Analysis Of Pareto Analysis

From the above Pareto analysis the four major defect type’s covers 79.6 % of total defects. Therefore minimizing these four major defect types help to reduce more than half of total defect occurrence.
As rework operation is classified on- line and off-line rework operation. Identifying percentage of on- line and off-line rework operations of the inspected defective pieces are inputs for the model development of existing system.
Table 4.5A: occurrence of off-line rework products
No Off-line rework operation
1 Stain 2192 pieces
2 contamination 228 pieces
Total 2420 pieces

Table 4.6A: occurrence of on-line rework products On-line rework operation Defect position Defect amount
1 Bottom hem 1093pieces
2 Cuff hem 1001pieces
3 Side seam 566 pieces
4 Sleeve attach 183pieces
5 Rip attach 177 pieces
6 Shoulder attach

4.2 Simulation model and Results of existing Ronny t-shirt production line Based on the above assumptions listed the model development process was started from the initial bundle close arrival until packaging process.
I. Part arrival station
The assembly process starts from bundle close arrival. All parts of Ronny items are ready to sewing and the items are sorted to each operation machines per average of 10 seconds. In this process, bundle close was arrived four times per 8:00 working hour and the raw material enters to the production line per average of 22.7 second. The arrived raw material are routed to three different workstations with 25% items to shoulder attach operation, 50% items to sleeve operation and 25% to rip tack operation. Figure 4.5: Existing simulation model of arrival station
II. Sewing