Identifying defect causes of weft greige knitted fabric: the Case of MAA-Garment & Textiles Factory

This research aims to address the above quality problem of knitting section by identifying the 80% causes of quality defects and proposing the possible solution for the critical ones. In dealing with the quality problem, direct observation, interview, check sheet & reports were used to collect data and these data were also analyzed using Pareto technique, and focus group discussion. After the data is analyzed, the four critical fabric defects (Needle line, Hole, Yarn variation and Lycra jump) are achieved and these fabric defects need to be corrected to minimize the rejection rate by 80%. The output of the research indicated that the existing 7.87% rejection rate can be reduced to 1.574% which resulted in the net difference of 6.296. This implies that the net monthly reduction in fabric rejection rate is about 5533.6 kilogram which really affects the total production in the section. This research has found results with a set of recommendation, remedies and standard operation procedure (SOP) that are proposed to be performed by the company.