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

Show simple item record

dc.contributor.author Nafiz, Afsan
dc.contributor.author Aziz, Md. Abdul
dc.date.accessioned 2022-04-16T15:30:28Z
dc.date.available 2022-04-16T15:30:28Z
dc.date.issued 2021-03-30
dc.identifier.citation Ab Rahman, M.N., Zain, R.M., Nopiah, Z.M., Ghani, J.A., Deros, B.M., Mohamad, N. and Ismail, A.R., 2009. The implementation of SPC in Malaysian manufacturing companies. European Journal of Scientific Research, 26(3), pp.453-464. Abdullah, F.M., 2003. Lean manufacturing tools and techniques in the process industry with a focus on steel (Doctoral dissertation, University of Pittsburgh). Alukal, G., 2007. Lean kaizen in the 21st century. Quality progress, 40(8), p.69. Awaj, Y.M., Singh, A.P. and Amedie, W.Y., 2013. QUALITY IMPROVEMENT USING STATISTICAL PROCESS CONTROL TOOLS IN GLASS BOTTLES MANUFACTURING COMPANY. International Journal for Quality Research, 7(1). Bakker, A., Kent, P., Derry, J., Noss, R. and Hoyles, C., 2008. Statistical inference at work: Statistical process control as an example. Statistics Education Research Journal, 7(2), pp.130- 145. Bala, S. and Gupta, T., 2003. Factors influencing costing of woven fabrics. The Indian Textile Journal, 1(2), pp.57-68. Barsalou, M.A., 2014. Root cause analysis: A step-by-step guide to using the right tool at the right time. CRC Press. Beamon, B.M. and Ware, T.M., 1998. A process quality model for the analysis, improvement and control of supply chain systems. Logistics Information Management. Benjamin, S.J., Marathamuthu, M.S. and Murugaiah, U., 2015. The use of 5-WHYs technique to eliminate OEE’s speed loss in a manufacturing firm. Journal of Quality in Maintenance Engineering. Berg, A. and Ohlsson, F., 2005. Lean manufacturing at Volvo Truck Production Australia: development of an implementation strategy. Berwick, D.M., 1991. Controlling variation in health care: a consultation from Walter Shewhart. Medical care, pp.1212-1225. Brannstrom-Stenberg, A. and Deleryd, M., 1999. Implementation of statistical process control and process capability studies: requirements or free will?. Total Quality Management, 10(4-5), pp.439-446. Chahal, V. and Sharma, S., 2013. Advance Industrial Approach for Waste Reduction (Lean Manufacturing). Chen, K.H., Boning, D.S. and Welsch, R.E., 2001, June. Multivariate statistical process control and signature analysis using eigenfactor detection methods. In The 33rd Symposium on the Interface of Computer Science and Statistics, Costa Mesa Ca. 61 | P a g e Cho, J. and Kang, J., 2001. Benefits and challenges of global sourcing: perceptions of US apparel retail firms. International marketing review. Czabke, J., 2007. Lean thinking in the secondary woodproducts industry: challenges and benefits. Dabade, U.A. and Bhedasgaonkar, R.C., 2013. Casting defect analysis using design of experiments (DoE) and computer aided casting simulation technique. Procedia Cirp, 7, pp.616- 621. Dean, J. and Evans, J., 1994. Total Quality: Management, Organization, and Strategy. Cincinnati, Ohio: South-Western College Pub. Deming, W., 1982. Out of the crisis. 1st ed. Massachusetts: MIT Press. Ding, S., Muhammad, N., Zulkurnaini, N., Khaider, A. and Kamaruddin, S., 2013. Production System Improvement by Integration of FMEA with 5-Whys Analysis. Advanced Materials Research, 748, pp.1203-1207. Ding, S.H., Muhammad, N.A., Zulkurnaini, N.H., Khaider, A.N. and Kamaruddin, S., 2013. Production system improvement by integration of FMEA with 5-WHYS analysis. In Advanced Materials Research (Vol. 748, pp. 1203-1207). Trans Tech Publications Ltd. Does, R.J., Roes, C.B. and Trip, A., 1999. Statistical process control in industry: Implementation and assurance of SPC (Vol. 5). Springer Science & Business. Doggett, A.M., 2004. A statistical comparison of three root cause analysis tools. Journal of Industrial Technology, 20(2), pp.2-9. Dolcemascolo, D., 2006. Problem Solving Tools Fishbone Diagram Five Why’s. Duggett, A.M., 2004. A statistical comparison of three root cause tools. Journal of Industrial technology, 20(2), pp.1-9. Eberle, H., Hermeling, H., Hornberger, M., Kilgus, R., Menzer, D. and Ring, W., 2004. Clothing technology. Beuth-Verlag GmbH, Berlin. El-Din, M.S., Rashed, H.I. and El-Khabeery, M.M., 2006. Statistical process control charts applied to steelmaking quality improvement. Quality Technology & Quantitative Management, 3(4), pp.473-491. El-kourd, R.M., 2009. A study of lean construction practices in Gaza Strip. ElMaraghy, H., 2014. Managing variety in manufacturing. Procedia CIRP, 17, pp.1-2. En.wikipedia.org. 2012. Five Ws. [online] Available at: <http://en.wikipedia.org/wiki/Five_Ws> [Accessed 25 October 2012]. En.wikipedia.org. 2012. Sakichi Toyoda. [online] Available at: <http://en.wikipedia.org/wiki/Sakichi_Toyoda> [Accessed 25 October 2012]. 62 | P a g e Finison, L.J., Finison, K.S. and Bliersbach, C.M., 1993. The use of control charts to improve healthcare quality. Journal for Healthcare Quality, 15(1), pp.9-23. Forrester, P.L., Shimizu, U.K., Soriano‐Meier, H., Garza‐Reyes, J.A. and Basso, L.F.C., 2010. Lean production, market share and value creation in the agricultural machinery sector in Brazil. Journal of Manufacturing Technology Management. Fouad, R.H. and Mukattash, A., 2010. Statistical process control tools: a practical guide for Jordanian industrial organizations. JjMIE, 4(6), pp.693-700. Hallgren, M. and Olhager, J., 2009. Lean and agile manufacturing: external and internal drivers and performance outcomes. International Journal of Operations & Production Management. Handfield, R.B. and Nichols Jr, E.L., 1999. Introduction to. Supply Chain Management, Prentice Hall, Englewood Cliffs, NJ. Hanna, S.M., 2003, May. Application of Statistical Process Control (SPC) in the manufacturing of medical accelerators. In Proceedings of the 2003 particle accelerator conference (Vol. 2, pp. 1077-1079). IEEE. Islam, M., Khan, M. and Khan, M., 2013. Minimization of Reworks in Quality and Productivity Improvement in apparel Industry. International Journal of Engineering and Applied Sciences, 1(4), pp.147-164. John, B., The Lean Toolbox, 2nd ed, Picsie Books, Buckingham, England, 2000. PP-21-24. Kabir, A.B.M.Z. and Shihan, S.M.A., 2003, August. Selection of renewable energy sources using analytic hierarchy process. In International symposium on the analytic hierarchy process, Bali. Kabir, A.B.M.Z. and Shihan, S.M.A., 2003, August. Selection of renewable energy sources using analytic hierarchy process. In International symposium on the analytic hierarchy process, Bali. Kasul, R.A. and Motwani, J.G., 1997. Successful implementation of TPS in a manufacturing setting: a case study. Industrial Management & Data Systems. Kayaalp, I.D. and ERDOĞAN, M.Ç., 2009. Decreasing Sewing Defects by Using Statistical Process Control Methods in the Apparel Factory. Tekstil ve Konfeksiyon, 19(2), pp.169-174. Kincade, D.H., Cassill, N. and Williamson, N., 1993. The quick response management system: structure and components for the apparel industry. Journal of the Textile Institute, 84(2), pp.147- 155. Knutsen, H.M., 2004. Industrial development in buyer-driven networks: the garment industry in Vietnam and Sri Lanka. Journal of Economic Geography, 4(5), pp.545-564. Koh, H.C., Sim, K.L. and Killough, L.N., 2004. The interaction effects of lean production manufacturing practices, compensation, and information systems on production costs: a recursive partitioning model. In Advances in Management Accounting. Emerald Group Publishing Limited. 63 | P a g e Krafcik, J.F., 1988. Triumph of the lean production system. Sloan management review, 30(1), pp.41-52. Kumar, S.A. and Suresh, N., 2006. Production and operations management. new age international (P) ltd. Lee, C.K.H., Choy, K.L., Ho, G.T., Chin, K.S., Law, K.M. and Tse, Y.K., 2013. A hybrid OLAP-association rule mining based quality management system for extracting defect patterns in the garment industry. Expert Systems with Applications, 40(7), pp.2435-2446. Lorenzo, D.K. and Jackson, L.O., 2008. Root cause analysis handbook: A guide to efficient and effective incident investigation. Rothstein Publishing. Low, S., Kamaruddin, S. and Azid, I., 2015. Categorisation of process improvement models from a conceptual perspective. International Journal of Process Management and Benchmarking, 5(1), p.113. Low, S.N., Kamaruddin, S. and Azid, I.A., 2015. Categorisation of process improvement models from a conceptual perspective. International Journal of Process Management and Benchmarking, 5(1), pp.113-132. Lubben, J.E., 1988. Assessing social networks among elderly populations. Family & Community Health: The Journal of Health Promotion & Maintenance. McGrath, W., 2007. Impact analysis of large-scale lean manufacturing initiatives upon manufacturing process innovation in Irish companies (Doctoral dissertation, Waterford Institute of Technology). Meyers, F.E. and Stewart, J.R., 2002. Motion and time study for lean manufacturing. Pearson College Division. Mitra, A., 2016. Fundamentals of quality control and improvement. John Wiley & Sons. Mohammed, M.A., Worthington, P. and Woodall, W.H., 2008. Plotting basic control charts: tutorial notes for healthcare practitioners. BMJ Quality & Safety, 17(2), pp.137-145. Mottaleb, K.A. and Sonobe, T., 2011. An inquiry into the rapid growth of the garment industry in Bangladesh. Economic Development and Cultural Change, 60(1), pp.67-89. Murugaiah, U., Benjamin, S.J., Marathamuthu, M.S. and Muthaiyah, S., 2010. Scrap loss reduction using the 5‐whys analysis. International Journal of Quality & Reliability Management. Mustafi, C.K., 1996. Operations Research methods and practice. New Age International. Nakajima, S., 1988. Introduction to TPM: total productive maintenance. (Translation). Productivity Press, Inc., 1988, p.129. Nave, D., 2002. How to compare six sigma, lean and the theory of constraints. 3rd ed. Estados Unidos: ASQ American Society for Quality, p.73. 64 | P a g e Ohno, T., 1988. Toyota production system: beyond large-scale production. crc Press. Omar, M.H., 2010. Statistical process control charts for measuring and monitoring temporal consistency of ratings. Journal of Educational Measurement, 47(1), pp.18-35. Piercy, N. and Rich, N., 2009. High quality and low cost: the lean service centre. European Journal of Marketing. Poppendieck, M., 2011. Principles of lean thinking. IT Management Select, 18(2011), pp.1-7. Pylipow, P.E. and Royall, W.E., 2001. Root cause analysis in a world-class manufacturing operation. Quality, 40(10), p.66. Rahman, M.H. and Al Amin, M., 2016. An empirical analysis of the effective factors of the production efficiency in the garments sector of Bangladesh. European Journal of Advances in Engineering and Technology, 3(3), pp.30-36. Rahman, M.N.A., Zain, R.M., Nopiah, Z.M., Ghani, J.A., Deros, B.M., Mohamad, N. and Ismail, A.R., 2008, October. Rai, B.K., 2008. Implementation of statistical process control in an Indian tea packaging company. International Journal of Business Excellence, 1(1-2), pp.160-174. Rathi, N. and Farris, J.A., 2009. A framework for the implementation of lean techniques in process industries. In IIE Annual Conference. Proceedings (p. 1114). Institute of Industrial and Systems Engineers (IISE). Raymond, W.P., 1992. Use of Statistical Process Control (SPC) Versus Traditional Statistical Methods in Personal Care Applications. In 17th IFSCC International Congress Yokohama October (pp. 13-16). Reed, S. and Reed, J.H., 1997. The use of statistical quality control charts in monitoring interviewers. In Proceedings of the American Statistical Association, Section on Survey Research Methods. Roush, M. and Webb, W., 2006. Applied reliability engineering. College Park, MD: Center for Reliability Engineering, University of Maryland, p.218. Rungasamy, S., Antony, J. and Ghosh, S., 2002. Critical success factors for SPC implementation in UK small and medium enterprises: some key findings from a survey. The TQM Magazine. Ryan, T.P., 2011. Statistical methods for quality improvement. John Wiley & Sons. 65 | P a g e Saaty, T.L., 1990. Decision making for leaders: the analytic hierarchy process for decisions in a complex world. RWS publications. Saha, R., 2017. Integrated economic design of quality control and maintenance management using CUSUM chart with VSIFT sampling policy. Saleh, M., 2011. The Role of Thinking Capital in the Possibility of Establishing Lean Manufacturing Foundations (Doctoral dissertation, Master Thesis, University of Mosul). Scribd.com. 2021. [online] Available at: <https://www.scribd.com/document/260955894/Solutions-to-Sewing-Problems> [Accessed 14 March 2021]. Semel, F.J., Kasputis, D.J. and Gummeson, P.U., 1988. Statistical Process Control in Iron Powder Production and New Product Development (No. 880114). SAE Technical Paper. Shamsuzzaman, M. and Wu, Z., 2012. Design of EWMA control chart for minimizing the proportion of defective units. International Journal of Quality & Reliability Management. Shamsuzzaman, M., 2005. Integrated control chart systems (Doctoral dissertation, Nanyang Technological University, School of Mechanical and Aerospace Engineering). Shamsuzzaman, M., Haridy, S., Alsyouf, I. and Rahim, A., 2020. Design of economic X̄ chart for monitoring electric power loss through transmission and distribution system. Total Quality Management & Business Excellence, 31(5-6), pp.503-523. Shamsuzzaman, M., Haridy, S., Maged, A. and Alsyouf, I., 2019. Design and application of dual-EWMA scheme for anomaly detection in injection moulding process. Computers & Industrial Engineering, 138, p.106132. Shewhart, W.A. and Deming, W.E., 1986. Statistical method from the viewpoint of quality control. Courier Corporation. Shingo, S., Quick Changeover for operators: The SMED system, Productivity press, Portland, Oregon, 1996, PP-16. Smith, A.L. and Chaudhry, S.S., 2005. Use of statistical process control in bus fleet maintenance at SEPTA. Journal of Public Transportation, 8(2), p.4. Sower, V.E., Motwani, J.G. and Savoie, M.J., 1994. β Charts for Short Run Statistical Process Control. International Journal of Quality & Reliability Management. Statistical process control in SMEs: A case study. In Proceedings of the 4th WSEAS/IASME international conference on Dynamical systems and control (pp. 145-152). Stephen, P., 2004. Application of DMAIC to integrate Lean manufacturing and six sigma (Doctoral dissertation, Virginia Tech). Su, J., Gargeya, V. and Richter, S., 2005. Global sourcing shifts in the U.S. textile and apparel industry: a cluster analysis. Journal of the Textile Institute, 96(4), pp.261-276. 66 | P a g e Sultana, F., Razive, N.I. and Azeem, A., 2009. Implementation of statistical process control (SPC) for manufacturing performance improvement. Journal of Mechanical Engineering, 40(1), pp.15-21. Taha, H.A., 2013. Operations research: an introduction. Pearson Education India. Taj, S., 2008. Lean manufacturing performance in China: assessment of 65 manufacturing plants. Journal of Manufacturing Technology Management. Talapatra, S. and Rahman, M.H., 2016. Safety awareness and worker’s health hazards in the garments sector of Bangladesh. European Journal of Advances in Engineering and Technology, 3(9), pp.44-49. Tennant, G., 2001. Six Sigma. Aldershot, England: Gower Publishers Ltd. Wilson, P.F., Dell, L.D. and Anderson, G.F., 1996. Root Cause Analysis: A Tool for Total Quality Management. The Journal for Healthcare Quality (JHQ), 18(1), p.40. Wood, M., 1994. Statistical methods for monitoring service processes. International Journal of Service Industry Management. Wu, Z., Shamsuzzaman, M. and Pan, E.S., 2004. Optimization design of control charts based on Taguchi's loss function and random process shifts. International Journal of Production Research, 42(2), pp.379-390. Yamashita, K., 2004. Implementation of lean manufacturing process to XYZ Company in Minneapolis area. Youthbd.com. 2015. Comfit Composite Knit Ltd. – Youth BD. [online] Available at: <http://youthbd.com/sister-concern/comfit-composite-knit-ltd/> [Accessed 14 March 2015]. Zakaria, N.H., Mohamed, N.M.Z.N., Ab Rahid, M.F.F. and Rose, A.N.M., 2017. Lean manufacturing implementation in reducing waste for electronic assembly line. In MATEC Web of Conferences (Vol. 90, p. 01048). EDP Sciences en_US
dc.identifier.uri http://hdl.handle.net/123456789/1323
dc.description Supervised by Dr. A.R.M. Harunur Rashid, Associate Professor, Department of Mechanical and Production Engineering (MPE), Islamic University of Technology (IUT), Gazipur, Dhaka en_US
dc.description.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. en_US
dc.language.iso en en_US
dc.publisher Department of Mechanical and Production Engineering en_US
dc.title Assessment of Quality Management System and Intervention of Lean Six Sigma Tools in a Ready Made Garments (RMG) Factory en_US
dc.type Thesis en_US


Files in this item

This item appears in the following Collection(s)

Show simple item record

Search IUT Repository


Advanced Search

Browse

My Account

Statistics