A Case Study for Process Improvement with Lean Six Sigma in A Textile Industry

Abstract

Purpose – The main purpose of this research is; It is the determination of waste and errors in process improvement in the textile industry with lean six sigma methodology. And also; Whether there is adecrease in values such as Production Flow Time, Processing Time, Per Unit Error Rate and PreparationTime; It is to determine whether there is an increase in the values of First Time Efficiency and GeneralEquipment Effectiveness.

Design/Methodology/Approach – The model of this research applied in the textile industry is presentedwithin the framework of the define, measure, analysis, improve and control criteria of lean six sigma. Theresearch data were collected by the researcher herself, using the observation technique, betweenSeptember 2019 and August 2020. Lean production techniques in research; value stream mapping, totalproductive maintenance, 6S, just in time production, kaizen, takt, standard work, andon and visualmanagement techniques are used. Minitab and excel programs were used in the analysis andinterpretation of the data.

Findings – With the successful implementation of Lean Six Sigma's IdentificationMeasurement-Analysis-Phase Improvement-Control cycle, many waste and defective products in the business have been reduced.In this context, there is a decrease of 75.13% in Production Flow Time, 32.5% in Process Time, 12.6% inPreparation Time, 41.2% in Error Rate Per Unit, First Time Efficiency It was concluded that there was anincrease of 4.4% in and 32.4% in General Equipment Effectiveness.