Quality Approaches for Mass-Produced Fashion: A Study in Malaysian Garment Manufacturing
The garment manufacturing industry involves
sequential processes that are subjected to uncontrollable variations.
The industry depends on the skill of labour in handling the varieties
of fabrics and accessories, machines, as well as complicated sewing
operation. Due to these reasons, garment manufacturers have created
systems to monitor and to control the quality of the products on a
regular basis by conducting quality approaches to minimize variation.
With that, the aim of this research has been to ascertain the quality
approaches deployed by Malaysian garment manufacturers in three
key areas - quality systems and tools; quality control and types of
inspection; as well as sampling procedures chosen for garment
inspection. Besides, the focus of this research was to distinguish the
quality approaches adopted by companies that supplied finished
garments to both domestic and international markets. Feedback from
each company representative has been obtained via online survey,
which comprised of five sections and 44 questions on the
organizational profile and the quality approaches employed in the
garment industry. As a result, the response rate was 31%. The results
revealed that almost all companies have established their own
mechanism of process control by conducting a series of quality
inspections for daily production, either it was formally set up or
otherwise. In addition, quality inspection has been the predominant
quality control activity in the garment manufacturing, while the level
of complexity of these activities was substantially dictated by the
customers. Moreover, AQL-based sampling was utilized by
companies dealing with exports, whilst almost all the companies that
only concentrated on the domestic market were comfortable using
their own sampling procedures for garment inspection. Hence, this
research has provided insights into the implementation of a number
of quality approaches that were perceived as important and useful in
the garment manufacturing sector, which is truly labour-intensive.
[1] K. Fernandez-stark, S. Frederick, G.Gereffi, “The Apparel Global Value
Chain Economic Upgrading and Workforce Development” (online),
2011http://www.cggc.duke.edu/pdfs/2011-11-11_CGCC_Apparel-
Global-Value-Chain.pdf.
[2] V. Varukolu and H. Park-poaps, "Technology Adoption by Apparel
Manufacturers in Tirupur Town, India," Journal of Fashion Marketing
and Management, vol. 13, 2009, pp. 201-214.
[3] P. V. Mehta, An Introduction to Quality Assurance for the Retailers.
New York: iUniverse, Inc., 2004, ch.3.
[4] G. Cooklin, S. Hayes, J. McLoughlin, "Quality Systems and Methods,"
in Introduction to Clothing Manufacturer, 2nd ed. Oxford: Blackwell
Publishing, 2006, pp. 174-189.
[5] J. R. Evans and W. M. Lindsay, Managing for Quality and Performance
Excellence, 9th ed. United States: South-Western, Cengage Learning,
2014, ch.1.
[6] S. J. Kadolph, Quality Assurance for Textiles and Apparel, 2nd ed. New
York: Fairchild Publications, 2007, ch.11.
[7] M. M. Islam, A.M. Khan, M.M.R. Khan, "Minimization of Reworks in
Quality and Productivity Improvement in the Apparel Industry,"
International Journal of Engineering and Applied Sciences, vol. 1, 2013,
pp. 147-164.
[8] R. E. Glock and G.I. Kunz, Apparel Manufacturing Sewn Product
Analysis, 4th ed. New Jersey: Pearson Prentice Hall, 2005.
[9] P. Brown and J. Rice, "Apparel Quality: The Priority of Industry and
Consumers," in Ready-to-Wear Apparel Analysis, 3rd ed New Jersey:
Prentice Hall, 2001, pp. 46-74.
[10] P.V. Mehta, “Quality Control in Apparel Production” in Testing &
Quality Management, V.K. Kothari, Ed. New Delhi: IAFL Publications,
1999, pp. 444-493.
[11] M. Chowdhury, H. Paul, "The Impact of Top Management Commitment
on Total Quality Management Practice: An Exploratory Study in the
Thai Garment Industry," Global Journal of Flexible Systems
Management, vol. 8, 2007, pp. 17-29.
[12] Cushman and Wakefield, “Where in the World: Manufacturing Index
(Online) 2014 http://www.cushmanwakefield.com/~/media/globalreports/
ManufacturingIndex2014_NT_MReilly.pdf.
[13] Malaysian Investment Development Authority. “Textiles and Textile
Product” (online) 2013 http://www.mida.gov.my/home/textiles-andtextile-
product/posts/.
[14] V. D. Crinis, "Global Commodity Chains in Crisis: The Garment
Industry in Malaysia," Institutions and Economies, vol. 4, 2012, pp. 61-
82.
[15] V. Crinis, "Sweat or No Sweat: Foreign Workers in the Garment
Industry in Malaysia," Journal of Comtemporary Asia, vol. 40, 2010, pp.
589-611.
[16] J. Bubonia, Apparel Production Terms and Processes, 2nd ed. New
York: Fairchild Publications, 2011.
[17] I. Norton, "Quality Assurance Framework for Small Manufacturing
Companies in the Clothing Industries in the Cape Metropolitan Area,"
M.Tech, Cape Peninsular University of Technology, 2007.
[18] S. Gunesoglu, B. Meric, "The Analysis of Personal Allowance using
Work Sampling Technique in the Sewing Room of a Clothing
Manufacturer," International Journal of Clothing Science and
Technology, vol. 19, 2007, pp. 145-150.
[19] J. A. Rosenau, D.L. Wilson, "Quality," in Apparel Merchandising: The
Line Starts Here, 2nd ed New York: Fairchild Publication, 2007.
[20] M. Fatima, E. Ahmed, "Quality Management in Pakistan's Readymade
Garments Industry," Quality Engineering, vol. 17, 2005, pp. 459-465.
[21] R. Bheda, “Do you know the cost of quality in your organisation?”
(Online). 2003http://rajeshbheda.com/pdf/rbc-article.pdf.
[22] B. G. Dale, T. Van Der Wiele, J. Van Iwaarden., Managing Quality, 5th
ed. Oxford: Blackwell Publishing Ltd, 2007.
[23] British Standard Institution, "Quality Management Systems:
Fundemental and Vocabulary," ed. London, 2005.
[24] P. Romano, A. Vinelli, "Quality Management in a Supply Chain
Perspective," International Journal of Operations & Production
Management, vol. 21, 2001, pp. 446-460.
[25] M. Fatima, E. Ahmed, "Quality Management in Pakistan's Bedwear
Industry," Quality Engineering, vol. 18, 2006, pp. 443-451.
[26] Z. Chen, R. Murray and R.M. Jones., "Fashion Supply Chain
Organisation and Management between the UK and China," Journal of
Fashion Marketing and Management, vol. 11, 2007, pp. 380-397.
[27] M. F. Rahman, L.M. Baral, M.A.M. Chowdury and A.N. Khan, "Quality
Management in Garment Industry of Bangladesh," The Management of
Sustainable Development (MSD) Journal, vol. 01, 2009, pp. 29-35.
[28] I. U. Hasan, M.M. Sohail, J. L. Piracha, and K. Ahmad, "Implementation
Status of TQM Practices in Textile and Apparel Industrial Organization:
A Case Study from Faisalabad, Pakistan," British Journal of Economics,
Management & Trade, vol. 3, 2013, pp. 201-223.
[29] L. D. Burns and N.O. Bryant, "Production Processes and Quality
Assurance," in The Business of Fashion: Designing, Manufacturing and
Marketing, 3rd ed. New York: Fairchild Publications, 2007, pp. 426-460.
[30] M. Fatima and E. Ahmed, "Quality Management in Pakistan's Knitwear
Industry," Quality Engineering, vol. 18, 2006, pp. 15-22.
[31] E. Soltani, A. Azadegan, Y. Liao, P. Phillips, "Quality Performance in a
Global Supply Chain: Finding Out the Weak Link," International
Journal of Production Research, vol. 49, 2011, pp. 269-293.
[32] British Standard Institution, “Sampling Procedures for Inspection by
Attributes-Part 1: Sampling Scheme Indexed by Acceptance Quality
Limit (AQL) for Lot-by-Lot Inspection,” London, 2011.
[33] W.A. Taylor, Guide to Acceptance Sampling. Libertyville: Taylor
Enterprises Inc, 1992.
[34] R. Bheda, “What is Acceptable Quality Level?” (Online) 2004.
http://rajeshbheda.com/pdf/rbc-article9.pdf.
[35] T.C. Kimbrough, “What Says Quality?” (Online) 2009
http://www.wearablesmag.com/issues/0609/swfs/wu5.swf.
[36] R. Kumar, Research Methodology: A Step-by-Step Guide for Beginners,
3rd ed. London: SAGE Publications Ltd., 2011.
[37] V. M. Sue and L.A. Ritter, Conducting Online Surveys, 2nd ed. London:
SAGE Publications Ltd. 2012.
[38] N. Towers and J. McLoughlin, “Effective Total Quality Management in
the Textile Fashion Retail Supply Chain: A Pilot Survey of the UK
Textile Manufacturers”, Journal of the Textile Institute, vol. 96, no.2,
2005, pp.87-92.
[39] Y. Yu, and V. Lindsay, “Operational Effects and Firms Responses:
Perspectives of New Zealand Apparel Firms on International
Outsourcing”, The International Journal of Logistics Management, vol
22, no.3, 2011, pp. 306-323.
[1] K. Fernandez-stark, S. Frederick, G.Gereffi, “The Apparel Global Value
Chain Economic Upgrading and Workforce Development” (online),
2011http://www.cggc.duke.edu/pdfs/2011-11-11_CGCC_Apparel-
Global-Value-Chain.pdf.
[2] V. Varukolu and H. Park-poaps, "Technology Adoption by Apparel
Manufacturers in Tirupur Town, India," Journal of Fashion Marketing
and Management, vol. 13, 2009, pp. 201-214.
[3] P. V. Mehta, An Introduction to Quality Assurance for the Retailers.
New York: iUniverse, Inc., 2004, ch.3.
[4] G. Cooklin, S. Hayes, J. McLoughlin, "Quality Systems and Methods,"
in Introduction to Clothing Manufacturer, 2nd ed. Oxford: Blackwell
Publishing, 2006, pp. 174-189.
[5] J. R. Evans and W. M. Lindsay, Managing for Quality and Performance
Excellence, 9th ed. United States: South-Western, Cengage Learning,
2014, ch.1.
[6] S. J. Kadolph, Quality Assurance for Textiles and Apparel, 2nd ed. New
York: Fairchild Publications, 2007, ch.11.
[7] M. M. Islam, A.M. Khan, M.M.R. Khan, "Minimization of Reworks in
Quality and Productivity Improvement in the Apparel Industry,"
International Journal of Engineering and Applied Sciences, vol. 1, 2013,
pp. 147-164.
[8] R. E. Glock and G.I. Kunz, Apparel Manufacturing Sewn Product
Analysis, 4th ed. New Jersey: Pearson Prentice Hall, 2005.
[9] P. Brown and J. Rice, "Apparel Quality: The Priority of Industry and
Consumers," in Ready-to-Wear Apparel Analysis, 3rd ed New Jersey:
Prentice Hall, 2001, pp. 46-74.
[10] P.V. Mehta, “Quality Control in Apparel Production” in Testing &
Quality Management, V.K. Kothari, Ed. New Delhi: IAFL Publications,
1999, pp. 444-493.
[11] M. Chowdhury, H. Paul, "The Impact of Top Management Commitment
on Total Quality Management Practice: An Exploratory Study in the
Thai Garment Industry," Global Journal of Flexible Systems
Management, vol. 8, 2007, pp. 17-29.
[12] Cushman and Wakefield, “Where in the World: Manufacturing Index
(Online) 2014 http://www.cushmanwakefield.com/~/media/globalreports/
ManufacturingIndex2014_NT_MReilly.pdf.
[13] Malaysian Investment Development Authority. “Textiles and Textile
Product” (online) 2013 http://www.mida.gov.my/home/textiles-andtextile-
product/posts/.
[14] V. D. Crinis, "Global Commodity Chains in Crisis: The Garment
Industry in Malaysia," Institutions and Economies, vol. 4, 2012, pp. 61-
82.
[15] V. Crinis, "Sweat or No Sweat: Foreign Workers in the Garment
Industry in Malaysia," Journal of Comtemporary Asia, vol. 40, 2010, pp.
589-611.
[16] J. Bubonia, Apparel Production Terms and Processes, 2nd ed. New
York: Fairchild Publications, 2011.
[17] I. Norton, "Quality Assurance Framework for Small Manufacturing
Companies in the Clothing Industries in the Cape Metropolitan Area,"
M.Tech, Cape Peninsular University of Technology, 2007.
[18] S. Gunesoglu, B. Meric, "The Analysis of Personal Allowance using
Work Sampling Technique in the Sewing Room of a Clothing
Manufacturer," International Journal of Clothing Science and
Technology, vol. 19, 2007, pp. 145-150.
[19] J. A. Rosenau, D.L. Wilson, "Quality," in Apparel Merchandising: The
Line Starts Here, 2nd ed New York: Fairchild Publication, 2007.
[20] M. Fatima, E. Ahmed, "Quality Management in Pakistan's Readymade
Garments Industry," Quality Engineering, vol. 17, 2005, pp. 459-465.
[21] R. Bheda, “Do you know the cost of quality in your organisation?”
(Online). 2003http://rajeshbheda.com/pdf/rbc-article.pdf.
[22] B. G. Dale, T. Van Der Wiele, J. Van Iwaarden., Managing Quality, 5th
ed. Oxford: Blackwell Publishing Ltd, 2007.
[23] British Standard Institution, "Quality Management Systems:
Fundemental and Vocabulary," ed. London, 2005.
[24] P. Romano, A. Vinelli, "Quality Management in a Supply Chain
Perspective," International Journal of Operations & Production
Management, vol. 21, 2001, pp. 446-460.
[25] M. Fatima, E. Ahmed, "Quality Management in Pakistan's Bedwear
Industry," Quality Engineering, vol. 18, 2006, pp. 443-451.
[26] Z. Chen, R. Murray and R.M. Jones., "Fashion Supply Chain
Organisation and Management between the UK and China," Journal of
Fashion Marketing and Management, vol. 11, 2007, pp. 380-397.
[27] M. F. Rahman, L.M. Baral, M.A.M. Chowdury and A.N. Khan, "Quality
Management in Garment Industry of Bangladesh," The Management of
Sustainable Development (MSD) Journal, vol. 01, 2009, pp. 29-35.
[28] I. U. Hasan, M.M. Sohail, J. L. Piracha, and K. Ahmad, "Implementation
Status of TQM Practices in Textile and Apparel Industrial Organization:
A Case Study from Faisalabad, Pakistan," British Journal of Economics,
Management & Trade, vol. 3, 2013, pp. 201-223.
[29] L. D. Burns and N.O. Bryant, "Production Processes and Quality
Assurance," in The Business of Fashion: Designing, Manufacturing and
Marketing, 3rd ed. New York: Fairchild Publications, 2007, pp. 426-460.
[30] M. Fatima and E. Ahmed, "Quality Management in Pakistan's Knitwear
Industry," Quality Engineering, vol. 18, 2006, pp. 15-22.
[31] E. Soltani, A. Azadegan, Y. Liao, P. Phillips, "Quality Performance in a
Global Supply Chain: Finding Out the Weak Link," International
Journal of Production Research, vol. 49, 2011, pp. 269-293.
[32] British Standard Institution, “Sampling Procedures for Inspection by
Attributes-Part 1: Sampling Scheme Indexed by Acceptance Quality
Limit (AQL) for Lot-by-Lot Inspection,” London, 2011.
[33] W.A. Taylor, Guide to Acceptance Sampling. Libertyville: Taylor
Enterprises Inc, 1992.
[34] R. Bheda, “What is Acceptable Quality Level?” (Online) 2004.
http://rajeshbheda.com/pdf/rbc-article9.pdf.
[35] T.C. Kimbrough, “What Says Quality?” (Online) 2009
http://www.wearablesmag.com/issues/0609/swfs/wu5.swf.
[36] R. Kumar, Research Methodology: A Step-by-Step Guide for Beginners,
3rd ed. London: SAGE Publications Ltd., 2011.
[37] V. M. Sue and L.A. Ritter, Conducting Online Surveys, 2nd ed. London:
SAGE Publications Ltd. 2012.
[38] N. Towers and J. McLoughlin, “Effective Total Quality Management in
the Textile Fashion Retail Supply Chain: A Pilot Survey of the UK
Textile Manufacturers”, Journal of the Textile Institute, vol. 96, no.2,
2005, pp.87-92.
[39] Y. Yu, and V. Lindsay, “Operational Effects and Firms Responses:
Perspectives of New Zealand Apparel Firms on International
Outsourcing”, The International Journal of Logistics Management, vol
22, no.3, 2011, pp. 306-323.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:71323", author = "N. J. M. Yusof and T. Sabir and J. McLoughlin", title = "Quality Approaches for Mass-Produced Fashion: A Study in Malaysian Garment Manufacturing", abstract = "The garment manufacturing industry involves
sequential processes that are subjected to uncontrollable variations.
The industry depends on the skill of labour in handling the varieties
of fabrics and accessories, machines, as well as complicated sewing
operation. Due to these reasons, garment manufacturers have created
systems to monitor and to control the quality of the products on a
regular basis by conducting quality approaches to minimize variation.
With that, the aim of this research has been to ascertain the quality
approaches deployed by Malaysian garment manufacturers in three
key areas - quality systems and tools; quality control and types of
inspection; as well as sampling procedures chosen for garment
inspection. Besides, the focus of this research was to distinguish the
quality approaches adopted by companies that supplied finished
garments to both domestic and international markets. Feedback from
each company representative has been obtained via online survey,
which comprised of five sections and 44 questions on the
organizational profile and the quality approaches employed in the
garment industry. As a result, the response rate was 31%. The results
revealed that almost all companies have established their own
mechanism of process control by conducting a series of quality
inspections for daily production, either it was formally set up or
otherwise. In addition, quality inspection has been the predominant
quality control activity in the garment manufacturing, while the level
of complexity of these activities was substantially dictated by the
customers. Moreover, AQL-based sampling was utilized by
companies dealing with exports, whilst almost all the companies that
only concentrated on the domestic market were comfortable using
their own sampling procedures for garment inspection. Hence, this
research has provided insights into the implementation of a number
of quality approaches that were perceived as important and useful in
the garment manufacturing sector, which is truly labour-intensive.", keywords = "Garment manufacturing, quality approaches, quality
control, inspection, acceptance quality limit (AQL), and sampling.", volume = "9", number = "10", pages = "1800-7", }
