Six Sigma methodology implementation for minimising yarn breakages in the apparel industry

Seleman Kalinga Hussein and Ismail W.R. Taifa

International Journal of Industrial and Systems Engineering, 2024, vol. 48, issue 2, 228-258

Abstract: This research applied the Six Sigma methodology (SSM), mainly the define-measure-analyse-improve-control (DMAIC) approach to minimise the yarn breakages in the weaving loom during the woven fabric manufacturing. The product rejects were 512,000 metres, and the production quantities were 13,273,512 metres of fabrics. The calculated sigma level was 4.84, and the cost of poor quality (COPQ) was 14.36%. After the improving and control phases, the company implemented the solutions for four months, thus leading to a COPQ of 7.18%. The potential solutions include the effective performance of the weaving preparatory process, analysis of material parameters and yarn unevenness testing, and improving the adequate weaving loom's atmospheric condition. Other recommendations include regular machine maintenance, installation of stretch control devices on warping machines and tension control device (tensiometer) on a sizing machine, proper weaving machine setting and providing technical skills to operators and quality control staff about weaving production and quality management techniques.

Keywords: Six Sigma; SS; Six Sigma methodology; SSM; DPMO; DMAIC; cost of poor quality; COPQ; yarn breakage minimisation; weaving loom; fabric weaving; apparel industry. (search for similar items in EconPapers)
Date: 2024
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