How to Calculate Cost of Poor Quality (COPQ) in Garment Manufacturing?

1. Improve Quality Control Measures

✅ Implement Inline and End-Line Inspections

• Conduct inline inspections at different production stages to catch defects early.

• Use end-line quality checks to prevent defective garments from being packed.

✅ Use Statistical Quality Control (SQC)

• Track defect rates and identify trends using data-driven approaches like Pareto Analysis and Six Sigma Tools.

✅ Increase First-Pass Yield (FPY)

• Set quality checkpoints to reduce rework and increase first-time right production.

2. Train and Upskill Workers

✅ Conduct Regular Training for Sewing Operators

• Train workers on sewing techniques, proper machine handling, and defect prevention.

• Organize Quality Awareness Programs for employees.

✅ Implement a Skill-Based Pay System

• Motivate workers to reduce defects by linking quality performance to incentives.

3. Optimize the Production Process

✅ Use Standard Operating Procedures (SOPs)

• Document and implement SOPs for stitching, cutting, and finishing to standardize operations.

✅ Reduce Excessive Handling & Movement

• Implement Lean Manufacturing to minimize unnecessary material handling and avoid fabric damage.

✅ Use Right-First-Time (RFT) Production Techniques

• Focus on error-proofing (Poka-Yoke) to prevent defects rather than fixing them later.

4. Improve Raw Material and Supplier Quality

✅ Perform Incoming Material Inspections

• Check fabric, trims, and accessories for defects before production starts.

• Reject or replace low-quality materials before they cause defects in bulk production.

✅ Work Closely with Suppliers

• Collaborate with suppliers to ensure consistent quality and on-time delivery of raw materials.

5. Strengthen Process Monitoring and Automation

✅ Implement Real-Time Quality Monitoring

• Use digital tracking systems to record defect rates and provide instant feedback to operators.

✅ Invest in Automation

• Automated cutting machines, sewing aids, and AI-based inspection systems can reduce human errors and improve consistency.

6. Minimize Rework and Waste

✅ Reduce Defective Pieces in the First Place

• Identify and fix common defect sources like needle damage, seam puckering, and fabric shrinkage.

✅ Recycle Defective Garments

• Reuse rejected fabrics for sampling or smaller garment parts (e.g., pockets, trims).

✅ Optimize Cutting Efficiency

• Use fabric utilization software to minimize material wastage during cutting.

7. Implement a Continuous Improvement System

✅ Use Root Cause Analysis (RCA)

• Apply 5 Whys and Fishbone Diagrams to determine why defects are occurring.

✅ Encourage a Quality Culture

• Involve employees in Kaizen (Continuous Improvement) activities to create a quality-driven environment.

✅ Benchmark Against Industry Standards

• Compare quality performance with leading factories to identify gaps and improve.

8. Focus on Customer Feedback and Returns Reduction

✅ Analyze Customer Complaints & Returns

• Track return reasons and work on corrective actions.

✅ Improve Packaging & Handling

• Use proper folding, tagging, and packaging to avoid damage during transit.

✅ Enhance Communication with Buyers.