Implementation of TQM Tools to Elevate Product Quality in RMG Industry: A Case Study
Maharub Hossin Manik, Md. Ariful Ferdous, Nazia Muhsin, Faruk Ahmed, Md. Rafiqul Islam Manik
Email: ariful.ferdous@buft.edu.bd
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The garment industry of Bangladesh continues to experience rate of defects higher than international buyer requirements, where acceptable Defects per Hundred Units (DHU) typically range between 2–3%, particularly in sewing operations that lack robust quality management systems. This study aims toreduce sewing defects and improve Overall Equipment Effectiveness (OEE) through the wellstructured implementation of Total Quality Management (TQM) tools. One of the sewing line producing short pants at Khan Fashion Limited was selected as a case study. Where Common defects named uneven stitch, broken stitch, skipped stitch, and puckering, were identified and systematically analyzed using basic tools of TQM named flowcharts, check sheets, histograms, control charts, scatter plots, Pareto analysis, and fishbone diagrams. These tools were applied to assess process capability, identify critical defect types, analyze the relationship between defect rates and production time, and determine root causes related to materials, methods, machinery, manpower, measurement, and environment. Based on the analytical findings and structured brainstorming sessions, appropriate corrective actions were introduced in the sewing line. The results found that the overall defect rate was reduced by 39.40%, achieving a final defect level of 3.26%, which aligns with international buyer requirements. Additionally, Overall Equipment Effectiveness (OEE) improved from 73.26% to 80.76% in that sewing line. Finally, it represents that application of TQM tools can significantly improve product quality and operational efficiency.