Lean Six Sigma In Textile Industry
How can Lean Six Sigma help the textile industry?
Before explaining the benefits of Lean and Six Sigma, let’s see some of the problems in the textile industry that can occur!
- Waste in the Industry
- Shortage in supply of raw material
- Increase in cost of raw material
- Power shortage
- Competition in foreign markets
- Rejections in shipments
- Manufacturing defects etc
To sum it all, the major problem faced is that the resources are less and the targets are difficult to reach.
This is when Lean Six Sigma comes to the rescue. Textile industry is a field dealing with a lot of variations and defects in each process and is the ideal place for Six Sigma application, and speedy implementation of the right method will make a significant and successful difference.
Why is Lean Six Sigma so important in this industry?
Anexas has implemented Lean Six Sigma in Textile, Fashion Houses, Export Houses, and Buying Houses and has achieved the following benefits-
- Improved first sample approval percentages while working with buyers
- Improved buyer satisfaction levels
- Increased repeat business
- Improved supplier evaluation processes
- Improved merchandiser performance
- Reduced non conformances in audits by buyers
- Reduced Business Risks
- Improved processes at the source to reduce rejections at later stages.
- Eliminated manufacturing errors
- Reduced costs.
- Reduced delays.
- Reduced rejections in shipments.
Here is a Case study-
Define : Annual customer complaints were well over 10%
Measure: Major faults that occurred in Final product were analysed using Histogram and control charts.
Analyse : FMEA tool was used to find out the RPN value and action taken accordingly. It is a systematic analysis of potential failure modes aimed at preventing failures or errors. An FMEA is a two-phase process
- First the potential failure modes and corrective actions are identified.
- Then after the corrective actions are implemented, process is re-
evaluated to determine if the result is acceptable.
Improve: Various suggestions for improvements were given. Some of the major ones were:
- Proper training was imparted to the Quality Inspector
- Quality Awareness Program was conducted for Operators and Checkers
- A suitable Quality Manual was prepared for the unit
- Work Instructions were developed and issued to each of the departments
- “Quality Defects Identifiable Boards” were put up across the departments
Introduction of new control charts, quality checking systems or formats and constant monitoring by a trained Quality Inspector brought about drastic reduction in quality defects level. There was a significant decrease in Defects Per Million Opportunities (DPMO) The Process Sigma level has also improved for both the product types. Sales of the product increased by $30000 per month.
Control : Create control Chart and control plan