CONSTRAINTS IDENTIFICATION AND ANALYSIS USING PARETO CHART AND CAUSE & EFFECT DIAGRAM IN THE GARMENT INDUSTRY: A CASE STUDY OF THE APPAREL INDUSTRY IN PAKISTAN, KARACHI

Abstract

Readymade garments are a major textile value chain industry and play a significant role in Pakistan’s economic growth, as they make up approximately 54% of export revenues in the textile sector. Because of its importance, companies face intense local and international competition in this region. Currently, textile companies compete for consistency, reliability, customer loyalty, process efficiency, consistency, and distribution costs. Bottlenecks are the key causes of the decreased production, performance, and power of the entire system. It is often within the scheme in various forms, such as management constraints, resources, materials, facilities, procedures, policies, environment, etc., but the approaches and methods for finding the bottlenecks are almost the same. The primary purpose of this paper is to provide a wider range of bottlenecks in the garment production unit, identify root causes, and evaluate and suggest possible solutions to eliminate these bottlenecks from a selected garment industry in Karachi, Pakistan. To do this, we have worked in a specific section (i.e., cutting and stitching) on a specific product (i.e., woven pants). Data from factory records, management, and observations have been collected for two months. Pareto Analysis is carried out on the data to find the bottleneck’s key area. Cause-Effect Diagrams are then arranged to define hierarchies of causes for individual problems. Finally, potential solutions are being presented for eliminating these bottlenecks to improve the company’s performance and productivity.