Curriculum
- 5 Sections
- 18 Lessons
- 1 Day
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- 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