Reducing Outgoing Quality Level (OQL) in Textile Manufacturing Through Six Sigma Methodology: A Case Study

Shuaib Kaka, Muttahira Maryam, Rano Khan Wassan, Umair Sarwar, Ali Akbar, Jansher Ansari

Article
2024 / Volume 7 / Pages 1252-1272
Received 29 May 2024; Accepted 19 July 2024; Published 8 August 2024
https://doi.org/10.31881/TLR.2024.133

Abstract
Globally, the textile industry plays a significant role in production but faces many challenges that affect its operation and sustainability. Product quality remains an essential concern despite technological advancements and quality control measures. Raw materials, production methods, and skills differ, resulting in customer dissatisfaction and damage to reputation. A quality management strategy is necessary to overcome these problems and promote quality improvement. This includes the implementation of the Lean Six Sigma approach. This article focuses on improving textile quality by developing the Six Sigma DMAIC method. An analysis of three months’ data from a textile company shows that an increase in the Outgoing Quality Level (OQL) from 3% to 6% resulted in significant economic losses, amounting to PKR-240,000 due to rework, residual costs, customer returns, and lost sales time. By utilizing Six Sigma tools, the company reduced OQL from 6% to 4%, thus lowering product losses and increasing operational efficiency. As a result of these findings, the textile industry can improve quality and profitability through a Lean Six Sigma approach.

Keywords
outgoing quality level, lean manufacturing, Six Sigma, DMAIC