Identification of the Vital Causes of Defects in a Dyeing Textile Industry

다국어 초록 (Multilingual Abstract)

The study aims to identify causes of defects in textile industry through a comprehensive analysis of manufacturing processes and associated factors. This applied research, based on the defect data collected from a textile industry of Lahore, Pakistan, aims to articulate and resolve the defect causes of that industry. The interesting findings are also helpful for other textile manufacturers. The six-sigma DMAIC (Define, Measure, Analyze, Improve and Control) roadmap based on five phases used to identify root causes of defects associated with textile industry. The research reveals common types of defects, their distribution across production stages and primary causes contributing to their occurrence. The five phase of DMAIC cycle extracted the significant defect contributors. The analysis shows that out of 61 selected lots, the slub (Max value=45; Mode=32) and stain (Max value=95; Mode=36) are most frequently occurring types of defects. For the statistical implication, factor analysis is applied to identify the major factors causing defects in the dyeing process. Based on the highest factor loadings, three main factors are identified: F1 (Material Defects), F2 (Fabric Imperfections), and F3 (Yarn Defects).The research addresses the causes, including regular machinery maintenance, employee training, quality control improvements and enhanced communication channels. Implementing these measures can help textile manufacturers to improve product quality, customer’s satisfaction, and overall business performance. This research makes a novel contribution to the identification and problem-solving in textile manufacturing industries.