Application of Lean Manufacturing Tools in a Garment Industry as a Strategy for Productivity Improvement Lean Manufacturing Implementation in the Sewing Industry Sewing lean technology

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80% of quality problems are from management, and only 20% of problems are from employees!
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Chuangjia said: Product quality is produced, not tested. - American quality management
guru William Deming, before proposing the concept of "product quality is produced, not
tested", early quality management Only for quality inspection, only the quality of the
product can be checked afterwards.
William Deming's quality quote points out that the quality of the product can only be
guaranteed in every step of the production process, strictly in accordance with the
requirements of the production process and work instructions. If the process control is
neglected, it is impossible to guarantee the quality of the product by inspection alone.
Because the quality inspection can only eliminate the defective products and waste products,
it cannot improve the product quality. That is to say, the focus of quality control must not
be placed after the fact, but must be placed in the manufacturing stage, that is, the
production process stage.

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However, many companies, once they have quality problems, push the responsibility to the
quality department, thinking that this is the responsibility of the quality department,
because many companies have such a wrong view:
➢ Allowing a few bad, accidental flaws is inevitable;
➢ Quality is the responsibility of the quality control department;
➢ Only pay attention to the inspection of the product, and the inspectors need to be
responsible for solving the defective products;
➢ If something goes wrong, I feel that it is a matter of the quality department.
I think many of my friends who have done quality work have experienced this feeling more
or less. Often when writing a report, the quality department is completed by one person,
and the other departments basically do not care; the boss feels that quality is not very
important, research and development is very important, and making money is the most
important. Therefore, the quality department does not have any status in the company. It
often says a few truths and is flashed.
Why are there quality problems?
➢ The problems before product development are not handled well, and the throughput
rate of production is too low. I hope that by means of quality firefighting, I want to
improve the frequency of testing and reduce defective or unqualified products.
➢ Adding reworked materials and unqualified materials, but without prior testing and
verification, there is no accurate awareness of product quality fluctuations;
➢ The customer urges the goods, the pressure on them, the boss speaks according to
his so-called actual experience, and implements special release for products that are
not in the standard range, resulting in product problems;
➢ The industry has improved the quality standards of its products, and the company
is still producing according to the original standards;
➢ Non-human quality problems occur during the production process, but they are not
within the detection frequency range.

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How to control product quality in all aspects
The product is basically positioned at the design stage, and then the quality is guaranteed
by purchasing, processing, manufacturing, packaging, and transportation. By controlling
these links, the quality is naturally controlled. Therefore, product quality is achieved in the
design and production process, and quality is achieved through process management.
How to control product quality:
First, establishing quality is the lifeblood consciousness of enterprises
It is necessary for all members to realize that the quality of products is not good, there is
no market for products, and there is no market for products. Enterprises lose their sources
of profit. When the time is long, enterprises will fail, and employees will be unemployed.
Of course, for the company, even if the product market is good, it must be “safe in times
of danger” to make the product quality better and create a better corporate reputation. As
the saying goes: "If you are in full bloom, the breeze comes."
Second, establish a quality customer awareness
Everything is customer-centric, seeing itself as a customer, seeing itself as the operator of
the next process, and seeing itself as a consumer of the product. In this way, in the work,
the work will be done consciously, everyone will do the work well, and the quality of the

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products will be guaranteed. If you cut corners at work, the harm will be your own vital
interests.
Third, establish a sense of prevention of quality
"The quality of the product is produced and designed. It is not by inspection. It is necessary
to do things right the first time." This is not a slogan, which is a good example of the
preventive nature of product quality, if the quality control It is difficult to control the
quality of the product without starting from the source.
Even if a large amount of inspection manpower is put into production to control, and the
production of a large number of defective products or even waste products due to no control
from the source, the cost of the product will be greatly improved. Moreover, the quality
problems of some products may not be found and compensated from the subsequent
processes, which requires us to do things in the first place to prevent quality problems.
Fourth, establish a procedural awareness of quality
Quality management is the whole process and the whole company. The work between all
departments of the company must be orderly and effective. All quality management

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personnel and operators must be strictly in accordance with the procedures. The chances
of making a mistake will increase, and the quality of the product cannot be guaranteed.
Fifth, establish a sense of responsibility for quality
80% of quality problems are out of management, and only 20% of problems originate from
employees. That is to say, managers have controllable defects of about 80%, and operators
have controllable defects of less than 20%. While the manager is improving the management
level, the operator must also understand the following four points:
➢ The operator knows what he does and why he does it;
➢ The operator knows whether the products he produces meet the requirements of
the specification;
➢ The operator knows what will happen if the product he produces does not meet the
specifications;
➢ The operator has the ability to properly handle abnormal conditions.
If the above four points have been met and the material conditions such as equipment,
tooling, testing and materials are in production and the fault still occurs, it is considered
to be a controllable defect of the operator; if any of the above four points cannot be satisfied
or It is the responsibility of the manager that the production, equipment, tooling, testing,
and materials do not have the necessary conditions to cause failure. Only by understanding
the responsibility of quality issues can we improve the quality of the problem in a targeted
manner.
Sixth, establish a continuous awareness of quality
Quality is not the best, only better; quality improvement is a continuous, continuous
improvement process, it follows the PDCA model, PDCA mode can be briefly described as
follows:
P-plan: develop improvement plans based on product requirements;
D—Implementation: implementation plan;
C—Inspection: Inspection of processes and products according to product requirements;

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A—Disposal: Take measures to continuously improve product quality.
Only in this way will our product quality continue to rise, and only by continuously
improving quality and innovation will we continue to win the market.
Seventh, establish a cost consciousness of quality (ie quality standard awareness)
Guarantee quality, the pursuit of profit is the company's eternal goal. To develop, enterprises
have to pay attention to the cost of production. However, cost is closely related to quality.
If quality is done well, the cost of the product can be reduced to a minimum. If the quality
of the product is not good and the customer returns a complaint, the cost will be Will stay
high, and even push the company to desperate.
The reason for the decline of many enterprises: not because there are no customers, no
orders, but because the internal management of the enterprise is not good, the cost can’t
be reduced and can’t participate in market competition, enterprises should take the lead.
But the quality is not the stricter and more favorable to the company. Conversely,
excessively improving product quality will result in excess quality and also increase
production costs. Therefore, when we are in production, we require all processes and links
to be strictly in accordance with customer standards, so that we will minimize costs and
increase market competitive advantage.
Eighth, establish a quality education awareness

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With the development of the times, the concept of quality management is constantly
updated and needs to be learned. Successful companies in the 21st century will belong to
those who learn to grow, strengthen internal training, and improve their ability to innovate
in their work. This will make the company thriving and changing with each passing day.
Therefore, "Quality begins with education and finally education."
Facts have proved that those successful enterprises strictly carry out the production of
products according to the concept of “products are produced”. They strictly control every
link of product production to ensure that the quality of each link is not wrong. The products
produced in this way are qualified good products and can stand the test of the market.
The details determine success or failure, attitude determines everything, only establish a
super quality consciousness, strive for excellence in quality, persevere and persistent pursuit,
in order to improve the quality of Tongli, in order to upgrade the quality to a new height,
to gain the power of this giant in the stormy waves, ride the wind and waves, and live
bravely to go higher and farther.
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