Prioritisation and Analysis of Faults in Shirt Production by the A3 Technique

In this study, it was aimed to solve the problems occurring in a clothing company’s shirt manufacturing line. For this Pareto charts and A3 reporting philosophy were used to organise the process in the best way. In line with the examinations and analyses made, an apparatus was developed to shorten the unit time and standardise the quality for the collar preparation process, which is the fault with the highest frequency. Afterward, the collar preparation process was compared according to the situation with the apparatus, manual and automat. As a result of the implementation of the Pareto charts and A3 reporting technique, it can be seen that while the total time spent on the process with the automat is 24.6 seconds, this time is 87% quicker than the apparatus developed, which is 46.2 seconds; however, it needs 95% more investment.