Quality Excellence In

Textile Industry

Case Study
INDIA

About Client:
Client is the one of the leading manufacturers suppliers &
exporters in textile industry. The major products of client
For private circulation only. are polyester chips, yarn and greige fabric.
This document is the property of The client has also received triple ISO certification. The
Faber Infinite Consulting and must
not be copied or distributed in client serves customers in India as well as overseas with
hardcopy or electronic form products and services focused on textile.
without the prior written approval
of Faber Infinite Consulting.

© 2014 FICS Pvt Ltd.

All Rights Reserved.

1 Faber Infinite Consulting

 Analysis. Approach.
Project Implementation.

Analysis

Faber Infinite identified five significant opportunities:

• There was potential to improve first grade production

• Wastage percentage was high
Objectives • There was high variation in Continuous Polymer plant
process parameters
To increase the first grade • Pack Cleaning and Changing was not Standardized
production • Scope to improve Equipment reliability

To reduce second grade Approach

production
Project Initiation
To reduce wastage
• Studied the end to end process and worked out all
percentage
the possibilities which can affect the quality/thread
Best industry practice to breakages
be established • Formed project teams in each department with
responsible team leaders
• Detailed data collection and analysis of past two
years
• Training given to the team regarding quality
improvement tools and prepared road map for the
quality improvement project
• Initiated the quality improvement project via Six
Sigma methodology

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Project Implementation Results
Results Delivered
Delivered
Six Sigma Approach

Define: Waste reduction

Productivity by 0.99%
improved from
• Detailed project charter was prepared i.e. 30,000 kg/month of
2 compressors per shift to 3
• Analyzed the baseline and finalized the targets production
compressorswhich delivered
per shift
• Prepared SIPOC (suppliers, inputs, process, outputs, and savings of ₹ 3.2 Cr (INR 32
customers)
Measure:
Million)
Work content
annually
reduced by
40%
• Sample data collected of key process parameters First grade Quality
• All possible reasons for thread breakages analyzed through Total labor cost
production reduced
improved by by
fish bone analysis
50% monthly revenue
4.89%,
• Sigma Level, DPMO (Defects Per Million Opportunities)
calculation and Process mapping were completed growth by ₹ 1.4
Productivity Cr (INRby
improved 14
Analyze:
Million)
50%
• Process Capability analysis was conducted, analyzed the
value of Cp and Cpk Designed total
Reduction 10 work
in second grade
• Drilled down all the possible factors to vital few by Pareto station layout
analysis
production byas per
1.65%,
• Identified parameters with high correlation to Quality by ergonomic design
monthly revenue growth ₹
scatter plot and Multiple regression analysis 41.4 lacs (INR 4.4 Million)
• Established major reasons / causes of thread breakages in Sustenance
spinning by Pareto and Why-Why Analysis
Improve: Improved the Sigma level
from 3.25 to 4.80 results are
The implemented
• SMART Action Plan prepared and Implemented to improve
existing condition sustaining over a period of
• SOP (Standard Operating Procedure) created for key time by implementation of
processes and implemented effectively Sustenance
Control:
Daily Work management

• Upper and Lower Control limits defined for each parameter Implemented results shall be
by taking all practical variations in consideration sustained over a period
• Control Charts Implemented and displayed at Gemba
• Assured Sustenance of project improvements by robust using Systematic Audit &
Daily Work Management Framework. Improvement Loop (SAIL) &
Visit Faber at www.faberinfinite.com for more information and a Daily Work Management
complete list of regional contacts or send us e-mail: (DWM)
[email protected]

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