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Project Report for Certification of
Lean Six Sigma Black Belt
of
Roshan Sujeewa Weeratunga
Project Name: Improve the Quality of Bulk Production.
Project Leader: Roshan Weeratunga
Project Champion: Managing Director of Supertex Group
Date : 7th of March, 2015
Special Thanking for Guru
Mr. Prabhas Surana
Consultant Master Belt of
Define Phase Research Case: We have got new product category from new France Buyer
under the product category of work wear which is belong to France automobile company named Renault. This product with new fabrication and designed which is not familiar with the production floor.
During the production period we have got high percentage of visual sewing defects with less production which we expected.
The management expectation is to increase 200% of order placement for next season due to this customer is very important for the our round the year business.
Problem Statement:
The production line having highest percentages of Visual defects on past months.
Goal Statement :
To reduce the 70 % visual sewing defects.
Expected Result – Business case:
A) Relevant Metrics.
1. To Reduce the Rework Cost.
2. To Increase the Productivity.
3. To Increase the Efficiency.
B) Improvement Target.
60% of Reduce the Rework Cost.
C) Hard Benefits.
1. Reduce the Defects per month around 2500 pcs in
Production Line.
2. Reduce the Rework Cost around US$ 3125.00 in a line at a month.
D) Soft Benefits.
1. Improve the Customer Satisfaction.
2. Improve the Company reputation.
3. Increase the skill of company manufacturing
Product range.
Roles and Team Membership. 1.Project Champion / Sponsor: MD of Supertex Group
Will Approved the Cost of manpower for this Project.
2. Project Team Leader / Black Belt : General Manager
Will Drive the project as per the Classification of Six Sigma
With the help of his team and given the solution to top
Management with the result of achieved.
3. Project Team Members / Green Belt:
Production Line Qc’s , Line Supervisors and mechanic will
Be the project team members and they will follow the
Instructions of team leader as per the project needs.
High Level of Process Map ( SIPOC)
Supplier Inputs Process Out Put Customer
Supertex Group.
# Fabric. # Machinery. # Threads. # Needles. # Sewing Trims. # Packing Trims.
# Cutting. # Fabric Parts. # Stitching. # Trimming. # Checking. # Washing. # Trimming. # Checking. # Pressing. # Packing. # Auditing.
Stitched and Packed Work wear Garment.
Betran Court At France
Project Plan.
Date /
Event
Oct-
01
Oct-
02-10
Oct-
11-20
Oct-
21-31
Nov-
01-10
Nov-
11-20
Nov-
21-30
Dec-
01-10
Dec-
11-20
Dec-
21-31
Jan
01-20
Define X
Measure X X X X
Analyze X
Improve X X X X
Control X X X X
Measure Phase Data Collection Period
Characteristic Data Type How Measured and Who
Sampling Notes
Period
Rejection % of
at sewing line
End table
Attribute Visual
Checking by
QC,
Comparing
with
approved
Sample.
100% of
Finished
Garments
From 01st of
October to
December,
2014
Visual Defects Data Table For Measure Phase.
Type Of Defects
No Defects Id
Defects Type Occurrence % of Occurrence
1 A Uneven Width of Seams 251 10.04%
2 B Skip Stitches 375 15.00%
3 C Waist Band Uneven Width 1125 45.00%
4 D Broken Stitches 201 8.04%
5 E Side Seam Length Uneven 182 7.28%
6 F Side Pocket Hi-Low 105 4.20%
7 G Wrong Button Placements 85 3.40%
8 H Open Seams 59 2.36%
9 I Damage Button Holes 45 1.80%
10 J Raw Edges 40 1.60%
11 K Others 32 1.28%
Total 2500 100
Re-arrange the Data In the Descending Order
Defects ID C B A D E F G K H I J Total
No of
defective
1125 375 251 201 182 105 85 59 45 40 32 2500
Defect % 45 15 10.04 8.04 7.28 4.20 3.40 2.36 1.80 1.60 1.28 100
Cumulated
Defect %
45 60 70.04 78.08 85.36 89.56 92.96 95.32 97.12 98.72 100
Validated the Data Measurement System
The Data has collected by the Line Quality Controller and those data has validated and conformed by the Quality Assurance Manager.
Major Defects Identified from Pareto Chart
SL No Defects ID Code Defects Types
1 C Waist Band Uneven Width
2 B Skip Stitches
3 A Uneven Width Seam
4 D Broken Stitches
Measure Base Line Performance Calculation of DPMO. ( Defects Per Million Operations)
Total Checked Garments : 30162 pcs.
No of Defects Founds : 2500 Pcs
% of Defects : 2500/30162 x 100 = 8.29%
Current
DPMO = 82885.75
Z Value of DPMO( Sigma Level) = 2.9
Defect % = 8.29%
Measure Process Capability at Measure Phase
No of Data ( n) = 30
Z Value ( Sigma Level) = 2.9
Pp. ( Long Term Process Capability ) = Z value = 2.9 = 0.96
3 3
(Target Should Be -1.33)
Cp.( Short Term Process Capability) = Z value + 1.5 = 2.9 +1.5 = 1.46
3 3
(Target Should Be - 2.0)
U - Chart at Measure Phase
Analyze Phase Brain Storming During the Team Brain Storming meeting with following s in Production Line,
1. Sample room Technician.2. Line Quality Controller. 3. Line Chief .
4. Line Supervisor. 5. Line Mechanic.6. Sewing Operators
Following conclusion has taken to improve the Quality and production of this production Line.
1. To have training section for all critical operations by Line Chief or
Technician.
2. All work instruction should be written in Local Language in working
Patens in production floor by sample Room.
3. All critical Operations Must have QC approved mock- up to follow
The quality standard of Operation during the production by
Machine operator.
4. Machine during the Line setting, Need to minimum 05 pcs of sample
as per the particular operation and need to get the conformation
form conformation from Line Chief / QC to released the machine for
Bulk Production.
5. QC / Line Chief need to give overall demonstration to all operators that
how to handle the fabric if fabrication is new and difficult to handle .
Course and Effect Diagram
Summery of Couse and Main Factor
S.R.
No.
Cause Main factor Sub Factor Sub – Sub
Factor
01. In Sufficient Training to
Operator that, how to use
waist band shape Patten
when stitching.
Man
Training
-
02. Supervisor Unable to read
the how to use Patten
instructions written on the
Patten.
Man
Language
-
03. Not fixed correct type of
Gauge to machine which is
operator can easily guild
the out line when stitching.
Machine
Tool
-
04. Not Available of Correct
Quality Guide Line
( Mock Up) to verify after
stitching by Operator.
Method
Quality Tool
-
05. Fabric Softness Material
-
Awareness of
fabric
Thickness.
-
Improve Phase Remedial Action Plan for Defects of Waist Band Width
Uneven Stitching
S.L.
No.
Course Action Responsible By
01. In Sufficient of Training to
Operators before start the
Production
Operator must under go the short
Training period of particular operation
before start the bulk production
Line Chief and Line
Quality Controller
02. Supervisor Unable to read the
how to use Patten instructions
written on the Patten.
All Patten work instructions must be
written on the Patten by Local Language.
Sample Room
Technician and
need to verify by the
Line QC and Line
chief.
03. Not fixed correct type of
Gauge to machine which is
operator can easily guild the
out line when stitching
Line mechanic need to stitch 05 pcs
sample pcs of particular operation and
need to get the conformation /Approval
form Line Chief and Line QC before
machine hand over to operator.
Line mechanic/ Line
Chief / Line
supervisor
04. Not Available of Correct
Quality Guide Line
( Mock Up) to verify after
stitching by Operator.
Line QC need to make sure that , every
critical operations has to be with Mock Up
which is stitch by particular operator and
signed by Line QC before start the
stitching of bulk Production.
Line QC / Operator
05. Fabric Softness
It is Line Chief or Line QC is responsible
to make understand to operator need
any additional care during the stitching if
need.
Line Chief and Line
QC
Data Collection after Remedial Action's has Taken.
Improve Base Line Performance Calculation of DPMO. ( Defects Per Million Operations)
Total Checked Garments : 20389 pcs.
No of Defects Founds : 240 Pcs
% of Defects : 240/20389 x 100 = 1.18%
Current
DPMO = 11771.05
Z Value of DPMO( Sigma Level) = 3.75
Defect % = 1.18%
Measure Process Capability after Remedial Action are
Taken at Improve Phase No of Data = 25
Z Value ( Sigma Level ) = 3.75
Pp. ( Long Term Process Capability ) = Z value = 3.75 = 1.25
3 3
( Target Should Be - 1.33 )
Cp.( Short Term Process Capability) = Z value + 1.5 = 3.75 +1.5 = 1.75
3 3
( Target Should Be - 2.0 )
U - Chart
After Remedial Action has Taken
Project Result
Past ( At Measure phase) Improved ( At Improve Phase)
DPMO 82885.75 11771.05
Sigma Level 2.9 3.75
Defect % 8.29% 1.18%
Pp. 0.96 1.25 (Target should Be 1.33 )
Cp. 1.46 1.75 (Target should Be 2.0 )
U - Charts of Project Result Comparison
Up dated Process Map Supplier Inputs Process Process Up dated Out Put Customer
Supertex Group.
# Fabric. # Machinery. # Threads. # Needles. # Sewing Trims. # Packing Trims.
# Cutting. # Fabric Parts # Stitching. # Trimming. # Checking. # Washing. # Trimming. # Checking. # Pressing. # Packing. # Auditing.
Date : 21/02/2015
Revision - 001
1. All worked Instruction
Must be with local
language for the easy
understanding.
2. Need Training for
operators for all
Critical Operations,
Before Start the Bulk
Production.
3. Mechanic need to be
get the approval from
Line Chief
after setting the
machine ,before it
Released to the
Bulk production.
4. QC need to Approved
a Mock - Up for All
Critical operations as
An Quality Guide Line
for the Operator’s
During the Bulk
Production.
5. Need to Guide the
Operators, If fabric is
New for them.
Stitched and Packed Work Wear Garment.
Betran Court At France
Control Phase Data Collection During Control Phase
U - Chart to Monitoring Process
Training / SOP has Implemented
1. For All Critical Operations , Operators has to be trained by the Line Chief or
Technician.
( SOP # 04 ( Production Department ))
2. Mock – Up samples which is stitched by the operator has to be review and approved by
The Line Quality Controller before Start the bulk Production .
( SOP # 08 ( Quality Department ))
3. Line Mechanic need to be stitch minimum 05 Pcs of samples of each operation to make
sure that machine and all attachment in right condition to meet the buyer quality
Standard with easy to handling by Operator.
( SOP # 04 ( Maintained Department.))
4. All work Instructions which is given by the sample department to Production floor ,has
To be address on Local language for the easy understanding of work force.
( SOP # 05 ( Sample Department ))
5. Line Chief or Line QC is responsible to make understand that Fabric Quality and
Handling method to operator and need any additional care during the Stitching due
To behavior of fabric if needed.
( SOP # 09 ( Quality Department ))
Process Check List
Item
No
Event to be Checked Yes No N/A Comments /
Action Taken
Who When
01 Operator has Under go the Short
Training Period of Particular
Operation before start the Bulk
Production
02 All Production Patten's Work
Instruction written by Local
Language
03 Machine and all attachments has
Checked and conformed by Line
Chief before released to Production
Line.
04 Has Mock – Up’s available for all
Critical operations which is signed
and approved by Line QC.
05 Has Line chief / QC has
demonstrated about fabric quality
and how to handled those during the
sewing.
Monitoring Benefits
Hard Benefits.
1. Reduce the Defects per month around 2000 pcs in a
Production Line.
2. Reduce the Rework Cost around US$ 2500.00 from In a line
At a Month. So that annual re-work cost serving is
2500 x 12 = USD 30,000.00 Per Sewing Line /per annual.
D) Soft Benefits.
1. Has improved the customer satisfaction.
2. Has improved the company reputation.
3. Has increase the skill of the workers to manufacturing and
Handling of deferent product ranges with profitable
Manner.
Lessons Learned
1. The Operator Of Garment Industry Must be Given Training on a Continuous
Basis on the Issue of Quality.
2. The Management Focus Should be on Preventing defects Rather than
Correcting Defects.
3. The Visual Mock – Up of All Operations has to be available in all machines
Due to It is very Easy to understand to Operator that what she has to do
And what She / He has to achieved during the stitching process to achieve
The quality Standard of her operation same as end Product to meet the
Buyers Quality requirement.
4. The Management should give Incentives for High Quality Performance of the
Operators.
5. Need do continually do the Six Sigma projects to improve the process of
Production floor as much as possible.
Thanking You for Reading This Presentation.
