Assessment of Quality Management System and Intervention of Lean Six Sigma Tools in a Ready Made Garments (RMG) Factory

Abstract

Quality Management Systems have become an integral part of modern manufacturing processes. Lean Manufacturing approach, Six Sigma Methodologies and the various tools of Lean Six Sigma approaches are increasingly being applied to improve and sustain the production process. Pareto Charts, Cause and Effect Diagram, 5 Whys Analysis, Control Charts, etc. are some of the most popular tools that modern industries are implementing in order to maximize their production rate and minimize waste and non-value-added activities. Implementation of Advanced Control Charts is one the innovative means of determining the status quo of the production line and to recognize the trends associated with a particular production line. But in the current perspective of the manufacturing industries of Bangladesh, this invaluable process control tool is not being used to full effect. Also, the root cause analysis tools like Cause-and-Effect Diagram, 5 Whys Analysis, etc. are scarcely used in the industries, leading to fewer effective measures being taken to mitigate major defects and problems. In this study, initially we reviewed a number of advanced control chart, in order to find the most suitable one for implementation in the manufacturing industries of Bangladesh. Then a P-chart was implemented in the sewing department of a renowned RMG industry of Bangladesh to determine the defect rate and trend. After that various quality control tool like Pareto Chart, Cause and Effect Diagram and 5 Whys Analysis were implemented to find out the root causes of the defects and to provide some effective corrective action plan. Finally, a questionnaire survey was undertaken among the industry leaders to determine the best suitable lean six sigma tool for implementation in the RMG industries of Bangladesh.