Reducing Reject and Reworks in Garment Industries by Using an Improved Failure Modes and Effects Analysis (FMEA): A Case Study in Lucy Garment Industry

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Addis Ababa University


The garment industry faces significant challenges in reducing reject and rework rates, which adversely impact productivity, costs, and customer satisfaction. This thesis proposes an approach to improve the existing Failure Mode and Effect Analysis (FMEA) methodologies, aiming to address these critical issues more effectively. The problem statement highlights the limitations of current FMEA practices in tackling reject and rework issues comprehensively. Traditional FMEA techniques often fail to account for the dynamic nature of garment production and the complex interplay of various factors contributing to failures. Consequently, conventional FMEA methodologies fall short in providing comprehensive and accurate risk assessments and mitigation strategies for reducing reject and rework rates. This research aims to bridge these gaps by developing an improved FMEA framework specifically tailored for the garment industry. It has integrated identification of potential failure modes, assessed their impacts, and prioritized them based on criticality. Furthermore, the framework has incorporated real-time monitoring and feedback mechanisms to enable proactive identification of failure modes during the production process. The proposed research employed a mixed-methods approach, combining quantitative data analysis and qualitative expert interviews to validate the effectiveness of the enhanced FMEA framework. Additionally, case studies will be conducted within garment manufacturing companies to evaluate the framework's practical implementation and assess its impact on reject and rework The anticipated outcomes of this research include a refined FMEA methodology that addresses the limitations of existing approaches, leading to enhanced accuracy in identifying potential failure modes, evaluating their severities, and developing effective mitigation strategies. The proposed framework has the potential to significantly reduce reject and rework rates in the garment industry, thereby improving productivity, reducing costs, and enhancing customer satisfaction. Overall, this thesis presents a new and inclusive approach for minimizing reject and rework rates in the garment industry through an improved FMEA methodology. It offers valuable insights and actionable recommendations for industry practitioners, researchers, and decision-makers to optimize production processes and achieve higher operational efficiency.reduction.