Applying Lean Six Sigma to Improve Garment Production Processes. A Case Study

Abstract

The company under study is specializing in producing garment products. The production process of the company has so much iste, long production time, high cycle time, high defect rate, leading to low productivity, low quality, then late deliveries, affecting competitive edge of the company. The paper applied Lean Six Sigma to improve the company production process to reduce iste, reduce the process production time, and cycle time, reduce the process defect rate, and then to improve productivity, improve quality, and finally increase on-time delivery rate, and the competitive edge of the company. Lean Six Sigma tools and techniques, according to the DMAIC procedure, has been used, helping the company reduce production lead time by 89.21% from 279 minutes to 30.1 minutes, reduce production cycle time by 36% from 25 sec. to 16 sec., reduce process defect rate by 37.45% from 14.9% to 9.32%, that improved the on-time delivery rate.