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

Sufyan Sikander, Afshan Naseem, Asjad Shahzad, Muhammad Jawad Akhtar and Ali Salman

International Journal of Productivity and Performance Management, 2024, vol. 74, issue 5, 1796-1827

Abstract: 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.

Keywords: Voice of the customer (VOC); Quality function deployment; DMAIC; Pareto chart; Monte Carlo simulation; Solutions; Cause; Effect analysis (search for similar items in EconPapers)
Date: 2024
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Persistent link: https://EconPapers.repec.org/RePEc:eme:ijppmp:ijppm-04-2024-0254

DOI: 10.1108/IJPPM-04-2024-0254

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