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Textiles Committee,
Mumbai
Promoting Indian Garments to Perfection
Structure of Presentation
Part- A
Strategy for Approaching Zero Defects in
Manufacturing of Readymade Garments
(RMGs)
Promoting Indian Garments to Perfection
Sector being labor intensive Market Size of Indian RMG Sector (in US $ Bn.)
provides highest employment in the
entire value chain and employs
Sector Domestic Export Total
significant women work force.
Market
Highest value added segment on T
&C RMG Woven 39.30 8.74 48.04
Total Market Size of RMG during RMG Knitted 4.92 7.00 11.92
2012-13 is $ 68.57 Bn
Made-ups 3.90 4.71 8.61
More than 50 % of contribution to Total 48.12 20.45 68.57
the sectoral export
Source: Market for Textiles & Clothing and WITS database
Promoting Indian Garments to Perfection
Purpose
Mission
Facilitate manufacturing of defect free garments
Bring technology of RMG manufacturing at par with leading RMG manufacturing and
competing countries.
Enhancing the existing manpower skills to match up the latest technology and create
new generation skill manpower to produce quality garments.
Establish and implement effective Quality Management Systems (QMS) in the supply
chain to achieve zero defects.
Promoting Indian Garments to Perfection
Objectives
1. To upgrade the backward supply chain technology like weaving, knitting, processing and
finishing for quality raw materials.
5. To develop and upgrade the skill sets to match up the new technology.
6. Establish Quality Management Systems (QMS) in RMG process with a view to inculcate
quality culture and thereby promoting higher quality produce.
7. Regular assessment for updating the changes in technology, quality and productivity for
policy interventions.
Promoting Indian Garments to Perfection
Source of Defects
15.90
12.62 12.09
9.04
7.28 6.64
Talioring Washing Overlock Folding Pressing Mending Button fault Knitting Embroidery Size fault Discolor Washing Lj
(Stain) fault (Oil)
Promoting Indian Garments to Perfection
Part-B
TC Benchmarking Survey on Man, Machine &
Management (3Ms) for approaching
Zero Defects
Promoting Indian Garments to Perfection
Methodology
Selected Centers:
Ludhiana and Tirupur for Knitted RMGs
Product profile of knitted RMGs - T-shirt, Jacket, Sweatshirts, Leggings, Kids & Baby Garments
Product basket of the woven RMGs - Kids & Baby Garments, Mens & Boys Shirts, Trousers
Market Shares
Market Shares of the selected RMGs:
Selected units
7.75%
92.25%
Export Domestic
Promoting Indian Garments to Perfection
Overview of the Defects in the Selected
Units
11.18
2.75
1.3
Selected knitted & woven units are producing less defective as compared to industry average
Raw material Source Selected Units (%) Inspection used as an important tool to
address the defect.
Fabrics Domestic 3-10
The manpower used by units is properly
Imported 2-5
trained & technology use is minimal
Trim & Domestic 1.5-3 A back-lit Inspection machine with roll
Accessory
Imported 1-2 length recorder used by some units as
ideal method.
Promoting Indian Garments to Perfection
Stages of Production Sub stages Defects Rework Rejection Preventive & Corrective
(%) (%) Action
Spreading, laying & 0 0 0 Quality & Compliance
Cutting Technology & Regular
Training
Sewing Inline Inspection 7 6.5 0.5 Regular Training
Third party AQL 2.5 GIL II /AQL 1.5 GIL II inspections are carried
out by these units to ascertain the acceptability of the lot after
packing.
Promoting Indian Garments to Perfection
Best Manufacturing Practices &
QMS
Operations Selected Units
Fabric Inspection 100%
Accessories inspection AQL 2.5
Cutting plan yes
Sewing plan yes
Finishing plan yes
Bundle tracking yes
Inline/ End line Checking reports 100%
Final inspection reports ( rejection data) AQL 2.5 GIL II /AQL 1.5 GIL II
Piece Quality
Cutting In process Day's
goods control of Process Two hourly Lot final
quality quality control final
quality finishing inspection audit audit
control (sewing) audit
control sections
Inline
Inspection
Visual, pass
End line Done to Done in
only the
NA Done inspection AQL 2.5 attain AQL NA presence
defect free
Finished 2.5 of buyer
garment
garment
inspection
Promoting Indian Garments to Perfection
Major findings
Part-C
Suggestive Measures
Promoting Indian Garments to Perfection
Suggestive measures:
Management
Suggestive measures:
Others
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