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Improving product quality and quality management system to enter polish market a case study of a vietnamese garment factory

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in the field of study Management and Production Engineering and specialisation Management and Engineering of Globalized Production Improving product quality and quality management system to enter Polish market: a case study of a Vietnamese garment factory thesis number in the Faculty thesis register 110C-MSP-ZP/309220/1208869 Thi Hoang Ni VO student record book number 309220 thesis supervisor , prof uczelni consultation - WARSAW 2021 ii iv ABSTRACT Improving product quality and quality management system to enter Polish market: a case study of a Vietnamese garment factory Quality improvement is an effective and imperative direction to improve the competitiveness of enterprises in the market through increasing production efficiency in both productivity and quality of products and systems This study is about finding effective solutions to a company's current real demands and problems First, the research provides the company with a thorough insight into how to use concept, tools and techniques of Kaizen and Lean six sigma method in analyzing the current state of a company's problem Typically, the skill of using 5Whys tool, pareto chart and case and effect diagram based on collected data to identify the root causes of the company's problems come from high defect rate Accordingly, the main problem facing the company, determined by the data of the second half of 2020, is that the plant's production capacity is not high while production demand is constantly increasing Not to mention the plan to develop export markets to Europe in the coming time, will boost production demand even more It is also this strategic plan to expand the market that sets the requirements for changing the quality management system model to meet customer requirements Therefore, a study has been conducted to analyze and make the right choice for the new quality management model and to solve the problem of factory productivity and production quality Through careful analysis, the study proposed to upgrade the quality management system model to ISO 9001: 2015 standards in coordination using the concept of Kaizen, Lean six sigma to continuously improve quality Two projects have been proposed to work on this synergy to achieve two goals One is reducing the defect rate on the sewing line, improving product quality and production productivity The second is to upgrade the quality management system through the addition, modification and documentation of testing standards for materials, semi-products, finished products and processes, inspection procedures, and control of those items The company also pays attention to Corporate social responsibility with the orientation of pursuing ISO 14001: 2015 and ISO 45001: 2018 certification as well as strongly promoting local community programs Despite the barriers and limitations, this study is the basis for opening many other research directions on integrated management systems of enterprises All aim to fully achieve international standards towards long-term and sustainable development of the business Key words: Quality improvement, Kaizen application, quality management system, ISO 9001: 2015, Corporate social responsibility STRESZCZENIE Doskonalenie jak Poprawa jako ci jest skutecznym i koniecznym kierunkiem poprawy konkurencyjno ci przedsi biorstw na rynku poprzez zwi kszenie wydajno ci produkcji zar wno w zakresie produktywno ci, jak i jako ci produkt w i system w Niniejsze badanie dotyczy znalezienia skutecznych rozwi za aktualnych, rzeczywistych wymaga i problem w firmy d w to, jak wykorzysta koncepcj , narz dzia i techniki metody Kaizen i Lean six sigma w analizie aktualnego stanu problemu przedsi biorstwa Zwykle umiej tno narz dziem 5Whys, wykresem Pareto oraz diagramem przypadk w i efekt w na podstawie zebranych danych w celu zidentyfikowania przyczyn problem w firmy wynika z wysokiego wska nika defekt w W zwi wnym problemem firmy, okre y 2020 roku, jest to, e zdolno ci produkcyjne wysokie, a zapotrzebowanie na produkcj stale ro nie Nie wspominaj c o planie rozwoju rynk w eksportowych Europy w nadchodz cym czasie, jeszcze bardziej zwi kszy si popyt produkcyjny Jest to r wnie ten strategiczny plan rozszerzenia rynku, kt ry stawia wymagania dotycz ce zmiany modelu systemu zarz dzania jako ci klient w Dlatego ciwego wyboru nowego modelu zarz dzania jako ci oraz rozwi zania problemu produktywno ci fabryki i jako ci produkcji analiz , w badaniu zaproponowano aktualizacj modelu systemu zarz dzania jako ci standard w ISO 9001: 2015 w koordynacji z wykorzystaniem koncepcji Kaizen, Lean six sigma w celu ci ci Zaproponowano dwa projekty, aby pracowa nad t synergi , aby osi gn dwa cele Jednym z nich jest zmniejszenie wska d w na linii szycia, poprawa jako ci produktu i wydajno ci produkcji Drugim jest unowocze nienie systemu zarz dzania jako ci poprzez dodanie, modyfikacj i udokumentowanie standard w testowania w, p w, gotowych produkt w i proces w, procedur inspekcji i kontroli tych pozycji Firma zwraca r wnie uwag odpowiedzialno biznesu, kieruj c si realizacj certyfikacji ISO 14001: 2015 i ISO 45001: 2018, a tak e mocno promuj ci lokalnych Opracowanie to, mimo barier i ogranicze , jest podstaw otwarcia wielu innych kierunk w badawczych nad zintegrowanymi systemami zarz dzania przedsi biorstwami Wszystkie d gni cia mi dzynarodowych standard wego i zr wnowa onego rozwoju firmy vi viii TABLE OF CONTENTS 1.2.1 Improve quality and implementation methods 14 1.2.2 Continuous improvement 15 1.2.3 Necessary knowledge, tools and techniques used in research 18 1.2.4 ISO 9001 standards for quality management system 20 REACH Regulation 24 Intellectual property 25 3.3.1 Internal analysis 29 3.3.2 PEST analysis 34 3.4.1 Main products of the company 44 3.4.2 Production processes 45 4.4.1 Proposal of project 61 4.4.2 Practical implement have been studied for the project 66 4.5.1 Proposal of project 75 4.5.2 Practical implement have been studied in the project 81 4.6.1 Standard ISO 14001: 2015 and ISO 45001: 2018 for the company 97 4.6.2 Series of campaigns for the local community 101 4.6.3.Covid-19 protection on the work floor 102 10 17 CBI, 2020 What are the requirements for apparel to enter the European market? [Online] Available at: https://www.cbi.eu/market-information/apparel/buyer-requirements [Accessed 19 12 2020] 18 Comission, E., 2020 CE marking [Online] Available at: https://ec.europa.eu/growth/single-market/ce-marking_en [Accessed 19 12 2020] 19 Commission, E., 2020 Safety Gate: Rapid Alert System for dangerous non-food products - Search alerts [Online] Available at: https://ec.europa.eu/consumers/consumers_safety/safety_products/rapex/alerts [Accessed 19 12 2020] 20 Commission, E., 2020 Standardisation - Mandates [Online] Available at: https://ec.europa.eu/growth/toolsdatabases/mandates/index.cfm?fuseaction=txtSearch.search [Accessed 19 12 2020] 21 ECHA, 2020 Substances restricted under REACH [Online] Available at: https://echa.europa.eu/substances-restricted-under-reach [Accessed 19 12 2020] 22 EUR-Lex, 2002 Directive 2001/95/EC of the European Parliament and of the Council on general product safety [Online] Available at: https://eur-lex.europa.eu/legalcontent/EN/TXT/HTML/?uri=CELEX:32001L0095&from=EN [Accessed 19 12 2020] 23 Eur-lex, 2011 Regulation (EU) No 1007/2011 of the European parliament and of the Coumcil [Online] Available at: https://eur-lex.europa.eu/legal-content/EN/TXT/?uri=CELEX:02011R100720180215 [Accessed 19 12 2020] 24 EUR-Lex, 2016 Regulation (Eu) 2016/425 of the European Parliament and of the Council [Online] Available at: https://eur-lex.europa.eu/legal-content/EN/TXT/?uri=CELEX:32016R0425 [Accessed 19 12 2020] 25 Inspection, Q., 2018 [Online] Available at: https://qualityinspection.org/what-is-the-aql/ [Accessed 16 12 2020] 26 NCIF, 2019 Tình hình ngành d nv th c t Hi i T [Online] Available at: http://ncif.gov.vn/Pages/NewsDetail.aspx?newid=21878 [Accessed 17 12 2020] rms? i thách 27 Statista, 2020 Apparel industry in Vietnam - Statistics & Facts [Online] Available at: https://www.statista.com/topics/5820/apparel-industry-in-vietnam/ [Accessed 17 12 2020] 108 28 Wikipedia, 2020 5S (methodology) [Online] Available at: https://en.wikipedia.org/wiki/5S_(methodology) [Accessed 16 12 2020] 29 Wikipedia, 2020 Brainstorming [Online] Available at: https://en.wikipedia.org/wiki/Ishikawa_diagram [Accessed 16 12 2020] 30 Wikipedia, 2020 Five whys [Online] Available at: https://en.wikipedia.org/wiki/Five_whys [Accessed 16 12 2020] 31 Wikipedia, 2020 Flowchart [Online] Available at: https://en.wikipedia.org/wiki/Flowchart [Accessed 16 12 2020] 32 Wikipedia, 2020 Ishikawa diagram [Online] Available at: https://en.wikipedia.org/wiki/Ishikawa_diagram [Accessed 16 12 2020] 33 Wikipedia, 2020 ISO 9000 [Online] Available at: https://en.wikipedia.org/wiki/ISO_9000 [Accessed 16 12 2020] 34 Wikipedia, 2020 Pareto chart [Online] Available at: https://en.wikipedia.org/wiki/Pareto_chart [Accessed 16 12 2020] 35 Wikipedia, 2020 PEST analysis [Online] Available at: https://en.wikipedia.org/wiki/PEST_analysis [Accessed 18 12 2020] 36 Wikipedia, 2021 Comprehensive and Progressive Agreement for Trans-Pacific Partnership [Online] Available at: https://en.wikipedia.org/wiki/Comprehensive_and_Progressive_Agreement_for_TransPacific_Partnership [Accessed 17 12 2020] 37 Wikipedia, 2020 Corporate social responsibility [Online] Available at: https://en.wikipedia.org/wiki/Corporate_social_responsibility#Definition [Accessed 16 2021] 38 Wikipedia, 2020 ISO 14000 [Online] Available at: https://en.wikipedia.org/wiki/ISO_14000 [Accessed 16 2021] 109 110 111 112 113 Source: own study Source: own study 114 Source: own study Source: own study 115 Source: own study Source: own study 116 Source: own study Source: own study 117 Source: own study based on data of the factory Source: own study based on data of the factory Source: own study based on data of the factory 118 Source: own study based on data of the factory Source: own study based on data of the factory Source: own study based on data of the factory 119 Source: the data from the factory Source: the data from the factory 120 Source: the data from the factory Source: own study 121 Source: own study 122 ...ii iv ABSTRACT Improving product quality and quality management system to enter Polish market: a case study of a Vietnamese garment factory Quality improvement is an effective and imperative... world market, America and western have continued to learn and improve the Japanese way of becoming a total quality management (TQM) system (Yang, 2017) Total quality management is seen as a performance... new quality management model and to solve the problem of factory productivity and production quality Through careful analysis, the study proposed to upgrade the quality management system model to
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