Reducing defects in textile weaving by applying Six Sigma methodology: a case study

Abstract

Textile and clothing account for more than 50% of Pakistan's exports. However, total share of Pakistani exports in the global textile and clothing market is less than 1%. One of the reasons of this low share is the manufacturing of less value–added products; another reason is the poor quality of some product categories. Although the country produces some of the world's best quality yarns due to well–organised spinning sector, the quality of some fabric categories produced in the country is not as good because of the sector being less–organised and poorly managed. The objective of this study was to explore the application of Six Sigma methodology for reducing the defect percentage in fabric manufacturing sector. A representative textile weaving unit was selected for this study and it was found that by the suitable application of Six Sigma tools, the sigma level was improved from 2.2 to 3. Profit per month was observed to be increased worth $26,000.