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A Real Case Study

on

Quality Improvement
at

IKAL-01, (American Eagle)

Cut panel audit


(28th Dec-2011 to 4th Jan-2012)

Total Audit panel = 27,544 pcs Total Defect panel = Panel Defect % = 790 pcs 3%

Cut panel accepted rate is 1 %

Inline Roaming audit summary (28th Dec-2011 to 4th Jan-2012) Total Audit Qty Total Defect Qty Defect % = 12,543 pcs = = 550 pcs 4%

End line audit summary (28th Dec-2011 to 4th Jan-2012)


Total Audit Bundle = Total Defect Bundle = Bundle Defect % =
Total Audit Qty Total Defect Qty Defect % = = =

410 Bundle 100 Bundle 24 %


2,050 pcs 138 pcs 6.7 %

Before Iron audit summary


(28th Dec-2011 to 4th Jan-2012)

Total Audit Bundle = Total Defect Bundle = Bundle Defect % =

555 Bundle 256 Bundle 46 %

Total Audit Qty = 3,380 pcs Total Defect Qty = 410 pcs Defect % = 12 % AQL- 2.5

2 Hours audit summary


(28th Dec-2011 to 4th Jan-2012)

Total Quantity Total Audit Qty Total Defect Qty

= 12,550 pcs = = 1,250 pcs 137 pcs

Defect %

=
AQL- 2.5

11 %

Daily Final audit summary


(28th Dec-2011 to 4th Jan-2012)

Total Audit Qty = Total Defect Qty = Defect % =

715 pcs 27 pcs 4%

AQL- 2.5

American eagle Inspection summary


(28th Dec-2011 to 4th Jan-2012)

Total Lot Qty Total Lot pass Lot Acceptable Rate Total Inspection Qty Total Check Qty Total Defect Qty Defect %

= 3 Lot = 3 Lot = 100 % = 24,459 pcs = 640 pcs = 21 pcs = 3.3 %

AQL- 2.5 (Double Sampling plan)

Defect Trend from Sewing End Line to Final American Eagle Inspection
(28th Dec-2011 to 4th Jan-2012 )
Process Cut panel audit Check Qty 27,544 Defect Defect 12% Qty % 790 3%
10% 8% 7% 4% 3% 4%

14%

12% 11%

Inline Roaming
End line Audit Before iron audit 2 hours Audit Day final audit

12,543
2,050 3,380 1,250 715

550
138 410 137 27

4%
7% 12% 11% 4%

6%
4% 2% 0%

Inline Roaming

Cut panel audit

End line Audit

Before iron audit

2 hours Audit

Day final audit

LAR:
American Eagle Lot Acceptable Rate is 100%

OQL:
Outgoing Quality Level is 3.3 %

Input , Output & Efficiency status of A/E


(28th Dec-2011 to 4th Jan-2012)
Date 28th dec-2011 29th dec-2011 31st Dec-2011 1st JaN-2013 Input 1481 1018 1082 986 Output 1450 775 1400 910 Efficeincy 38% 40% 36% 24%

2nd JaN-2013 3rd JaN-2013


4th JaN-2013

1574 1984
1789

1390 1850
1380

36% 48%
36%

Thank you

Thank you
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Suggested Quality Management Process


Incoming Fabric

Cutting

Sewing

Washing

Buttoning

Pressing

Packing

Production Inspection

100% Panel Inspection

100% SemiProduct Inspection (Optional)

100% Endline Inspection

100% Inspection before Packing

QA

Fabric Inspection (4-point)

Panel Audit

Sewing Rolling QA

Sewing Audit

Washing QA

Final Audit

Trim Inspection (AQL 2.5)

Buyers Inspection

Buyer s Final QA

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Beximco Quality Management Process


Incoming Fabric Cutting Sewing Washing Buttoning Pressing Packing

Production Inspection

Trim Inspection

Fabric Inspection

100% Panel Inspection

100% process Inspection

100% End-line Inspection

100% End-line Inspection

100% before ironing Inspection

100% after ironing Inspection

100% Inspection before Packing

QA

Trim Inspection (AQL 2.5)

Fabric Inspection (4-point)

Panel Audit

Sewing Roaming QA

Sewing Audit

Washing QA

After press audit

2 hours Audit AQL-2.5

Final Audit

Buyers Inspection

Buyer s Final QA

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