Applications of Statistical Process Control Tools in Apparel Industry

Project Supervisor:

Sir Imtiaz Ahmed Khan

Presenter:

Hera Mazhar (06-NTU-154)

What is Statistical Process Control? a tool for monitoring and controlling

manufacturing processes. 

an analytical decision making tool

It eliminates variation

History of SPC

1920s – SPC tools were laid for conducting research on quality improvement methods and to lower the costs.

Walter Shewhart of Bell Telephone Laboratories

History of SPC

Dr. W. Edwards Deming

took the concepts to Japan following WWII

known as the “God of Quality” in Japan

History of SPC

H.F. Dodge – Bell Labs statistician H.G. Romig – contribution to sampling

inspection Japan World-renowned high quality of Japanese

products

Eight Basic SPC Tools

Check Sheet Defect Concentration Diagram Scatter Diagram Histogram Pareto Chart Cause-and-Effect Sheet Flow Chart Control Charts

SPC involves:

Determining the critical process parameters that need to be monitored

Setting up an initial control chart and confirming that the process is in-control, and 

Collecting and plotting future data on the chart and interpreting the chart to determine if the process has gone out-of-control.

What is the importance of application of SPC in Apparel Industry?

Decisions must be made on facts – opinions cannot be risked

Objectives of the Project Identification and data gathering of the

problems and areas requiring improvement

Check Sheets

Identification and data gathering of the problems and areas requiring improvement

Defect Concentration Diagram

Identification and data gathering of the problems and areas requiring improvement

Histograms

Prioritizing the problems

Pareto Charts

Analysis of a selected problem

Cause & Effect Diagram

Flowcharting of the problem Flow Chart

Development of Control charts and their study

Control Chart

PDSA Cycle

What are the advantages of this type of application to the industry?

“Prevention is better than cure”

Focus on prevention rather than detection

What are the advantages of this type of application to the industry? Places the responsibility for quality in the

hands of the operator Quick and accurate decisions Customer satisfaction Decreased scrap, rework and inspection

costs Decreased operating costs Maximized productivity Predictable and consistent level of quality