Abstract:
Rework issue in mass production effect the organization productivity as well as the efficiency. To identify the
appropriate causes for the rework issue may generate beneficial to the organization especially in terms of reducing
material and labor cost. The major objective of the study is to construct the cause and effect diagram for rework
issue in apparel industry in Sri Lanka in the view point of material issues. Primary and secondary data are used
for the study. Primary data are collected from 100 sample size of apparel employees by conducting the interviews
to get identified the causes for the effects for rework. Apparel company daily rework data were used as secondary
data. 150 days Rework records are used. Descriptive analysis, content and pattern matching technique were used
to analyze the data.
According to the analyzed data the major causes identified in course and effect diagram for rework issues are
Fabric fault, Mending, Insecure stich, Uncut loose thread, Measurement out, Stiching issues. Slippery fabric is
identified as a cause for fabric fault. Improper rolling, Miss matched sewing thread, exposed incorrect Raw stitch
are identified as causes for Mending and Wrong pattern, Different composition of thread and needle and bobbin
are the causes for Insecure stich. Mismatching Thread to materials is a cause leads for Uncut loose thread and
Template is not given is leads for the Measurement out issue and Incomplete thread used identified as cause for
the Stiching issues. Organizations should draw their attention towards main issues which effects on reworks when
they are improving the quality.
