Department of Industrial Engineering

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Browsing Department of Industrial Engineering by Author "Adeel Ahmad"

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    Reduction in rejection rate of garment at master textile through implementation of six sigma
    (University of Management and Technology, 2014) Umar Farooq; Adeel Ahmad; Saad Ahmed; Iqbal Nisar
    Due to global competition it becomes impossible for an organization to earn profits without reducing the rejection rate of the manufactured products. Rejection rate of any product plays a very important role for customer satisfaction and financial conditions of any company. Rejection rate causes a direct effect on profit margin of a product and decreases the quality of a product. Therefore the companies are struggling to reduce their rejection rate during the process of manufacturing through different quality tools, checking and inspection during different operations and implementing changes and strict quality checks where more defects are produced. High rejection rate of garments due to different number of defects during sewing is the major problem faced by Master textile mills. This project is very important from industry point of view because high rejection rate is creating customer dissatisfaction and financial loss to organization. Reduction in rejection rate is the project in which it is successfully attempted to prompt-out root causes along with a number of factors by adopting Six Sigma methodology. It was decided to implement DMAIC methodology in sewing department where high rejection rate stitched garment was recorded. This research presents a comprehensive study which focuses on the implementation of Six Sigma. The main aim of this study is to introduce DMAIC process of Six Sigma. The problem was identified practically in garments manufacturing industry in research. It was then measured to identify the extent of the problem so that it can be eliminated or reduced. Potential causes of problem was identified in the analyze phase. Finally, a pilot production run was made in order to make sure that the improvements being made does actually work and in control phase the work being doni previous phases properly implemented and sustained for providing the desired results. The statistical work for the project was done using Microsoft Excel 2010 and Smart Draw .After that an optimum solution was suggested along with the areas of improvement which reduced rejection rate and provided a significant financial benefit.