Enhancing Garment Manufacturing Process Efficiency: A DMAIC Case Study for Process Improvement

This study showcases the practical application of the Six Sigma DMAIC methodology to tackle the issue of high defect rates observed in the stitching process within the garment manufacturing industry. It presents a systematic approach to problem-solving, particularly beneficial for professionals in the field. By highlighting the economic advantages associated with defect reduction, the paper serves as a valuable guide for enhancing manufacturing processes. The research centered on a prominent garment manufacturing firm and specifically targeted the production of basic 5-pocket denim jeans spanning 18 days. The DMAIC phases—Define, Measure, Analyze, Improve, and Control—were methodically executed, employing tools such as Pareto charts and cause-and-effect diagrams. Quality assessments were conducted at crucial junctures: during front stitching, back stitching, and assembly.

Initially, the defect per million opportunities (DPMO) was recorded at 3363, signifying ample room for enhancement. Analysis unveiled primary defects like pleat/puckering, slip stitch, and uneven stitch, attributed to operator errors, machine malfunctions, and inadequate training. Interventions such as operator training, machine upkeep, and process standardization resulted in a significant reduction in defects. Subsequently, the DPMO decreased to 228, accompanied by a rise in the sigma level from 4.2 to 5.01. Furthermore, the project enhanced worker safety, cost management, and operational efficiency within the stitching department. The successful integration of the Six Sigma DMAIC methodology not only tackled immediate challenges but also paved the way for future quality enhancement endeavors in the garment manufacturing realm. This documented achievement presents a scalable blueprint for organizations striving to refine their manufacturing processes.