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Minimization of Defects in the Sewing Section of a Garment Factory through DMAIC Methodology of Six Sigma

Author Affiliations

  • 1 Department of Industrial and Production Engineering, Shah Jalal University of Science and Technology, Sylhet-3114, BANGLADESH

Res. J. Engineering Sci., Volume 3, Issue (9), Pages 21-25, September,26 (2014)


The fast changing economic conditions such as global competition, declining profit margin and customer demand for high quality product at low cost push the manufactures to reduce their production cost without compromising quality in order to survive in business arena. Defects minimization is the first condition of reducing production cost and improving the quality. It will also reduce the cycle time by reducing reworks and finally result higher productivity. Concerning this matter, the present study explores the use of DMAIC methodology of six sigma to minimize the defects rate in a selected garment factory. This is a systematic approach towards defects minimization through five phases of DMAIC methodology named define, measure, analyze, improve and control. Different six sigma tools were used in different phases. Pareto analysis was done to identify the major types of defects. Root causes of those defects were detected by cause and effect analysis. Finally some potential solutions are suggested to overcome those causes. The result found after implementation of the solutions is very significant. The defect percentage has been reduced from 12.61 to 7.7 and consequently the Sigma level has been improved from 2.64 to 2.9255.


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