Applying DMAIC Method in Six Sigma to Improve Productivity: A Case Study at a Fabric Manufacturing Company

This study aims to analyse the root causes of fabric creases in a company specialising in Denim production to reduce defect rates and increase productivity. The project team applied Six Sigma and DMAIC method to achieve the research objectives. Based on historical data, crease was the highest defect rate in the define phase. In the measure phase, we use a check sheet and Pareto chart to measure the crease defect rate. Then, we use a fishbone diagram and expert method to analyse the root causes of the crease defect in the analysis phase. In improve phase, we use experts to evaluate the feasibility of the solution and choose the most effective solution. Finally, after applying the solutions, the good product rate increased from 88.44% to 96.26%, surpassing the quality target set by the company of 95%. The solutions also reduced monthly defective fabric products from 6050 to 3046 metres.