A Case Study of Six Sigma Define-Measure-Analyze-Improve-Control (DMAIC) Methodology in Garment Sector

Main Article Content

Abdur Rahman
Salaha Uddin Chowdhury Shaju
Sharan Kumar Sarkar
Mohammad Zahed Hashem
S. M. Kamrul Hasan
Ranzit Mandal
Umainul Islam


This paper demonstrates the empirical application of Six Sigma and Define-Measure-Analyze-Improve-Control (DMAIC) methodology to reduce product defects within a garments manufacturing organization in Bangladesh which follows the DMAIC methodology to investigate defects, root causes and provide a solution to eliminate these defects. The analysis from employing Six Sigma and DMAIC indicated that the broken stitch and open seam influenced the number of defective products. Design of experiments (DOE) and the analysis of variance (ANOVA) techniques were combined to statistically determine the correlation of the broken stitch and open seam with defects as well as to define their optimum values needed to eliminate the defects. Thus, a reduction of about 35% in the garments defect was achieved, which helped the organization studied to reduce its defects and thus improve its Sigma level from 1.7 to 3.4.


Download data is not yet available.

Article Details

Author Biography

Abdur Rahman, Shahjalal University of Science and Technology, Sylhet

Department of Statistics, M.Sc. Student


ADAMS, C. W.; GUPTA, P.; WILSON JR., C. E. (2003) Six Sigma deployment, Elsevier Science, Burlington USA.

ALBRIGHT T.; LAM M. (2006) Managerial Accounting and Continuous Improvement Initiatives: A Retrospective and Framework., Journal of Managerial Issues, v. 18, n. 2, p. 157-174.

ANTONY, J.; BANUELAS, R. (2001) Six Sigma: A Business Strategy for Manufacturing Organization. Manufacturing Engineering, v. 8, n. 3, p. 119-121.

BANUELAS, R.; ANTONY, J.; BRACE, M. (2005) An application of Six Sigma to reduce waste, Quality and Reliability Engineering International, v. 21, n. 6, p. 553-570.

BHOTE, K. R.; BHOTE, A.K. (1991) World-class quality: using design of experiments to make it happen, 2nd Edition, American Management Association, New York.

BREYFOGLE III, F. W.; CUPELLO, J. M.; MEADOWS, B. (2001) Managing Six Sigma, John Wiley & Sons Inc., New York.

BRUE, G.; HOWES, R. (2005) Six Sigma: the MacGraw-Hill 36 hours course, MacGraw-Hill, New York.

DALE, B. G.; WIELE, T.; IWAARDEN, J. (2007) Managing Quality, 5th Edition, Blackwell Publishing Ltd., Oxford.

DEMING, W. E. (1993) The new economic for industry, government, education, MIT Center for Advanced Engineering Studies, Cambridge, MA.

EVERE, L.; BLACK, K. (2003), Integrating Six Sigma with total Quality Management: A Case Example for Measuring Medication Errors. Journal of Healthcare Management, v. 48, n. 6, p. 377-391.

FURSULE, N. V.; BANSOD, S. V.; FURSULE, S. N. (2012) Understanding the Benefits and limitations of Six Sigma Methodolgy, International Journal of Scientific and Research publications, v. 2, n. 1, p. 1-9.

GARZA-REYES, J. A.; ORAIFIGE, I.; SORIANO-MEIER, H.; HARMANTO D.; ROCHA-LONA, L. (2010) An empirical application of Six Sigma and DMAIC methodology for business process improvement, Proceedings of the 20th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM), July 12-14, California, US, p. 92-100.

GEOFF, T. (2001) SIX-SIGMA: SPC and TQM in Manufacturing and Services. Gower Publishing, Chapter 1, The development of quality, p. 1-3.

GIJO, E. V.; SCARIA, J.; ANTONY, J. (2011) Application of Six Sigma methodology to reduce defects of a grinding process, Quality and Reliability Engineering International, [Online] (3 May 2016).

HAMMER, M.; GODING, J. (2001) Putting Six Sigma in perspective, Quality, v. 40, n. 10, p. 58-63.

HARRY, M. J. (1998), Six-Sigma: A breakthrough strategy for profitability. Quality Progress, v. 31, n. 5, p. 60-64.

HENDERSON, K. M.; EVANS, J. R. (2000). Successful implementation of Six Sigma: benchmarking general electric company. Benchmarking: An International Journal, v. 7, n. 4, p. 260-281.

HOERL, R. W. (2001), Six-Sigma and the future of the quality profession, Quality Progress, v. 31, n. 6, p. 35–42.

HOLTZ, R.; CAMPBELL, P. (2004), Six Sigma: Its implementation in Ford’s facility management and maintenance functions. Journal of Facilities Management, v. 2, n. 4, p. 320-329.

KNOWLES, G.; WHICKER, L.; FEMAT, J.; CANALES, F. (2005) A conceptual model for the application of Six Sigma methodologies to supply chain improvement. International Journal of Logistics: Research & Applications, v. 8, n. 1, p. 51-65.

KUMAR, U.D.; NOWICKI, D.; RAMIREZ-MARQUEZ, J. E.; VERMA, D. (2008) On the optimal selection of process alternatives in a Six Sigma implementation, International Journal of Production Economics, v. 111, n. 2, p. 456-467.

LINDERMAN, K.; SCHROEDER, R.; ZAHEER, S.; CHOO, A. (2003) Six Sigma: a goal-theoretic perspective. Journal of Operations Management, v. 21, n. 2, p. 193-203.

MARKARIAN, J. (2004) Six Sigma: quality processing through statistical analysis, Plastics. Additives and Compounding, v. 9, n. 4, p. 28-31.

OMACHONU, V. K.; ROSS, J. E. (2004) Principles of total quality, 3rd Edition, CRC Press LLC, Florida.

PYZDEK, T.; KELLER, P. A. (2010) The Six Sigma handbook: a complete guide for greenbelts, black belts, and managers at all levels, 3rd Edition, McGraw-Hill Companies Inc., New York.

PYZDEK, T. (2003) The Six Sigma handbook: a complete guide for green belts, black belts, and managers at all levels, McGraw-Hill Companies Inc., New York, NY.

RYLANDER, D.; PROVOST, T. (2006) Improving the Odds: Combining Six Sigma and Online Market Research for Better Customer Service. SAM Advanced Management Journal, v. 71, n. 1, p. 13-19.

SHAHRIZAL, B. M. R. (2013) The Use of Design for Six Sigma (DFSS) Methodology in Product Design. Proceedings of the World Congress on Engineering, v. I, July 3 - 5, London, U.K.

STAMATIS, D. H. (2004) Six Sigma fundamentals: a complete guide to the system, methods and tools, Productivity Press, New York.

WYPER, B.; HARRISON, A. (2000) Deployment of Six Sigma methodology in Human Resource function: a case study. Total Quality Management, July, v. 11, n. 4, p. 720-727.

Most read articles by the same author(s)