Using Pareto Diagram to Improve Textile Product Quality: A Case Study

In today’s competitive global market, organizations must adhere to stringent quality standards, fulfill consumer expectations, optimize energy consumption, and foster continuous product development. This study examines a case involving a textile factory that specializes in the production of gabardine fabrics. To facilitate improvements in quality, a Pareto chart was utilized to analyze samples of the fabric, identifying defects that significantly affect overall quality. The analysis revealed five predominant defects: dirt, lint, weft filling, twill, and assortment issues. To further investigate these findings, an Ishikawa cause-and-effect diagram was employed to determine the underlying causes of these defects. Subsequently, seven potential solutions were proposed to mitigate the identified defects, which included regular maintenance of machinery, implementation of training programs for personnel, conducting quality assessments of supplied threads, and the installation of a monitoring device for temperature and humidity levels. After the implementation of these solutions, a follow-up analysis of a new set of samples demonstrated an impressive 80% enhancement in product quality. Notably, the incidence of dirt defects decreased from 8 to 2, lint defects from 6 to 1, and weft filling issues from 5 to 1.