Using TQM'S common tools to improve quality performance at Garment Factory of Choishins (VINA)

HO CHI MINH CITY OPEN UNIVERSITY UNIVERSITÉ LIBRE DE BRUXELLES

SOLVAY BRUSSELS SCHOOL

OF ECONOMICS & MANAGEMENT

MBQPM 6

NGUYEN NGOC HIEU

USING TQM’S COMMON TOOLS TO IMPROVE QUALITY PERFORMANCE

AT GARMENT FACTORY OF

CHOISHINS(VINA)

MASTER FINAL PROJECT

MASTER IN BUSINESS QUALITY & PERFORMANCE MANAGEMENT

HO CHI MINH

(2018)

HO CHI MINH CITY OPEN UNIVERSITY UNIVERSITÉ LIBRE DE BRUXELLES

SOLVAY BRUSSELS SCHOOL

OF ECONOMICS & MANAGEMENT

MBQPM 6

NGUYEN NGOC HIEU

USING TQM’S COMMON TOOLS TO IMPROVE QUALITY PERFORMANCE

AT GARMENT FACTORY OF

CHOISHINS(VINA)

MASTER FINAL PROJECT

MASTER IN BUSINESS QUALITY & PERFORMANCE MANAGEMENT

HO CHI MINH

(2018)

STATEMENT OF AUTHENTICATION:

This work has not been submitted for a degree or diploma in any University. To the best

of my knowledge and belief, the project contains no materials published or written by

another person except reference is made in the project itself.

Nguyen Ngoc Hieu

March 20th,2018

ACKNOWLEDGEMENTS:

This projected has been instructed and supervised by Professor Jacques Martin to whom I

would like to extend my sincere gratitude for taking time to guide me from beginning to

the end of this report.

All research, workshops, trial run were carried out at Choishins(Vina) in Tien Giang

Province, Viet Nam with the supports of the management and colleagues there.

I would like to thank Mr. Kwon - General Director, Mr. Leo – Merchandise Manager, Mrs.

Anita – QA manager and Mr. Loc – Production Manager for close coordination.

I would like to thank my family for their encouragement & support.

Academic Tutor and Practical Tutor’s comments:

ACCEPTANCE OF FINAL PROJECT REPORT FOR DEFENSE

Mr Nguyen Ngoc Hieu’s final project report for degree of Master in Business Quality and

Performance Management is official accepted for defense.

The Thesis titled “USING TQM’S COMMON TOOLS TO IMPROVE QUALITY

PERFORMANCE AT GARMENT FACTORY OF CHOISHINS(VINA)”

On ……date…………….

Dr. Jacques M.A. Martin

Academic Director

Master in Master Business in Quality and Performance Management

Solvay Brussels School of Economics and Management – Ho Chi Minh City Open

University.

TABLE OF CONTENTS:

ABSTRACT:.................................................................................................................................................. i

INTRODUCTION ........................................................................................................................................ ii

BACKGROUND OF THE STUDY: ............................................................................................................ ii

OBJECTIVES OF THE STUDY:................................................................................................................ iii

SIGNIFICANCE OF THE STUDY:............................................................................................................ iii

RESEARCH METHODOLOGY:................................................................................................................ iv

REPORT OVERVIEW:................................................................................................................................ v

PART I: ASSESSMENT & ANALYSIS CURRENT TQM IMPLEMENTATION STATUS AT

CHOISHINS(VINA).....................................................................................................................................1

CHAPTER 1: INTRODUCTION ABOUT CHOISHINS(VINA): ..............................................................1

1.1 Choishins(Vina) Company:...........................................................................................................1

1.2 Existing customers:.......................................................................................................................2

1.3 Item producing:.............................................................................................................................2

1.4 Company organization:.................................................................................................................3

CHAPTER 2: REVIEW OF THE EXISTING QUALITY SYSTEM AND MANUFACTURING

PROCESS IN CHOISHINS(VINA). ............................................................................................................4

2.1Description of Quality System:............................................................................................................4

2.1.1Quality Policy: ..............................................................................................................................4

2.1.2 Quality Management System in factory:......................................................................................4

2.1.3 Quality Performance Objectives:.................................................................................................4

2.1.4 Total Quality Management System: ............................................................................................4

2.1.5 Environment management system: follow Buyer’s requirement.................................................5

2.1.6 Factory Quality organization chart ..............................................................................................5

2.1.7 Internal audit procedures:.............................................................................................................6

2.2 Introduce about manufacturing flow:..................................................................................................7

2.2.1 Fabric and Trim:...........................................................................................................................8

2.2.2 Sample Room:..............................................................................................................................9

2.2.3 Cutting Section: ...........................................................................................................................9

2.2.4 Sewing Section: .........................................................................................................................11

2.2.5 Manufacturing flow in finishing section:...................................................................................13

CHAPTER 3: ASSESSMENT OF TQM IMPLEMENTATION AT CHOISHINS(VINA)......................15

3.1 Defining the Quality Management System maturity level:...............................................................15

3.2 Maturity Diagnostic Instrument Interpretation: ..........................................................................16

3.3 Score Table: ................................................................................................................................22

3.4 TQM practices against TQM ‘s Elements:..................................................................................23

3.5 Quality findings: .........................................................................................................................24

3.5.1 Quality findings in cutting department: ..............................................................................24

3.5.2 Defect findings from Endline QC: ......................................................................................26

3.5.3 Defect findings from finishing section:...............................................................................32

PART II: IMPROVEMENT PLAN............................................................................................................38

CHAPTER 1: SOURCES OF IMPROVEMENT:......................................................................................38

1.1Organization maturity ........................................................................................................................38

1.2 Outstanding points of TQM adoption and implementation: .......................................................39

1.3 Quality Performance pending points: ...............................................................................................39

CHAPTER2: ACTION PLANS..................................................................................................................41

2.1 Suggested action plans:.....................................................................................................................41

2.2 Implement action plan: .....................................................................................................................42

2.2.1 Set Up Improvement Committee. ..............................................................................................42

2.2.2 Committee’s Objectives:............................................................................................................42

2.2.3 Conduct training for both management, QC and worker...........................................................43

2.2.4 Traffic Light System application in place:..........................................................................46

2.2.5 Revised inline format.................................................................................................................48

2.2.6 Revised Production Quality Tracking Chart:.............................................................................49

2.2.7 Action taken from Root Cause Analysis of Physical defect. .....................................................50

2.3 Measure the result after implemented:..............................................................................................58

2.3.1 Quality control of incoming material:........................................................................................58

2.3.2 Quality control of fabric inspection area:...................................................................................59

2.3.3 Quality control in cutting area: ..................................................................................................59

2.3.4 WIP (Work in Process) moving:................................................................................................60

2.3.5 Comparison about Quality Performance Effectiveness. ............................................................62

2.3.6 Non-Conformance performance tracking: .................................................................................62

2.3.7 Operator Skill Improvement: .....................................................................................................63

2.3.8 TQM knowledge of the teams:...................................................................................................64

2.3.9 Maturity improvement: .......................................................................................................65

CONCLUSION:..........................................................................................................................................66

References:..................................................................................................................................................67