lean six sigma black belt project by iftakhar

Lean Six Sigma Million Dollar Money Belt

Project Undertaken By

Md.Iftakhar Islam

Trainer

Mr. Prabhas Surana

FACTORY HISTORY

• Established : 2005

• Number of Employee : 3500

• Total Land Area : 2.9 acres

• Factory Floor Space : 2,10,000 sft

• Geographical Location : Latitude -23.984335

Longitude-90.382762

COMPOSITE MANUFACTURING CAPACITY

• Capacity /day

Own printing unit at Narayangonj

MAIN BUYERS

EXPERTISE IN PRODUCT LINES

• Text

• T-Shirt / Tank Tops

• Polo Shirt

• Shorts / Trousers

• Sweat Shirt /Jackets

• Any Kinds of Infant

Garments

• All Kind of Knit

Garments

Define – Present Pain Areas

Short Term

Long Term

- Reduce defects ,delays and deviations .- Use data to focus on improvement efforts .- Evaluate and realign the work flow into production .- Ensure measuring tools accuracy .- CAP implementation in each production process to

introduce the zero defect concept .- Improve machine & its operators performance .

- Ensure Kanban for RFT manufacturing .- Reduce process constraints & errors .- Improve suppliers delivery lead time .- Reduction in export lead time - Increase cut to ship ratio.- Recognize , review and refocus efforts .- Stabilize and sustain the improvements .

Define Phase – Project Charter

Business Case

TEXEUROP (BD ) LTD impacted by huge

loss from 1st January 2015 to 30 June

2015 , USD $ 18,00000 accounted for 10%

defect which was higher than desired and

resulted a big challenge by delivering

defective product to retail stores in Europe

& USA .Where the sigma level counted 2.7

& Saving Target USD 200,400/-

Opportunity Statement

TEXEUROP (BD ) LTD started its

quality improvement journey with TUV

SUD , South Asia on April 2015 . TUV

SUD ‘s coach is providing guidance &

training to improve production process

by statistical tools & lean techniques. .

We confidence in to accomplish our

goal by 31st Dec.2015 .

Goal Statement

( By 31st December 2015 )

- Attain sigma level -3.000

DPMO - 66,800

Yield % - 93.32

Savings Target - USD 200,400

- 90 % reduction in Lead time .

- 90% reduction in all inventories .

- 100% increase in productivity.

- 50% reduction in process errors

Project Scope

The project scope covers all production

process of TEXEUROP ( BD ) LTD , its

products performance ,process input –

out put , suppliers , brands , retail

stores & all other stake holders .

Define Phase – Project Time Line

Team

Selection

Activity Sep 2015 Oct 2015 Nov’2015 Dec’2015

Form Team 02.09.15

Finalize Charter 03.09.15

Training 06.09.15 To be

continued

To be continued To be

continued

Gather Data 15.09.15 To be

continued


continued

Analyze Data 30.09.15 To be

continued


continued

Select Solutions 22.10.15

Develop Implementation

Plan

25.10.15

Monitor Results 28.10.15 To be continued To be

continued

Closure and Recognition 31.12.15

Team Members

S.No Name of the

Team Member

Functional

Role

Project

Responsibility

1 Engr. Zulfiker Ahmed Team Member Project Sponsor

2 Md.Iftakhar Islam Project Leader Project Leader

3 Mr. Minhaj Rahman Team Member Production Process

Improvement

4 Mr. Hasib Team Member Data Analysis & Project

Planning

5 Mr. Tapan Team Member Product Quality

Improvement

Targeted Benefits

- Attain sigma level -3.000

DPMO - 66,800

Yield % - 93.32

Cost Reduction -

- 90 % reduction in Lead time .

- 90% reduction in all inventories .

- 100% increase in productivity.

- 50% reduction in process errors

- 5% defect reduce at finished product stage

Establish Performance Parameters

1. Pilot Line efficiency baseline is 39.% ( As per August 2015 ) & will

improve by 20% points by 31st December 2015 .

2. Pilot Line sewing cost produced baseline per person in 10 hours is 765

taka ( as per August ) & will improve by 20 % by 31st December 2015 .

3. Pilot line Productivity baseline per person is 37.9 pcs ( as per August )

& will improve by 15 % by 31st December 2015.

4. Factory cut to ship ratio baseline is 93.67 ( as per June , July , Aug

2015 ) and will improve 1% by 31st December 2015 .

5. Up Skilling 10 Number of workers in sewing lines .

6. Improve method at least 07.

7. Convert 06 numbers of operators as zero defect operators .

8. Root cause of skip stitch , broken stitch , Oil , Stain needs to be found

out and actions should be taken .

Process Mapping ( Macro Process )

Dyed Fabrics as

Input

Dyed Fabrics Quality Check

process

Fabrics Cutting process

Sewing Process

Finished Garments Fabrics as

Output

Finishing Process

Process Mapping ( Micro Process )

Dyed Fabrics Quality Check process

Fabrics

Receive from

Dyeing

GSM Check

Check the

dimensional

stability

10% Fabrics

Roll Inspection

per Lot Based

on 4 Point

System .

Check the

Shrinkage of

Fabrics

Fabrics Ready

For delivery

to Cutting .


Fabrics Cutting Check process Fabrics from

warehouse

CAD Program for Bulk cutting

Lay Spreading

Cutting

Number Sticker Attachment /Numbering

Bundling

Cut parts ready for

Input


Sewing Process

Cut panel Receive from cutting section

10% Cut Panel Check From Each Bundle

Stitch Monitoring

Hourly In Line processes Inspection

Sewing End Line 100 % Inspection

Garments are ready to deliver for finishing


Finishing process

Receive sewing Garments

Pressing As Per Finished Pattern

After Pressing Quality Check

Hourly Audit of Finishing

Metal Detection With Conveyer belt

Assortment & Carton the packs

Day Audit

Pre - Final Inspection

Garments are ready for Final Inspection as per buyers standard

Folding & Poly

Measurement System Analysis for

Laboratory Measuring Equipment's

ISO 105 C10:2006

ISO 105 C06:2008

Crock Meter

ISO 105X -12:2001(E)

Color Fastness to Wash Color Fastness to Rubbing

Wash Fastness Testing M/c

Spectrophotometer –SF600 X

AATCC 173 -2009 ( Revised )

Electronically Shade Check

ICI Pilling Box

ISO 12945-1:2000

Color Fastness to ICI Pilling

Measurement System Analysis for

Laboratory Measuring Equipment's

Perspiration Test Incubator

ISO 105E 04:2008

Pneubrust

ISO 13938-2:1999

Color Fastness to Perspiration Bursting strength

Xenon Arc Light Fastness Tester

ISO 105B 02:2000

Test – Color Fastness to Light Dimensional Stability

Washcator

ISO 6330:2008 Amd 1:2008

ISO 3759:2007

ISO5077:2007

Calibration Certification forMeasuring devices From Accredited Laboratory

Calibration Schedule of Factory

SL.No Description Certificate No Issue dateDate of

Calibration

Suggested

Due Date

1 Color Assesment Cabinet(Light Box) 015/(26-07)/6369 29-Jul -15 27-Jul -15 27-Jul -16

2 Fus ing Machine 015/(26-07)/6399 29-Jul -15 27-Jul -15 27-Jul -16

3 Metal Detector Machine 015/(26-07)/6398 29-Jul -15 27-Jul -15 27-Jul -16

4 Digi ta l Lux Meter 015/(26-07)/6401 29-Jul -15 27-Jul -15 27-Jul -16

5 Heat Seal Machine 015/(26-07)/6400 29-Jul -15 27-Jul -15 27-Jul -16


7 Color Assesment Cabinet(Light Box) 015/(26-07)/6369 29-Jul -15 27-Jul -15 27-Jul -16

8 Heat Seal Machine 015/(26-07)6400 29-Jul -15 27-Jul -15 27-Jul -16

9 Fus ing Machine 015/(26-07)/6399 29-Jul -15 27-Jul -15 27-Jul -16


11 Digi ta l Lux Meter 015/(26-07)/6401 29-Jul -15 27-Jul -15 27-Jul -16


13 Electronic Balance 015/(11-08)/6558 16-Aug-15 11-Aug-15 11-Aug-16

14 Hand Driven Crock Meter 015/(11-08)/6557 16-Aug-15 11-Aug-15 11-Aug-16

15 Incubator 015/(11-08)/6559 16-Aug-15 11-Aug-15 11-Aug-16

16 ICI Pi l l ing Tester (Orbitor) 0158/(11-08)/6556 16-Aug-15 11-Aug-15 11-Aug-16

17 Wascator 015/(11-08)/6560 16-Aug-15 11-Aug-15 11-Aug-16

18 Tumble Dryer 015/(11-08)/6561 16-Aug-15 11-Aug-15 11-Aug-16

19 Gyrowash 015/(11-08)/6552 16-Aug-15 11-Aug-15 11-Aug-16

20 Washing Machine 015/(11-08)/6563 16-Aug-15 11-Aug-15 11-Aug-16

21 Steel Sca le 015/(16-08)/6609 18-Aug-15 16-Aug-15 16-Aug-16

22 Button Pul l Tester 015/(21-09)/6971 21-Sep-15 20-Sep-15 21-Sep-16

Tex eu ro p (B D) L tdVogra,Joydevpur,Gazipur

Calibration Schedule

Data Collection Check Sheets

Skipped

Stitch

Broken

Stitch Oil Dirt

Print

Defect

Embroide

ry Defect

Fabric

Defect

/Sewing

Reject

Dyeing

Defect

Measerm

ent

Problem

Stitching

Defect (

open

seam ,

uncut

thread

Neck Shape

defect

Wavy (

Zipper

,Bottom

etc )

Insecure

Label

/Button/E

yelet Etc

Twisting Shape

Problem

Placemen

t

Up-down(

Back-

Front ,

Sleeve)

Pressing

Defect Insect

1-Sep jok/8166/011 184 95 157 95 127 142 18 33 3 8 23 21 906 11059 700 10359 8.19 6.33

2-Sep jok/553/011 194 170 167 176 239 148 25 30 5 20 23 1197 11014 995 10019 10.87 9.03

3-Sep jok/66/95/16 116 175 98 180 14 230 150 29 35 8 26 25 1086 11626 996 10630 9.34 8.57

4-Sep

5-Sep 110/66/jok/16 180 158 98 155 125 123 14 31 5 19 24 932 9699 915 8784 9.61 9.43

6-Sep 66/63/jok/17 175 115 75 150 124 137 15 28 21 25 865 10671 836 9835 8.11 7.83

7-Sep 63/66/jok 166 151 72 149 119 234 11 27 17 18 964 10224 932 9292 9.43 9.12

8-Sep 8166/110 193 177 166 174 138 145 23 32 8 21 24 1101 11205 1009 10196 9.83 9.00

9-Sep 8166/200 192 175 179 261 124 139 17 35 12 28 23 1185 10625 1095 9530 11.15 10.31

10-Sep 201/8166 160 115 152 149 119 134 12 27 17 18 903 8164 835 7329 11.06 10.23

11-Sep

12-Sep 66/63/746 174 175 170 80 130 150 29 35 8 26 24 1001 11662 936 10726 8.58 8.03

13-Sep 63/73 180 155 159 51 125 238 15 28 21 25 997 8409 700 7709 11.86 8.32

14-Sep 8166/89/90 156 145 148 44 95 129 9 26 16 17 785 6424 639 5785 12.22 9.95

15-Sep 746/8166 144 128 124 13 65 118 15 10 11 13 641 4677 555 4122 13.71 11.87

16-Sep 453/690 184 168 157 56 68 145 18 33 10 25 23 887 10706 778 9928 8.29 7.27

17-Sep 8166/140 180 170 155 56 125 142 18 33 8 25 20 932 9738 923 8815 9.57 9.48

18-Sep

19-Sep 8166/571 185 168 158 56 128 139 20 33 10 23 22 942 10449 936 9513 9.02 8.96

20-Sep 66/6423/775 181 159 161 56 98 138 15 32 5 22 20 887 9997 846 9151 8.87 8.46

21-Sep 8166/6423/401 191 172 175 58 124 120 17 35 12 27 22 953 10280 884 9396 9.27 8.60

22-Sep 23/01/66/63 113 196 188 92 129 149 28 39 11 27 26 998 8911 918 7993 11.20 10.30

23-Sep

24-Sep

25-Sep

26-Sep

27-Sep

28-Sep

29-Sep

30-Sep

3248 2967 2759 2051 14 2432 2820 348 582 3 110 415 413

1.75 1.60 1.49 1.11 0.01 1.31 1.52 0.19 0.31 0.00 0.06 0.22 0.228.85%

D.H.U.

Total:18162 185540 16428 169112 9.79

TEXEUROP (BD) LTD Unit-3Finishing Inspection Sheet

Date Style No.

Defects

Total

Defects

Total No. of

Pieces

Inspected

Total No. of

Defective

Pieces

Total No.

of Pieces

Pass

DHU Percentage of

Defective

Month: September-15

Pareto Analysis on Major Defects

Major Defects

6. Dirt

7. Insecure Label

8. Up & down 2. Broken Stitch

1. Skipped Stitch

3. Stitching Defect

5. Measurement Problem

4. Oil

Others : Unexpected dot mark , Print Bleed , Broken Print ,Design Displaced , Tension Tight , Irregular Stitch , Stitch Wavy , Puckering , Label Slanted, Yarn Shading .

Stitching Defect : open Seam , Raw Edge , Uneven Stitch Margin , Uneven Top Stitch , Twisting , Pleated Form , Poor Neck Shape , Destroyed Side Seam , Measurement Discrepancy , Excess thread , Drop Stitch , Needle Cut .

9. Others

Process Base Line Sigma Level

Define Performance Goals

1. Increase sewing line efficiency

2. Increase productivity

3. Introduce Zero defect Operators

4. Up Skilling the sewing Operators

5. Improve the cut to ship ratio

6. Reduce the defect level in process

7. Consistent MSA

8. Improve the sigma level .

9. Reduction in process errors

Process Improvement Target

1. Identify supply chain constrains

2. Identify supplier performance

3. Improve Fabrics inspection process

4. Assure proper fabric relaxation process .

5. Garments sewing In Line inspection

6. Avoid measurement discrepancy .

7. Continuous improvement in supply chain

8. Regular customer survey

Cause & Effect Diagram

much Higher

& Defect

Sewing Alter

Working Condition

Measurements

Methods

Material

Machines

Men

Bundle Mistake

Poor Trimming

Creased CAD Marker

Improper Check

Munsell test

Record Tracking

Handling

Blunt Needle

Adjustment

Dyeing Problem

Knitting Problem

Wrong Thread Flow

Spring Tension

Curled edge

Cleanliness

Maintence

Amount

Washing chemical

Print Density

Excess pilling

No needle change schedule

No defect Standard

Improper fabric Relaxation

Yarn lot are not same

Non Calibrated measurment tape

No before & after wash Comparision

Dorito stitch failed

No GSM test before wash

Dust Accumulation

Poor House Keeping

High Defect Diagram

Why Why Analysis ( Broken Stitch )

5 S & Workplace Findings

Sl. No. Unit / Location Findings Major Findings / Evidence Corrective Action Plan Responsible Person Due Date Follow up date

1 Cutting-1

Sharp tool as Safety Hazards

( Equipment is not kept

safely)

2 Cutting-1Unneeded Materials Blocked

Aisles

3

Cutting-2

(Naim-

160571)

Cutting work continude

without Gloves /PPE,

It’s a great cause of Safety

hazards

Date: 06.10.2015

TEXEUROP (B D) L TD 5 S & workplace Audit Findings

7 Waste Audit Findings in Facility

-

Transportation Inventory Motion Waiting

Over Processing Over Production Defect ( Oil Spot )

Measurement System Analysis Checked by Customer

Preventive Action by Factory

To reduce the measurement discrepancy factory

introduced Calibrated measuring tapes for 06 ( six )

months .Recheck process shall be in 3 month interval

for the issued measuring tapes .

Major Findings

Customer Checked MSA in production Floor & found

unacceptable range of deficiency for measuring tapes

of Quality Department.

•

Vital Few X’s Chosen for Improvement

Y( Dependable Variable )

X( Independent Variable )

Fabrics Defect Reduction( Hole , needle mark , Sinker mark )Measurement Accuracy

100% fabrics check &proper relaxation

No of Defect in Sewing end Line TLS in Sewing Line , OperatingProcess monitoring , Training

Time to fulfill a Job Requisition Accurate job profile , interviewing of process operators

Time to fulfill an order Type of Garment , Supplier , Value of garments , Location , time of day when order is received .

Improvement Action Plan

Texeurop (BD) LtdIdentification of Expectation From Supplier Department

Coustomer Supplier Expectation and Improvement

Merchandising Dept

Sample Dept Reduce Sample remake issue.

Planning DeptReduce of changing plan per month.

Revised plan will issue on time.

Planning Dept Merchandising DeptComplete file will given by Merchandiser in one pakage.

Attend Weekly meeting in regular basis.

Cutting Dept

Cad DeptMarker for Sizeset within 3 hours.

Hard copy of Marker- provide along with Sizeset marker.

Planning DeptComplete file need for cutting ( Booking sheet,Mini Marker,Measurement Sheet, Update comments, Trim card).

Store Dept

Woven Fabric,Interling most of the case quantity are not right according to challan.In the time of issue both will ensure quantity.

Sticker bleed with this issue Mr.Nasim & Mr.Mamun will help

Sewing Dept

Cutting Dept Colorwise & sizewise input close, bellow 5000 pcs qty input close at a time

Store Dept Trims will issue in one time

QA Dept Strenthen Sewing inline process quality.

QA Dept Trafic light system implement within this month.

Maintenance Dept (sewing)

Folder issue- line are waiting for folder.

In Pre-production meeting Maintenance manager will present.

Machine servicing- how many days after 1 machine will service. Every 40 days

Machine Oil change- how long.depends on oil quality

Improve Process Mapping ( Macro Process )

Dyed Fabrics as

Input

Dyed Fabrics Quality Check

process

Fabrics Cutting process

Sewing Process

Finished Garments Fabrics as

Output

Finishing Process

No Change In Macro Process

Improve Process Mapping ( Micro Process )

Dyed Fabrics Quality Check process

Fabrics

Receive from

Dyeing

GSM Check

Check the

dimensional

stability

100% Fabrics

Roll Inspection

per Lot Based

on 4 Point

System .

Check the

Shrinkage of

Fabrics

Fabrics Ready

For delivery

to Cutting .

Process Changed Factory is checking 100% Fabrics Roll instead of 10% roll ( 4 Point System )


Fabrics Cutting Check process

Fabrics from

warehouse

CAD Program for Bulk cutting

Lay Spreading

Cutting

Number Sticker Attachment /Numbering

Bundling

Cut parts ready for

Input

Fabrics Proper Relaxation as per Fabrics New Process Added Ensure 100 % Fabrics Proper Relaxation as per fabrics


Sewing process Cut panel Receive from

cutting section

10% Cut Panel Check From Each Bundle

Stitch Monitoring

Hourly In Line processes Inspection

Sewing End Line 100 % Inspection

Garments are ready to deliver for finishing

Traffic Light System Inspection ( 5 Pcs )

Audit 20% Quality Pass Garments

New Process Added 1. Traffic Light System

( Check 5 Pcs ) 2. Audit 20 % QC pass

Garments .


Finishing process

Receive sewing Garments

Pressing As Per Finished Pattern

After Pressing Quality Check

Hourly Audit of Finishing

Metal Detection With Conveyer belt

Assortment & Carton the packs

Day Audit

Pre - Final Inspection

Garments are ready for Final Inspection as per buyers standard

Folding & Poly

No Change In Finishing Process

Verify Process

Improvement

New Sigma Level

New Process Performance Result

New Sigma Level 2.98 from 2.77 and total saving USD 2,00,090/-

( Saving came in Sep to December 2015 )

1. Pilot Line efficiency improved from baseline 39.% to 52% by 31st

December 2015 .

2. Pilot Line sewing cost produced as 865 taka from baseline per person

in 10 hours is 765 taka ( as per August by 31st December 2015 .

3. Pilot line Productivity finally reached 56 from baseline per person is

37.9 by 31st December 2015.

4. Factory cut to ship ratio increased .5% from baseline is 93.67

5. 10 Number of workers unskilled in sewing lines .

6. 05 Sewing method improved instead of 07.

7. 06 numbers of operators made as zero defect operators .

8. Root cause conducted on skip stitch , broken stitch , Oil , Stain needs

to be found out and actions should be taken .

Improvement Done in SOP’s /WI’s / Control Plan etc.

1.Dyeing Fabric quality SOP added new process to check the

100% fabrics roll check in 4 point system .

2. Fabrics Proper relaxation procedure added in Fabrics Cutting

SOP .

3. Traffic Light System & 20% sewing garments audit procedure

added with sewing SOP.

4.Work Instruction issued for the calibration of measuring tapes

internally .

5. Tools Added : (a) Why why Analysis , ( b) CED , ( C) Daily

Parito analysis for defect level , (d) 5 S Implementation &

audit , (e ) Waste Identification in process .

lean six sigma black belt project by iftakhar

Engineering