Skip to main content

Cost of poor quality!!!

Garment Company can save money if there is no quality issue in the products. All cost goes to poor quality. Cost of poor quality explained in another way - the total money factory spends to make the product up to acceptable quality level to customer. But when come poor quality then have to spend money in extra manpower, material, and garments repair. Most of the processes like cutting, printing, stitching, washing may produce defective garments. As result to detect defective pieces, factories install check points (inspection process) in the processes.
Defective pieces need to be screen out from the good pieces through Check point then defective pieces need to repair. Some defective pcs may be damaged and can’t be include those damaged garments in shipment. You have to reject those garments.
Cost of poor quality in a garment manufacturing unit:
Repair works - As additional man hours needed for repair work to complete the shipment – delay in shipment can happen then it turn may cost factory as shipping goods at discount rate or/and factory may need to send shipment by air.
Rejections - Are loss of potential revenue. Also cost of raw materials of those rejected garments.
Inspection - Rechecking garments are also a cost due to poor quality. Quality checkers are employed to check garments. Cost of poor quality is categorized as internal failure cost, external failure cost, prevention cost and appraisal cost.

Steps to calculate COPQ
Step-1: Measure amount of rework and rejection level. Amount of rework can be measured through DHU and Percentage defective. From the DHU value, calculate total number of defects need to be repaired daily (A).
Step-2: Calculate how much time need to remove stitches from a defective garment due to stitching defects (T1)
Step-3: Calculate how much time (average time) operators need to re-stitch the garment (T2). It may vary defect wise.
Step-4: Calculate cost of manpower for repair work. It would equal number manpower involved in rework multiply by their daily wages.

To find rework labor requirement see below way
Number of labor needed for repair (L) = (A * (T1+T2))/480
Here one labor is equivalent to 480 minutes or 8 hours.
Then calculate it into extra wages for excess labor hours used their average salary.
Labor cost in repair = L * Wages per day per labor

Step-5: Excess fabric consumed - To change garment parts, how much extra fabric is issued for re-cutting. Calculate cost of excess fabric (FC).
Step-6: Calculate cost of re-cutting (manpower cost) in case re-cutting/additional cutting is done (CC).
Step-7: Calculate how many garments are rejected (percentage of total pieces of an order). Calculate total loss of potential FOB earning.
Step-8: Find internal failure cost from salary of alteration tailors + Cost of rejected garments + cost of excess material usage (FC) + re-cutting cost (CC)
Step-9: Calculate total COPQ per month = (rework cost + rejection cost+ excess manpower cost+ cost of quality team)
Step-10: Value of total shipments per month
Step-11: Calculate COPQ percentage of total shipment value.

Comments

  1. AnonymousSeptember 6, 2020 at 9:42 PM

    I will recommend anyone looking for Business loan to mr benjamin who helped me with Four Million USD loan to startup my  business and it's was fast When obtaining a loan from them it was surprising at how easy they were to work with.The process was fast and secure. It was definitely a positive experience.Avoid scammers on here and contact mr benjamin On.  247officedept@gmail.com  . WhatsApp...+ 19893943740. if you looking for business loan.

    ReplyDelete
  2. persgutWspic-heApril 23, 2022 at 10:15 AM

    persgutWspic-he Adrian Viher https://wakelet.com/wake/DK1eRL09_oW0kitGI2I5a
    almeseari

    ReplyDelete
  3. nimusyng-meAugust 25, 2022 at 4:12 PM

    lincnaOcentshi Haley Johnson ESET NOD32 Internet Security
    Avid Pro Tools
    ScreenHunter Pro
    sahedkiefi

    ReplyDelete
  4. theibracMin-guNovember 30, 2022 at 10:38 AM

    theibracMin-gu Brandy Sipes software

    olsunveco

    ReplyDelete

Post a Comment

Popular posts from this blog

H&M SUPPLIER COLOR GUIDELINE

H&M has established this Colour Guideline to guide suppliers to achieve a quicker and better result in their colour work. For H&M Cosmetic products a separate Colour Guide Book is available. The guidelines and requirements in this Colour Guideline apply to all products in textile, leather/suede, plastic, bone, wood, metal, straw, paper etc. Colour evaluation using instrumental method should be used when applicable. All parts of a product are equally important to check according to the same guidelines; shell, details, accessories (including: threads, buttons, badges, zippers, interlinings, drawstrings, stoppers) etc. Therefore these guidelines are made for everyone involved in the colour process – garment makers, accessory suppliers, dyers, print houses, embroidery units etc. Each supplier to H&M is responsible for informing all of their suppliers and subcontractors about the content of these guidelines and requirements and to make sure that they al...
2 comments
Read more

How Can Improve Production Quality

To become quality conscious, it might look at improving existing quality standards at various stages of manufacturing process. Producing a good quality product is a result of combined efforts of management, employees and workers by developing system, implementing good practices in floor and setting up standards.  Following tips can help to improve quality at production. Communicate the importance of quality production to your employees and floor workers, and explain quality expectations by the management.  Maintain a clean and dry workplace, including storage rooms and shipping areas.  Select and utilize appropriate equipment in cutting, sewing and finishing processes.  Provide appropriate tools, machines and equipment to each department. Provide on-the-job training to workers for new comer with existing.  Plan an ongoing program for machine maintenance.  Establish agreed-upon quality standards with all fabric ...
1 comment
Read more

Cutting Quality Control & Re-cut procedure.

Cutting Quality Control: To be established a work process by which QC personnel able to run in a same path for continuous improvement.  The procedure can be control / feedback to cutting to produce smoothly & Good Quality production. Responsibility :  The responsible person in-charge of related department. Preparation for Bulk cutting: v   According cutting plan cutting Executive collects Approved sample, manufacturing order sheet, approved paper pattern / hard pattern & Marker paper with ratio chart. v   As per Order Qty. cutting Executive collects fabrics from WH & relaxes the fabric according estimated time. v   QA checks between ratio paper, marker paper, hard pattern & fabric inspection report. He confirms the marker with signature. v   QC makes mock up by style related parts to be check & ensure parts Shading. If have taken approval from Quality Manager or Merchandiser. v   According cutting plan ...
Post a Comment
Read more