Applying Six Sigma Methodology Based On “DMAIC” Tools to Reduce Production Defects in Textile Manufacturing

Abstract

Six Sigma is a systematic methodology for continuous process quality improvement and for achieving operational excellence. Six Sigma methodology is designed to provide for the application of statistical tools in the context of a process improvement structure summarized by the acronym DMAIC– Define, Measure, Analyze, Improve, and Control. The DMAIC model provides a framework to identify and eliminate sources of variation in a process, improve and sustain performance with well-executed control plans, and promote one process improvement language for all members of an organization to employ. This paper deals with the application of Six Sigma based methodology based on “DMAIC” (define-measure-analyzeimprove-control) tools to reduce production defects in textile manufacturing. The DMAIC approach has been followed to solve an underlying problem of reducing process variation and the associated high defect rate. This paper explores how to use a systematic and disciplined approach to move towards the goal of Six Sigma quality level. The application of the Six Sigma methodology resulted in a reduction in the overall quality level from 7.7 % to 2%.

Key-words: Six Sigma, DMAIC approach, Production Defects, Textile Manufacturing, Quality, overall quality level

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