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Six Sigma Approach for Industrial Quality

Improvement and Defect Elimination

Supervised by:

Engr. Prithbey Raj Dey


Assistant Professor
Dept. of Industrial & Production Engineering

Md. Injamamul Haque Md. Saiful Amin Chowdhury Shaim Mahamud


St. Id. 117001 St. Id. 117005 St. Id. 117012

Dept. of Industrial & Production Engineering


Dhaka university of Engineering and Technology, Gazipur.
Objective with specific Aims

• Identifying a set of defects occur in the production system.


• Evaluating the major defects by statistical analysis.
• Obtaining sigma level of the current state of the quality.
• Finding the background causes of the major defects.
• Proposing the appropriate tool to reduce the defect rate.

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Motivation
Ready Made Garments (RMG) sectors in Bangladesh faces some common
problems:

Data taken from:


• High rate of rejection.
1. A Plus industries Ltd.
• Rework.
2. Anthony Young Garments Ltd.
• Wastage of resources.
• Long cycle time.
• Low productivity.

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Outline of Methodology

• Collecting the relevant data.


• Developing the probability distribution function.
• DPMO and sigma level calculation.
• Selecting the major defects
• Cause Effect diagrams to identify the root causes.
• Suggesting appropriate and efficient solutions to eliminate the defects.

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What is Six Sigma?
• Six Sigma is a disciplined, data-driven approach for process improvement

Methodology Set of statistical tools Metric

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Graphical representation of Six Sigma

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Objectives of Six Sigma

 Overall
Business
Improvement

 Remedy Defects

 Reduce Costs

 Reduce Cycle Time

 Increase Customer
Satisfaction
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Six Sigma Methodologies

Control Verify
Improve Design
Analyze
Analyze

Measure

Define 8
DMAIC Approach

Define Measure Analyze Improve Control

Identify root Identify Define


Data
Problem collection
causes of possible control
defects solutions method

Process Prioritize Implement


Project Select
performance opportunities &
goals solution
to improve Document

Identify
Customer
requirements
sources of Implement
variation

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DMADV Approach

Define Measure Analyze Design Verify

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

Skip stitch Uneven Stitch missing

Broken stitch Puckering Shading 11


Analysis for A Plus Industries Ltd.
Production line no. : 1 Section: Sewing

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

Fig. Control chart for Skip Stitch 15


Analysis for Anthony Young Garments Ltd.
Allowable tolerance for Uneven Defects

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

Defect Name: Uneven in Sleeve length shoulder


Designed Measure (Mean) = 63 cm
Standard Deviation = 1.66
Number of defected items = 18
Fig. 4.24 Normal distribution curve for uneven in
sleeve length shoulder

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Analysis for Anthony Young Garments Ltd.

Number of defects Opportunities 500


Defects L-1 L-2 L-3 L-4 L-5 L-6 L-7 L-8 L-9 L-10 Total Defects 998

Shading 2 6 1 0 0 2 1 3 8 2 25 Units 10

Uneven 180 60 110 110 60 40 20 30 70 40 720


Stitch Missing 1 4 2 0 4 6 2 7 7 6 39 DPMO 199,600
Broken Stitch/ Uncut 2 1 0 1 4 1 3 5 2 3 19
% Defects 19.96
Puckering 6 2 0 2 6 0 2 10 7 2 37
% Yield 80.04
Bubble 1 0 0 4 7 2 0 9 9 5 37
5 12 5 3 2 4 2 9 11 10 63
Sigma 2.34
Skip Stitch
Stain/Dirt spot/Oil mark 1 0 5 3 1 3 2 0 2 0 17 Cp 0.78
Slanted 1 0 2 5 3 5 3 2 7 0 28 Fig. DPMO calculation
Damage fabric 0 0 0 0 1 1 4 3 2 2 13 for Anthony Young
Total 199 85 125 128 88 64 39 78 125 70 998 Garments Ltd.

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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

51.5 LCL 46.544


31.5
11.5
L-1 L-2 L-3 L-4 L-5 L-6 L-7 L-8 L-9 L-10
No. of Line

Fig. Control chart for Uneven 20


Cause-effect Diagram for Skip Stitch

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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

Anthony Young Garments Ltd.


• Sigma level For Anthony Young Garments Ltd. was 2.34.
• That means 1,99,600 defects per million opportunities.
• Major defect was Uneven

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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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