Once the faults have been collected they should be written down and recorded on a fault analysis card or chart. These are also known as FACERAP cards.
FACERAP is a mnemonic for Fault, Appearance, Cause, Effect, Responsibility, Action, And Prevention.
The information is recorded under the following headings to facilitate teaching: –
Fault – Correct name/agreed name. So that trainees can report to the Instructor/Supervisor/Mechanics).
Appearance – Clear description or an example attached. Trainee cannot take remedial action unless he can recognize the appearance or feel of the fault.
Cause – All the main causes, for example: – faulty cutting, incorrect machine setting, machine breakdown, mistake by operative or previous operatives.
Effect – Result of the fault, cost of the fault, and weak edges for example: – likely to break away, scrapped or seconds, loss of incentive pay.
Responsibility – Which defects are trainees’ own fault and which are the responsibility of others. Do not encourage the passing of blame, similarly, do not blame unfairly.
Action – What action is to be carried out on discovery of the fault, for example: –
Reject, unpick and re-sew, report to Instructor/Supervisor/Mechanic.
Prevention – Any action which can or should be taken to avoid a recurrence of the fault should be recorded, for example: – check tensions and stitches on every third garment. Ensure edges match before sewing, etc.
Fault Analysis Card
|Half stitch or part
|Failure to place whole stitch on point||Weak part in seam which under pressure will break away||Operative||Remove fabric from points and run on||Check each stitch is on a constructive point when fabric is run on|
Good quality products or processes can only be produced by the operatives. They cannot produce quality without being fully aware of what exactly is required. Responsibility for the production of good quality lies with, and is in the hands of, the person teaching the job, primarily by good communication, by making the newcomer aware of specifications and tolerances, faults themselves, their effect and the appropriate action to take.
Such communication or training if properly planned and executed will greatly assist in minimizing the cost of poor quality. Only in this way will quality be controlled, costs remain at an acceptable level and customers be satisfied.
Orga Garments check and investigate each and every factor for the best quality and best design.