Quality Management Practices
Of
Nasna Impex Garments Industries (Pvt) Ltd
(Group Assignment)
Course: BBA 3306 – Managing for Quality
Course Facilitator: Prof. KASP Kaluarachchi
Level II - Semester v
April, 2020
Department of Management and Organizational studies
Faculty of Management and finance
University of Colombo
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Work load Matrix
Registration
Number
Name
Contribution
2017/MS/7531
Dinushan A.H.A.T.
Preparation of the
introduction and cover pages
2017/MS/7668
Kodikara K.S.C
Preparation of the quality
management practices in the
Organization
2017/MS/7578
Gunarathna H.Y.D.M Preparation of the
organization introduction,
conclusion and references
2017/MS/7539
Dissanayake M.A.
Preparation of the analyses
based on the practices
2017/MS/7711
Maduranga I.H.G.S.
Preparation of the drawbacks
in the quality practices and
suggestion for improvement
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signature
ACKNOWLEDGMENT
We would like to take this opportunity to thank our lecturer, Professor. KASP Kaluarachchi for
the continuous guidance and support provided for us in completing this report successfully.
We also take this opportunity to express our gratitude to Nasna Impex Garments Industries (pvt)
LTD and the operation Manager of Nasna Impex Garments (Pvt) Ltd, Mr. Suwane ludowyke,
and all others who support us to gain the industrial knowledge
Further, we are also thankful for the individuals and friends who helped us in many ways to
complete this case study.
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Contents
Introduction ..................................................................................................................................... 1
About the Organization ................................................................................................................... 3
Quality Management Practices in the Organization ....................................................................... 3
Analysis Based On Best Practices .................................................................................................. 6
Drawbacks in the current quality management practices ............................................................... 9
Suggestions ................................................................................................................................... 10
Conclusion .................................................................................................................................... 11
References ..................................................................................................................................... 11
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Introduction
Background
Nowadays the organization is one of the main economic sectors, with a major contribution to
achieving and maintaining a high rate economic growth. The processing industry operation to
high economic performance requires changes in structural terms, the re-engineering of process
and management. In this regard, one of the main actions taken at the level of companies in
manufacturing company is the implementation of quality system. Practicing quality management
system not only allows business to react to changes taking places in business, but also to inflict
them by the controlling of the future. These days all organization has to face some challenges in
their business environment the economic crisis, globalization, as well as the competition in its
market. Moreover, the increase in technology and especially in IT requires new action. For
example, it is well known that the e-commerce has opened new doors in business, which means
an increased competitive environment. And if we consider the area of social media, we realize
that organization that do not meet the ‘’quality’’ of product or service have no chance to stay on
the market. The conclusion is that ‘’Quality’’ is very important for every business.
Quality is one of the topmost principal of management. Maintaining the spheres of quality in
each and every and every facet of the business helps the firm to attract loyal customers, keep the
cash flows regular, and beat the competition in the market. It ensures customer satisfaction to the
core and helps the firm to carve a niche for itself in the market and industry as a whole. Quality
management helps an organization to maintain their desired level of quality, basing on four key
components;
1. Quality Planning- Determine which quality standards are necessary and provide guidance to
stakeholders on how management will be performed on the project
2. Quality Assurance- Quality reviews are a key tool for quality assurance but could also be
used for quality control. The way they will be conducted will be set out in the quality plan
3 .Quality controls – Check whether the standards are met if not take corrective action
4. Quality Assurance-Ensure that the specific requirements are met
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Using Quality Management can ensure that customers get consistent, good quality product and
services. This can, in turn, lead to new business, as well as;
1.
Consistent quality and make of the products.
2.
Greater efficiency and less waste
3.
A Better understanding of customer needs
4.
Regulation of successful working practices
5.
Increased customer satisfaction
6.
Better internal communication
7.
Increased profit
8.
Reduction of costly errors
Purpose
• Quality management tools help an organization to design and create a product which the
customer actually wants and desires. Quality management ensures increased revenues and higher
productivity for the organization. Quality management process makes the organization a better
place to work.
• In a manufacturing organization, QM generally starts by sampling a random selection of their
product. The sample is then tested for thing that matter to the real customers. The cases of any
failures are isolated, secondary measures of the production process are designed, and then the
causes of the failure are corrected. The statistical distributions of important measurements are
tracked. When parts, measures drift out of the error band the process is fixed.
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About the Organization
Nasna Impex Garments Industries is a Board of Investment of Sri Lanka approved garment
factory situated in Homagama srilanka, established in year 1999. Having started with 50 machine
manufacturing plant in 1999, today the organization is operate on 9 Production lines with 250
machines having a capacity to produce 1million pieces per annum. Today the organization is
specializing in produce Work wear, Children Garments, Men's Wear & Ladies Wear empowered
with over 300 skilled workforce. During its 18 years in the industry Nasna Impex Garments
Industries has been able to widen its market share to Europe and the USA.
Quality Management Practices in the Organization
When we talk about the apparel industry quality is one of utmost section that has always
discussed about. The evaluation in the apparel industry from industry revolution up to now
quality in the apparel section has also evolved within it. That is how much the quality has bond
within the industry. The organization that we have selected for this assignment is also concern
about their quality in organization; especially their customers are from Europe and USA. The
Organization is practicing world class quality management practices in order to comply with
quality standard. In the site visit to the garment we have mainly identified three methods of
quality practice methods.
1. Inspection
2. Testing
3. Research and laboratory test
Inspection
Inspection is the one method that organization is used maintains their quality in the products.
Under the inspection organization practices various quality control methods,
•
Quality Inspection in the sample section - In this inspection company is ensuring that
the measurement of the fabric they bought are according to the standard, maintain buyer
specification standard, Inspecting fabric color & fastness and inspecting the sample and
its different issues.
•
Quality Inspection in the maker making - In this inspection company is ensuring that
the fabric length and width are higher than the marker length and width, drill marks are in
the correct palace and inspecting he stripes are in correct manner.
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•
Quality Inspection in the fabric spreading – In this inspection company ensuring that
they maintain the requirement of spreading, inspecting the fabric spreading are according
to correct alignment with marker length and width and controlling the fabric spreading.
•
Quality Inspection in fabric cutting – In this inspection company is ensuring that
needles size and thread count are check, checking measurement, inspecting shade
variation of the fabric etc.
•
Quality Inspection in sewing section – In this inspection company is ensuring that the
input materials are check, size fault check, seam fault check, tread and needle count
check, stitching fault check, machine check etc…
•
Quality Inspection in finishing section - In this inspection company is ensuring that the
product default like button or broken chain checks, wrong folds, shading variation, collar
closing and side seam checks and etc..
•
Quality Inspection in Human resource – In this inspection company is looking quality
and efficiency of their human resource, under that company is looking that target of
workers are completed according to the requirement, Safety procedures are been followed
by the employees and waste material per employee, daily attendance of the employee etc.
In order to ensure that the garment quality inspection process implementing in the perfect
manner Nansa Impex is following world renowned quality control practices.
•
Four point system in fabric inspection – The four Point System also called the
American Apparel Manufacturers (AAMA) point-grading system for determining fabric
quality. The 4-Point System assigns 1, 2, 3 and 4 penalty points according to the size and
significance of the defect. No more than 4 penalty points can be assigned for any single
defect. Defect can be in either length or width direction, the system remains the same.
Only major defects are considered. No penalty points are assigned to minor defects.
•
AQL 2.5 - AQL means Accepted Quality Level. AQL is designed as the maximum
average defective items in a lot. It is expressed in a percentage number of average
defective items. AQL 2.5% means, maximum average defective item is 2.5%, which is
acceptable in the inspection system.
•
Traffic light monitoring system - Traffic light system is the most effective inspection
tool to reduce defect generation at source. This is a random inspection system. Traffic
Light System is a visual control for highlighting quality issues in sewing line. Traffic
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light quality system works in a similar fashion the transportation traffic light system
works. Three different color cards are placed in each operators place.
•
Independent Auditing - Independent auditors will monitor the each finished sewn
bundles before deliver it to Customers.
•
CAD SYSTEM – computer aided design. The garment is using the CAD system to
enhance their quality in the production process.
Testing
Physical test are been used by the garment in order to maintain their quality in the final product.
Under the physical test the garment will test their final product with the pre define testing quality
•
GSM test – Simply it measures the weight of the fabric. GSM means grams per square
meter.
•
Shrinkage Test – It measure the changes in length and width after the washing the fabric.
•
Tensile strength test – It measures the maximum force that can bear or support in the
fabric before it elongate.
•
Abrasion resistance test – It test the abrasive resistance of solid materials.
•
Pilling Resistance test – It measure the
•
Button strength test – It measure the strength in the buttons that attached to the cloth.
Research and laboratory test
This can be described as one of advanced practices that are used by the garment in order to
maintain their quality. Certain laboratory tests have been done in the laboratory to ensure that the
final product is up to the standards.
•
Color fastness to washing
•
Color fastness to lighting
•
Color fastness to heat
•
PH test
•
Color fastness to chlorinated water
•
Color fastness to seawater
Other than the laboratory test researches are been conduct by the garment in aiming to continue
improving of the quality standards and product quality.
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Analysis Based On Best Practices
Quality management practices that we had observed in the organization can be analyzed with the
best practices and general quality concepts that we learn in the subject.
Quality control
Quality control is focus on identifying a defect. Quality control ensure that the approaches,
techniques, methods and process are designed in the procedure are following correctly. Quality
control activities monitor and verify that the project deliverables meet the define quality
standards. As per the definition we can observe that the organization is following the quality
control methods in order comply with quality standard.
To achieve quality control in the product process mainly we can identify that the
organization have develop quality control tools and procedure in order to achieve desired level
quality. Mainly we can identify inspection procedure, quality test procedure and chemical test
procedure in order to achieve quality control in the production process. In the inspection the
company is trying to achieve their quality level by inspection the quality of the product from the
warehouse to package. The inspection procedure is conducting throughout the production
process in order to identify defect in the cloth. The inspection procedure is done in every phrase
of the production in order to ensure that the product is in according to standard and to ensure that
the product is free from any defect by using quality control practices like four point system, AQL
2.5 and traffic light system. Other than the quality inspection physical test and chemical test are
been conducted by the garment in order to fulfill the customer quality requirements and other
quality requirements as per predefine quality requirements, And by practicing these quality
practices has help the organization control the quality of the products and to fulfill the quality
requirements of as defined.
Quality Assurance
Quality assurance is focus on preventing defect. Quality assurance ensures that the approaches,
techniques, methods and process are designed for the projects are implemented correctly. Quality
assurance activities monitor and verify that the processes used to manage and create the
deliverables have been followed and are operative. As per the definition we can observe that the
organization is following quality assurance practices in order to assure that quality control
techniques and process that are been in practice in the organization are implemented correctly.
Most of the time quality control and quality assurance seems to be one but practically it is
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Different .Quality assurance seeks to measure the processes and system in order to reduce
defective product. But in quality control seeks to measure the number or quality of the final
products.
The selected organization is implementing quality assurance practices in order to guarantee their
quality practices. From the initial stage to up to where that the final product is deliver to the
customer and post customer service it is all quality assurance practices that company has
implementing. The inspection, physical test to chemical test the process are been review by the
organization and collect data about defect in order improve quality standards and to find process
defects. Other than that mechanics will check the machines in the garments in order to find out
machine defects and will report about machine breakdown in order to control the quality. Quality
assurance process is not only the responsibility of the quality assurance team but it is
responsibility of everyone. The employees of all level are part of the quality assurance,
employees must follow the safety proceed and code of conduct of the organization. Other than
that employees and management are individually responsible for their work and to support for
quality assurance process. By implementing these practices has helped the garment to assure
their quality in product as well as in work environment also. Rather than these process quality
assurance tools such as Pareto chart, histogram, check sheet etc… will use with the help of the
software to collect data, find defect in the quality process and to improve quality assurance
methods. Other than those Researches are been conduct by the garment in aiming to continue
improving of the quality standards and product quality.
Quality management principles
The company is following quality management principle that is introduced by the ISO
(9001:2005) in order to enhance their quality management practices and process.
•
Customer focus
The primary focus of quality management is to meet customer requirements and to exceed their
expectations. Especially in the garment industry customer loyalty and customer trust is important
because the garment is working with few loyal international customers. Identify this factor the
organization is always concern about customer satisfaction therefor the garment is always try to
maximize the customer satisfaction by implementing quality practices throughout the production
process and to fulfill customer quality requirements.
•
Leadership
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Leadership at all levels establishes unity of purpose and direction and creates conditions in which
people are engaged in achieving the organization’s quality objectives. The company ensures the
unity of purpose, direction and peoples’ engagement are align with organization’s strategies,
policies, processes and resources to achieve its quality objectives and inspire, encourage and
recognize peoples contribution.
•
Engagement of people
Competent, empowered and engaged people at any level throughout the organization are
essential to enhance organization’s capability to create and deliver value. Identify this factor
company is ensure that all level of the employees are part of the quality control process and the
decision making process other than that employees and management are individually responsible
for their work and to support for the quality assurance process.
•
Process approach
Consistent and predictable result are achieved more effectively when activities are understood
and managed as interrelated process that function as a coherent system. As define the process of
the quality control process and the standard of the each process is pre define and inter related
each other. From inspection process to up to chemical test all the process is predefine and their
outcomes are stated in the standards.
Quality framework
As a garment all the quality practices of the organization are aligned according to best quality
standards and framework.
•
SEDEX Certification – Sedex defines the Supplier Ethical Data Exchange, it is a nonprofit organization and introduces to drive ethical business practices. Sedex helps to
maintain ethical information in a simple and effective manner. It is a secure online
database which allows the registered members to share, store the information in four key
areas, Health and Safety standard, Labor standard, the environment and Business ethics.
•
ISO 9001: The international standard that specifies requirements for a quality
management system which designed to help organization to ensure that they meet the
needs of customers and stake holders while meeting the statutory and regulatory
requirements of the products.
•
Sri Lanka Apparel - Garments without Guilt - garments with conscience and care. By
protecting worker's rights, creating opportunities for education and personal growth, and
helping to alleviate poverty in our communities, Sri Lanka Apparel does business with
integrity and helps create a more equitable society. We call it "Garments Without Guilt".
•
ITS CERTIFICATE
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Drawbacks in the current quality management practices
•
Unfit machine usage in the production – When we observing the garment we have seen
that usage of old machine in the production line. Because of usage of old machine will
result frequent breakage of sewing thread during sewing, frequent breakage of needle etc.
and also it will require much time to settle the machine and causes damage in the fabric.
•
Shortage in the labor – According to the experience of the supervisors they state that, it
is difficult to find more labor for the production process and to train them for the quality
practices. As a result they predict it will be difficult to find committed labor force to
enhance the quality of the product in future, and also it means that the garment is not
utilizing their full capacity of the production.
•
Problems in the samples – Before the order is sent to mass production, a sample of the
final product will be sewing in the sample section. For the mass production in the order
that sample will be taken. After completing the cloth sometimes the sample and final
product will not be match. Therefore the whole quantity has change according
specification because of that there will be arise quality issue in the fabric and problems in
customer specification also.
•
Lack of training – The employees and also line supervisors get minimum two week
training before they appoint to job. The training duration that is providing by the
company is inadequate because after the training employees are put to the job. Lack of
training will effect to the company quality as well as in efficiency also.
• Inspection of fabric – As mention in the earlier sample in the section is undertaken by
the supervisors in order check the quality of the clothes. This happens in every two hours
and randomly fabric will be taken in to inspection, therefor the whole clothes will not be
checked.
• Target pressure – The employees who are work in garment have a target that they need
to complete in their working hours. These targets will change according to the change in
the demand. Because of that targets of employees will increase and it will result pressure
on the employees to complete those targets in time. Therefore it will result to increase in
defects of the product.
•
Lack of proper monitoring – If the line responsibility person is not aware about the
production and have little knowledge it will cause to alteration of the quality of the
product and to detect defect fabrics. Eventually it will result to increase faulty checking
of the production and it cause inferior quality of the products.
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Suggestions
•
Proper maintenance of machinery – In a factory machines should be properly installed
by relevant experts who have long installation experience in this field. Proper
maintenance of machinery is a must to avoid any accident due to the non-fit machineries.
Workers feel comfortable to work with a fit machine and the production rate is increased.
•
Arranging training programs – Arranging training programs will help to increase the
efficiency of the labor. Currently the garment is offering training program for the
employees. If the garment can increase the time period of the training it will help increase
the quality of the human resource eventually it will lead to the increase in the quality.
•
Flexible work hours – As per many researches has found that working hours of an
employee have direct impact of the productivity and the quality of the product. In this
situation garment has shortage of employees, because of that current employees must
work for long hours to complete their targets. But if the management can flexible the
working hours of employees will help to increase the quality of the human resource.
•
Automation of the process – By automating some process in the garments will help
solve the problem of shortage in the labor force. As mention earlier because of shortage
labor it is hard to find quality labors in future and train them, by automating the process
will reduce the dependent on the labor force and it will be a solution for the Nasna impex
in the future to shortage of quality work force.
•
Making multiple samples – As stated in the upwards mistakes of sample will lead to
lead time in the production and also it will result to have defect, inferior quality in the
final product.by making multiple samples using sample techniques will help to prevent
problems sample in the.
•
Establish proper monitoring system – All the person involves in the production line
must have a clear idea on the production process in the floor. Therefor it is better to
establish system and evaluation system in order to ensure that the processes are
implementing in the correct manner, and if f any problems arise in the production floor
immediate step should be taken to overcome the problem.
•
Fabric inspection – Quality assurance supervisors and line supervisors must check the
fabric in order to ensure the fabric quality and to ensure desire output.
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Conclusion
In the modern world quality is one of most important factor in the product that customer is
concern about. Especially in the garment sector quality is the major important thing that
customer is concern about. Identifying this factor Nasna Impex garments has implemented
various quality control practices from warehouse to customer delivery to ensure that quality is
assured throughout their value chain. From inspection process up to the where the final product
is deliver to the customer Nasna Impex garments has adopt world renowed quality control
practice to ensure that their quality is maintained. There is no doubt that Nasna Impex garments
has one of premier quality control process to ensure there quality process. But still there has
areas that the Nasna Impex garments should be considered on improving their quality and by
doing so it will be more beneficiary for them.
References
1. Mia, M.S., et al., Effective Processing Time & Cost Management of Dyes, Chemicals &
Utilities Used in the Combed & Compact Knit Fabric Colouration in the Dyeing Textile
Industries. American Journal of Energy and Environment, 2016.
2. PK Balaji, (2012) Quality Control in Apparel production, Research Journal of Management
Sciences, ISCA, 2(2), pp.57-69
3. Haskin & Ahsan Akhtar, (2007), Quality Control and Management; Bangladesh Business
Solutions, Dhaka, Bangladesh.
4. Pradip V. Mehta ,(1985) An introduction to quality control for the apparel industry,
5. Managing quality in the apparel industry, Pradip V. Mehta, Satish K. Bhardwaj – 1998.
6. Causes and Remedies of Garments Production Hampering in Textile Industries Retrieved
from http://article.sapub.org/10.5923.j.textile.20170602.05.html
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