Capstone Project: Reducing Fabric Waste in Kasince Apparel

This project is completed in collaboration with Audrey Abanes, Kevin Carpena, and Cyrus Enriquez.

This capstone project helped me uncover the root cause of issues, teaching me that what we initially see isn't always the actual problem—it’s often a symptom of something deeper. It also sharpened my problem-solving skills, particularly in technical aspects, by applying structured analysis to address real-world challenges.

This study tackled waste reduction in Kasince Apparel and Digital Printing through Root Cause Analysis. By pinpointing key issues like excess fabric, ink smudging, and print ghosting, the study implemented a Material Utilization approach to streamline fabric use. The result? A significant cost saving of ₱102,015.48 and a reduction in excess fabric from 1200 kg to 392 kg. This project highlights how effective design can drive cost savings and enhance efficiency in the apparel industry.

Kasince Apparel and Digital Printing, founded in 2019, faced challenges with fabric waste impacting profitability. With waste estimates between 10-25%, this study addresses the need for effective waste reduction strategies. By investigating the causes and implementing solutions, we aim to improve financial performance and operational efficiency in the textile sector.

Using Root Cause Analysis, including Pareto and Ishikawa diagrams, the study identified excess fabric as the primary waste source. The approach involved data collection, problem identification, and visual tools to uncover and address root causes, leading to actionable waste reduction strategies.

This research aims to identify and reduce waste in Kasince Apparel and Digital Printing. Key questions include the primary waste sources, the most significant factors, potential solutions, and the benefits of these solutions. The goal is to provide practical insights for sustainable practices in the apparel industry.

Combining qualitative and quantitative methods, this study explored waste generation through interviews, observations, and data analysis. This dual approach offers comprehensive insights into waste reduction strategies, guiding improvements in Kasince Apparel and Digital Printing.

Data was collected through interviews, observations, and literature reviews. Insights from employees, company processes, and existing records informed the research, complemented by secondary sources for broader context.

Primary data came from observations and interviews with key personnel. Secondary sources included published research and online resources, providing a well-rounded view of the waste reduction process.

The study used non-participant observation, Root Cause Analysis, Ishikawa Diagrams, and Pareto Charts to identify waste causes and develop effective solutions. These tools enabled a detailed understanding of waste issues and informed targeted interventions.

Key findings include excess fabric as the major waste contributor. Addressing this through optimized fabric layout led to significant reductions in waste and cost savings. The Material Utilization approach improved efficiency and provided actionable insights for waste management.

The Material Utilization strategy optimized fabric layout to reduce excess. A new process flowchart was introduced, enhancing fabric efficiency. The approach led to notable cost savings and reduced fabric waste, demonstrating the benefits of effective material utilization.

Cost-benefit analysis revealed potential savings of ₱102,015.48, with excess fabric reduced from 1200 kg to 392 kg. Daily fabric waste decreased significantly, showcasing the financial and material advantages of the implemented solution.

The study found excess fabric, ink smudging, and print ghosting as major waste sources. Implementing Material Utilization reduced waste and costs, with daily fabric waste cut down significantly. These findings underline the effectiveness of the new approach in enhancing efficiency and reducing waste.