Textile/ Fashion Houses/ Export Houses or Buying Houses have potential of applying Six Sigma in following improvement projects

• Improving first sample approval percentages while working with buyers


• Improving buyer satisfaction levels


• Increasing repeat business


• Improving supplier evaluation processes


• Improving AQL performance in shipments.


• Improving merchandiser performance


• Reducing non conformances in audits by buyers


• Reducing Business Risks


• Improving processes at the source (including fabric purchase and inspection, stitching, embroidery, packing and shipping) to reduce rejections at later stages.


• Eliminating manufacturing errors/ defects


• Reducing costs.


• Reducing delays.


• Reducing rejections in shipments.

thx sir! but how one could follow these steps described by you

Dear Anum, 

If you attend our Green Belt training, you shall learn about Six Sigma improvement approach which follows DMAIC (Define-Measure-Analyze-Inprove-Control) roadmap. Once you learn this approach, you shall know how each improvement area can be converted into project and how powerful techniques can make it happen in a structured and systematic manner. 

We also provide support during implementation after you complete the training. 

Regards,

VK 

 

Dr.P.L.Narasimhan

Textile Industry has a great potential for applying Six Sigma. Unknown problems, chronic defect areas etc can be identified and real improvement can be made. Advisable to take one area for study and implement.

One more area of significance is the area of power saving which is critical to Textile Industry.

Textile Industry includes spinning where a lot of saving could be achieved in material.

 

narasimhan

Dear sir,

well taken your point, but the thing is how all the above parameter can be achieved through the application of Lean Six Sigma concept.

the other vital point is what is the methodology for applying these concepts.

Thanks and Regards

S.Vivek Anand

Dear Anum,

Your query is fair but it needs a detail study of lean and its right application through our process to get tangible benefits. Mr. VK is explaining clearly and we need to do project for each area of improvement and find its rootcause and then remedial control action to improve further. during my lean projects we find very interesting facts during waste walk in our organization. We made a waste walk to our transportation area, Canteen area and so other.. in this we find lot of Laconas which is under carpet not easily traced out. Normally, in any Organization effective utilisation of Man, Machine and Materials are not upto the mark and it needs further fine tuning identifying through study and then finding feasible solutions. I hope VK will agree with me.

Regards

Hrudananda

Another area which I would suggest is procurement and stores handling which includes Raw material, Spares and finished goods.

However we can also look into areas of optimisation of working capital and generating synergy

 

sir, iam working in gokaldas exports ltd, and iam kaizen promotion officer manager, and i have finished my yellow belt, and i applied in facctories, and it is very effective to know the defects and how is checkers gives different opinion on diff cycle, so i need your help how to solve this problem, because all my checkers are not so educated, need your advise how to go about it.

 

regs

sasikumar

Dear Mr.Viswadeep Khatri,

I was completed my GB @ chennai on the date of 22ND april. It was given lot of oppotunities to find & solve the problems in our manufacturing organisation.

We have different type of mfg organisation. like petro chemicals, cellular systems and textile yarn manufacturing, fabric, etc…

We had all the sources for all but we don't have a propper systems for create a bransd name in outside. Now we have realized to establish our product through with the brand name.so we are planned to implement lot of systems through proper explorer. like ISO,5s,6Sigma, etc…

Above all is overview of present situation…

Last week i had prepared and submitted my observation for focusing the improvements, key area to develop, how can we make them proper.

etc….. ( lot many focusses involved but not mentioned here all..)

Just i told you that, i have taken a small project(short term) for improving the productivity through applying the concept of DMADV methodology of six sigma. It was announced by our management for evaluation of myself for how i will propose and follow to keep the results better after i attended the GB?

Problem : Frequent Breakdown in new production oriented machine during achieving the targetted oee.

Targeted prod/day : 620 kgs

targetted cost / day : 2926 us$

achievable production : 411 kgs /day

acheived cost : 1927 us$

After i covered all the date and i had prepared a team for study and approach the problem through propper suggested way.

and i make a checklists, take a photograph for graphical view and represent the before & after solutions, etc….

lot of data, we had and covered all the area like operator malfuctions, rawmaterial capability,process particulars,mechanical elements & conditions through lab analysis. etc,..

After we find a problem and make a solutions with our tean and exposed to our management for how to process, lead time, etc…

They approved and implement the new design concept.We were implemented the same after the problem was eliminated and productivity was improved, profit also improved. the data below….

Targeted prod/day : 620 kgs

targetted cost / day : 2926 us$

Before:

achievable production : 411 kgs /day

acheived cost : 1927 us$

after:

achievable production : 598 kgs /day

acheived cost : 2803 us$

productivity improved by 188 kgs /day and the gain is improved by 880us$

I was submitted my last report to our management with How It IS possible and consistency level. why,we have not done before and what we had done after? and lot many parameters.

Now they judged me as a result oriented person with structured approach to solve the problems.

I am happily to anounced to u, They incrementd 180 US $of my salary for approach the problem in systematic way and provide the solution on time.I salutation to six sigma.

(I have briefly explained the problems, if u want detailed report. sure i will submit)

Once again i Thank to SIX sigma.This is one of the milestone of my career achievements.

Regards,

J.Kosalram.

Note: our mgmt has send the detailed information to SWISS machine manufacturers for upgraded the existing all machines with free of cost.

VK SIR - After completing the certification of Lean Sigma... What is the exposure and how are we going to be placed outside as Lean trainer or consultant or Employed by a company???

Dear Naresh

About your query, allow me to clarify that while Lean and Six Sigma courses can help you excel in your current job or leverage them for a new job in similar/different industry, these courses are not pursued with an intention of 'getting' a job. The true beauty and potential of Six Sigma and lean models lie in their application. Secondly, it takes years of experience and expertise to work as a Six Sigma trainer or consultant.

What I can suggest you is to pursue a Six Sigma Green Belt and then utilize the learning in your current work domain. Using methodologies of Six Sigma and Lean you can bring breakthrough improvements in your organisation and thus strengthen your career achievements.

If you want to know more, please read the following:

http://forum.benchmarksixsigma.com/topic/702-what-is-six-sigma/

You may also seek more information at 1800 102 3003 (toll free)

Warm regards

AbhishekM

Dear kosalram jayabalan ,

sir my self amit ojha im also a textile engg. and six sigma black belt im very interested in ur project as u describe ur production was very low as per ur data how u improve u apply only lean or sixsigma bcoz as per Lean management theory for increase speed or reduce wast we use it

and for decrease varation and reduce defect we use six sigma

im interested to know how u balance these two method

if possible mail ur project to me it will help full for increase my knowledge

mail id is [email protected]

thanks in advance

regards

amit ojha

basic view of six sigma in textile industry.. as given in Indian Textile Journal..

 

http://www.indiantextilejournal.com/articles/FAdetails.asp?id=2896