Lean Six Sigma in Personal Goods Industry
As per the industry classification benchmark, this industry sector includes the following subsectors –
Clothing & Accessories – Manufacturers and distributors of all types of clothing, jewellery, watches or textiles. Includes sportswear, sunglasses, eyeglass frames, leather clothing and goods, and processors of hides and skins.
Footwear – Manufacturers and distributors of shoes, boots, sandals, sneakers and other types of footwear.
Personal Products – Makers and distributors of cosmetics, toiletries and personal-care and hygiene products, including deodorants, soaps, toothpaste, perfumes, diapers, shampoos, razors and feminine-hygiene products. Includes makers of contraceptives other than oral contraceptives, which are classified under Pharmaceuticals.
Applications in Garments Industry
Garment industry has great potential for applying Six Sigma in projects having following improvement objectives.
1. Reducing rejections in shipments.
2. Improving first sample approval percentages while working with buyers
3. Improving buyer satisfaction levels
4. Increasing repeat business
5. Improving supplier evaluation processes
6. Improving AQL performance in shipments.
7. Improving merchandiser performance
8. Reducing non conformances in audits by buyers
9. Reducing Business Risks
10.Improving processes at the source (including fabric purchase and inspection, stitching, embroidery, packing and shipping) to reduce rejections at later stages.
11.Eliminating manufacturing errors/ defects
A global leader in undergarments manufacturing found that it had highest rejections coming from causes like heat transfer labels, stains and skip stitches. A DMAIC project led to reduction in rejections by more than 50% and millions of dollars in savings. Rejection levels were brought down from 3% to 1.5% within 4 months.
PU footwear rejection was resulting in INR 7.5 million losses per year. The critical defects were contamination, side bubbles, overlaps and marks. By use of statistical techniques, it was found that temperature control, mixing sequence and cleaning were found to be critical X’s at process level. DoE was carried out with temperature and mixing sequence combinations to generate the best possible combination that minimizes rejections. The project led to big competitive advantage for the footwear manufacturer.
Feedback from participants
Brilliant instruction, great venue, Six sigma has some very interesting concepts. Very good training, highly recommended for anyone wishing to do something worthwhile in the company.
-Glen George, Merchandiser, Imperial Readymade Garments.
Inspiring Minds & Facilitating Excellence!!!!
-Aravind Mariyapan, Head – Quality Assurance, Pratik Apparels Pvt. Ltd.
Six Sigma is not only a tool that can be applied in a process or company; it’s a tool which can be applied in everybody’s life.
-Ankit Kariwal, Management Personal, Aura Clothing Pvt. Ltd.
I have been a participant of a Green belt program in my earlier organizations. Reason for approaching Benchmark was just for certification. I don’t feel hesitated in accepting that after being through this training I realized that I didn’t know even 10% of what I learnt here. It’s just outstanding.
-Satish.B.Vishwakarma, Manager, Fine Jewellery.
A fabulous program which enhances the process management capabilities, cutting errors in industries.
-V. Vinod Kumar, Sr. Area Manager, Colgate Palmolive (I) Ltd.
The sessions were extremely interactive. Lots of brainstorming happened. Statistical analysis was made very simple with high-tech presentation with high precision of the highly competent trainer.
-Jay Prakash Kakade, Sr. Executive, Pantaloon Retail (I) Ltd.