It was really excited to run my First Lean Six Sigma Black Belt Project in my factory . And during the project im really great full to my honorable management . Now im posting this project for the audience of this site .

1. Lean Six Sigma
Million Dollar Money Belt
Project Undertaken By
Md.Iftakhar Islam
Trainer
Mr. Prabhas Surana

2. FACTORY HISTORY
• Established : 2005
• Number of Employee : 3500
• Total Land Area : 2.9 acres
• Factory Floor Space : 2,10,000 sft
• Geographical Location : Latitude -23.984335
Longitude-90.382762

3. COMPOSITE MANUFACTURING CAPACITY
• Capacity /day
Own printing unit at Narayangonj

4. MAIN BUYERS

5. EXPERTISE IN PRODUCT LINES
• Text
• T-Shirt / Tank Tops
• Polo Shirt
• Shorts / Trousers
• Sweat Shirt /Jackets
• Any Kinds of Infant
Garments
• All Kind of Knit
Garments

6. Define – Present Pain Areas
Short Term
Long Term
- Reduce defects ,delays and deviations .
- Use data to focus on improvement efforts .
- Evaluate and realign the work flow into production .
- Ensure measuring tools accuracy .
- CAP implementation in each production process to
introduce the zero defect concept .
- Improve machine & its operators performance .
- Ensure Kanban for RFT manufacturing .
- Reduce process constraints & errors .
- Improve suppliers delivery lead time .
- Reduction in export lead time
- Increase cut to ship ratio.
- Recognize , review and refocus efforts .
- Stabilize and sustain the improvements .

7. Define Phase – Project Charter
Business Case
TEXEUROP (BD ) LTD impacted by huge
loss from 1st January 2015 to 30 June
2015 , USD $ 18,00000 accounted for 10%
defect which was higher than desired and
resulted a big challenge by delivering
defective product to retail stores in Europe
& USA .Where the sigma level counted 2.7
& Saving Target USD 200,400/-
Opportunity Statement
TEXEUROP (BD ) LTD started its
quality improvement journey with TUV
SUD , South Asia on April 2015 . TUV
SUD ‘s coach is providing guidance &
training to improve production process
by statistical tools & lean techniques. .
We confidence in to accomplish our
goal by 31st Dec.2015 .
Goal Statement
( By 31st December 2015 )
- Attain sigma level -3.000
DPMO - 66,800
Yield % - 93.32
Savings Target - USD 200,400
- 90 % reduction in Lead time .
- 90% reduction in all inventories .
- 100% increase in productivity.
- 50% reduction in process errors
Project Scope
The project scope covers all production
process of TEXEUROP ( BD ) LTD , its
products performance ,process input –
out put , suppliers , brands , retail
stores & all other stake holders .

8. Define Phase – Project Time Line
Team
Selection
Activity Sep 2015 Oct 2015 Nov’2015 Dec’2015
Form Team 02.09.15
Finalize Charter 03.09.15
Training 06.09.15 To be
continued
To be continued To be
continued
Gather Data 15.09.15 To be
continued
To be continued To be
continued
Analyze Data 30.09.15 To be
continued
To be continued To be
continued
Select Solutions 22.10.15
Develop Implementation
Plan
25.10.15
Monitor Results 28.10.15 To be continued To be
continued
Closure and Recognition 31.12.15

9. Team Members
S.No Name of the
Team Member
Functional
Role
Project
Responsibility
1 Engr. Zulfiker Ahmed Team Member Project Sponsor
2 Md.Iftakhar Islam Project Leader Project Leader
3 Mr. Minhaj Rahman Team Member Production Process
Improvement
4 Mr. Hasib Team Member Data Analysis & Project
Planning
5 Mr. Tapan Team Member Product Quality
Improvement

10. Targeted Benefits
- Attain sigma level -3.000
DPMO - 66,800
Yield % - 93.32
Cost Reduction -
- 90 % reduction in Lead time .
- 90% reduction in all inventories .
- 100% increase in productivity.
- 50% reduction in process errors
- 5% defect reduce at finished product stage

11. Establish Performance Parameters
1. Pilot Line efficiency baseline is 39.% ( As per August 2015 ) & will
improve by 20% points by 31st December 2015 .
2. Pilot Line sewing cost produced baseline per person in 10 hours is 765
taka ( as per August ) & will improve by 20 % by 31st December 2015 .
3. Pilot line Productivity baseline per person is 37.9 pcs ( as per August )
& will improve by 15 % by 31st December 2015.
4. Factory cut to ship ratio baseline is 93.67 ( as per June , July , Aug
2015 ) and will improve 1% by 31st December 2015 .
5. Up Skilling 10 Number of workers in sewing lines .
6. Improve method at least 07.
7. Convert 06 numbers of operators as zero defect operators .
8. Root cause of skip stitch , broken stitch , Oil , Stain needs to be found
out and actions should be taken .

12. Process Mapping ( Macro Process )
Dyed
Fabrics as
Input
Dyed Fabrics
Quality Check
process
Fabrics Cutting
process
Sewing
Process
Finished
Garments
Fabrics as
Output
Finishing
Process

13. Process Mapping ( Micro Process )
Dyed Fabrics Quality Check process
Fabrics
Receive from
Dyeing
GSM Check
Check the
dimensional
stability
10% Fabrics
Roll Inspection
per Lot Based
on 4 Point
System .
Check the
Shrinkage of
Fabrics
Fabrics Ready
For delivery
to Cutting .

14. Process Mapping ( Micro Process )
Fabrics Cutting Check process
Fabrics from
warehouse
CAD Program for Bulk cutting
Lay Spreading
Cutting
Number Sticker Attachment /Numbering
Bundling
Cut parts
ready for
Input

15. Process Mapping ( Micro Process )
Sewing Process
Cut panel Receive from
cutting section
10% Cut Panel Check From Each Bundle
Stitch Monitoring
Hourly In Line processes Inspection
Sewing End Line 100 % Inspection
Garments are ready to
deliver for finishing

16. Process Mapping ( Micro Process )
Finishing process
Receive sewing
Garments
Pressing As Per Finished Pattern
After Pressing Quality Check
Hourly Audit of Finishing
Metal Detection With Conveyer belt
Assortment & Carton the packs
Day Audit
Pre - Final Inspection
Garments are ready for
Final Inspection as per
buyers standard
Folding & Poly

17. Measurement System Analysis for
Laboratory Measuring Equipment's
ISO 105 C10:2006
ISO 105 C06:2008
Crock Meter
ISO 105X -12:2001(E)
Color Fastness to Wash Color Fastness to Rubbing
Wash Fastness Testing M/c
Spectrophotometer –SF600 X
AATCC 173 -2009 ( Revised )
Electronically Shade Check
ICI Pilling Box
ISO 12945-1:2000
Color Fastness to ICI Pilling

18. Measurement System Analysis for
Laboratory Measuring Equipment's
Perspiration Test Incubator
ISO 105E 04:2008
Pneubrust
ISO 13938-2:1999
Color Fastness to Perspiration Bursting strength
Xenon Arc Light Fastness Tester
ISO 105B 02:2000
Test – Color Fastness to Light Dimensional Stability
Washcator
ISO 6330:2008 Amd 1:2008
ISO 3759:2007
ISO5077:2007

19. Calibration Certification for
Measuring devices From Accredited Laboratory

20. Calibration Schedule of Factory
SL.No Description Certificate No Issue date
Date of
Calibration
Suggested
Due Date
1 Color Assesment Cabinet(Light Box) 015/(26-07)/6369 29-Jul-15 27-Jul-15 27-Jul-16
2 Fusing Machine 015/(26-07)/6399 29-Jul-15 27-Jul-15 27-Jul-16
3 Metal Detector Machine 015/(26-07)/6398 29-Jul-15 27-Jul-15 27-Jul-16
4 Digital Lux Meter 015/(26-07)/6401 29-Jul-15 27-Jul-15 27-Jul-16
5 Heat Seal Machine 015/(26-07)/6400 29-Jul-15 27-Jul-15 27-Jul-16
6 Metal Detector Machine 015/(26-07)/6397 29-Jul-15 27-Jul-15 27-Jul-16
7 Color Assesment Cabinet(Light Box) 015/(26-07)/6369 29-Jul-15 27-Jul-15 27-Jul-16
8 Heat Seal Machine 015/(26-07)6400 29-Jul-15 27-Jul-15 27-Jul-16
9 Fusing Machine 015/(26-07)/6399 29-Jul-15 27-Jul-15 27-Jul-16
10 Metal Detector Machine 015/(26-07)/6398 29-Jul-15 27-Jul-15 27-Jul-16
11 Digital Lux Meter 015/(26-07)/6401 29-Jul-15 27-Jul-15 27-Jul-16
12 Metal Detector Machine 015/(26-07)/6397 29-Jul-15 27-Jul-15 27-Jul-16
13 Electronic Balance 015/(11-08)/6558 16-Aug-15 11-Aug-15 11-Aug-16
14 Hand Driven Crock Meter 015/(11-08)/6557 16-Aug-15 11-Aug-15 11-Aug-16
15 Incubator 015/(11-08)/6559 16-Aug-15 11-Aug-15 11-Aug-16
16 ICI Pilling Tester (Orbitor) 0158/(11-08)/6556 16-Aug-15 11-Aug-15 11-Aug-16
17 Wascator 015/(11-08)/6560 16-Aug-15 11-Aug-15 11-Aug-16
18 Tumble Dryer 015/(11-08)/6561 16-Aug-15 11-Aug-15 11-Aug-16
19 Gyrowash 015/(11-08)/6552 16-Aug-15 11-Aug-15 11-Aug-16
20 Washing Machine 015/(11-08)/6563 16-Aug-15 11-Aug-15 11-Aug-16
21 Steel Scale 015/(16-08)/6609 18-Aug-15 16-Aug-15 16-Aug-16
22 Button Pull Tester 015/(21-09)/6971 21-Sep-15 20-Sep-15 21-Sep-16
Tex eu ro p (BD) L td
Vogra,Joydevpur,Gazipur
Calibration Schedule

21. Data Collection Check Sheets
Skipped
Stitch
Broken
Stitch
Oil Dirt
Print
Defect
Embroide
ry Defect
Fabric
Defect
/Sewing
Reject
Dyeing
Defect
Measerm
ent
Problem
Stitching
Defect (
open
seam ,
uncut
thread
Neck Shape
defect
Wavy (
Zipper
,Bottom
etc )
Insecure
Label
/Button/E
yelet Etc
Twisting
Shape
Problem
Placemen
t
Up-down(
Back-
Front ,
Sleeve)
Pressing
Defect
Insect
1-Sep jok/8166/011 184 95 157 95 127 142 18 33 3 8 23 21 906 11059 700 10359 8.19 6.33
2-Sep jok/553/011 194 170 167 176 239 148 25 30 5 20 23 1197 11014 995 10019 10.87 9.03
3-Sep jok/66/95/16 116 175 98 180 14 230 150 29 35 8 26 25 1086 11626 996 10630 9.34 8.57
4-Sep
5-Sep 110/66/jok/16 180 158 98 155 125 123 14 31 5 19 24 932 9699 915 8784 9.61 9.43
6-Sep 66/63/jok/17 175 115 75 150 124 137 15 28 21 25 865 10671 836 9835 8.11 7.83
7-Sep 63/66/jok 166 151 72 149 119 234 11 27 17 18 964 10224 932 9292 9.43 9.12
8-Sep 8166/110 193 177 166 174 138 145 23 32 8 21 24 1101 11205 1009 10196 9.83 9.00
9-Sep 8166/200 192 175 179 261 124 139 17 35 12 28 23 1185 10625 1095 9530 11.15 10.31
10-Sep 201/8166 160 115 152 149 119 134 12 27 17 18 903 8164 835 7329 11.06 10.23
11-Sep
12-Sep 66/63/746 174 175 170 80 130 150 29 35 8 26 24 1001 11662 936 10726 8.58 8.03
13-Sep 63/73 180 155 159 51 125 238 15 28 21 25 997 8409 700 7709 11.86 8.32
14-Sep 8166/89/90 156 145 148 44 95 129 9 26 16 17 785 6424 639 5785 12.22 9.95
15-Sep 746/8166 144 128 124 13 65 118 15 10 11 13 641 4677 555 4122 13.71 11.87
16-Sep 453/690 184 168 157 56 68 145 18 33 10 25 23 887 10706 778 9928 8.29 7.27
17-Sep 8166/140 180 170 155 56 125 142 18 33 8 25 20 932 9738 923 8815 9.57 9.48
18-Sep
19-Sep 8166/571 185 168 158 56 128 139 20 33 10 23 22 942 10449 936 9513 9.02 8.96
20-Sep 66/6423/775 181 159 161 56 98 138 15 32 5 22 20 887 9997 846 9151 8.87 8.46
21-Sep 8166/6423/401 191 172 175 58 124 120 17 35 12 27 22 953 10280 884 9396 9.27 8.60
22-Sep 23/01/66/63 113 196 188 92 129 149 28 39 11 27 26 998 8911 918 7993 11.20 10.30
23-Sep
24-Sep
25-Sep
26-Sep
27-Sep
28-Sep
29-Sep
30-Sep
3248 2967 2759 2051 14 2432 2820 348 582 3 110 415 413
1.75 1.60 1.49 1.11 0.01 1.31 1.52 0.19 0.31 0.00 0.06 0.22 0.22
8.85%
D.H.U.
Total:
18162 185540 16428 169112 9.79
TEXEUROP (BD) LTD Unit-3
Finishing Inspection Sheet
Date Style No.
Defects
Total
Defects
Total No. of
Pieces
Inspected
Total No. of
Defective
Pieces
Total No.
of Pieces
Pass
DHU
Percentage of
Defective
Month: September-15

22. Pareto Analysis on Major Defects

23. Major Defects
6. Dirt
7. Insecure Label
8. Up & down2. Broken Stitch
1. Skipped Stitch
3. Stitching Defect
5. Measurement Problem
4. Oil
Others : Unexpected dot mark , Print Bleed , Broken Print ,Design
Displaced , Tension Tight , Irregular Stitch , Stitch Wavy , Puckering
, Label Slanted, Yarn Shading .
Stitching Defect : open Seam , Raw Edge , Uneven Stitch Margin ,
Uneven Top Stitch , Twisting , Pleated Form , Poor Neck Shape ,
Destroyed Side Seam , Measurement Discrepancy , Excess thread ,
Drop Stitch , Needle Cut .
9. Others

24. Process Base Line Sigma Level

25. Define Performance Goals
1. Increase sewing line efficiency
2. Increase productivity
3. Introduce Zero defect Operators
4. Up Skilling the sewing Operators
5. Improve the cut to ship ratio
6. Reduce the defect level in process
7. Consistent MSA
8. Improve the sigma level .
9. Reduction in process errors

26. Process Improvement Target
1. Identify supply chain constrains
2. Identify supplier performance
3. Improve Fabrics inspection process
4. Assure proper fabric relaxation process .
5. Garments sewing In Line inspection
6. Avoid measurement discrepancy .
7. Continuous improvement in supply chain
8. Regular customer survey

27. Cause & Effect Diagram
much Higher
& Defect
Sewing Alter
Working Condition
Measurements
Methods
Material
Machines
Men
Bundle Mistake
Poor Trimming
Creased CAD Marker
Improper Check
Munselltest
Record Tracking
Handling
Blunt Needle
Adjustment
Dyeing Problem
Knitting Problem
Wrong Thread Flow
Spring Tension
Curled edge
Cleanliness
Maintence
Amount
Washing chemical
Print Density
Excess pilling
No needle change schedule
No defect Standard
Improper fabricRelaxation
Yarn lot are not same
Non Calibrated measurment tape
No before & after wash Comparision
Dorito stitch failed
No GSMtest before wash
Dust Accumulation
Poor House Keeping
High Defect Diagram

28. Why Why Analysis ( Broken Stitch )

29. 5 S & Workplace Findings
Sl. No. Unit / Location Findings Major Findings / Evidence Corrective Action Plan Responsible Person Due Date Follow up date
1 Cutting-1
Sharp tool as Safety Hazards
( Equipment is not kept
safely)
2 Cutting-1
Unneeded Materials Blocked
Aisles
3
Cutting-2
(Naim-
160571)
Cutting work continude
without Gloves /PPE,
It’s a great cause of Safety
hazards
Date: 06.10.2015
TEXEUROP (BD) L TD
5 S & workplace Audit Findings

30. 7 Waste Audit Findings in Facility
-
Transportation Inventory Motion Waiting
Over Processing Over Production Defect ( Oil Spot )

31. Measurement System Analysis Checked by Customer
Preventive Action by Factory
To reduce the measurement discrepancy factory
introduced Calibrated measuring tapes for 06 ( six )
months .Recheck process shall be in 3 month interval
for the issued measuring tapes .
Major Findings
Customer Checked MSA in production Floor & found
unacceptable range of deficiency for measuring tapes
of Quality Department.
•

32. Vital Few X’s Chosen for Improvement
Y
( Dependable Variable )
X
( Independent Variable )
Fabrics Defect Reduction( Hole ,
needle mark , Sinker mark )
Measurement Accuracy
100% fabrics check &
proper relaxation
No of Defect in Sewing end Line TLS in Sewing Line , Operating
Process monitoring , Training
Time to fulfill a Job Requisition Accurate job profile ,
interviewing of process
operators
Time to fulfill an order Type of Garment , Supplier ,
Value of garments , Location ,
time of day when order is
received .

33. Improvement Action Plan
Texeurop (BD) Ltd
Identification of Expectation From Supplier Department
Coustomer Supplier Expectation and Improvement
Merchandising Dept
Sample Dept Reduce Sample remake issue.
Planning Dept
Reduce of changing plan per month.
Revised plan will issue on time.
Planning Dept Merchandising Dept
Complete file will given by Merchandiser in one pakage.
Attend Weekly meeting in regular basis.
Cutting Dept
Cad Dept
Marker for Sizeset within 3 hours.
Hard copy of Marker- provide along with Sizeset marker.
Planning Dept
Complete file need for cutting ( Booking sheet,Mini Marker,Measurement
Sheet, Update comments, Trim card).
Store Dept
Woven Fabric,Interling most of the case quantity are not right according to
challan.In the time of issue both will ensure quantity.
Sticker bleed with this issue Mr.Nasim & Mr.Mamun will help
Sewing Dept
Cutting Dept Colorwise & sizewise input close, bellow 5000 pcs qty input close at a time
Store Dept Trims will issue in one time
QA Dept Strenthen Sewing inline process quality.
QA Dept Trafic light system implement within this month.
Maintenance Dept (sewing)
Folder issue- line are waiting for folder.
In Pre-production meeting Maintenance manager will present.
Machine servicing- how many days after 1 machine will service. Every 40 days
Machine Oil change- how long.depends on oil quality

34. Improve Process Mapping ( Macro Process )
Dyed
Fabrics as
Input
Dyed Fabrics
Quality Check
process
Fabrics Cutting
process
Sewing
Process
Finished
Garments
Fabrics as
Output
Finishing
Process
No Change In Macro Process

35. Improve Process Mapping ( Micro Process )
Dyed Fabrics Quality Check process
Fabrics
Receive from
Dyeing
GSM Check
Check the
dimensional
stability
100% Fabrics
Roll Inspection
per Lot Based
on 4 Point
System .
Check the
Shrinkage of
Fabrics
Fabrics Ready
For delivery
to Cutting .
Process Changed
Factory is checking
100% Fabrics Roll
instead of 10% roll
( 4 Point System )

36. Improve Process Mapping ( Micro Process )
Fabrics Cutting Check process
Fabrics from
warehouse
CAD Program for Bulk cutting
Lay Spreading
Cutting
Number Sticker Attachment /Numbering
Bundling
Cut parts
ready for
Input
Fabrics Proper Relaxation as per FabricsNew Process Added
Ensure 100 % Fabrics
Proper Relaxation as
per fabrics

37. Improve Process Mapping ( Micro Process )
Sewing process
Cut panel Receive from
cutting section
10% Cut Panel Check From Each Bundle
Stitch Monitoring
Hourly In Line processes Inspection
Sewing End Line 100 % Inspection
Garments are ready to
deliver for finishing
Traffic Light System Inspection ( 5 Pcs )
Audit 20% Quality Pass Garments
New Process Added
1. Traffic Light System
( Check 5 Pcs )
2. Audit 20 % QC pass
Garments .

38. Improve Process Mapping ( Micro Process )
Finishing process
Receive sewing
Garments
Pressing As Per Finished Pattern
After Pressing Quality Check
Hourly Audit of Finishing
Metal Detection With Conveyer belt
Assortment & Carton the packs
Day Audit
Pre - Final Inspection
Garments are ready for
Final Inspection as per
buyers standard
Folding & Poly
No Change In
Finishing
Process

39. Verify Process
Improvement

40. New Sigma Level

41. New Process Performance Result
New Sigma Level 2.98 from 2.77 and total saving USD 2,00,090/-
( Saving came in Sep to December 2015 )
1. Pilot Line efficiency improved from baseline 39.% to 52% by 31st
December 2015 .
2. Pilot Line sewing cost produced as 865 taka from baseline per person
in 10 hours is 765 taka ( as per August by 31st December 2015 .
3. Pilot line Productivity finally reached 56 from baseline per person is
37.9 by 31st December 2015.
4. Factory cut to ship ratio increased .5% from baseline is 93.67
5. 10 Number of workers unskilled in sewing lines .
6. 05 Sewing method improved instead of 07.
7. 06 numbers of operators made as zero defect operators .
8. Root cause conducted on skip stitch , broken stitch , Oil , Stain needs
to be found out and actions should be taken .

42. Improvement Done in SOP’s /WI’s / Control Plan etc.
1.Dyeing Fabric quality SOP added new process to check the
100% fabrics roll check in 4 point system .
2. Fabrics Proper relaxation procedure added in Fabrics Cutting
SOP .
3. Traffic Light System & 20% sewing garments audit procedure
added with sewing SOP.
4.Work Instruction issued for the calibration of measuring tapes
internally .
5. Tools Added : (a) Why why Analysis , ( b) CED , ( C) Daily
Parito analysis for defect level , (d) 5 S Implementation &
audit , (e ) Waste Identification in process .