Implementation of the Six Sigma Methodology for Reducing Fabric Defects on the Knitting Production Floor: A Sustainable Approach for Knitting Industry

Abstract

Reducing fabric faults in the textile knitting industry is one of the main challenges for knit fabric production. Due to the fabric defects, the sigma level of knit fabric production is between 3 to 3.5. This study aims to increase the sigma level of knit fabric productions. Here, we implement a six sigma strategy in the textile knitting industry. The Six Sigma methodology is applied step by step on the knitting fabric production floor. The DMAIC approach is clearly stated through the phases of defining, measurement, analysis, improvement and control. The types and reasons for different fabric defects are identified by using the cause and effect diagram. The Pareto chart showed that the highest percentages (51%) of defects are related to yarn quality. In the improvement phase, the defects are eliminated by utilizing the Six Sigma methodology. Then, the sigma level of our knit fabric production went to 4. The risk priority number was calculated and suggestions for preventive actions were analysed in the control phase. Implementing the six sigma methodology on the knitting production floor also reduces the cost of production. As a result, this real time study on the knitting production floor has proved to be an economically sustainable production of knit fabric.