Applying DMAIC Methodology to Reduce Defects of Sewing Section in RMG: A Case Study

Abstract

Global competition, crying off profit margin, customer requirement for high quality product at near to the ground cost and other economic factors set in motion the manufacturer to reduce their production cost without concession of quality in order to stand up in business area. Defect or wastages reduction is the initial step to reduce production cost as well as improve the quality. Higher quality comes with the reduced cycle time by reducing alternation. Apprehensive this issue, this work walks around the use of DMAIC methodology of six sigma to lessen the defect rate in sewing section of FCI (BD) LTD. Throughout five phases of DMAIC methodology, named Define, Measure, Analyze, Improve and Control, this approach minimizes defects analytically. In different phases, different types of six sigma tools were exercised. Pareto analysis was acted to identify the top defects and root causes of those defects were sensed. These were done for Ladies' tops and trousers. Brainstorming and literature review helped to endow with some potential solutions to overcome the problem. With the remedial action and implementation in pilot run, the result found is very noteworthy. The defect percentage has been reduced from 11.67 to 9.672 and as a result, the sigma level has been upgraded from 2.69 to 2.8.

Implementation of six sigma approach for increasing quality formal men’s jackets in the garment industry

“…Previous literature reviews can be discussed due to the similarities with this study. Six Sigma is a method for reducing product variance and increasing productivity [30]. This method can also identify complex problems.…”

Implementation of the Dmaic Approach for Quality Improvement at the Elastic Tape Industry

“…This method can also identify complex problems. In general, the implementation of six sigma is carried out in the DMAIC stage (Zaman & Zerin, 2017), (Setyaningrum et al, 2020), and (Kurnia, Jaqin, et al, 2021).…”

“…Reducing production costs while improving quality in the garment industry, using the DMAIC approach in the sewing section, with the methods used are SIPOC, Six Sigma, Pareto Diagrams, and SOPs with research results before the sigma level improvement is 2.69. After repairs, it increases to 2.80 (Zaman & Zerin, 2017). in this study, the same use the DMAIC approach with a six sigma method, Pareto diagrams, and fishbone diagrams.…”

Six Sigma in preconstruction: case study on improving of reinforcement steel processing

“…A módszer látszólag lineáris és egyértelműen meghatározott lehet, de meg kell jegyezni, hogy a DMAIC legjobb eredményei akkor érhetők el, ha a folyamat rugalmas, és így kiküszöböli a termelékenynek nem minősülő lépéseket [2].…”