KALİTE GELİŞTİRME ARACI OLARAK İSTATİSTİKSEL PROSES KONTROLÜ: KOT PANTOLON ÜRETİMİNDE BİR VAKA ÇALIŞMASI
Abstract
Bu çalışmada, kalite ve kalite kontrol kavramlarının tanımları yapıldıktan sonra istatistiksel proses kontrol araçları kavramı etraflıca irdelenmiştir. Ardından, hazır giyim sektöründe faaliyet gösteren bir tekstil firmasında üretilen denim pantolonlardan elde edilen veriler sonucunda hataların analizleri, istatistiksel proses kontrol teknikleri ile yapılmıştır. Çalışmada akış şemaları, kontrol şemaları, pareto analizi, kontrol şemaları, neden-sonuç diyagramı ve gruplama tekniği kullanılmıştır. Temel istatistiksel proses kontrol araçlarının kullanılmasıyla, en çok tekrar eden hatalar tespit edilmiş ve bu hatalar daha detaylı analiz için alt başlıklara ayrılmıştır. Bu sayede tespit edilen hataların kök nedenlerine inilerek hataların tekrarı engellenmeye çalışılmıştır. Üretim sırasında oluşabilecek olası hataların nedenleri ve çözüm önerileri kategorize edilmiştir. Tespit edilen hatanın temel nedenlerine inilerek ve kategorize edilmiş, çözüm önerileri sunulması ve uygulanması ile hataların önüne geçilmiştir. Bu farklı bakış açısı ile çalışmanın sektöre ve ilgili alanlara alternatif bir yöntem olarak örnek olması beklenmektedir. Bu çalışmanın amacı, hazır giyim sektöründe kalite kontrol uygulamalarını incelemek, istatistiksel kontrol yöntemleri ve problem çözme prosedürlerine katkı sağlamak, problem çözme yaklaşımları için öneriler üretmek ve iyileştirme çalışmalarını yaygınlaştırmaktır.
Project Number
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References
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- S. Kaya and M. Ç Erdoğan, "Konfeksiyon İşletmelerinde Operatör Özelliklerinin Dikim Bölümündeki Kalite Hatalarina Etkisi," Tekstil ve Konfeksiyon, vol. 17, no. 3, pp. 207-213, 2007.
- M. Erdoğan and İ. D. Kayaalp, "Konfeksiyon İşletmesinde Dikiş Hatalarının İstatistiksel Proses Kontrol Yöntemlerini Kullanarak Azaltılması," Textile and Apparel, vol. 2, no. 7, pp. 23-31, 2009.
- S. M. Uddin and C. Rahman, "Minimization of Defects in The Sewing Section of a Garment Factory Through DMAIC Methodology of Six Sigma," Research Journal of Engineering Sciences, pp. 21-26, 9 11 2014.
- B. Kırık, Bir Konfeksiyon İşletmesindeki Son Kontrol Hatalarının İstatistiksel Yöntemlerle Analizi, Tekirdağ: Namık Kemal Üniversitesi Fen Bilimleri Enstitüsü, 2017.
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- N. Çetin, Kalite Kontrol Uygulamaları ve Örnek Bir Çalışma, Ankara: Gazi Üniversitesi Eğitim Bilinleri Enstitüsü, 2008.
- C. Duran and A. Çetindere "Konfeksiyon Sanayiinde Faaliyet Gösteren Bir İşletmede İstatistiksel Proses Kontrol Teknikleri ile Ürün Hatalarının Analiz Edilmesi," Ç.Ü. Sosyal Bilimler Enstitüsü Dergisi, vol. 21, no. 2, pp. 233-254, 2012.
- B. Behera, S. Chand, T. Singh and P. Rathee, "Sewability of Denim," International Journal of Clothing Science and Technology, vol. 9, no. 2, pp. 128-140, 1997.
- E. Akcagun, N. Öz Ceviz, A. Yılmaz and A. A. Mazari "Analyzing The Effects of Special Washing Processes on Characteristics of Sewing Threads," The Journal of The Textile Institute, vol. 108, no. 11, pp. 1926-1932, 2017.
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- A. Majumdar, A. Das, R. Alagirusamy and V. K. Kothari Process Control in Textile Manufacturing, India: Woodhead Publishing Series in Textiles, 2014.
- K. Marilyn and F. Robert, Statistical Process Control Techniques, Oregon: Statit Software, 2007.
- S. Jadhav, G. S. Sharma, A. M. Daberao, "Improve Productivity in Garments Industry with Time Study," International Journal on Textile Engineering and Processes, vol. 3, no. 4, pp. 1-6, 2017.
- S. Ata, M. S. Yıldız and İ. Durak, "Statistical Process Control Methods For Determining Defects of Denim Washing Process," Textile and Apparel, vol. 30, no. 3, pp. 208-219, 2020.
- A. Pedro and C. Carlos, P. Paranhos, S. Ribeiro and H. Gouveia, "Selection of the Most Suitable Statistical Process Control Approach for Short Production Runs: A Decision-Model," International Journal of Information and Education Technology, vol. 5, no. 2, pp. 303-310, 2015.
- G. Koksal, W. A. Smith Jr. and C. B. Smith, "A System Analysis of Textile Operations," Textile Chemist & Colorist, vol. 24, no. 10, pp. 30-35, 2016.
- V. Arya, V. Jain, "Basics of Process Control in Textile Manufacturing," in Indian Institute of Technology, Delhi, India, Woodhead Publishing Limited, 2013, pp. 3-13.
- M. A. Abtew, S. Krop, Y., Hong and L. Pu, "Implementation of Statistical Process Control in the Sewing Section of Garment Industry for Quality Improvement," AUTEX Research Journal, vol. 18, no. 2, pp. 160-172, 2018.
- T. K. Kapuria, M. Rahman and S. Haldar, "Root Cause Analysis and Productivity Improvement of An Apparel Industry in Bangladesh Through Kaizen Implementation," Journal of Applied Research on Industrial Engineering, vol. 4, no. 4, pp. 227-239, 2017.
- C. Prakash, "Implementation of Lean Tools in Apparel Industry to Improve Productivity and Quality," Current Trends in Fashion Technology & Textile Engineering, vol. 4, no. 1, pp. 1-6, 2018.
- B. Durakovic and H. Basic, "Continuous Quality Improvement in Textile Processing by Statistical Process Control Tools: A Case Study of Medium-Sized Company," Periodicals of Engineering and Natural Sciences, vol. 1, no. 1, pp. 39-46, 2013.
- İ. Ertuğrul and A. Özçil, "The Application of "p" and "p-Cusum" Charts into Textile Sector in the Statistical Quality Control Process," Textile and Apparel, vol. 24, no. 1, pp. 9-14, 2014.
- İ. Ertuğrul and E. Aytaç, "Construction of Quality Control Charts by Using Probability and Fuzzy Approaches and an Application in a Textile Company," Journal of Intelligent Manufacturing, vol. 20, no. 4, pp. 139-149, 2009.
- A. A. Yazdani and R. T. Moghaddam, "Integration of the Fish Bone Diagram, Brainstorming and AHP method for Problem Solving and Decision Making," The International Journal of Advanced Manufacturing Technology, vol. 63, no. 9, pp. 651-657, 2012.
STATISTICAL PROCESS CONTROL AS A TOOL FOR QUALITY IMPROVEMENT: A CASE STUDY IN DENIM PANT PRODUCTION
Abstract
In this study, after defining the concepts of quality and quality control, the concept of statistical process control tools is examined. As a result of the data obtained from denim pants produced by a textile company operating in the ready-to-wear sector, defects were analyzed using statistical process control techniques. In this study, flowchart, control charts, pareto analysis, p-control diagram, cause-effect diagram, and grouping techniques were used. With the use of basic statistical process control tools, the most recurring defects were, and these defects were divided into subheadings for more detailed analysis. In this way, it was tried to prevent the repetition of defects by going down to the root causes of the detected defects. The causes of possible defects that may occur during production and solution suggestions were categorized. By going down to the basic causes of the detected defects and categorized them, defects were prevented by presenting and implementing solution suggestions. It is expected that the study with this different perspective will be an example of the sector and related fields as an alternative method. The aim of this study is to examine quality control practices in the garment industry, contribute to statistical control methods and problem-solving procedures, produce suggestions for problem-solving approaches, and disseminate improvement studies.
Supporting Institution
The study was not supported by any institution.
Project Number
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Thanks
As the authors, we are grateful to the OMS company officials who shared data with us during the writing of this project. We are also grateful for the interest shown by the editors of the journal.
References
- M. İslam and A. Khan, M. R. Khan, "Minimization of Reworks in Quality and Productivity Improvement in The Apparel Industry," International Journal of Engineering and Applied Sciences, vol. 1, no. 4, pp. 38-40, 2013.
- İhkib, "İstanbul Hazır Giyim ve Konfeksiyon İhracatçıları Birliği," Denim Konfeksiyon Uluslararası Rekabetçiliğin Geliştirilmesi Projesi, 18 December 2016. [Online]. Available: https://www.ihkib.org.tr/fp-icerik/ia/d/2017/01/26/denim-konfeksiyon-urge-ihtiyac-analizi-raporu-web-versiyonu-201701261511540063-80CD6.pdf. [Accessed 7 April 2023].
- S. Kaya and M. Ç Erdoğan, "Konfeksiyon İşletmelerinde Operatör Özelliklerinin Dikim Bölümündeki Kalite Hatalarina Etkisi," Tekstil ve Konfeksiyon, vol. 17, no. 3, pp. 207-213, 2007.
- M. Erdoğan and İ. D. Kayaalp, "Konfeksiyon İşletmesinde Dikiş Hatalarının İstatistiksel Proses Kontrol Yöntemlerini Kullanarak Azaltılması," Textile and Apparel, vol. 2, no. 7, pp. 23-31, 2009.
- S. M. Uddin and C. Rahman, "Minimization of Defects in The Sewing Section of a Garment Factory Through DMAIC Methodology of Six Sigma," Research Journal of Engineering Sciences, pp. 21-26, 9 11 2014.
- B. Kırık, Bir Konfeksiyon İşletmesindeki Son Kontrol Hatalarının İstatistiksel Yöntemlerle Analizi, Tekirdağ: Namık Kemal Üniversitesi Fen Bilimleri Enstitüsü, 2017.
- S. Ata, M. S. Yıldız, İ. Durak "Statistical Process Control Methods For Determining Defects of Denim Washing Process: A Textile Case From Turkey," Tekstil ve Konfeksiyon, vol. 30, no. 10, pp. 208-219, 2020.
- H. C. Pham, I, Ulhaq, P. Yeow and M. Akbari, Other Lean Tools in Fashion and Textile Manufacturing, Singapore: Springer Singapore, 2022.
- R. Brad, Statistical Quality Control Practices in Clothing Industry, Austria: DAAAM International, 2010.
- G. Bek, Bir Konfeksiyon İşletmesinde Proses ve Kalite Kontrol, Adana: Çukurova University, 2008.
- Ö. Yücel, "Dikimde Hata Oluşturulan Nedenlerin Belirlenmesine Yönelik İstatistiksel Bir Araştırma," Journal of Engineering Sciences , vol. 9, no. 3, pp. 327-332, 2003.
- N. Çetin, Kalite Kontrol Uygulamaları ve Örnek Bir Çalışma, Ankara: Gazi Üniversitesi Eğitim Bilinleri Enstitüsü, 2008.
- C. Duran and A. Çetindere "Konfeksiyon Sanayiinde Faaliyet Gösteren Bir İşletmede İstatistiksel Proses Kontrol Teknikleri ile Ürün Hatalarının Analiz Edilmesi," Ç.Ü. Sosyal Bilimler Enstitüsü Dergisi, vol. 21, no. 2, pp. 233-254, 2012.
- B. Behera, S. Chand, T. Singh and P. Rathee, "Sewability of Denim," International Journal of Clothing Science and Technology, vol. 9, no. 2, pp. 128-140, 1997.
- E. Akcagun, N. Öz Ceviz, A. Yılmaz and A. A. Mazari "Analyzing The Effects of Special Washing Processes on Characteristics of Sewing Threads," The Journal of The Textile Institute, vol. 108, no. 11, pp. 1926-1932, 2017.
- M. Saunders, P. Lewis and A. Thornhill, Research Methods for Business Studies, India: Financial Times, 2010.
- J. S. Oakland, Statistical Process Control, London: Routledge, 2007.
- A. Majumdar, A. Das, R. Alagirusamy and V. K. Kothari Process Control in Textile Manufacturing, India: Woodhead Publishing Series in Textiles, 2014.
- K. Marilyn and F. Robert, Statistical Process Control Techniques, Oregon: Statit Software, 2007.
- S. Jadhav, G. S. Sharma, A. M. Daberao, "Improve Productivity in Garments Industry with Time Study," International Journal on Textile Engineering and Processes, vol. 3, no. 4, pp. 1-6, 2017.
- S. Ata, M. S. Yıldız and İ. Durak, "Statistical Process Control Methods For Determining Defects of Denim Washing Process," Textile and Apparel, vol. 30, no. 3, pp. 208-219, 2020.
- A. Pedro and C. Carlos, P. Paranhos, S. Ribeiro and H. Gouveia, "Selection of the Most Suitable Statistical Process Control Approach for Short Production Runs: A Decision-Model," International Journal of Information and Education Technology, vol. 5, no. 2, pp. 303-310, 2015.
- G. Koksal, W. A. Smith Jr. and C. B. Smith, "A System Analysis of Textile Operations," Textile Chemist & Colorist, vol. 24, no. 10, pp. 30-35, 2016.
- V. Arya, V. Jain, "Basics of Process Control in Textile Manufacturing," in Indian Institute of Technology, Delhi, India, Woodhead Publishing Limited, 2013, pp. 3-13.
- M. A. Abtew, S. Krop, Y., Hong and L. Pu, "Implementation of Statistical Process Control in the Sewing Section of Garment Industry for Quality Improvement," AUTEX Research Journal, vol. 18, no. 2, pp. 160-172, 2018.
- T. K. Kapuria, M. Rahman and S. Haldar, "Root Cause Analysis and Productivity Improvement of An Apparel Industry in Bangladesh Through Kaizen Implementation," Journal of Applied Research on Industrial Engineering, vol. 4, no. 4, pp. 227-239, 2017.
- C. Prakash, "Implementation of Lean Tools in Apparel Industry to Improve Productivity and Quality," Current Trends in Fashion Technology & Textile Engineering, vol. 4, no. 1, pp. 1-6, 2018.
- B. Durakovic and H. Basic, "Continuous Quality Improvement in Textile Processing by Statistical Process Control Tools: A Case Study of Medium-Sized Company," Periodicals of Engineering and Natural Sciences, vol. 1, no. 1, pp. 39-46, 2013.
- İ. Ertuğrul and A. Özçil, "The Application of "p" and "p-Cusum" Charts into Textile Sector in the Statistical Quality Control Process," Textile and Apparel, vol. 24, no. 1, pp. 9-14, 2014.
- İ. Ertuğrul and E. Aytaç, "Construction of Quality Control Charts by Using Probability and Fuzzy Approaches and an Application in a Textile Company," Journal of Intelligent Manufacturing, vol. 20, no. 4, pp. 139-149, 2009.
- A. A. Yazdani and R. T. Moghaddam, "Integration of the Fish Bone Diagram, Brainstorming and AHP method for Problem Solving and Decision Making," The International Journal of Advanced Manufacturing Technology, vol. 63, no. 9, pp. 651-657, 2012.
Details
| Primary Language | English |
|---|---|
| Subjects | Textile Quality Control |
| Journal Section | Articles |
| Authors | |
| Project Number | - |
| Early Pub Date | December 21, 2023 |
| Publication Date | December 31, 2023 |
| Published in Issue | Year 2023 Volume: 9 Issue: 2 |
Cite
Mugla Journal of Science and Technology (MJST) is licensed under the Creative Commons Attribution-Noncommercial-Pseudonymity License 4.0 international license.