STUDY ON QUALITY CONTROL IN SPINNING INDUSTRY

Operations Management

The study investigates the usage of six sigma DMAIC approach to reduce defect rates in Jaisar spintex pvt ltd,.This is a systematic approach to defect minimization based on the DMAIC methodology's five phases of Define, Measure, Analyze, Improve, and Control. It focuses on the reduction/elimination of four basic types of defects in the Weaving section of Jaisar spintex pvt ltd., including Starting mark,Knot, Faulty weaving, Missing and double pick/ end. In different phases, different six sigma tools were used. The define phase clearly describe process map, which includes how they used to assess quality of product. In Measurement phase the calculation of level of sigma has been done by calculating number of defects per beam. Continuous evaluation of the weaving process during the analysis phase, with rigorous brainstorming sessions for the cause and effect diagram. Cause and effect analysis was used to discover the root causes of those faults, and Pareto analysis was used to identify the major types of defects. The improve phase focuses on optimizing the critical root causes that effect faults with their variables and levels. A risk matrix table was constructed to depict the risk, likelihood of occurrence, and impact of various scenarios (Table 2). These problems were recognized, and the procedures that could be taken to fix each fault were determined. In control phase, FMEA table has been used to identifying potential failure modes, their impacts and severity, causes, risk priority numbers (RPN), and preventive actions. The result By eliminating three major defects due to loom settings and the other improvement measures, the percentage of B-grade fabric was reduced dramatically than the previous level resulting in improvement in sigma level from 3.1 to 3.5, and increase in profits of 1.23 lakh per month.

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