<![CDATA[Quality control is essential for maintaining process consistency and minimizing defective products in garment manufacturing. This study aimed to evaluate the quality of the shirt production process, identify the dominant defect, test the defect proportion against the company’s tolerance limit, and determine its contributing factors. A mixed-method approach with quantitative dominance was applied to a garment manufacturer in Kemiri District, Purworejo Regency. Quantitative data consisted of the production and defect records of 8,910 shirts collected from April 28 to May 4, 2025, while qualitative data were obtained through interviews, observations, and documentation. The data were analyzed using a check sheet, Pareto chart, one-sample proportion test, fishbone diagram, and triangulation. The results showed that 467 units were defective, resulting in an overall defect rate of 5.24%. Sewing defects were the most dominant, accounting for 218 units or 46.7%, followed by overlock defects at 31.9% and labeling defects at 21.4%. The one-sample proportion test produced a Z-value of 21.85 and a p-value of less than 0.001, indicating that the defect proportion was significantly higher than the company’s tolerance limit of 2%. Sewing defects were associated with human, method, machine, material, and environmental factors. Recommended improvements include realistic production targets, visual work instructions, in-process inspections, preventive maintenance, material adjustment, improved ventilation, and implementation of 5S. These recommendations have not yet been implemented; therefore, their effectiveness requires further evaluation.]]>
Copyrights © 2026
