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TITLE OF THE PROJECT

A Six Sigma project Report

TOTAL QUALITY MANAGEMENT

College of Management & Administrative Sciences,GOVERNMENT COLLEGE UNIVERSITY FAISALABAD

June, 2012


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TITLE OF THE PROJECT

A Six Sigma project Report

Under the guidance of

Mr. Masood Nawaz Kalyar

Submitted by

Muhammad Abdullah 203Yahya Amin 205

Mah Gull 223

BBA(Hons) 2009-2013

in partial fulfilment of the subject

Total Quality Management

College of Management & Administrative Sciences,

Government College University Faisalabad


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A c k n o w l e d g e m e n t :

We wish to acknowledge our regards and indebtedness to our guide and benevolent Sir. Masood

Kalyar teaching Total Quality Management in G.C. University Faisalabad. Whose kind and

precious suggestions enriched our thoughts and helped us to accomplish this Business plan. We

also want to thank our families who supported us. Thanks to Almighty ALLAH for giving us

such will and power to complete this business plan on time

A deep sense of appreciation is owed to Mr. Ikram ilahi for his kind attitude and keen interest

during my internship.

Last but not least we offer our humble heart felt gratitude and deepest affections to my great

mother and respected father for being inspired for higher ideals of life, supported morally and

financially throughout my studies, and always prayed for glorious success about my pursuits

throughout all of my life.


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P r e f a c e :

We have chosen this Textile Mill to make our project on it. We had a good time while doing the

survey about our problem and gathering the information about solving our problem to increase

employee efficiency through different ways into a project.

The project is basically about the Increasing employee efficiency, skills, knowledge. We also

used the source of internet for gathering information. We think that we have done our job in

solving the problem we hope that

We have given all the complete information required by our teacher, and hope that our hard work

pays off.


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Executive Summary:

YAT is the organization that deals in the manufacturing of Lawn and Cotton suits. This

organization is innovatory product in the Pakistani market. The organization name is Yasir Afzal

Textile Pvt. Ltd.

In the first phase, we had conducted the Organization survey and we found the main problem in

organization . The survey was very successful in which we observed all the procedure of

manufacturing clothe and different type of machines which helped to produce clothe and then we

get sample knowledge about employees their efficiencies, skills and knowledge about their work.

In the whole survey the main problem that we found is that there is no sufficient output as there

should be. Then with our survey report and knowledge we found the cause of this problem. The

cause is that employees are not satisfied from their job. In which we found that there is

insufficient salary, lack of commitment, no incentives and working environment which

discomforts the employees. Therefore, we decided to solve this problem and increase the

efficiency of employees.


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Serial No. Topic Pg #02 Dedication 04

03 Acknowledgement 05

04 Preface 06

05 Executive Summary 6

Ch. # 1 Company Introduction 08

o Company Name 08o Slogan & Logo 08o History of organization 09o Vision & 11o Mission Statement 12o Objectives 13o Brief History of organization

Ch. # 2 Six Sigma Process 15

o DMAIC Process 17Ch. # 3 Define 19

Ch # 4 Measure 20

o Cost per meter 25o Six sigma Calculation 26o Process Flow 28o Prato Diagram 29o Time Series 30

Ch # 6 Analysis 31

Ch #7 Improvement 32

Six Sigma Calculation After improvement 33

o Prato Diagram and Time Series 34Ch # 8 Control 35


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Ch # 1: Introduction

Company Name:

Yasir Afzal Textile Pvt Ltd.

Our Slogan:

Be Different

Our Logo:


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History of Organization:

Yasir Afzal Textile Industries Pvt. Limited Faisalabad is the grooming industry in Faisalabad in

textile. Founded in 1991 by the most famous person, Haji Muhammad Afzal and Haji

Muhammad Islam, is now led by the young Mr. Umer Afzal and Mr. Amir Afzal , a dynamic

second generation leader of Faisalabad textile industry.

Yasir Afzal Textile is one of the largest manufacturer of textile goods in Pakistan. It is

manufacturing high quality products. Its product brand name is Ashi and Rabi are amongst

leader in the market. Yasir Afzal Textile has designing, and printing departments. The bedding

and fabric collection of Yasir Afzal Textile are sent to the different parts of the country such as

Lahore Karachi Islamabad and Peshawar.

Yasir Afzal Industry by now is in textile cloth finishing and processing, textile product packing.

Haji Muhammad Afzal the present Chairman of the Industry, the creative and courageous man,

latter joined by second generation, making a blend of experience and modern business

knowledge, managed the business growth and development with assistance of highly qualified

team of professionals. Faith in Almighty Allah and in their own abilities & commitment to the

cause, untiring efforts and leadership qualities of the family, established the industry, which now

stands amongst Leading Industrial Industry of the Country, under the Chairmanship of Haji

Muhammad Afzal.

The daily production round about 1 lac meter and the parties of YAT are in Lahore, Karachi,

Faisalabad, and Multan through the different parties they export cloth in different Asian

countries like Seri Lanka, India, Malaysia and Thailand. Via Karachi they send cloth to Dubai.

For many years YAT working with Maria B Designer. They manufacture Maria B Lawn on

order which have many outlets inside the country Karachi, Lahore, Faisalabad etc and outside the

country like Dubai.

They start with one rotary Machine and then expand the business with the passage of time and

now working with 3 rotary machines. Start business with personal manufacture and sold their

cloth through outlet in market and later on manufacture cloth on order .Now many domestic

trader prepare their cloth from YAT on order.


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Vision:

To become one of the Best brands in the country


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Mission:

Satisfying ourcustomers by providing them best qualitative stuff and Unique designs keeping

in view their comforts and excellence

Excellence in quality and improved efficiency at lower operating cost by Utilizing blend of state

of art technologies.


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Our Objectives:

There are two types of objectives

1-Non-Financial Objectives:

To be among the top ten favorite brands. Yasir Afzal Textile is the growing Organization in the Textile Sector ISO certified Company Having a Qualified and Experienced Staff Proper Utilization of Human Resources Having a latest Machinery to Compete Globally Friendly Environment

2-Financial Objectives:

To maintain an inflation growth in earning per year at a rate of 12%. To obtain a return on equity of at least 30%. Providing stitching facilities to other boutiques in 2010 which are Lacking this facility.


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BRIEF HISTORY OF ORGANIZATION

Yasir Afzal Textile Industries Pvt. Limited Faisalabad is the grooming industry in Faisalabad in

textile. Founded in 2005 by the most famous person, Haji Muhammad Afzal and Haji

Muhammad Islam, is now led by the young Muhammad Umer and Muhammad Amir , a

dynamic second generation leader of Faisalabad textile industry.

Yasir Afzal Textile is one of the largest manufacturers of textile goods in Pakistan. It is

manufacturing high quality products. Its product brand name is Ashi and Rabi are amongst

leader in the market. Yasir Afzal Textile has designing, stitching, and printing departments. The

bedding and fabric collection of Yasir Afzal Textile are sent to the different parts of the country

such as Lahore Karachi Islamabad and Peshawar.

Yasir Afzal textile is one of the largest manufacturers of textile in Pakistan. Specializing in home

textiles, printed, dyed, bleached fabrics, an apparel and fashion garment, Yasir afzal is delivering

quality to virtually all parts of the country. With latest State-of-the-art machinery and

equipment, it is a complete printing, dyeing, finishing and stitching plant. Three huge spinning

mills, a high caliber weaving unit and a made-up / garment unit is working under one roof. The

unit is capable of producing high quality with a capacity of 75000 meters of finished cloth every

day.

Yasir Afzal textiles industries private limited has proudly maintaining its leadership in 100

percent pure cotton products along with the man made fiber. The product range in pure cotton is

available as sateen both in mono cotton and poly cotton, bed sheets, pillow, quilt covers, aprons,

boxer shorts, and ready made garments are available in most exotic and fascinating designs.

A sizeable percentage of Yasir Afzal textiles, daily textile production by the meter are converted

in-house into a ready, saleable retail product. There Cut & Sew division enjoys the cuttingedge in assembling and sewing of bed sheets and sets, quilt covers, curtains, table linen, bed

spreads, comforter covers, pillow cases, kitchen linen and ready made garments as per the specs

defined by the customers.


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From a fiber to a finished product, nothing gets spared from our ultra-sensitive, extra vigilant

laboratory. Equipped with the most modern and precision equipment, products are frequently

subjected to tests against most relevant international standards at every stage of manufacture.

Tests are conducted to control shrinkage (dimensional change), pilling resistance, and abrasion,

color fastness and washing fastness etc.

Much of their wide success and popularity is attributed to there technically being ahead in there

printing. There printing staff and design teams combine years of practical experience in printing

with top-of-the-range Austrian J. Zimmer rotary printing machines producing 280 cm finished

width up to 12 colors per design and maximum repeat of 91 cm. Flat bed printing facility

comprised Reggiane machine with 320 cm working width and 320 cm repeat.

Thanks to their modern and sophisticated facility, processing to finishes like chintz, silicon,

scotchgard, fire retardant down proof and raisin etc, is invariably a pleasure. With YASIR

AFZAL, their clients gets quick quality sampling on Austrian J. Zimmers latest rotary strike off

machine facilitating production of strike offs up to 15 meter length


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CH # 2: SIX SIGMA PROCESS

What is six sigma?

Six sigma is a customer based approach realizing that defects are expensive. Fewer defects mean

lower costs and improved customer loyalty. The lowest cost, high value producer is the mostcompetitive provider of goods and services. Six sigma is a way to achieve strategic business

results.

Six Sigma is a business management strategy, originally developed by Motorola, USA in

1986. Six Sigma became well known after Jack Welch made it a central focus of his businessstrategy at General Electric in 1995, and today it is widely used in many sectors of industry.

Six Sigma seeks to improve the quality of process outputs by identifying and removing thecauses of defects (errors) and minimizing variability in manufacturing and business processes. It

uses a set of quality management methods, including statistical methods, and creates a special

infrastructure of people within the organization ("Black Belts", "Green Belts", etc.) who are

experts in these methods. Each Six Sigma project carried out within an organization follows adefined sequence of steps and has quantified financial targets (cost reduction and/or profit

increase).

The term Six Sigma originated from terminology associated with manufacturing, specificallyterms associated with statistical modeling of manufacturing processes. The maturity of a

manufacturing process can be described by a sigma rating indicating its yield, or the percentage

of defect-free products it creates. A six sigma process is one in which 99.99966% of the products

manufactured are statistically expected to be free of defects (3.4 defects per million). Motorolaset a goal of "six sigma" for all of its manufacturing operations, and this goal became a byword

for the management and engineering practices used to achieve it.


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Ch #3: DMAIC Process

1-D= DEFINE: Define the problem, the voice of the customer, and the project goals,specifically. The objective of this phase is to define opportunities for improvement. Defining theproblem answers the questions such as "what are the problems?"

Define is the first step in our six sigma approach of DMAIC. DMAIC first asks leaders to defineour core process. It is important to define the selected project scope, expectations, resources and

timelines . The definition step in the six sigma approach identifies specially what is part of the

project and what is not, and explains the scope of the project .

2-M=MEASURE: Measure key aspects of the current process and collect relevant data.Many think when they start a journey the most important thing to know is where they are going.while we agree knowing where you want to go is very important, we believe some of the first

information you need before starting any journey is your current location. The six sigma

approach asks the black belt project manager to quantify and benchmark the process using actualdata. At a minimum consider the mean or average performance and some estimate of the

dispersion or variation.

3-=ANALYSIShave been considered. Seek out root cause of the defect under investigation.Analyze the data to investigate and verify cause-and-effect relationships. Determine what therelationships are, and attempt to ensure that all factors

Once the project is understood and the baseline performance documented and verified that there

is real opportunity, it is time with the six sigma approach to do an analysis of the process . in

this step , the six sigma approach applies statistical tools to validate root causes of problems. Anynumber of tools and tested can be used .The objective is to understand the process at a level

sufficient to be able to formulate options for improvement. We should be able to compare the

various options with each other to determine the most promising alternatives.

4-I=IMPROVE: During the improve step of the six sigma approach ideas and solutions areput to work. the six sigma black belt has discovered and validated all known root causes for the

existing opportunity. the six sigma approach requires black belt to identify solutions. few ideas

or opportunities are so good that all are an instant success. as part of the six sigma approach

there must be checks to assure that the desired results are being achieved. some experiments and

trails may be required in order to find the best solution. when making trails and experiments it isimportant that all project associates understand that these are trails and really are part of the six

sigma approach.

Improve or optimize the current process based upon data analysis using techniques such

as design of experiments, poke yoke or mistake proofing, and standard work to create a new,future state process. Set up pilot runs to establish process capability.
http://en.wikipedia.org/wiki/Poka_yokehttp://en.wikipedia.org/wiki/Process_capabilityhttp://en.wikipedia.org/wiki/Process_capabilityhttp://en.wikipedia.org/wiki/Poka_yoke


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5-C=CONTROL: Control the future state process to ensure that any deviations from targetare corrected before they result in defects. Implement control systems such as statistical process

control, production boards, visual workplaces, and continuously monitor the process.

Many people believe the best performance you can ever get from a process is at the very

beginning. Over time there is expectancy that slowly things will get a little worse until finally it

is time for another major effort towards improvement. Contrasted with this is the kaizen

approach that seeks to make everything incrementally better on a continuous basis. The sum of

all these incremental improvements can be quite large. As part of the six approach performance

tracking mechanism and measurement are in place to assure, at a minimum, that the gains made

in the project are not lost over a period f time.
http://en.wikipedia.org/wiki/Control_systemshttp://en.wikipedia.org/wiki/Statistical_process_controlhttp://en.wikipedia.org/wiki/Statistical_process_controlhttp://en.wikipedia.org/wiki/Statistical_process_controlhttp://en.wikipedia.org/wiki/Statistical_process_controlhttp://en.wikipedia.org/wiki/Control_systems


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Define

PROJECT: Yasir Afzal Textile Pvt. Ltd.

PROJECT INFORMATION :

Leader: Abdullah Shahzad

Black belt : Yahya Amin

Green Belt : Mah Gull

Project start: 28 April 2012

Project end : 28th may 2012

PROCESS START /STOP

START POINT: enter the grey into factory

END POINT: Manufacture the cloth and Dispatched

PROJECT TIME FRAME :

MILESTONE: visit and identified the problem

Data collection ANALYSIS

DATE: 28-04-12

30-04-12 07-05-12

MILESTONES: MAKE THE SOLOUTIONS

IMPLIMENTATION STUDIED THE

OUTCOMES

Critical to Quality:

Cost of poor quality:10,000-20,000 Meter.

TEAM MEMBERS :

SPONSOR: Yasir Afzal Textile (PVT LTD).

BLACK BELT: Abdullah Shahzad, identification of

problem is the main responsibility of Abdullah

Shahzad.

GREEN BELT: Yahya Amin collection , analysis of

data and implementations are the responsibilities of

Yahya Amin

PROCESS PROBLEM :

Problem is that no output from employees and no

efficiency level .there are many reasons behind this

but we took main reasons that environment is not

suite able, 2nd employees are not satisfied, 3rd lack

of motivation

PROJECT IMPORTANCE:

This project is about the increase the employees

efficiencies and increase the output of employees &through which increase the production

Provide the cloth to customer on time and

increase the daily production.

10-05-12 13-05-12 25-05-12


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Ch#4: Measure

No

Yes

Dying

printing

Yes

Grey

Entry in

System

Mending

Is GreyBe good

Refuses Order

check Inventory

Jigger Machine

Standard Machine

Rotary &

Boozer

Ager Machine

Finishing

Super Machine

Checker

Packing

Calendar or Press

Folding

bleaching

Wait

Resize

Mercerize

Care

Printing

or Dying

1 or 2 Hours

Dispatched


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For manufacturing cloth 1st of all receive grey in factory then enter inventory of grey in recordthen check the fault about grey and if defect in grey then reject the grey but in case of acceptation

then send for bleaching in which three steps involve

Bleaching:-Bleaching improves whiteness by removing natural coloration and remaining trace

impurities from the cotton; the degree of bleaching necessary is determined by the

required whiteness and absorbency. Cotton being a vegetable fiber will be bleached using

an oxidizing agent, such as dilute sodium hypochlorite or dilute hydrogen peroxide. If the

fabric is to be However, for white bed sheeting and medical applications, the highest

levels of whiteness and absorbency are essential. dyed a deep shade, then lower levels of

bleaching are acceptable.

Desizing:-Depending on the size that has been used, the cloth may be steeped in a dilute acid and

has been used, the cloth may be steeped in a dilute acid and then rinsed, or enzymes may be used

to break down the size. Then rinsed, or enzymes may be used to break down the size.

Mercerize:-A further possibility is mercerizing during which the fabric is treated with caustic soda

solution to cause swelling of the fibres. This results in improved lustre, strength and dye

affinity. Cotton is mercerized under tension, and all alkali must be washed out before the

tension is released or shrinkage will take place. Mercerizing can take place directly on

grey cloth, or after bleaching.

Many other chemical treatments may be applied to cotton fabrics to produce low

flammability, crease resist and other special effects but four important non-chemicalfinishing treatments

Care :-This step use for whiteness of cloth
http://en.wikipedia.org/wiki/Oxidizing_agenthttp://en.wikipedia.org/wiki/Sodium_hypochloritehttp://en.wikipedia.org/wiki/Hydrogen_peroxidehttp://en.wikipedia.org/wiki/Shrinkage_(fabric)http://en.wikipedia.org/wiki/Shrinkage_(fabric)http://en.wikipedia.org/wiki/Hydrogen_peroxidehttp://en.wikipedia.org/wiki/Sodium_hypochloritehttp://en.wikipedia.org/wiki/Oxidizing_agent


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Drying:-After the step of bleaching the grey send for drying

Printing or Dying Printing:-

Printing, on the other hand, is the application of color in the form of a paste or ink to the

surface of a fabric, in a predetermined pattern. It may be considered as localized dyeing.

Printing designs on to already dyed fabric is also possible.

problem occur in our printing department due to defect in machinery and machinery is

stop for 1 or 2 hours and it is effect on efficiency of employees and production.

20%-25% production decrease due to defect in machinery and Total daily production is

1,30,000 Meter

Dying:-Finally, cotton is an absorbent fiber which responds readily to coloration processes.

Dyeing, for instance, is commonly carried out with an anionic direct dye by completely

immersing the fabric (or yarn) in an aqueous dye bath according to a prescribedprocedure. For improved fastness to washing, rubbing and light, other dyes such as vats

and reactive are commonly used. These require more complex chemistry during

processing and are thus more expensive to apply.


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Ager MachineAger machine use for dry the cloth through heating. Depending on the size that

has been used, the cloth may be steeped in a dilute acid and then rinsed, or enzymes may be used

to break down the size

Super MachineIt use for washing the cloth

Finishing department:-For finishing the cloth use standard machine and problem can be occur in finishing

Department and may be delay the production

Calendaring:-Calendaring is the third important mechanical process, in which the fabric is passed

between heated rollers to generate smooth, polished or embossed effects depending on

roller surface properties and relative speeds.


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Folding :-Folding machine use for rolling the cloth on role

Checker:-After preparing the cloth then check for overview about defects .

Packing:-After the checking and clearance of clothe then we will pack the cloth.

Dispatched:-Dispatching is the last step of the manufacturing cloth.


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Cost per Meter

Daily Production 130,000 Meter

Grey per Meter Rs.63

Grey cost Daily 63*130,000 81,90,000

Daily Wages 1,10,000

Electricity per Day 14000 Unit*8 1,12,000

Sui Gas Per Day 62,500 Units*4 300,000

Chemical Per Day 550,000

Other Expense 40,000

Total Expense per day 93,02,000

Per Meter Cost = Total Expense/ Daily Production

= 93,02,000/130,000

= 71.55 Rs. Per Meter Cost


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Six Sigma Calculations Before Improvement

Daily Production = 130,000 Meter

NO of Defects = 10,000

Size Of the Sample = 130,000

Defects per million = 76923

Sigma Metric = 3.00


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Problem is that there is no output of employee and no efficiency of employee, and there are three main

causes

Defect in machinery Environment is not suite able for employee Employee not satisfied from job


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Pareto Diagram

Daily Production =130,000 Meter Problem=10,000

Following are the problem in % of 10,000

working environment 5000 m, Employee Dissatisfaction 3000 m, Defect in Machinery 2000 m

Problem: Employees are not satisfied from job.

Y-axis: Percentage of problem

X-axis: Causes of problem

50%

30%

20%

0%

10%

20%

30%

40%

50%

60%

Employee Inefficiency

Working Environmeent

Employee Dis Satisfaction

Defect in Machinery


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Time Series

Employee Inefficiency

0%

10%

20%

30%

40%

50%

60%

Day 1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 7

Working Environment

Employee inefficiency

Defect in machinery


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Ch # 5 3-Analysis

Skills Competition

Laziness Prejudice

Drug addiction Politics

Top management Load shedding

Communication Financial problem

Human Resource

Employees Environment

Commitment Resources

Employees are n

satisfied from j


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Ch # 6:

Improvement

we discussed many causes above that were reason of inefficiency of employees and employees

not showing performance so we think that delay in printing department

due to defect in printing machine so we repaired our machinery and replaced ourmachinery then problem is minimized

for maintain and providing good environment to employees we delivered lecture oncooperation, collaboration and mutual understanding and it is helpful for good

environment. for the satisfaction of employees we give incentives to employees and increase the

satisfaction level

we appreciate and motivate the employees work and performance


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Six Sigma Calculations After Improvement

Daily Production = 130,000 Meter

NO of Defects = 1550 Meter

Size Of the Sample = 130,000

Defects per million = 11923

Sigma Metric = 3.8


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After the implementation, the improvement in production and deficiency in error.

0%

5%

10%

15%

20%

25%

Day 1 Day 2 Day 3 Day 4 Day 5 Day 6

Working environment

Employee Dis Satisfaction

Defect in Machinery

20%

15%

5%

0%

5%

10%

15%

20%

25%

employees inefficiency

working enviorenment

emloyee dis satisfaction

defect in machinery


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Control:

After implementing the solution, we concluded that improvement implementation brought

significant benefit to YAT. That is why, we standardized these solutions to further avoid such

problems.

Standardized Solution:

Repair and replace our machinery and install some new plants and machinery that works more

efficiently.

Put emphasis on co-operation and collaboration in the organization to make environment

friendly.

Provide incentives and allowances to satisfy employees.

Appreciate employees to increase motivation.

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