Supervised by:
2
Motivation
Ready Made Garments (RMG) sectors in Bangladesh faces some common
problems:
3
Outline of Methodology
4
What is Six Sigma?
• Six Sigma is a disciplined, data-driven approach for process improvement
5
Graphical representation of Six Sigma
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Objectives of Six Sigma
Overall
Business
Improvement
Remedy Defects
Reduce Costs
Increase Customer
Satisfaction
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Six Sigma Methodologies
Control Verify
Improve Design
Analyze
Analyze
Measure
Define 8
DMAIC Approach
Identify
Customer
requirements
sources of Implement
variation
9
DMADV Approach
Develop
Identify Evaluate
Problem customers
Explore data detailed
pilot
design
Refine
Project Research Design Scale-up
predicted
goals VOC solution design
performance
Customer
Benchmark
Predict Develop pilot Begin
requirements performance production
Quantify
CTQs
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DMAIC Approach: Case Study
Number of Quantity
skipped found
stitch
0 771
1 127
2 39
3 20
4 10
5 10
Total 977
Fig. Poisson distribution curve for line 1
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Analysis for A Plus Industries Ltd.
Number of defects
Defects L-1 L-2 L-3 L-4 L-5 L-6 L-7 L-8 L-9 L-10Total
Shading 0 13 16 0 0 17 3 22 8 29 108
Uneven 11 0 20 2 53 0 26 24 14 29 179
Stitch Missing 0 0 11 2 0 0 0 19 0 0 32
Broken Stitch/ Uncut 0 0 12 2 0 0 0 5 0 0 19
Puckering 16 0 18 9 0 0 0 16 15 17 91
Bubble 0 0 12 8 19 0 0 16 12 0 67
Skip Stitch 49 108 16 13 59 76 16 16 13 14 380
Stain/Dirt spot/Oil mark 44 0 10 4 12 10 0 21 1 6 108
Slanted 16 0 10 13 0 0 0 8 0 21 68
Damage fabric 0 2 5 0 0 4 0 16 0 0 27 Fig. DPMO calculation for
Total 136 123 130 53 143 107 45 163 63 116 1079 A Plus Industries Ltd.
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Pareto Analysis: A Plus Industries Ltd.
Pareto Chart
98.2% 100.0%
95.7%
1000 92.8%
90.0%
86.6%
80.3% 80.0%
Number of Defects
800
71.8% 70.0%
61.8% 60.0%
600
51.8% 50.0%
380 40.0%
400 35.2%
30.0%
179 20.0%
200
108 108 91 68 67 10.0%
32 27 19
0 0.0%
Types of Defects
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Control Chart: A Plus Industries Ltd.
To find out the relative impact of defects in different lines, control charts are drawn for each
defect. Among defects, Stitch skip causes that the maximum number of production line (L-2,
L-5, and L-6) out of control.
Skip Stitch
126.8
106.8
Number of Defects
86.8
66.8
UCL 56.493
46.8
CL 38.000
26.8
6.8
L-1 L-2 L-3 L-4 L-5 L-6 L-7 L-8 L-9 L-10
Line No
Design Allowable
Defects AQL* level
Specification Tolerance
Uneven in Sleeve length shoulder 63 ±1.5 >4.0
Uneven in Cuff Height 5 ±0.5 >4.0
Uneven in bottom height 7 ±0.4 >4.0
Uneven in Collar Stand Height 3 ±0.2 >4.0
Uneven in Neck Width 20 ±0.5 >4.0
Uneven in Pocket Length Centre 12.5 ±2.4 >2.5
Uneven in Placket width 3 ±0.4 <2.5
Uneven in Placket Length 31 ±4.5 =2.5
Uneven in Pocket width Upper 12.5 ±1.0 >4.0
Uneven in Shoulder Across 42 ±1.5 >2.5
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Analysis for Anthony Young Garments Ltd.
Line No: 1 Section: Sewing
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Analysis for Anthony Young Garments Ltd.
Shading 2 6 1 0 0 2 1 3 8 2 25 Units 10
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Pareto Analysis: Anthony Young Garments Ltd.
Pareto Chart
98.7% 100.0%
95.1% 97.0%
900 92.6% 90.0%
89.8%
86.1%
800 82.4% 80.0%
720 78.5%
700 72.1% 70.0%
Number of Defects
600 60.0%
500 50.0%
400 40.0%
300 30.0%
200 20.0%
100 63 10.0%
39 37 37 28 25 19 17 13
0 0.0%
Types of Defects
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Control Chart: Anthony Young Garments Ltd.
To find out the relative impacts of defects, control charts are drawn for each one. Among defects,
Uneven causes that the maximum number of production line (L-1, L-3 and L-4) out of control.
Uneven
191.5
171.5
Number of Defects
151.5
131.5
111.5
UCL 97.456
91.5
71.5 CL 72.000
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Cause-effect diagram for Uneven
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Suggested Solutions
Category Skip stitch Uneven Shading Oil Mark puckering
Man 1. Train unskilled 1. Train properly 1. Supervision 1. Must stop 1. Provide
operator. 2. Incentive mishandling. adequate
2. Maintain SOP. 2. ‘5S’ should be training on
3. Time study & Motion practiced. sewing.
study.
Machine 1. Adjust timing 1. Automatic marker 1. Clean machine at 1. Must avoid high
between needle & lay. least twice a day. tension in fabric.
looper. 2. No. of fabric plies 2. Avoid rusty
2. Adjust fabric tension, less than 300. eyelids and
select good thread. thread guide.
Method 1. Adjust right thread 1. Sewing speed must 1. Set SOP 1. Set the right SPI.
and needle size. be controlled. before 1. Keep workplace 2. Fix the right
2. Follow SOP. 2. Use checking operation. neat and clean. pressure foot.
3. Reduce gap between devices.
pressure foot and
needle plate.
Material 1. Needle, thread and 1. Ensure homogeneous 1. Fabric 1. Avoid twisted
fabric’s combination. fabric. inspection. thread.
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Results
A Plus Industries Ltd.
• Sigma level For A Plus Industries Ltd. was 2.56.
• That means 1,45,261 defects per million opportunities.
• Major defect was Skip Stitch
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Limitations & Future Scope
Limitations:
• Time consuming
• Data privacy
Future Scope:
• Growing awareness in small and medium manufacturing
industries.
• Much broader than other quality management programs
• It can be applied to every process of an organization.
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