Reduction in defects rate using DMAIC approach- A Case Study

The paper is related to the thread manufacturing process. This work clearly identified the different problems occurring during manufacturing. In the last process (winding), DMAIC tool is applied. The reason for choosing this work is to provide a better analysis of different processes in thread manufacturing. This textile firm has large departments where the thread produced from the waste clothes, after passing through different processes. Thousands of defects opportunities create in the final package of thread. That’s why it is decided to do work and implement DMAIC methodology in winding departments where the final package of thread is to be made. Final package of thread is the end product and it is directly sent to the customers, any defect may lead to the customer’s complaints. With the help of DMAIC approach the defects has been reduced from 13012 to 513 and the sigma level of the industry has been increased from 3.8 to 5.03.