Key Challenges in Denim Product Handling and Solutions

Shamsul Kabir Shamim
ASQ Certified Auditor | Diploma in Total Quality Management (TQM) | Diploma in Productivity & Quality Management | ISO Trained | Lean & Six Sigma Trained | QA Professional

Introduction

Denim has become a global fashion phenomenon, with its popularity soaring worldwide. Its unique charm lies in the versatility of its fabric, which can be transformed through various washes and treatments. Denim enthusiasts are growing in number, creating immense business opportunities—especially for Bangladesh, a key player in denim manufacturing. However, these opportunities come with challenges that demand innovative solutions.

Challenges in Denim Product Handling

1. Proper Risk Analysis
   Comprehensive risk assessment is often neglected, yet it is critical for identifying root causes and preventing issues during bulk production.
2. Right Fit
   Achieving the perfect fit is a major challenge. Fabric stretchability, shrinkage, and shade variations complicate the task further. Misaligned patterns or improper seam allowances often result in fitting issues.
3. Shade Variations
   Multiple washes of denim fabrics cause shade variations. Maintaining consistency is challenging, as even slight dyeing differences can create noticeable discrepancies.
4. Fabric Shrinkage
   Variations in fabric shrinkage from roll to roll can result in size discrepancies, directly affecting the final fit of the product.
5. Pattern Adjustment and Seam Allowance
   Accurate pattern adjustments and maintaining proper seam allowances are essential for the right fit and appearance. Operations involving folders require meticulous attention to avoid errors.
6. Machine and Tension Settings
   Proper machine adjustments and tension settings are critical to avoiding defects like skipped stitches, puckering, or pleating.
7. Dry-Process Intensity
   Ensuring the correct dry-process intensity is necessary to achieve the desired finish on denim products.
8. Tensile and Tearing Strength
   Denim must meet specific strength standards, including tensile and tearing strength, to ensure durability. Failing these standards can lead to product returns and damage to brand reputation.
9. Hazardous Chemicals
   Consumers increasingly demand denim free of harmful chemicals. Meeting these expectations requires adherence to safety regulations and eco-friendly processes.
10. Moisture Control
    Proper moisture control during washing and drying stages is crucial for fabric stability and achieving consistent results.
11. Rework and Rewash
    Excessive rework and rewashing due to quality lapses increase production costs and delays.
12. Ineffective Checkpoints
    Inactive quality control points often fail to catch defects, impacting the final product’s quality.

Solutions Through Modern Tools and Methods

Bangladesh’s denim industry can address these challenges by adopting quality control methods and modern tools, including 7QC tools, Lean, Six Sigma, and TQM.

1. 7QC Tools
   Tools like Check Sheets, Pareto Analysis, Histograms, and Fishbone Diagrams help identify and track common issues. Systematic data collection and root cause analysis enable effective corrective actions.
2. Lean Manufacturing
   Lean techniques streamline production processes, reduce waste, and improve efficiency. Optimized workflows and organized workstations minimize time waste during manufacturing.
3. Six Sigma
   By applying the DMAIC (Define, Measure, Analyze, Improve, Control) methodology, Six Sigma optimizes processes and reduces defects, ensuring consistency in denim production.
4. Automation
   Automation, including machines like pocket setters, J-stitchers, and loop attachers, enhances consistency, reduces human error, and ensures precise stitching and measurements.
5. Bridging Traditional and Modern Expertise
   Combining traditional expertise with modern technologies is key to overcoming challenges. Experienced professionals can provide invaluable insights, while new technologies introduce innovative quality control techniques.
6. Pre-Production Activities
   Timely procurement of fabrics and trims, along with pilot runs and size-set reviews, prevents last-minute issues. Consistent processes for fabric shrinkage, size sets, and bulk production ensure uniformity.
7. Corrective Action Plans
   Thorough root cause analysis using tools like Fishbone Diagrams and the 5 Whys helps identify and address quality issues. Implementing corrective action plans and closely monitoring outcomes ensures sustainability.

Building a Quality Culture in Bangladesh

Creating a culture of quality, where excellence becomes a habit rather than an obligation, is essential. Active quality checkpoints and accountability at every production stage ensure early detection of issues. Encouraging continuous improvement, supported by training and technology, will elevate Bangladesh’s denim industry to global standards of excellence.

By eliminating defects, reducing waste, and adopting innovative technologies, Bangladesh can solidify its position as a global leader in denim production, offering high-quality, sustainable products to the world.