Application of Lean Six Sigma in Textiles

The Lean System 

The Birth of the Lean System In light of information gathered by Eiji Toyoda in 1950 during his visit to the United States to learn about and examine Ford’s automotive business, it was decided that the mass production system of which Ford was the pioneer since the turn of the century was not at all suitable for Japan. This decision paved the way for a whole new understanding of production.

In other words, in the light of the information mentioned above, the foundations of the Management and production system which today is called “Lean Production” was established in the 1950s within the Japanese company Toyota under the direction of engineer Eiji Toyoda, member of the Toyoda family, and his colleague engineer Taiichi Ohno.

Textile industry

As the textile and clothing industry occupies an important place in the progress of developing countries due to its labor-intensive production structure, the employment opportunities it offers, the added value created in the production process and export possibilities, it is very desirable to see the application of lean six sigma in this area.

The industrialization of a country and the creation of an industrial society were usually achieved through the textile and clothing industry. The Lean production system, which first appeared in the automotive industry in the world, is considered to find an application area in textiles, which is also a capital intensive sector.

Thanks to the automation and modernization practices implemented in textile companies, the production processes of yarns and fabrics are simplified, labor costs can be reduced and quality defects caused by errors in production. work can be avoided.

Improvements in the business at the same time save space, shorten the process and remove the processes that do not create value for the customer by eliminating some production steps, which can also reduce the cost. of production.

Lean Six Sigma in Textiles

As the textile industry can use a lot of waste, this is where Lean Six Sigma (LSS) comes in. At THE LEAN SIX SIGMA COMPANY, we specialize in LSS because we know it helps reduce waste in the textile industry and to improve process techniques.

Starting from the different types of wastes mentioned in the Lean Six Sigma approach, this helps to ensure that overproduction does not increase inventory, that waits and delays are minimized while avoiding unnecessary transport of materials. Likewise, it reduces overprocessing, optimizes inventory levels, ensures that employees do not needlessly travel while they are working, and limits the production of defective parts.

This concept integrates the two concepts of quality management: Lean Manufacturing and Six Sigma, in order to maximize the scope and scale of the improvements brought about by one or the other of these ideas.

The tools and techniques in these two systems aim to achieve bottom-line results that improve quality management. They contribute to “zero defect” manufacturing in companies, as well as to the elimination of worthless activities. As a result, wastage is reduced, productivity is increased and costs are minimized in production.

If you are familiar with Lean Six Sigma, you know that it is a proven method for maximizing profits and that it uses applied science to achieve those goals.

Lean Six Sigma Business Improvement Methodologies will help you understand your customers and manage their requirements. They will also help to consolidate business processes to meet these requirements, use data analytics to reduce variation, and create quick and lasting solutions to improve business strategies.

Companies that do not use Lean Six Sigma strategies will notice that their costs increase and that they spend most of their income on problem solving and the loss of quality of their products. However, if you are working with a team of experts who use Lean Six Sigma approaches, like the team at THE LEAN SIX SIGMA COMPANY , you can expect to spend less than 10% of your income to fix the issues.

Contact us

We are passionate about working with customers in the textile industry. We know that there are many challenges that can arise in this complex area, which is why our team of experts can provide leadership for your organizational strategy.

If you want to maximize your profits, increase the efficiency of your business, reduce your costs and improve the quality of your products, contact us today or fill out the contact form on our website.

If you are interested in Lean Six Sigma solutions , please do not hesitate to contact us and we will guide you through our process and our offerings.

We look forward to discussing your potential for improvement with you!