Application of six sigma methodology to reduce the cycle time of acceptable quality level (AQL) audit procedure: a study based on Hela Intimates (Pvt) Ltd, Narammala

Abstract

Many organizations make an attempt to apply new concepts to improve the business processes which address the customer’s requirement. Lean Manufacturing, Six Sigma are few systematic approaches that can be practice to reduce waste and improve value, make products with fewer defects with customer focus (high quality, low cost, shorter delivery time) (Itkin, 2008; Chee, 2008), as well as robust production operations, reduce the cost (Fliedner, 2008, Kaushik et al 2012).Six Sigma is a process- driven approach in the aim of reducing the defect in an organizational process focusing the customers’ requirements in greater value (Kwak and Anbari 2006).

Under quality Management Framework Six Sigma Methodology is considered as a set of Statistical tools which can be used for process improvement (Goh and Xie 2004; McAdam and Evans 2004). Under Six Sigma methodology, DMAIC process is a widely used methodology to improve quality and it can be extended to Total Quality Management (TQM) (Black and Reverer 2006; Kumar 2007).It stands each letter respectively Define, Measure, Analysis, Improve and Control. Define stage highlights the identification of quality problem and scope of the project. Measure stage is defined as measuring the current process of performance. Under Analysis stage, the data related to the quality problem is analyzed by using statistical tools and quality tools. Improve stage defines as to improve the current process by selecting critical solutions for the quality issue. Control stage highlights to maintain the improved process and leads to continues improvement. By applying Six Sigma application many organizations achieved, more benefits by improving their operations processes (Prasad et a., 2012); while many countries gained a significant contribution towards the overall economy by increasing their Gross Domestic Products (Tjahjono et al., 2013).

According to Stolzer and Halford (2004) studies, they have identified that this application is more sophisticated and relevant to gain more return on investment of particular air carrier organization. (Prasad et al 2012) applied Six Sigma methodology to engineering education institute and identified that this methodology is a powerful tool to eliminate waste and improve their operations process. (Zasadzień 2017) Highlighted that Six Sigma methodology was successfully applied to a maintenance process in Poland. Therefore, the researcher used this Six Sigma methodology to improve the Acceptable Quality Level (AQL - is the final quality audit procedure to clarify whether the produced items are tally with the specification) in sample checking process at Hela Clothing, Narammala as it takes more time than the standard time given by the SOP (Standard operating procedure). This is a critical quality problem of the organization and researchers made an attempt to reduce the AQL process time and improve the process by using Six Sigma methodology.