An Application of Six Sigma Methadology

Journal of Industrial Textiles
http://jit.sagepub.com An Application of Six Sigma Methodology to Reduce lot-to-lot Shade Variation of Linen Fabrics
Prasun Das, Shirshendu Roy and Jiju Antony Journal of Industrial Textiles 2007; 36; 227 DOI: 10.1177/1528083707072360 The online version of this article can be found at: http://jit.sagepub.com/cgi/content/abstract/36/3/227
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An Application of Six Sigma Methodology to Reduce lot-to-lot Shade Variation of Linen Fabrics
PRASUN DAS* AND SHIRSHENDU ROY
SQC & OR Unit, Indian Statistical Institute, 203 B.T. Road Kolkata 700 108, India
JIJU ANTONY
Director, Centre for Research in Six Sigma and Process Improvement, Caledonian Business School, Glasgow, Scotland, UK
ABSTRACT: There was a problem of shade variation of dyed fabrics in a reputed textile company leading to the increase in process cycle time due to the extra amount of color addition or stripping. The extent of reprocessing fabrics was estimated to be around 75%. The objective of this work was to reduce the shade matching time in the fabric dyeing process by optimizing the effect of the controllable parameters. The problem was tackled using the DMAIC cycle of disciplined Six Sigma methodology. Initially, the process baseline sigma level was found as 0.81 and a target sigma level was set at 1.76. The outcome of the analyses observed at every phase was explained based on textile technology. Actions taken on the critical activities led to the reduction in average excess time as 0.0125 h/m. The yield of the overall process has improved to 82% with an improved sigma level of 2.34. The estimated annual saving is to the tune of Rupees eighteen lakhs (over $40,000). The proposed control schemes from this study are already in place. KEY WORDS: Six Sigma, DMAIC methodology, case study, process improvement, fabric dyeing process.
*Author to whom correspondence should be addressed. E-mail: dasprasun@rediffmail.com Figures 1 and 2 appear in color online: http://jit.sagepub.com JOURNAL OF INDUSTRIAL TEXTILES, Vol. 36, No. 3January 2007
1528-0837/07/03 022725 $10.00/0 DOI: 10.1177/1528083707072360 2007 SAGE Publications
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INTRODUCTION
IX SIGMA IS a systematic methodology for continuous process quality improvement and the process of achieving operational excellence. Six Sigma has been on an incredible run for over 15 years, producing significant savings to the bottom line of many large and small organizations [8]. While the original goal of Six Sigma was to focus on manufacturing processes, today, marketing, purchasing, healthcare, financial services, billing, invoicing, etc. are also embarked on Six Sigma strategies with the aim of continuously reducing defects throughout the organizations processes. A number of papers and books have been published showing the fundamentals of Six Sigma, such as, what is Six Sigma [911]; why do we need Six Sigma [12,13]; what makes Six Sigma different from other quality initiatives [18], Six Sigma deployment [16,17]; critical success factors of Six Sigma implementation [14]; Six Sigma project selection [15] and supporting organizational infrastructure required for successful implementation of Six Sigma [13,18]. The five-stage process of Six Sigma begins with the define phase. Define phase involves identifying a projects critical to quality (CTQ) characteristics driven by the voice of the customer followed by developing team charter and finally defining a high level process map connecting the customer to the process and identifying the key inputs and requirements. In the measure phase, the team identifies the key internal processes that influence CTQs and measures defects currently generated relative to these processes. Analyze phase consists of three steps: establishing process capability, defining performance objectives by the team benchmarking, and identifying sources of variation. Based on the above information, root causes of defects and their impact on the business can be identified. The improve phase helps the team confirm the key variables and quantifies their effects on the CTQs. By implementing the optimum process parameters into practices, the performance is improved and the financial goal is reached. In the control phase, the improved process is monitored and documented to ensure that the financial improvements are sustained.
CASE STUDY Recognition of the Project The concerned company came into existence in the year 1949 with the initial goal of import substitution of a Flax product called Linen and earned the distinction of being the first linen textile manufacturing industry
Reduction in Shade Variation Problem of Dyed Fabrics
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in India. Today the manufacturing facility consists of flax yarn spinning, worsted yarn spinning, wool combing, synthetic yarn spinning, dyeing, and bleaching. Correspondingly, the product profile varies from wool combing and worsted yarns, flax yarn, fabrics, to synthetic yarn [5]. It has entered the new millennium riding on the crest of innovative product development and cost economization through adoption of world class manufacturing (WCM) concepts and philosophy. At the outset, the members of the project cell of the company adopted a project management approach and selected four burning topics like low strength of flax yarn, low productivity of autoconer, shade variation problem, and late delivery of production from dispatch. Subsequently, they evaluated all these four issues based on external customer complaints, degree of urgency, ease of technological solution, relevance to the departmental policy, and expected benefits. As a result, the problem of lot-to-lot shade variation of linen fabric was found on the top after bagging 53 points and hence selected by the members of the project cell as a Six Sigma project for improvement [15]. The basis for selection is shown through the topic evaluation chart (Appendix 1). The impact of the selected problem in the business was highlighted as:
. High cycle time of the dyeing process, which results in the increase in cost of production. . Unnecessary extra use of water, power, dye-stuff, and other associated chemicals. . Loss of potential customer due to late delivery and defective product delivery.
Project Background In the weaving department, for some qualities, fabrics are woven from the dyed yarn (called yarn dyed quality) and for other qualities, fabrics are prepared from grey/bleached yarn and coloring is carried out in the dyeing department (called piece dyed quality) [7]. These fabrics are single colored fabrics. Shade variation is found in the case of piece dyed quality of the fabrics, which literary means not meeting the customers expectation regarding that particular shade. (1) Suppose for a particular shade and quality of customer requirements, the dye house processes the fabric according to some recipe and the fabric is accepted by the customer. When the same customer sends the next order for the same quality of the fabric in the same shade, the dye house persons process the fabric of the same quality according to the previous recipe maintaining the relevant parameters of the process the same as the
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previous one but surprisingly the shade differs from the sample sent by the customer and also from the previously processed material of the same quality. (2) Sometimes the weaving department prepares the material ordered by the customer and delivers to the dye house for dyeing piece after piece. While dyeing the first piece, the dye house adjusts the recipe and other parameters according to the required shade. When they process the subsequent pieces of the same lot, variation with respect to the shade of the fabric sample occurs. Owing to variation of the shade as compared to the sample, color addition/ color stripping are carried out which unnecessarily increases the process cycle time, labor cost along with the wastage of dyes, chemicals, power, and sometimes fabrics also. The sole purpose of selection of this project was: (i) (ii) (iii) (iv) (v) to improve the productivity by reducing the shade matching time. to reduce the cost of poor dyeing quality. to reduce the process cycle time. to deliver the product to the customer on time. to impart moral strength to shop floor people regarding shade matching. Objective of the Project The core objective of the project is to reduce the shade matching time in the fabric dyeing process by optimizing the effect of the controllable parameters involved in the dyeing process through a disciplined Six Sigma methodology.
SIX SIGMA METHODOLOGY (DMAIC CYCLE) Define Phase of the Study The steps in this phase are: (1) Developing a project charter, where primarily the project team and the project boundary are identified. (2) Preparing a process diagram, which is shown in Table 1 in the form of supplier-input-process-output-customer (SIPOC). (3) Defining terms related to a Six Sigma like unit (each lot of fabric under the process of dyeing) and defect (a particular lot/unit generates a defect
Reduction in Shade Variation Problem of Dyed Fabrics Table 1. SIPOC details for dye house process.
Supplier HRD Weaving Utility Chemical supplier Maintenance Input Labor, technical personnel Grey fabrics Steam, plant air, D.M. water, power Dye stuff, other chemicals used for dyeing M/C parts Process Scouring Bleaching Dyeing Mercerizing Calendering Stentering Sanforizing Checking Delivery Output Dyed fabrics Special fabrics Chagall fabrics Heavy duty fabrics Flame proof fabrics
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Customer Common people Special customer Defense ministry Indian Railways Defense ministry, Airlines company, Indian Railways
if its shade does not meet the customers requirement at the first attempt after the dyeing process). (4) Estimating project completion time of four months including system standardization. A project charter is enclosed (Appendix 2) related to this study.
Measure Phase of the Study The steps in this phase are: (1) to identify the relevant parameters for measurement. (2) to develop proper data collection plans both for historical data and planned data. (3) to estimate the baseline process performance through the sigma level based on process yield and fixing the target sigma level. (4) to estimate the status quo of the dyeing process through the identified parameters. (5) to segregate the significant factors for the next course of study through analysis and improvement phase [1]. To meet the aforesaid objectives, past information on the dyeing process was collected for a period of two months detailing the:
. . . .
machine in which dyeing of lot was performed; quality of the fabrics for which dyeing was made; shade of the fabrics for which dyeing was made; length of the fabrics for which dyeing was made;
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. status of shade matching whether fabric was accepted or reprocessed/ rejected; . reason for reprocessing/rejection (more shade/less shade); and . standard dyeing time versus actual dyeing time.
Estimation of Baseline Process Performance The collected data produced the following result: Number of lots dyed and checked during two months 152. Number of reprocessed lots due to less tone (93) and dark tone (22) 115. Defect per unit (DPU) 115/152 0.7565. Yield probability of obtaining units (lots) with zero defect eDPU 0.4693061. Overall defects parts per million (PPM) ln (yield) 106 % 769896. Based on the relationship between PPM and sigma level, Baseline sigma level: ZST ZLt 1.5 0.69 1.5 0.81. Determination of Target Sigma Level (Benchmark) p Normalized yield: Ynorm (yield) 0.685099. Therefore, defects parts per million (PPM): ln (Ynorm) 106 % 378192, equivalent to 1.8-sigma. However, using the formula: Target sigma level 0:8407 one gets, Target sigma level 1.76. After estimating the sigma levels, collected information from historical data was analyzed to find out the vital groups of parameters for the problem. Status of Fabric Processed vis-a`-vis Dyeing Time (Cycle Time in Dyeing Process)
. . . . .
29:37 2:221 lnppm
Total number of lots produced 152. Total length of fabric produced 70,773 m. Total time taken 2436 h (against standard time of 1216 h). Total excess time taken (2436 1216) 1220 h. Average excess time taken (1220/70,773) 0.0172 h/m.
Reduction in Shade Variation Problem of Dyed Fabrics Table 2. Performance of fabric quality.
# Lots reprocessed Quality (coded) F/Q-1 F/Q-2 F/Q-3 F/Q-4 F/Q-5 F/Q-6 F/Q-7 F/Q-8 F/Q-9 F/Q-10 F/Q-11 F/Q-12 Total # Lots accepted 20 14 2 Less tone 56 28 2 1 1 1 1 1 1 1 1 93 More tone 11 11 Total defect 67 39 0 2 1 1 1 1 1 0 1 1 115
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Grand total 87 53 2 2 1 1 1 1 1 1 1 1 152
37
22
Performance of Fabric Qualities and Shades Table 2 shows the performance of fabric qualities with respect to acceptance/reprocessing of lots. It can be seen from the table that two qualities, namely, F/Q-1 and F/Q-2 were having maximum demand as compared to other qualities and subsequently magnitude of reprocessing/rejection was also very high during the period of study. In the next phase, collected data were arranged in the form of a clustered ` bar diagram (Figure 1) with respect to the number of defective lots vis-avis total number of lots produced for different shades to see the contribution of shades toward acceptance/reprocessing and rejection (defective) of lots. It is seen that only five shades: namely, olive, D.K. grey, teak, magenta, and navy were processed frequently along with the frequent generation of defective lots. From the Pareto analysis (Figure 2), these five shades were identified as the major shades (vital few) for which around 68% of the total defective lots were produced. It is clear from the earlier two graphs that the five shades, namely, D.K. grey, olive, magenta, navy, and teak were used more frequently. But as per the decision of the management, dyeing of teak color was stopped. Further, a single color, namely, D.K. grey is now available for which recipe preparation is not necessary. Apart from that, a proportion of
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defective lots with respect to these shades was high as compared to other shades during the period of study. Hence, eventually, three shades, namely, olive, magenta, and navy were selected for the next phase of study.
Clustered bar diagram Defective vs total lots 45 40 35 30 # Lots 25 20 15 10 5 APC blue Black Blue DK grey DK navy Deep blue Green Grey Khaki MN blue Magenta Mix Navy Olive P(2416) Pista RP green Red Sh-170 Sh-178 Sh-191 Sh-193 Sh-242 Sh-6 Sh-784 Sh-641 Teak 0 Total Defect
Shade
FIGURE 1. Clustered bar diagram for defective vs total lots over different shades of
fabrics.
Pareto diagram of shade distribution Data: # defective lots produced 120 100 # Defective lots 80 60 40 20 0 33 14 14 9 Olive DK grey Teak Magenta Navy Blue Khaki Black Red Grey MN blue Sh-170 APC blue DK navy Deep blue Mix P(2416) Pista RP green Sh-178 Sh-191 Sh-193 Sh-6 Sh-784 Sh-641 Green Sh-224 25 75 % Contribution 100
50
Shade
FIGURE 2. Pareto diagram for defective lots over different shades of fabrics.
Reduction in Shade Variation Problem of Dyed Fabrics Table 3. Machinewise performance of fabric lots.
# Lots not okay due to M/C type (coded) P/Jig-A P/Jig-B P/Jig-C P/Jig-D # Lots ok 7 7 10 13 Less tone 26 20 24 23 More tone 7 6 5 4 Total defect 33 26 29 27
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%Defect 33/40 82.5 26/33 78.8 29/39 74.4 27/40 67.5
Performance of Dyeing Machines Table 3 summarizes machinewise stratification of lots processed onto them. It is clear from the analysis that M/c. type P/Jig-A (82.5%) and P/Jig-B (78.8%) were more prone toward generation of defective lots of fabrics and subsequently thought to be considered for further investigation. Conclusions of Measure Phase The conclusions drawn from this phase of study are: (a) (b) (c) (d) (e) (f) The estimated baseline process performance is 0.81 (sigma level); The estimated target sigma level is set as 1.76; The estimated average excess cycle time was 0.0172 h/m; Two qualities of fabrics (F/Q-1, F/Q-2) need further investigation; Three colors of fabrics (magenta, navy, and olive) were crucial; and Two machines for dyeing operations (P/Jig-A, P/Jig-B) may be prone to generation of problems. Analyze Phase of the Study In this phase, attempts were made to identify the root causes of the problem and to find out the possible remedies. The objectives of the analyze phase were: (1) to identify all possible causes contributing to shade variation. (2) to study the contribution of each significant cause of variation. (3) to decide actions necessary for the contributing factors in the dyeing process. At the outset, through a brainstorming session involving all the team members, a fish-bone diagram was prepared (Figure 3) for the lot-to-lot shade variation of linen fabric.
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MAN Poor inspection
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MACHINE Improper padding at the nip of the roller in the machine Malfunctioning of the automatic controlling system
Improper m/c condition Defect in measuring system Easy going attitude Abnormality in speed Fear about shed matching
SHADE VARIATION Due to inappropriate shade matching procedure Use of approximation in almost all operations High dependent on experience Variation of properties of chemical Variation of the water quality Variation in dye uptake of fabric
Variation of recipe Use of some problematic process
Variation in weaving process operation
Effects of other processing chemicals MATERIAL
METHOD
FIGURE 3. Cause and effect diagram for shade variation of fabric.
From this analysis, the following causes of the problem were considered for the study in detail: (1) Variation in dye uptake due to different shades and different lots of fiber (spinning); (2) variation in dye uptake due to different cloth tightness (cover factor) of same fabric quality (weaving); (3) variation in dye uptake due to different shades and different ready for dyeing (Rfd) (ground color) levels of fabrics (dyeing); (4) variation in dye uptake due to recipe prepared manually and through computer (dyeing); (5) variation of temperature in processing from the actual requirement (Jigger M/c.) (dyeing); and (6) variation in measurement system of shade due to checkers (dyeing). Analyze Phase 1 In the spinning department, attempts were made to find out the variation in dye uptake for different lots of fibers. Later it was found that due to the
Reduction in Shade Variation Problem of Dyed Fabrics Table 4. Test results (dE) of yarn of lot vs colors.
dE Values Color Yarn lot Lot A 0.66 0.68 0.76 0.88 (2.98) 1.21 1.33 1.44 0.99 (4.97) 7.95 0.76 0.88 0.92 0.76 (3.32) 1.26 1.29 0.98 1.32 (4.85) 8.17 0.77 0.82 0.68 0.76 (3.03) 1.42 1.36 1.20 1.00 (4.98) 8.01 Magenta Olive Navy
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Total 9.33
Lot B
14.80
Total
24.13
uneven distribution of fibers, it was not possible to use the spectrophotometer for analysis of dye uptake of fiber in a precise manner. Hence it was decided to measure the variation of dye uptake of yarn of the same fineness (count) but prepared from different lots of fiber. Two different lots of yarn of the same count were selected randomly. From each lot twelve samples were prepared. These twelve samples were again sub-grouped into three categories containing four samples each. These three subgroups were dyed separately with three different colors (fixed as decided in the measure phase), namely, magenta, olive, and navy. The recipe for each color was taken from a standard color sample analyzing through a spectrophotometer. The test results (dye uptake) with respect to dE values are given in Table 4. The deviation of the ray of light measured by the spectrophotometer during comparison of standard shade with other shade is called the deviance value or dE value. The dE value is measured by the instrument called a spectrophotometer. The associated software for the measurement is called data color software. The dE values are continuous, tested for normality through normal probability plot and found satisfactory. Model: The set of observations presented may be described by the two-factor mixed linear statistical model [2]: Yijk i j ij "ijk for i 1, 2; j 1, 2, 3; k 1, 2, 3, 4 1
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where, is the overall average; i is the random effect of ith lot; j is the fixed effect of jth color; ()ij is the lot color interaction: random effect; "ijk is the random error distributed as NID (0, 2); and yijk is an individual observation on dE value. Also assume that {j} are fixed effects such that j 0 and i is a 2 NID(0, ) random variable. Further, the interaction effect ()ij is a normal 2 random variable with mean 0 and variance [(b 1)/b] , where b is the number of levels of fixed effect factor. Here b 3. After performing ANOVA followed by the model adequacy checking, it can be concluded that the dyeing of different lots of yarns with the same recipe yields dyed yarn with different dye uptake. (i.e., shade variation in different lots of yarn is statistically significant when 0.05). There was no effect in color variation on the lot. Analyze Phase 2 In this phase of study, attention was given to the weaving department. It was observed in the weaving department that warping of yarn in a beam is carried out from the yarn of the same lot. But for the same quality of fabric prepared from the same beam, the lot number of weft may be different and due to this the weaving department supplies fabrics as separate pieces to the warehouse and the warehouse gives a separate piece number to the fabrics. Now if the same qualities of fabric are run in different machines, due to variation in weaving tension from machine to machine, some cloth may be tighter than others. The tightness of the cloth is measured by the cover factor of the fabric which depends upon the ends per inch (EPI) and picks per inch (PPI) of the concerned fabric. The ends in EPI means the set of parallel yarns running horizontally throughout the length of the cloth and the picks in PPI means the parallel set of yarns running vertically to the ends and throughout the width of the cloth per inch. The cover factor (K) is the ratio of the K(warp) EPI/(count)1/2 to K(weft) PPI/(count)1/2, where fineness of the yarn is defined as the count. Cloth cover factor [3] is defined as fKwarpKweftg Kcloth Kwarp Kweft 28 2 28 using the conversion of line to cotton count as: cotton count line=2:8: Measurements of EPI and PPI are carried out with the instrument called a watch glass, which is nothing but a powerful small lens attached in a handy frame. Measurement of the count of the yarn is carried out with the help of
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Table 5. Comparison of EPI and PPI of fabric quality (actual vs standard).

Fabric quality Sample Standard Actual (coded) code EPI PPI EPI PPI F/Q-1 A B C A B C A B C D A B C D 60 54 60 54 60 54 52 48 52 48 52 48 42 48 42 48 42 48 42 48 64 44 64 44 64 44 64 44 61 57 62 54 64 58 49 51 50 52 54 52 44 52 44 52 44 47 45 51 65 57 66 48 63 46 66 48 Warpa used 2/30s cotton 2/30s cotton 2/30s cotton Weftb used 25 line fl 25 line fl 25 line fl Standard Actual cover factor cover factor 23.56 23.56 23.56 21.78 21.78 21.78 Not Not Not Not Not Not Not Not required required required required required required required required 24.09 23.74 24.48 22.0 22.29 22.67 Not Not Not Not Not Not Not Not required required required required required required required required
F/Q-2
2/30s cotton 25 line fl. 2/30s cotton 25 line fl 2/30s cotton 25 line fl 2/30s 2/30s 2/30s 2/30s 2/40s 2/40s 2/40s 2/40s cotton cotton cotton cotton Viscous Viscous Viscous Viscous 22 22 22 22 25 25 25 25 line line line line line line line line fl. fl. fl. fl. fl fl fl fl
F/Q-4
F/Q-15
Warp the set of yarns which runs through the length of the cloth. Weft the set of yarns which runs throughout the width of the cloth.
the warp reel instrument and a weight balance, preferably a properly calibrated electronic balance. Then with the help of the formulae stated earlier, the cover factors are calculated. A sample set of observations on ends and picks of different fabrics were taken directly from the loom after measuring EPI and PPI. The results of the measurement are presented in Table 5. Those qualities of the fabrics, which are not included in this work, the values of cover factor which are not required and the corresponding cells in the table are marked accordingly. Two different qualities of fabrics (F/Q-1, F/Q-2) were selected for study. For each quality, three samples were collected randomly each having different EPI and PPI values. Again four sub-samples were prepared from each sample. Thus, altogether twelve sub-samples were selected for each quality of fabric. To find out whether there is any significant difference in the dye uptake of the fabric having different EPI and PPI values, all samples (of the same quality of the fabric) were dyed in an olive color prepared based on a standard sample recipe of the same quality. Model: The data, for each quality of fabric, may be described by the one-way random effect linear statistical model [2]: Yij i "ij 3
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for i 1, 2, 3; j 1, 2, 3, 4 where, is the overall average; i is the effect of the ith fabric sample; "ij is the random error distributed as NID (0, 2); and yij is an individual observation on dE value. Assumptions:
2 "ij % NID0, 2 ; i % NID0, ; "ij and i are independent:
The data on dye uptake were analyzed using ANOVA for both the fabric qualities F/Q-1 and F/Q-2. It was observed from the results that computed values of F-ratio (0.1659 and 0.4496) for both qualities of fabric are <F(0.05, 2, 9) 4.26. Thus, fabric samples do not differ significantly in respect of shade (dE value), although there are differences in EPI and PPI of the fabrics. The difference of EPI and PPI are within the tolerance limits specified in the weaving process as 4 EPI/PPI. Analyze Phase 3 In the next phase, the preparation of ground of the fabric was studied in the dyeing department. This process consists of scouring, bleaching, mercerization, peroxide treatment, and treatment with optical whitener operation in a sequential manner. As per requirement, treatments are given and fabric is then ready for dyeing and it is called ready for dyeing (Rfd). The whiteness index (or Rfd value) is the reflectance value of white light from the ground of the fabric. It was decided to test whether the dye uptake of a particular fabric depends on the Rfd value. Two different qualities of fabric (F/Q-1, F/Q-2) were selected, each having two random Rfd levels. For each Rfd level, twelve samples were selected. These twelve samples were again sub-grouped into three categories containing four samples. These three subgroups were dyed separately with three different colors (fixed as decided in the measure phase), namely, magenta, olive, and navy. The recipe for each color was taken from a standard color sample analyzing through the spectrophotometer. The test results (dye uptake) with respect to dE values are described by the two-factor mixed linear statistical model [2]: Yijk i j ij "ijk 4
for i 1, 2; j 1, 2, 3; k 1, 2, 3, 4 where, is the overall average; i is the random effect of ith Rfd level; j is the fixed effect of jth color; ()ij is the Rfd color interaction; random effect; "ijk is the random error distributed as NID (0, 2); and Yijk is an individual observation on the dE value.
Reduction in Shade Variation Problem of Dyed Fabrics Table 6. ANOVA table for dE values.
Quality: F/Q-1 Source Rfd Color Rfd color Error Total d.f. 1 2 2 18 23 S.S. 0.0066 0.0696 0.1874 0.5678 0.8314 M.S. 0.0066 0.0348 0.0937 0.0315 F-ratio 0.21 0.37 2.97 S.S. 0.0001 0.1344 0.0319 0.3795 0.5459 Quality: F/Q-2 M.S. 0.0001 0.0672 0.01595 0.02108 F-ratio 0.0047 4.21 0.76 F-tab
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4.41 (0.05,1,18) 19.00 (0.05, 2, 2) 3.55 (0.05, 2, 18)
Also assume that 2 {j} are fixed effects such that j 0 and i is a NID(0, ) random variable. Further, the interaction effect ()ij is a normal random variable 2 with mean 0 and variance [(b 1)/b] , where b is the number of levels of fixed effect factor. Here b 3. The results of ANOVA, for dye uptake, are presented in Table 6 for both quality fabrics. Considering both qualities of fabric, it is evident that there is no significant difference in the Rfd values of the fabrics (i.e., difference is statistically insignificant at 0.05). In addition, as it was found, colors and their interaction with Rfd levels are not significant at 0.05. Analyze Phase 4 Next came the question to verify the accuracy and precision of recipe prediction both by manually and data color computerized software [4]. As the method is same for all the fabrics, fabric quality F/Q-1 was, therefore, selected only for carrying the experiment. A total of twenty-four samples (grey fabric) were collected and two groups were formed one for manual and the other for computerized recipe prediction. From each group of 12 samples, four samples were dyed with magenta, four with navy, and four with olive, whose recipes were obtained manually. Similarly, another group of 12 samples were dyed with three shades, recipes of which were obtained through the computerized method. For each sample, deviation from the standard sample was noted (dE value). The structure of the experimental layout was conceived as a nested structure and is shown in Figure 4. The results obtained (dE values) from the above experiment are presented in Table 7. Model: The collected data were subjected to a two-stage fixed effect (recipe method, shade: fixed) nested analysis of variance for the different
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Recipe method
Manual
Computer
Magenta dE-1 dE-2 dE-3 dE-4
Olive dE-1 dE-2 dE-3 dE-4
Navy dE-1 dE-2 dE-3 dE-4
Magenta dE-1 dE-2 dE-3 dE-4
Olive dE-1 dE-2 dE-3 dE-4
Navy dE-1 dE-2 dE-3 dE-4
FIGURE 4. Nested data structure for designed experiment.
sources of variation as explained earlier. The following linear statistical model for this design was adopted [2]: Yijk i ji "ijk 5
where, is the overall average; i is the effect of the ith recipe method, i 1, 2; j(i) is the effect of jth shade within the ith recipe method, j 1, 2, 3; "(ij)k is the random error distributed as NID (0, 2); and S is an individual observation on dE value. It was observed from the results of ANOVA that there is significant difference in the manual and computerized recipe preparation (i.e., the difference is statistically significant when 0.05). Technically speaking, as in all cases of computerized recipe, dE values are <1 and all samples are accordingly accepted. But, for the manual recipe it is seen that out of a total of twelve samples, only two samples are of dE values <1. Thus one can conclude that the computerized recipe prediction system is more effective than the manual one. However, for any method of recipe preparation, the effect of colors is not statistically significant at 0.05. Analyze Phase 5 In this phase of study, the temperature profiles (actual) of the four Jigger machines, while under dyeing operation, were recorded randomly by immersing a calibrated thermometer once a day. In addition, the required (set) temperatures of that particular operation were noted from temperature
Reduction in Shade Variation Problem of Dyed Fabrics Table 7. Test results (dE) of manual vs computerized recipe.
Sl. no. dE values 1 2 3 4 Subtotal 1 Subtotal 2 Grand total Magenta 1.20 1.36 0.98 1.47 5.01 Manual Olive 1.28 1.31 1.36 0.99 4.94 15.04 23.53 Navy 1.46 1.38 1.19 1.06 5.09 Magenta 0.67 0.68 0.70 0.69 2.85 Computer Olive 0.79 0.68 0.70 0.69 2.86 8.49
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Navy 0.66 0.71 0.76 0.65 2.78
indicators provided in all the machines side by side. This was continued for 17 days. The data on required temperature, running temperature, and deviation from the required temperature were noted. The plant management showed that the allowable range of variation in temperature was 2 C. While studying the absolute deviation of the performance of temperatures, it was found that the average absolute deviation is maximum in Pacific Jigger-B (3.82 C), followed by P/Jig-A (3.17 C), P/Jig-D (1.29 C), and P/Jig-C (0.23 C). This indicates poor performance of the temperature indicators, particularly for Pacific Jigger-B and Pacific Jigger-A machines, with respect to specified tolerances. Hence, it was decided to rectify those indicators immediately. Subsequently, the representatives from the company service center recalibrated the indicators by changing the PCB and PLC of it. Analyze Phase 6 In this phase of study, the checkers performance was evaluated based on the decision making for acceptance of fabrics after dyeing with respect to standard samples provided by the customers and/or, according to standard shade cards. Generally shade matching is carried out in the department manually under specified light. To verify the accuracy of this checking system, a gauge capability study on checkers of three shifts was carried out. Fourteen samples of fabrics were prepared. Among them six were rejected samples and eight were accepted samples based on standard shade cards and the dE values obtained from the analysis through spectrophotometer. Each checker was provided with the standard sample and the fourteen pieces of sample to be judged and sufficient time and standard light was provided for him to give the judgment. The same process was repeated three times.
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Table 8. Inspection results.

# NOT OK # Samples # OK samples samples Total no. of rejected # Samples accepted accepted accepted as correct when actually when actually Total Checker as OK NOT OK decisions OK NOT OK samples Col. no. Ch. A Ch. B Ch. C (a) 21 24 22 (b) 18 16 17 (c) 39 40 39 (d) 2 1 2 (e) 1 1 1 (f) 42 42 42
The judgments given by all the three checkers were either accepted or rejected and all these were compared with the actual status of samples. The results of inspection are presented in Table 8. From the table, the following statistics were calculated:
. Effectiveness (E) number of samples correctly identified/total opportunities to be correct col. (c)/col. (f). . Probability of miss (Pmiss) number of misses/number of opportunities for a miss col. (e)/18. . Probability of false alarm (Pfa) number of false alarms/number of opportunities for false alarms col. (d)/24. . Bias (B) Pfa/Pmiss.
Using the above formulae and comparing with the table provided by the dWizards Innovation in System Management [6], the performance of all three checkers are marginally accepted with respect to the estimates of E, Pmiss, and Pfa. However, Checker B has bias toward rejecting (B 0.8) whereas the other two checkers have got bias (B 1.42) toward accepting the samples. Further, the results of the measurements in the spectrophotometer confirmed the accuracy of the instrument when compared with another similar type of instrument kept in the fiber dye house laboratory. Conclusions of Analyze Phase From analysis phase it is observed that: (1) Variation of dye uptake is significant from lot to lot of linen yarn. (2) Cover factor is found to have no significant effect on the dye uptake of the fabric within the range of tolerance (4 EPI or 4 PPI) in comparison with the standard for two qualities F/Q-1 and F/Q-2. (3) Dye uptake was found independent of Rfd value for three particular shades and two qualities of fabrics F/Q-1 and F/Q-2.
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(4) Recipe determination, which is the major concern for the dyeing process, is found significantly different in the case of manual prediction and computerized prediction. It is also observed that the computerized recipe is superior to that of the manually predicted recipe. (5) In Pacific Jigger-A and Pacific Jigger-B, temperature indicators were not working properly. The electronics department was informed and rectified by them. (6) Performance (effectiveness) of checkers with respect to shade matching of fabrics is found satisfactory which is also compatible with the computer shade matching system. Improve Phase of the Study The objective of this phase was to work on the root cause identified in the analyze phase and to eliminate them so as to achieve lasting improvement. The steps involved in this direction are: (1) (2) (3) (4) (5) Identify the list of actions to be taken for improvement. Develop a plan for trial implementation. Evaluate pilot result and refine solutions, if needed. Implement final result. Measure the sigma-level.
The following suggestions were given and based upon these, actions were taken to avoid the shade variation problem: (a) It is clear that computerized recipe preparation is more effective and scientific than the running system. Usually a Drimarene brand of reactive dyes are used in the dyeing of linen. In computerized software, ten primary shades are available for cotton, viscose, and polyester. So to make the system more effective, ten primary coloring effects on flax (seven shade percentages namely 0.1, 0.25, 0.5, 1.0, 1.5, 2.0, and 3.0% for each color) were scanned in a computer. Hence the software is now ready for giving a more accurate recipe on flax, flax cotton and flax-viscose fabrics. (b) The formulation of the recipe is to be carried out as per the following combinations provided by the dye manufacturer, as many times as possible DRIMARENE YELLOW CL 2R DRIMARENE RED CL 5B DRIMARENE NAVY R
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(c) The other suggestions for the dyeing process were mostly technical, such as:
. not to load the machines beyond its capacity, . check the padding pressure in different positions of the machines on a regular basis, . set the machines after running a thick fabric, and . check the level of process parameters like temperature, pH value and water hardness, possibly with the use of control charts, on a regular basis.
All actions, as decided by the factory management, were implemented on the shop floor. Later on, randomly 60 lots were selected to study the cycle time of the entire operation and the status of the lots of fabric with respect to acceptance/rejection/reprocessing. The result of improvement observed in the dyeing process is as follows:
. . . .
Number of lots processed 60. Number of reprocessed lots (less tone dark tone) 12. Defect per unit (DPU) 12/60 0.20. Yield probability of obtaining defect-free lots eDPU e0.20 0.818730753 % 82%.
It can be seen from the conversion table between ppm (DPMO) and sigma value that: Improved sigma level: ZST ZLt 1.5 % 0.84 1.5 % 2.34. The present sigma level indicates a significant improvement, even over the benchmark level set, related to the process of dyeing. Bottom Line Benefit: Expected The bottom line benefit, in monetary terms, has been estimated as follows ` (refer the subsection Status of Fabric Processed vis-a-vis Dyeing Time (Cycle Time in Dyeing Process)). Historical Information (Before Improvement):
. Total number of lots produced 152 . Total length of fabric produced 70,773 m
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. Total excess time required 1220 h. . Average excess time required 1220/70773 0.0172 h/m.
After Improvement (Adopted through Six Sigma Approach):

. Average excess time required (23.25/4950) 0.0047 h/m. . Reduction in average excess time (0.0172 0.0047) 0.0125 h/m. . Running cost of one Pacific Jigger (for 1 h) Rs. 275/- (This includes total salary, electricity bill, payback of the machine, maintenance cost, and depreciation). . Average savings by reducing average extra time 0.0125 275 Rs. 3.5/m (approximately). . Total production per month 25,000 m (approximately). . Cost savings per month (C1) 25,000 3.5 Rs. 87,500/-. . Cost savings per month (for water, dye and chemical, effluent treatment plant) (C2) Rs. 15,500/-. . Cost savings per month (for degradation, wastage of the fabrics) (C3) Rs. 7500/-. . Indirect cost savings (for low customer claim, customer retention, low business agent charge) (C4) Rs. 12,000/month. . Gain for achieving the excess than parta (accounts) target production in machine efficiency (C5) Rs. 20,500/month.
Then, total cost savings per month (direct and indirect) (C1 C2 C3 C4 C5) Rs 1,43,000/- and, annual savings Rs.17,16,000/- (Rupees seventeen lakh sixteen thousand only).
Control Phase of the Study In this phase of the study, it was attempted to hold the gains obtained through the improve phase. The steps in this phase are: (a) to develop a control scheme. (b) to train the operator for development of process knowledge and skill level. (c) to identify the specific unaddressed issues, if any, and report to the management.
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(d) to hand over the redesigned process to the users along with the method of control and reporting structure. In order to sustain the gain, based on the findings and technical considerations, the following actions are to be taken by the project team and the associated personnel of the dyeing process: (1) Regular checking of pH value, after soda addition and salt addition during dyeing, is to be carried out based on an appropriate schedule and the collected sample is to be sent to the central SQC laboratory for testing and approval. (2) Reduction of color consumption is to be ensured through preparation of a nomogram for salt and soda addition over different values of shades along with the maximum yield of color. (3) The monitoring of water hardness is to be started at least once per week on a fixed day. (4) Stringent checking for liquor ratio must be in place. (5) Checking the dyeability of yarn for every new lot of spinning must be carried out to ease out recipe formulation. (6) Adequate traceability for Rfd, color addition, soda fixation and the results of final samples must be ensured to keep track of the entire history. (7) Regular checking of temperature in different Jigger machines, particularly in two different sides and at the middle of the machines is to be carried out and recorded. (8) Continuous checking of Jigger machines condition for pneumatics, steam pipe, and working of other automatic systems is equally important. (9) Awareness programme for operators on a regular basis should be carried out for development of process knowledge, skill, and motivation.
CONCLUSIONS The major conclusions from this study are: (a) Yarn having a different lot number has a different dye uptake property. Hence no mix up of the yarn lot should be carried out in any stage of fabric preparation and fabric dyeing. (b) Cover factor (i.e., dependent on the EPI/PPI) has no effect in the dye uptake if the range of the EPI and PPI remain within the range
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(4 EPI/PPI) specified by the SQC cell of the company for a specified quality of the fabric. (c) Rfd value has no significant effect on the process of the dye uptake. But for safety dyeing, the range of Rfd should be kept within (49.2851.12). (d) The computerized predicted recipe gives better results than the manually predicted recipe. Hence the computerized prediction process must be accepted and used on a routine basis. Based on the suggested control schemes, the entire dyeing process has been standardized through developing various data recording formats to control or maintain the improved process. The entire documentation has been handed over to the process team members after explaining their structures and associated utilities. After adopting the disciplined problem-solving Six Sigma methodology, the yield of the overall dyeing process has improved to 82% from the earlier level of 47% indicating an improved sigma level of 2.34. The expected savings on implementation of the control schemes was about Rs. 18 lakhs per year. Six Sigma embodies a disciplined, data-driven analytical approach for reducing variation in any process and thereby eliminating defects. It is an operational system that gears up improvement through selection of appropriate projects in the organization. However, in general, this roadmap through DMAIC cycle can be followed for any business process with a thrust to mostly cost reduction and bottom line benefits.
APPENDIX 1 TOPIC EVALUATION CHART

Late delivery of product from dispatch Score 5 3 1 5 3 1 5 37
Potential project Parameters Commonality of topic Ease of tackling Ease of data collection Degree of urgency Degree of importance Relevance to the department policy Predicted benefits Total Weightage 1 1 1 2 2 2 2
Low strength of flax yarn Score 5 1 1 3 3 1 5 31
Low productivity of autoconer Score 3 1 5 3 5 1 3 33
Shade variation problem Score 5 3 5 5 5 5 5 53
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APPENDIX 2 PROJECT CHARTER

1. Title An application of Six Sigma methodology to reduce lot-to-lot shade variation of linen fabrics To reduce the shade matching time in fabric dyeing process by optimizing the effect of the controllable parameters involved in the dyeing process Flax spinning weaving warehouse dyeing department 0.81 (sigma level) 1.76 Assistant Vice President (Personnel): Project Champion, Sr. Technical Officer, WCM: Project Leader Manager dye house; Technical Officer dye house; Operator data color lab May 2004 August 2004 Rs. 15,000/- (approximately) Rs. 12,00,000/- (approximately) Rs. 10,00,000/- (approximately)
2.
Objective
3. 4. 5. 6.
Scope (project boundary) Present capability Target sigma Team leader
7. 8. 9. 10. 11. 12.
Team members Start time Expected time of completion Estimated cost (based on man, hours, salary) Estimated gross benefit Estimated net benefit
REFERENCES
1. Derek, B. (1994). Statistical Methods for SPC and TQM, Chapman & Hall, London, NY. 2. Montgomery, D.C. (1991). Design and Analysis of Experiments, 3rd edn, John Wiley & Sons, New York. 3. Booth, J.E. (1998). Principle of Textile Testing, 9th edn, Chap. 7, Textile Institute, Butter Worths Publication, Manchester, pp. 272275. 4. Gupta, V.C. and Roy, M. (1984). Computer Aided Colour Matching: Basic Principle, Testing Manual, The Bombay Textiles Research Association, India. 5. Tyrone, L. (1994). Textile Processing and Properties, Elsevier, Amsterdam, London. 6. DWizards Innovation in System Management (Attribute gauge capability) http://elsmar.com/pdf_files/Attr_R&R DOC.pdf 7. Shenai, V.A. (1995). Technology of Dyeing, Sevak Publications, Mumbai. 8. Hoerl, R. (2004). One Perspective on the Future of Six Sigma, International Journal of Six Sigma and Competitive Advantage, 1(1): 112119.
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9. Hoerl, R. (1998). Six Sigma and the Future of Quality Profession, Quality Progress, 33(4): 3542. 10. Breyfogle, F.W. III (1999). Implementing Six Sigma: Smarter Solutions using Statistical Methods, John Wiley and Sons, NY, USA. 11. Harry, M. and Schroeder, R. (1999). Six Sigma The Breakthrough Management Strategy Revolutionizing the Worlds Top Corporations, Doubleday, NY, USA. 12. Snee, R.D. (2000). Impact of Six Sigma on Quality Engineering, Quality Engineering, 12(3): 914. 13. Pande, P.S., Neuman, R.P. and Cavanagh, R.R. (2000). The Six Sigma Way: How GE and Other Top Companies are Honing their Performance, McGraw-Hill, NY, USA. 14. Antony, J. and Banuelas, R. (2002). Key Ingredients for the Effective Implementation of Six Sigma Program, Measuring Business Excellence, 6(4): 2027. 15. Snee, R.D. and Rodebaugh, W.F. (2002). Project Selection Process, Quality Progress, 35(9): 7890. 16. Keller, P.A. (2001). Six Sigma Deployment, Quality Publishing, Tucson, AZ. 17. Adams, C., Gupta, P. and Wilson, C. (2003). Six Sigma Deployment, Butterworth-Heinemann, Burlington, MA. 18. Snee, R.D. and Hoerl, R.W. (2003). Leading Six Sigma Companies, FT PrenticeHall, Upper Saddle River, NJ.
BIOGRAPHY Prasun Das is in the rank of associate professor in the SQC & OR Division, Indian Statistical Institute (ISI), Kolkata, India. He received his Masters degree in technology with specialties in quality, reliability, and operations research from ISI. His responsibilities are consultancy work in various industries, including service sectors, teaching, and applied research in the field of quality control, quality management, neural networks, and operations research. He is also engaged in interdisciplinary project studies. He has published many papers in various national and international journals during the past 12 years.

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Journal of Industrial Textiles

Reduction in Shade Variation Problem of Dyed Fabrics

29:37 2:221 lnppm

Grand total 87 53 2 2 1 1 1 1 1 1 1 1 152

%Defect 33/40 82.5 26/33 78.8 29/39 74.4 27/40 67.5

Variation of recipe Use of some problematic process

Variation in weaving process operation

Effects of other processing chemicals MATERIAL

FIGURE 3. Cause and effect diagram for shade variation of fabric.

Reduction in Shade Variation Problem of Dyed Fabrics

Table 5. Comparison of EPI and PPI of fabric quality (actual vs standard).

4.41 (0.05,1,18) 19.00 (0.05, 2, 2) 3.55 (0.05, 2, 18)

Magenta dE-1 dE-2 dE-3 dE-4

Olive dE-1 dE-2 dE-3 dE-4

Navy dE-1 dE-2 dE-3 dE-4

Magenta dE-1 dE-2 dE-3 dE-4

Olive dE-1 dE-2 dE-3 dE-4

Navy dE-1 dE-2 dE-3 dE-4

FIGURE 4. Nested data structure for designed experiment.

Navy 0.66 0.71 0.76 0.65 2.78

Table 8. Inspection results.

Reduction in Shade Variation Problem of Dyed Fabrics

Reduction in Shade Variation Problem of Dyed Fabrics

After Improvement (Adopted through Six Sigma Approach):

Reduction in Shade Variation Problem of Dyed Fabrics

APPENDIX 1 TOPIC EVALUATION CHART

Low strength of flax yarn Score 5 1 1 3 3 1 5 31

Low productivity of autoconer Score 3 1 5 3 5 1 3 33

Shade variation problem Score 5 3 5 5 5 5 5 53

APPENDIX 2 PROJECT CHARTER

Scope (project boundary) Present capability Target sigma Team leader

7. 8. 9. 10. 11. 12.

Reduction in Shade Variation Problem of Dyed Fabrics

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