Improving production processes with a customer-centric perspective using a novel hybrid approach in the textile sector

Purpose - In recent years, especially after the COVID-19 pandemic, home textile production orders decreased significantly. This sudden drop in production has increased industry competition, making customer satisfaction more challenging. As a result, it has become imperative for the industry to deftly navigate such ongoing challenges. Design/methodology/approach - This study examines textile production efficiency methodically. Customer requirements like quality, on-time delivery, better working conditions, cost-effectiveness and facility safety audits are understood first. Quality function deployment (QFD) turns client requirements into technical requirements. Prioritise and analyse risks using Monte Carlo simulation and Pareto charts. Consequently, experts and literature propose corrective measures, which are tested in a pilot run to see how they affect production. Findings - QFD, define, measure, analyse, improve and control (DMAIC) and Monte Carlo simulation were used to reduce high-priority risks and meet client requirements in this study. The house of quality helped relate customers’ requirements and technical requirements. Monte Carlo simulation has also improved risk prioritisation by providing a flexible mathematical structure for identifying and managing the most important risks. Originality/value - This study is novel in the way it applies this integrated approach to the understudied home textile sector. Unlike traditional DMAIC, this study introduces a novel matrix encompassing all defects. This study offers a data-driven approach to improve product quality, meet customer expectations and reduce prioritised risks in home textile manufacturing.