Root Cause Analysis and Productivity Improvement Of An Apparel Industry In Bangladesh Through Kaizen Implementation

Garments industry is playing the pioneering role in improving Bangladesh economic condition. It was started in late 1970’s and now the leading foreign currency earner for Bangladesh. It is no dubiousness to say that, the Bangladesh garment industry is ameliorating garment’s service quality and innovative design features to exist in the global competitive market. Global competition in the garment’s market is changing day to day. Leading garment manufacturer from all over the world are adopting new innovative features and techniques to sustain global fierce competitive market. However, the point is, Bangladeshi garment manufacturers are not lingered. They are also emphasizing on better service quality by adding latest design features and using the latest technologies to the garments. The sole purpose of this paper is to identify the root causes of sewing defects of an apparel industry in Bangladesh and continuous improvement in reducing the defects through Kaizen (Continuous Improvement) system. In short, productivity improvement of the apparel industry. Our studied garment manufacturing company is “ABONTI Color Tex. Ltd.” Pareto Analysis is used to identify the top defect items. Cause-Effect Analysis helped to identify the root causes of sewing defects. Then, Kaizen is used for continuous improvement of the minimization of sewing defects.