Six Sigma Implementation in Cutting Process of Apparel Industry

The present competitive market is focusing on industrial efforts in producing high-quality products with the lowest possible cost. In every real-life system, there are a number of factors that cause disturbance in the process performance and their output. Process improvements through minimizing or removing such factors provide advantages such as reduced wastage or re-machining and improved market share. To help in accomplishing these objectives, various quality improvement philosophies have been put forward in recent years that can maximize the quality characteristics to ensure the enhancement of product and process. Six Sigma is an emerging data-driven approach that uses methodologies and tools that lead to improved quality levels and fact-based decision-making. This paper presents the application of the Six Sigma methodology to reduce defects in a cutting process of a garment manufacturing company in India, which is concluded through an action plan for improving product quality level. The define–measure–analyze–improve–control (DMAIC) approach has been followed here to solve the underlying problem of reducing defects and improving sigma level through continuous improvement process. The process helps in establishing specific inspection methods adapted for defect type which causes maximum rejection and to prevent their appearance in product.