Asst. Professor, NIFT, New Delhi

ABSTRACT

Sigma is a highly disciplined process that helps us focus on developing and delivering near-perfect products and services. The word is a statistical term that measures how far a given process deviates from perfection. The central idea behind Six Sigma is that it Six Sigma is a disciplined, data-driven approach and methodology for eliminating defects (driving towards six standard deviations between the mean and the nearest specification limit) in any process from manufacturing to transactional and from product to service. To achieve Six Sigma Quality, a process must produce no more than 3.4 defects per million opportunities. An 'opportunity' is defined as a chance for nonconformance, or not meeting the required specifications. This means we need to be nearly flawless in executing our key processes."

The paper tries to introduce the concept of Six Sigma for the Apparel Industry. Various tools can be applied under Six Sigma concept for measuring and analysis of variations in a process. DMAIC is practiced in the garment manufacturing industry and problem is identified on car seat manufacturing It is observed that the factor was working at 2.58 sigma level. After implementation of six sigma process, it is found that, the process improved to 3.16 sigma level. It clearly shows the way and scope for the further improvement of the same process indicating the flaw in the process. For pointing out the priority of the problems, FMEA tool was used.
Keywords: DMAIC, Process Improvement, Six Sigma, FMEA

Introduction:

Six Sigma is a proven method for improving profits by pursuing perfection. Six Sigma, or 6s, is a disciplined use of applied science that improves profits by creating and systematically replicating breakthrough improvements.

A 6s Expert, called a Black Belt, can be expected to lead three to four projects per year. Their success, and your businesses success with 6s, depends on the commitment of top-level executive leaders for achieving perfect, 6s quality.

So, Six Sigma is a business improvement methodology that focuses an organization on:

• Understanding and managing customer requirements
• Aligning key business processes to achieve those requirements
• Utilizing rigorous data analysis to minimize variation in those processes
• Driving rapid and sustainable improvement to business processes.

For non-Six Sigma companies, these costs are often extremely high. Companies operating at three or four sigma typically spend between 25 and 40 percent of their revenues fixing problems. This is known as the cost of quality, or more accurately the cost of poor quality. Companies operating at Six Sigma typically spend less than 5 percent of their revenues fixing problems.