Six Sigma Analysis of Sopura Silk Mills

Slide 1
Introduction
Sopura Silk Mills LTD.
• established in 1983 and produces various silk based products
• The main providers of silk worms are the local farmers and exported high quality
• The main defects in product occurs mainly when silk fibers are transformed into thaan.
• Does not currently apply six sigma
Supply Chain Management

• Silk worm farmers and traders. (Main suppliers)
• Logistics include trucks that bring cocoons from
Tanor and Shibgonj, warehouse where the
cocoons are stored (In Sopura, rajshahi)
• Some high quality cocoons are imported from
China
Concept of six sigma Slide 2
• The often used six sigma is a set of tools and strategies used for process improvements originally
developed by Motorola in 1985. (1)
• Six sigma improves quality by identifying and removing the causes of defects and minimizing variability.
Literature review Slide 3
Author’s name Year Name of the Article Name of the Conclusion Recommendations
source
Dewan Maisha 2017 Applying DMAIC American . In the past, sigma level was Creation of awareness as a method
Methodology to Reduce Journal of 2.69. After Improve phase, it of preventive measure among the
Zaman, Nusrat Defects of Sewing Section has been upgraded to 2.8. stockholders.
Hossain Zerin Industrial and
in RMG: A Case Study
Business
Management
Md. Mazedul Islam, 2013 Minimization of Defects in Research Journal “Right first time, right on time, Record all faults found at final
Adnan Maroof Khan, the Sewing Section of of Management right every time. inspection for immediate.
Md. Mashiur Rahman Apparel Industry Sciences correction and to identify need for
Khan preventative specific stage of
production
Rajat Ajmera, Prabhuling 2017 Lean Six Sigma International The problem of batch processing of integrates Lean tools within Six
Umarani, K.G.Valase Implementation in Textile Research Journal existing is addressed
by using single piece movement of Sigma DMAIC
Industry of Engineering and methodology to enhance the
WIP. Thus by
Technology (IRJET) converting long assembly line into bottom-line results and win
work cells, the customer
assumed worker multi-skilling seems loyalty.s
effective as well as
communication between operators
is fast and accurate.
Slide 4
Based on the review, the Objectives are as follows
 Identifying company's inefficiency and degree of defects in

produced goods.
 Determining current level of sigma in the production process
 Analyzing the problem with current manufacturing process
Slide 5
Six Sigma Approach to design

Six sigma is approached in the design stage of the product manufacturing process. There are many methodologies
through which Six Sigma can be achieved. Sopura Silk MIlls does not apply any Six Sigma methods for either
defect reduction or cycle time reduction. (2)
Analysis of Supply Chain Delivery Performance Slide 6
Supplier Inputs Process Outputs Customers

Local farmers 1. Cocoons 1. Winding Silk fiber, thaan Thaan users
supply most of 2. Chemical 2. Bobing and silk based (Sharee and
the cocoons of agents 3. Double finished goods. other cloths
silkworm with 3. Water stringing manufacturers)
some export of 4. Looms 4. Warping Consumers of
higher quality 5. Gas drum Cycle finished goods.
cocoons from 6. stoves 5. Weaving
China
Data was Collected from Md. Bashar Ahmed, senior scientist,

Bangladesh Silk Board, Rajshahi division
Data presentation
Slide 7
Table 1: Defected products between July to September
Defects I have Month Inconsistent Discoloration Physical Total
found Texture damage
July 4 3.5 15 22.5
 Inconsistent
texture August 9 4.6 10 23.5
 Discoloration September 8 5 2.5 22.5
 Physical
Damage
Table 2: Defected % for the defected types
Defect type Total 3 months Defect percentage Cumulative %

defect in SQM
Inconsistent 21 30.88% 30.88%
texture
Discoloration 13.1 19.04% 49.92%
Physical Damage 34.8 50.58% 100%
Total 68.8% 100%
Table 3: DPO Slide 8
Month Total Defects in manufacturing Production per month DPO

July 22.5 225m .03333
August 23.5 237m .03305
September 22.8 225m .03377
Table 4: DPMO
Months DPO DPMO % defect %yield Level of
Sigma
July .03333 33330 3.333% 96.6677% 3
August .03305 33050 3.3035% 96.698% 3
September .03377 33770 3.377% 96.623% 3
Total .10015 100150 AVG: 3.338 96.66% 3
Slide 9
Materials Men
Low quality High
cocoons from maintenance Only 40 labor Skill gap that is
farmers cocoons working in in human
processing of resource
cocoons
Looms are not capable of

producing 22-25 mm Inefficiency in
fibre of international Delivery system
standard and order
acquisition
Machine System
Slide 10
Table 5: Analysis of defects
Type of defect Potential problem Root cause

Inconsistent texture Raw material cocoon Defected cocoons that
cannot induce sericin
protein on fibers properly
Discoloration Process of Chemical refinement Sometimes inconsistency
occurs due to improper
use of chemicals used for
refinement of fibers.
Physical damage Machines (old looms) Outdated old looms causes
much of the physical
damage that occurs
Design of Six Sigma Supply chain
Slide 11
There is no specific way for implementing Six sigma in Sopura Mills to improve their production efficiency
at this stage with the limited resources. But here are some precautionary measures by which Defect can
redeuce
number Root cause Improvement plans
1 Defected cocoons that cannot Implement PDCA proceedures when suppliers are delivering
induce sericin protein on fibers the products. set a standard, take in the cocoons, check
properly whether the cocoons match the standard and set up action
plans for yes or no scenario.
2 Sometimes inconsistency Designate chemists and train workers to maintain standards
occurs due to improper use of of chemical use.
chemicals used for refinement
of fibers.
3 Outdated old looms causes Import better state-of the art loom from china with better
much of the physical damage productivity and safer for production.
that occurs
Slide 14
Summary
Based on the previously mentioned findings, it can be concluded that Sopura Mills has a supply chain that lacks
efficiency in its production of thaan. Sigma level was found out to be 3 and sopura lacked any previous methods
of Six Sigma in its production. Some Literatures were reviewed to understand how Six sigma could be better
implemented. A proper Six sigma evaluation can help with the Company to get better profits.
References
(1) Kwak, Y. H., & Anbari, F. T. (2006). Benefits, obstacles, and future of six sigma approach.
Technovation, 26(5-6), 708-715.
(2) Uddin, S. M., Hasan, R., & Hosen, S. (2014, December). Defects minimization through DMAIC
methodology of Six Sigma. In International Conference on Mechanical, Industrial and Energy
Engineering, Khulna-Bangladesh.
Thank you

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Slide 1

Supply Chain Management

 Identifying company's inefficiency and degree of defects in

Six Sigma Approach to design

Supplier Inputs Process Outputs Customers

Data was Collected from Md. Bashar Ahmed, senior scientist,

Defect type Total 3 months Defect percentage Cumulative %

Month Total Defects in manufacturing Production per month DPO

Looms are not capable of

Type of defect Potential problem Root cause

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