Abstract

This research delves into how to utilize the DMAIC approach of Six Sigma to improve the cutting operation at Vinatex, a significant garment manufacturer of Vietnam. My study identified specific inefficiencies the wrong fabric being chosen, the bundle label was inaccurate, and the tension varied that increased defect rates and operational costs. Using a range of Six Sigma tools, we were able to run targeted interventions (operator training and development work, machine calibration, and automation of the tension control processes) to improve performance. We observed a 61.5% reduction in defect rates, a 66.7% decrease in machine downtime during cutting, and a 55.6% reduction in normative rates of product rework following interventions. Unfortunately, we did account for any impact on containment issues. Although we did not record any significant operational improvements concerning accuracy of measurements and training of operators, it was possible to put those processes in place. Overall, we confirmed that Six Sigma can make a significant contribution to the quality of production and efficiency in labor-intensive textile and garment environments, and that such a case can provide an effective vehicle for continuous improvement of productivity in the garment industry.

Keywords:Six Sigma; Inefficiencies; Garment Industry; Process Improvement