TITLE:
Applying DMAIC Methodology to Reduce Defects of Sewing Section in RMG: A Case Study
AUTHORS:
Dewan Maisha Zaman, Nusrat Hossain Zerin
KEYWORDS:
DMAIC, Sewing Defects, Six Sigma, Sigma Level
JOURNAL NAME:
American Journal of Industrial and Business Management,
Vol.7 No.12,
December
20,
2017
ABSTRACT: Global
competition, crying off profit margin, customer requirement for high quality
product at near to the ground cost and other economic factors set in motion the
manufacturer to reduce their production cost without concession of quality in
order to stand up in business area. Defect or wastages reduction is the initial
step to reduce production cost as well as improve the quality. Higher quality
comes with the reduced cycle time by reducing alternation. Apprehensive this
issue, this work walks around the use of DMAIC methodology of six sigma to
lessen the defect rate in sewing section of FCI (BD) LTD. Throughout five
phases of DMAIC methodology, named Define, Measure, Analyze, Improve and Control, this
approach minimizes defects analytically. In different phases, different types of six sigma tools were exercised.
Pareto analysis was acted to identify the top defects and root causes of those
defects were sensed. These were done for Ladies’ tops and trousers.
Brainstorming and literature review helped to endow with some potential
solutions to overcome the problem. With the remedial action and implementation
in pilot run, the
result found is very noteworthy. The defect percentage has been reduced from
11.67 to 9.672 and as a result, the
sigma level has been upgraded from 2.69 to 2.8.