Program Overview
This program, delivered by a textile manufacturing quality expert with over 25 years of Six Sigma and operational excellence experience, equips participants to apply Six Sigma principles to address real-world quality challenges in textile plants. Participants will learn how to map CTQ (Critical to Quality) parameters, analyze defect patterns, calculate sigma levels, and use tools like DMAIC, Pareto charts, control charts, and RCA to build sustainable quality improvement plans. Blending concepts, case studies, and simulation, this course helps transform quality assurance into process-driven excellence
Features
- Understand Six Sigma principles and metrics applied to textile manufacturing
- Identify defect generators and process variation drivers
- Apply Six Sigma tools (DMAIC, control charts, Pareto) to solve real quality issues
- Build a factory-specific quality improvement and defect reduction roadmap
Target audiences
- Quality Heads / QA-QC Managers
- Operations Excellence / CI / TPM Leaders and Production Managers
- Plant / Factory Managers
- Process / Industrial Engineers
Curriculum
- 5 Sections
- 18 Lessons
- 1 Day
Expand all sectionsCollapse all sections
- Six Sigma Demystified for Textile Manufacturing4
- 1.1Six Sigma as a problem-solving mindset, not just a toolset
- 1.2From Defect Rate to DPMO: How Six Sigma translates to your factory metrics
- 1.3Key Terms: CTQ (Critical to Quality), DPMO, Sigma Level, Voice of Customer (VOC), Process Capability (Cp, Cpk)
- 1.4Example: Why a fabric dyehouse struggled despite “passing inspections”
- Quality Reality – Textile Factory Pain Points4
- 2.1Common defect patterns: Shade variation, GSM inconsistency, holes, slubs, contamination, poor fastness
- 2.2Sources of variation: Raw material inconsistency, machine setting drift, operator skill gaps, environmental conditions
- 2.3Tool: CTQ Mapping Activity – Translate customer requirements to factory metrics
- 2.4Case Snippet: How a spinning mill reduced yarn breakage by 20% through data control
- Six Sigma Tools & Case Applications4
- 3.1DMAIC for textiles: Define: What defect matters?; Measure: Where and how is it happening; Analyze: Why is it happening?; Improve: What to fix and how?; Control: How to sustain?
- 3.2Six Sigma Tools: Fishbone (Ishikawa), Pareto, Control Charts, Process Mapping, FMEA
- 3.3Case Study 1: Fabric finishing unit reduced rejection rate by 15% through root cause analysis
- 3.4Case Study 2: Knitting plant improved GSM consistency using control charts
- Simulation – Solve a Quality Challenge Using Six Sigma2
- Sustaining Quality Excellence Through Six Sigma4
Instructor
