTIVE:

2014– Present
SECONDARY
Batangas National High School
Rizal Avenue, Batangas City
2013-2014
PRIMARY
Libjo Elementary School
2009-2010

Member
2014-2016

Active Member
2016 – Present
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(JPIIE)
Active Member
2013 – 2014


October 03- 04, 2014

and ICT Education

Breakthroughs”
Auditorium

February 3, 2017

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University of the Philippines Los Baños, D.L Umali
Auditorium
October 21, 2017

Backgorund Place of Birth : Libjo, Lamao Batangas City
Willing to learn.
JASMIN V. MALIBIRAN

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66

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Westmead International School

Six Sigma is a comprehensive and flexible system for achieving,

sustaining and maximizing business success. It is uniquely driven by close

understanding of customer needs, disciplined use of facts, data, and statistical

analysis, and diligent attention to managing, improving, and reinventing

including; Cost reduction, Productivity improvement, Market-share growth,

Customer retention, Cycle-time reduction, Defect reduction , Culture change,

Product/service development [10].

In Addition, Another definition of Six Sigma is that it’s aim of near-

“Six Sigma” itself refers to a statistically resulting performance target of

goal of few companies or processes can claim to have achieved.

However, understanding the key features, complications, and deficiencies

provides opportunities to better appliance six sigma projects. Meanwhile, the

force from globalization has made manufacturing organizations moving towards

three major competitive fields: quality, cost, and awareness. Quality is a

to provide customers with good products, manufacturing organizations are

required to guarantee that their processes are constantly supervised and

product quality is improved.

Nevertheless, quality can be defined as fulfilling specification or customer

requirement, without any defect. It refers to activities to ensure that produced

control quality are statistical techniques. Quality control techniques can be

among researchers in the classification [1].

However, defects in product have been and continue to be a major

source of seconds in finished garments. These defects continue despite several

buttons, broken seams, broken stitches, dropped stitches, untrimmed thread

Various kinds of imperfections are found in the article of clothing industry. In

pieces of clothing industry, these imperfections are dependent upon the

arrangement of defects and a supervisor’s capacity to decide.

Reduction of Dropped/Skipped Stitches through Implementation of Six Sigma in Vesja

Vesja Sub.Con Garments is a one of the newly-formed garments

organization in CALABARZON. This garment is one of the sub contracts of Jag

encountered. The broken buttons, broken seams, broken stitches, untrimmed

thread ends, inoperative zipper, unfinished buttonholes, incorrect labels,

uncut/loose threads, dropped/skipped stitches and lastly the wavy stitches.

Reduction of Dropped/Skipped Stitches through Implementation of Six Sigma in Vesja

Review of Related Literature

Quality can be defined as fulfilling specification or customer requirement,

without any defect. A product is said to be high in quality if it is functioning as

control quality are statistical techniques. Quality control techniques can be

among researchers in the classification [1].

causes By continuously monitoring the process, the manufacturing organization

immediate corrective action once a process is found to be out of control [2].

development. Taguchi methods, for instance, aim at making product or process

that robust to undesirable disturbances such as environmental and

manufacturing variations. However, the application of these two methods by

industries is limited [3].

Explore the difficulties in the application including improper understanding

Reduction of Dropped/Skipped Stitches through Implementation of Six Sigma in Vesja

the implementation. Process capability study is an efficient method to examine

the capability of a process to produce items that meet specifications [4].

production was carried out using other statistical techniques [5].

through process continuous improvement. The term six sigma originated at

sigma level of performance [6].

The application of six sigma has been mainly used in manufacturing

industry. An example of the use of six sigma in nonmanufacturing industry is in

software development [7].

Acceptance sampling is another statistical technique to make a decision

application of acceptance sampling allows industries to minimize product

and effectiveness [8].

The application of acceptance sampling has been mainly used in

manufacturing industry. Similarly, its application in nonmanufacturing industry is

widely reported [9].

Reduction of Dropped/Skipped Stitches through Implementation of Six Sigma in Vesja

A comprehensive and flexible system for achieving, sustaining and