Implementation of Lean Tools to Accelerate Performance in the RMG Industry: A Case Study

DOI

10.2991/978-94-6463-884-4_87How to use a DOI?

Keywords

Ready-made garment (RMG); Lean; Fishbone diagram; Pareto analysis; 5 why technique; Defect

Abstract

The ready-made garment (RMG) industry is vital for developing nations as it generates employment, attracts foreign investment, and boosts revenue. However, this industry suffers from inefficiencies due to significant waste generation. Numerous defects in products lead to quality degradation, increased costs, shipment delays, and loss of goodwill. Enhancing process performance can significantly improve product quality and efficiency. Therefore, in this study, lean tools were implemented to identify the root causes of defects in t-shirt sewing lines of a selected RMG industry. To do so, a fishbone diagram was employed to find potential causes. Pareto analysis was then performed to pinpoint the most critical operations contributing to a large fraction of the defects. Finally, the 5 Whys technique was used to uncover the root causes of the issues identified by Pareto analysis. The findings revealed that ‘Lack of Policy Deployment’, ‘Absence of Necessary Accessories’, ‘Lack of Total Productive Maintenance’, and ‘Lack of Documentation in Training’ are the primary causes of defects in the sewing line. Recommendations were then provided to address these root causes, aiming to reduce defects and improve product quality.

Copyright

© 2025 The Author(s)

Open Access

Open Access This chapter is licensed under the terms of the Creative Commons Attribution-NonCommercial 4.0 International License (http://creativecommons.org/licenses/by-nc/4.0/), which permits any noncommercial use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license and indicate if changes were made.

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TY  - CONF
AU  - Mohammad Muhshin Aziz Khan
AU  - Towhid Arsalan
AU  - Kaniz Fatema
AU  - Md. Asadur Rahman
AU  - Md. Jahedul Alam
PY  - 2025
DA  - 2025/11/18
TI  - Implementation of Lean Tools to Accelerate Performance in the RMG Industry: A Case Study
BT  - Proceedings of the 8th International Conference on Engineering Research, Innovation, and Education 2025 (ICERIE 2025)
PB  - Atlantis Press
SP  - 721
EP  - 729
SN  - 2352-5401
UR  - https://doi.org/10.2991/978-94-6463-884-4_87
DO  - 10.2991/978-94-6463-884-4_87
ID  - Khan2025
ER  -