Garment case-study assessment

Learning objectives

• Read a multi-symptom garment scenario and select the right project(s).
• Choose Lean and statistical tools by question, not by habit.
• Present evidence that a change protected safety, buyer and sustainability requirements.

Scenario

A new style shows high fabric variance, line imbalance, DHU, shade rework, packing errors, WIP, overtime and delivery risk across internal and supplier processes. Everything looks urgent.

Required response

• Select one to three linked projects with the highest financial and delivery leverage.
• Define CTQs, operational measures and financial logic.
• Propose an MSA/data plan; stratify and validate causes.
• Choose Lean/statistical tools by the questions they answer.
• Design pilots and a control plan with named owners.

Evidence a passing answer contains

• Charter, SIPOC/map, baseline, Pareto/time plots.
• Capability where valid; cause confirmation.
• Solution/risk selection and pilot result.
• Control plan, ownership and audit cadence.

Garment-factory example

A candidate selects two linked projects: (1) fabric utilization + marker efficiency, (2) DHU + FTR on the sewing line. Both share the same measurement system and produce a single financial roll-up so the plant reads one number.

Method

1. Read the scenario twice before choosing projects.
2. Draft one page per required evidence item.
3. Stress-test decisions against safety, compliance and sustainability guardrails before publishing.

Common mistakes

• Trying to solve every symptom in one project.
• Selecting tools without an explicit question.
• Claiming benefits before sustained validation.