Application of Six Sigma using Define Measure Analyze Improve Control (DMAIC) methodology in Garment Sector

Main Article Content

Abdur Rahman
Salaha Uddin Chowdhury Shaju
Sharan Kumar Sarkar
Mohammad Zahed Hashem
S. M. Kamrul Hasan
Umainul Islam

Abstract

This paper demonstrates the empirical application of Six Sigma and Define-Measure-Analyze-Improve-Control (DMAIC) methodology to reduce product defects within a garments manufacturing organization in Bangladesh which follows the DMAIC methodology to investigate defects, root causes and provide a solution to eliminate these defects. Design of experiments (DOE) and the analysis of variance (ANOVA) techniques were combined to statistically determine the correlation of the broken stitch and open seam with defects as well as to define their optimum values needed to eliminate the defects. The analysis from employing Six Sigma and DMAIC indicated that the broken stitch and open seam influenced the number of defective products. Thus, a reduction of about 35% in the garments defect was achieved, which helped the organization studied to reduce its defects and thus improve its Sigma level from 1.7 to 3.4.

Downloads

Download data is not yet available.

Metrics

Metrics Loading ...

Article Details

Section
Articles
Author Biography

Abdur Rahman, Shahjalal University of Science and Technology

Department of Statistics, M.Sc. Student

References

ADAMS, C. W.; GUPTA, P.; WILSON JR., C. E. (2003) Six Sigma deployment, Elsevier Science, Burlington USA.

BANUELAS, R.; ANTONY, J.; BRACE, M. (2005) An application of Six Sigma to reduce waste, Quality and Reliability Engineering International, v. 21, n. 6, p. 553-570.

BHOTE, K. R.; BHOTE, A. K. (1991) World-class quality: using design of experiments to make it happen, 2nd Edition, American Management Association, New York.

BORROR, C. M. (2009) The certified quality engineer handbook, ASQ Quality Press, 2nd ed., p. 321–332.

BREYFOGLE III, F. W.; CUPELLO, J. M.; MEADOWS, B. (2001) Managing Six Sigma, John Wiley & Sons Inc., New York.

BRUE, G.; HOWES, R. (2005) Six Sigma: the MacGraw-Hill 36 hours’ course, MacGraw-Hill, New York.

DALE, B. G.; WIELE, T.; IWAARDEN, J. (2007) Managing Quality, 5th Edition, Blackwell Publishing Ltd., Oxford.

DEMING, W. E. (1993) The new economic for industry, government, education, MIT Center for Advanced Engineering Studies, Cambridge, MA.

GARZA-REYES, J. A.; et al. (2010) An empirical application of Six Sigma and DMAIC methodology for business process improvement, Proceedings of the 20th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM), July 12-14, California, US, p. 92-100.

GIJO, E. V.; SCARIA, J.; ANTONY, J. (2011) Application of Six Sigma methodology to reduce defects of a grinding process, Quality and Reliability Engineering International, (Online), 3 May 2011.

HAMMER, M.; GODING, J. (2001) Putting Six Sigma in perspective, Quality, v. 40, n. 10, p. 58-63.

JURAN, J.; GODFREY, A. B. (1992) Quality Handbook, The McGraw-Hill Companies, Inc.

KUMAR, U. D.; et al (2008) On the optimal selection of process alternatives in a Six Sigma implementation, International Journal of Production Economics, v. 111, n. 2, p. 456-467.

MARKARIAN, J. (2004) Six Sigma: quality processing through statistical analysis, Plastics, Additives and Compounding, v. 9, n. 4, p. 28-31.

OMACHONU, V. K.; ROSS, J. E. (2004) Principles of total quality, 3rd Edition, CRC Press LLC, Florida.

PYZDEK, T. (2003) The Six Sigma handbook: a complete guide for green belts, black belts, and managers at all levels, McGraw-Hill Companies Inc., New York, NY.

PYZDEK, T.; KELLER, P. A. (2010) The Six Sigma handbook: a complete guide for greenbelts, black belts, and managers at all levels, 3rd Edition, McGraw-Hill Companies Inc., New York.

STAMATIS, D. H. (2004) Six Sigma fundamentals: a complete guide to the system, methods and tools, Productivity Press, New York.

Most read articles by the same author(s)