Six Sigma Green Belt Course

ISI New Delhi

PROJECT REPORT
On
Improve the Quality of Bulk Production.

For
Completing Six Sigma Green Belt

Submitted to:
Ms. Rina Chatuvadi
Indian Statistical Institute New Delhi
Prepared by:
Mr. Vishwa Kumbh
Oct-16 Batch
15-Jan-2017

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CONTENTS

Introduction
Define Phase

Problem Statement:
High Level of Process Map ( SIPOC)

Measure Phase
Data Collection Period
Visual Defects Data Table For Measure Phase.
Type Of Defect
Re-arrange the Data In the Descending Order
Validated the Data Measurement System
Major Defects Identified from Pareto Chart
Measure Base Line Performance
U - Chart at Measure Phase

Analyze Phase

Brain Storming
Course and Effect Diagram
Summary of Course and Main Factor

Improve Phase
Remedial Action Plan for Defects of Waist Band Width
Uneven Stitching
Data Collection after Remedial Action's has taken.
Improve Base Line Performance
Project Result
Up dated Process Map

Control Phase

Data Collection During Control Phase

U - Chart to Monitoring Process

Training / SOP has Implemented

Process Check List
Monitoring Benefits
Lessons Learned

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Define Phase
Research Case:

We have got new product category from new France Buyer

under the product category of work wear which is belong to
France automobile company named Renault. This product
with new fabrication and designed which is not familiar with
the production floor.

During the production period we have got high percentage

of visual sewing defects with less production which we
expected.

The management expectation is to increase 200% of order

placement for next season due to this customer is very
important for the our round the year business.

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Problem Statement:
The production line having highest percentages of Visual
defects on past months.
Goal Statement:
To reduce the 70 % visual sewing defects.
Expected Result Business case:
A) Relevant Metrics.
1. To Reduce the Rework Cost.
2. To Increase the Productivity.
3. To Increase the Efficiency.
B) Improvement Target.
60% of Reduce the Rework Cost.
C) Hard Benefits.
1. Reduce the Defects per month around 2500 pcs in
Production Line.
2. Reduce the Rework Cost around US$ 3125.00 in a line
at a month.
D) Soft Benefits.
1. Improve the Customer Satisfaction.
2. Improve the Company reputation.
3. Increase the skill of company manufacturing
Product range.

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High Level of Process Map ( SIPOC)

Supplier

Inputs

Supertex
Group.

# Fabric.

Process

Out Put

Customer

# Cutting.
# Fabric
# Machinery. Parts.
# Threads.
# Needles.

# Stitching.

Stitched and Betran Court

# Trimming.

Packed

# Checking.

Work wear

# Washing.

Garment.

# Trimming.
# Sewing
Trims.

# Checking.
# Pressing.
# Packing.

# Packing
Trims.

# Auditing.

At
France

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Project Plan.
Date / Oct- Oct- Oct02- 11Event 01
10
20
Define
Measur
e

Oct- Nov- Nov- Nov- Dec- Dec- Dec- Jan

21- 01- 11- 21- 01- 11- 21- 0131
10
20
30
10
20
31
20

X
X

Analyz
e

Improv
e

Control

X
X

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Measure Phase
Data Collection Period
Characteri
stic
Rejection %
of at
sewing line
End table

Data
Type
Attribu
te

How Measured
and Who
Visual Checking by
QC, Comparing
with approved
Sample.

Sampling
Notes
100% of
Finished
Garments

Visual Defects Data Table For Measure Phase.

Type Of Defect

Period
From 01st of
October to
December,
2014

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No

Defect
s ID

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Occurren
ce

% of
Occurren
ce

251
375

10.04%
15.00%

1125
201

45.00%
8.04%

182
105

7.28%
4.20%

85
59

3.40%
2.36%

1
2

A
B

3
4

C
D

5
6

E
F

7
8

G
H

Defects Type
Uneven Width of
Seams
Skip Stitches
Waist Band Uneven
Width
Broken Stitches
Side Seam Length
Uneven
Side Pocket Hi-Low
Wrong Button
Placements
Open Seams

9
10

I
J

Damage Button
Holes
Raw Edges

45
40

1.80%
1.60%

11

Others
Total

32
2500

1.28%
100

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Re-arrange the Data In the Descending Order

Defects
ID

Tot
al

No of
defectiv
e

11
25

37
5

251

201

182

105

85

59

45

40

32

Defect
%

45

15

10.
04

8.0
4

7.2
8

4.2

3.4

2.3
6

1.8

1.6

1.2
100
8

Cumula
ted
Defect
%

45

60

70.
04

78.
08

85.
36

89.
56

92.
96

95.
32

97.
12

98.
72

10
0

Validated the Data Measurement System

The Data has collected by the Line Quality Controller and those
data has validated and confirmed by the Quality Assurance
Manager.

250
0

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Major Defects Identified from Pareto Chart

SL No

Defects ID
Code

Defects Types

Waist Band Uneven Width

Skip Stitches

Uneven Width Seam

Broken Stitches

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Measure Base Line Performance

Calculation of DPMO. ( Defects Per Million Operations)
Total Checked Garments No of Defects Founds % of Defects
: 30162 pcs.
: 2500 Pcs
: 2500/30162 x 100 = 8.29%
Current
DPMO

= 82885.75

Z Value of DPMO( Sigma Level) =

2.9

Defect %

8.29%

Measure Process Capability at Measure phase

No of Data ( n)

= 30

Z Value ( Sigma Level)

= 2.9

Pp. ( Long Term Process Capability )

Z value
3
(Target

Cp.( Short Term Process Capability)

= 2.9 =
3
Should Be
-1.33)

= Z value + 1.5 = 2.9 +1.5

=
3

0.9
6

1.46

(Target Should Be - 2.0)

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U - Chart at Measure Phase

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Analyze Phase
Brain Storming
During the Team Brain Storming meeting with following s in
Production Line,
1. Sample room Technician.2. Line Quality Controller. 3. Line
Chief .
4. Line Supervisor. 5. Line Mechanic.6. Sewing Operators
Following conclusion has taken to improve the Quality and
production of this production Line.
1. To have training section for all critical operations by
Line Chief or Technician.
2. All work instruction should be written in Local Language
in working Patens in production floor by sample Room.
3. All critical Operations Must have QC approved mock- up
to follow The quality standard of Operation during the
production by Machine operator.
4. Machine during the Line setting, Need to minimum 05
pcs of sample as per the particular operation and need
to get the conformation form conformation from Line
Chief / QC to released the machine for Bulk Production.
5. QC / Line Chief need to give overall demonstration to all
operators that how to handle the fabric if fabrication is new
and difficult to handle.
Course and Effect Diagram

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Summary of Course and Main Factor

S.R.
No.
01.

02.

03.

04.

05.

Cause

Main factor

Sub Factor

Sub Sub
Factor

In Sufficient Training
to
Operator that, how to
use
waist band shape
Patten
when stitching.

Man

Training

Supervisor Unable to
read
the how to use
Patten
instructions written
on the
Patten.

Man

Language

Machine

Tool

Method

Quality Tool

Material

Awareness of

Not fixed correct

type of
Gauge to machine
which is
operator can easily
guild
the out line when
stitching.
Not Available of
Correct
Quality Guide Line
( Mock Up) to verify
after
stitching by
Operator.
Fabric Softness

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fabric
Thickness.

Improve Phase
Remedial Action Plan for Defects of Waist Band
Width Uneven Stitching
S.L. Course
No.
01.

In Sufficient of
Training to
Operators before
start the
Production

02.

03.

Action
Operator must under go the
short
Training period of particular
operation
before start the bulk
production

Supervisor Unable
to read the
how to use Patten
instructions
written on the
Patten.

All Patten work instructions

must be
written on the Patten by
Local Language.

Not fixed correct

type of

Line mechanic need to stitch

05 pcs

Gauge to machine
which is
operator can easily
guild the

sample pcs of particular

operation and
need to get the
conformation /Approval

Responsible
By
Line Chief
and Line
Quality
Controller

Sample Room
Technician
and
need to verify
by the
Line QC and
Line
chief.

Line
mechanic/
Line
Chief / Line

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04.

out line when

stitching

form Line Chief and Line QC

before
supervisor
machine hand over to
operator.

Not Available of
Correct

Line QC need to make sure

that , every
critical operations has to be
with Mock Up
which is stitch by particular
operator and
signed by Line QC before
start the
stitching of bulk Production.

Quality Guide Line

( Mock Up) to verify
after
stitching by
Operator.

05.

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Fabric Softness

Line QC /
Operator

It is Line Chief or Line QC is

responsible
to make understand to
Line Chief
operator need
and Line
any additional care during
the stitching if
QC
need.

Data Collection after Remedial Action's has taken.

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Improve Base Line Performance

Calculation of DPMO. ( Defects Per Million Operations)
Total Checked Garments : 20389 pcs.
No of Defects Founds
: 240 Pcs
% of Defects
: 240/20389 x 100 = 1.18%
Current
DPMO

= 11771.05

Z Value of DPMO( Sigma Level) =

Defect %

3.75
=

1.18%

Measure Process Capability after Remedial Action are

Taken at Improve Phase
No of Data
Z Value ( Sigma
Level )

= 25
= 3.75

Pp. ( Long Term Process

Capability )

Z value
3

3.75 =
1.25

=
3

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( Targ
et
Cp.( Short Term Process
Capability)

+
Z value 1.5
3
( Targ
et

U - Chart
After Remedial Action has Taken

Should Be - 1.33 )
= 3.75 +1.5 =
1.75
3
Should Be - 2.0 )

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Project Result
Past ( At Measure phase)
DPMO

82885.75

Sigma Level

2.9

Defect %

8.29%

Pp.

0.96

Cp. 1.46

Improved ( At Improve Phase)

Sigma Level 11771.05
Defect % 3.75
1.18%
Pp.

1.25 (Target should Be 1.33 )

Cp.

1.75 (Target should Be 2.0)

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U - Charts of Project Result Comparison

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Up dated Process Map

Supplie
r
Inputs
Process

# Cutting.
Supertex # Fabric.
Group.
#
Machinery.

# Fabric
Parts
#
Stitching.

#
Trimming.
# Threads.
#
Checking.
# Needles.

# Sewing
Trims.

Process Up
dated

Out
Put

Custome
r

Date :
21/02/2015
Revision - 001
1. All worked
Instruction
Must be with
local
language for
the easy
understandin
g.
2. Need Training
Betran
for
Stitched Court
operators for
all
and
At
Critical
Operations,
Before Start
Packed
France
the Bulk

Production.
Work
3. Mechanic
# Washing. need to be
get the
Wear
approval from
Garmen
t.
#
Line Chief
Trimming.
after setting
the
#
machine

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# Packing
Trims.

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,before it
Released to
the
Bulk
production.
# Pressing. 4. QC need to
Approved
a Mock - Up
# Packing.
for All
Critical
operations as
An Quality
Guide Line
# Auditing.
for the
Operators
During the
Bulk
Production.
5. Need to
Guide the
Operators, If
fabric is
New for them.

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Control Phase
Data Collection During Control Phase

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U - Chart to Monitoring Process

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Training / SOP has Implemented

1. For All Critical Operations , Operators has to be
trained by the Line Chief or Technician.
( SOP # 04 ( Production Department ))
2. Mock Up samples which is stitched by the operator has to
be review and approved by The Line Quality Controller
before Start the bulk Production .
( SOP # 08 ( Quality Department ))
3. Line Mechanic need to be stitch minimum 05 Pcs of samples
of each operation to make sure that machine and all
attachment in right condition to meet the buyer quality
Standard with easy to handling by Operator.
( SOP # 04 ( Maintained Department.))
4. All work Instructions which is given by the sample department
to Production floor ,has To be address on Local language for
the easy understanding of work force.
( SOP # 05 ( Sample Department ))
5. Line Chief or Line QC is responsible to make understand that
Fabric Quality and Handling method to operator and need
any additional care during the Stitching due To behavior of
fabric if needed.
( SOP # 09 ( Quality Department ))

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Process Check List

Item

Event to be
Checked

No

01

02

03

04

Operator has Under go the

Short
Training Period of Particular
Operation before start the
Bulk
Production
All Production Patten's
Work
Instruction written by
Local
Language
Machine and all
attachments has
Checked and conformed by
Line
Chief before released to
Production
Line.
Has Mock Ups available
for all
Critical operations which is
signed
and approved by Line QC.

Ye N
s
o

N/ Comments
A
/
Action
Taken

Wh Whe
o
n

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Has Line chief / QC has

demonstrated about fabric
quality
and how to handled those
during the
sewing.

Monitoring Benefits
Hard Benefits.
1. Reduce the Defects per month around 2000
pcs in a Production Line.
2. Reduce the Rework Cost around US$ 2500.00 from In a
line At a Month. So that annual re-work cost serving is
2500 x 12 = USD 30,000.00 Per Sewing Line /per
annual.
D) Soft Benefits.
1. Has improved the customer satisfaction.
2. Has improved the company reputation.
Has increase the skill of the workers to manufacturing and
Handling of deferent product ranges with profitable Manner

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Lessons Learned
1. The Operator Of Garment Industry Must be Given Training on
a Continuous Basis on the Issue of Quality.
2. The Management Focus Should be on Preventing
defects Rather than Correcting Defects.
3. The Visual Mock Up of All Operations has to be available in
all machines Due to It is very Easy to understand to
Operator that what she has to do And what She / He has to
achieved during the stitching process to achieve The quality
Standard of her operation same as end Product to meet the
Buyers Quality requirement.
4. The Management should give Incentives for High Quality
Performance of the Operators.
5. Need do continually do the Six Sigma projects to improve
the process of Production floor as much as possible.