Title: Enhancing garment manufacturing process efficiency: a DMAIC case study for process improvement

Authors: Komal Naseem; Syed Yahya Adil; Syed Mehmood Hasan; Satya Shah; Sharfuddin Ahmed Khan

Addresses: Industrial and Manufacturing Engineering Department, NED University of Engineering and Technology, University Road, Karachi, Pakistan ' Industrial and Manufacturing Engineering Department, NED University of Engineering and Technology, University Road, Karachi, Pakistan ' Engineering and Operations Management Unit – EE, School of Engineering, Physical and Mathematical Sciences, Royal Holloway University of London, Egham, UK ' Engineering and Operations Management Unit – EE, School of Engineering, Physical and Mathematical Sciences, Royal Holloway University of London, Egham, UK ' Industrial Systems Engineering, Faculty of Engineering and Applied Science, University of Regina, Regina, SK, Canada

Abstract: This study applies the Six Sigma DMAIC methodology to reduce high defect rates in the stitching process of garment manufacturing. Focused on a leading firm producing 5-pocket denim jeans over 18 days, it systematically identifies and addresses defects like pleat/puckering, slip stitch, and uneven stitch, primarily caused by operator errors, machine malfunctions, and inadequate training. Using tools like Pareto charts and cause-and-effect diagrams, interventions such as operator training, machine maintenance, and process standardisation reduced the defect per million opportunities (DPMO) from 3363 to 228, raising the sigma level from 4.2 to 5.01. The project also improved worker safety, cost management, and operational efficiency. This successful implementation of DMAIC not only resolved immediate quality issues but also provided a scalable model for future improvements in garment manufacturing, demonstrating the economic benefits of defect reduction and process optimisation.

Keywords: define, measure, analyse, improve, and control; DMAIC; Six Sigma; defects reduction; DPMO.

DOI: 10.1504/IJPQM.2025.148017

International Journal of Productivity and Quality Management, 2025 Vol.45 No.4, pp.459 - 487

Received: 08 Jul 2024
Accepted: 03 Feb 2025
Published online: 14 Aug 2025 *

Full-text access for editors Full-text access for subscribers Purchase this article Comment on this article