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Introduction of Organization
• Company Name: Yasir Afzal Textile Pvt Ltd.
Introduction
• Yasir Afzal Textile Industries Pvt. Limited Faisalabad is the grooming industry in Faisalabad in textile sector. Founded in 1991 by the most famous person, Haji Muhammad Afzal.
• Yasir Afzal Textile has designing, and printing departments. The bedding and fabric collection of Yasir Afzal Textile are sent to the different parts of the country such as Lahore, Karachi, Islamabad and Peshawar.
Vision
• “To become one of the Best brands in the country”
Mission• Satisfying our customers by providing them
best qualitative stuff and Unique designs keeping in view their comforts and excellence.
• Excellence in quality and improved efficiency at lower operating cost by Utilizing blend of state of art technologies.
Our Objectives
There are two types of objectives:
1-Non-Financial Objectives2-Financial Objectives
Non-Financial Objectives
• To be among the top ten favorite brands• growing Organization in the Textile Sector• ISO certified Company• Having a Qualified and Experienced Staff• Proper Utilization of Human Resources• Having a latest Machinery to Compete Globally• Friendly Environment
Financial Objectives
• To maintain an inflation growth in earning per year at a rate of 12%.
• To obtain a return on equity of at least 30%.
• Providing stitching facilities to other boutiques.
What is six sigma?
• Six Sigma is a business management strategy, originally developed by Motorola, USA in 1986.
• Six Sigma seeks to improve the quality of process outputs by identifying and removing the causes of defects (errors) and minimizing variability in manufacturing and business processes.
• A six sigma process is one in which 99.99966% of the products manufactured are statistically expected to be free of defects (3.4 defects per million).
DMAIC• Define: Define the problem.
• Measure: Measure the key aspects of the current process and collect relevant data.
• Analyze: Analyze the root causes of defects under investigation.
• Improve: During the improve step of the six sigma approach ideas and solutions are put to work.
• Control: Implement control system such as statistical process control, production boards, visual workplaces, and continuously monitor the process.
DMAIC Process
Define• PROJECT: Yasir Afzal Textile Pvt.
Ltd. • PROJECT INFORMATION :• Leader: Abdullah Shahzad
• Black belt : Yahya Amin• Green Belt :Mah Gull• Project start: 28 April 2012• Project end : 28th may 2012• Cost of poor quality:10,000-
20,000 Meter.• TEAM MEMBERS :• SPONSOR: Yasir Afzal Textile (PVT
LTD).• BLACK BELT: Abdullah Shahzad• GREEN BELT: Yahya Amin
• PROCESS PROBLEM :• Problem is that no output from
employees and no efficiency level.• PROJECT IMPORTANCE:• This project is about the increase
the employees efficiencies and increase the output of employees & through which increase the production.
• PROCESS START /STOP• START POINT: enter the grey into
factory • END POINT: Manufacture the
cloth and Dispatched.
measurement
Yes
No
Dying
printing
Define
• Problem is that there is no output of employee and no efficiency of employee, and there are three main causes :
• Defect in machinery • Environment is not suite able for employee • Employee not satisfied from job
Measure
• 1Unit=1meter
• Daily Production =130,000 Units • Problem=10,000 Units• • Following are the problem in % of 10,000 Units:• working environment 5000 Units, • Employee Dissatisfaction 3000 Units, • Defect in Machinery 2000 Units
Pareto Diagram
Employee Inefficiency0%
10%
20%
30%
40%
50%
60%
50%
30%
20%
Working Environmeent
Employee Dis Satisfaction
Defect in Machinery
Time Series
Day 1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 70%
10%
20%
30%
40%
50%
60%
Working EnvironmentEmployee inefficiencyDefect in machinery
Cost per Meter
• Daily Production 130,000 Meter• Grey per Meter Rs.63• • Grey cost Daily 63*130,000 81,90,000• Daily Wages 1,10,000• Electricity per Day 14000 Unit*8 1,12,000• Sui Gas Per Day 62,500 Units*4 300,000• Chemical Per Day 550,000• Other Expense 40,000• Total Expense per day 93,02,000• • Per Meter Cost = Total Expense/ Daily Production • = 93,02,000/130,000• = 71.55 Rs. Per Meter Cost
Six Sigma Calculations Before Improvement
• Daily Production = 130,000 Meter
• NO of Defects = 10,000
• Size Of the Sample = 130,000
• Defects per million = 76923
• Sigma Metric = 3.00
analysis
Skills Competition Laziness Prejudice Drug addiction Politics
Top management Load shedding Communication Financial problem Human Resource
Improvement• Due to defect in printing machine so we repaired our
machinery and replaced our machinery then problem is minimized.
• For maintain and providing good environment to employees we delivered lecture on cooperation, collaboration and mutual understanding and it is helpful for good environment.
• For the satisfaction of employees we give incentives to employees and increase the satisfaction level.
• We appreciate and motivate the employees work and performance.
After implementation
Time series
Six Sigma Calculations After Improvement
• Daily Production = 130,000 Meter
• NO of Defects = 1550 Meter
• Size Of the Sample = 130,000
• Defects per million = 11,923
• Sigma Metric = 3.8
control• After implementing the solution, we concluded that
improvement implementation brought significant benefit to YAT. That is why, we standardized these solutions to further avoid such problems.
• Repair and replace our machinery and install some new plants and machinery that works more efficiently.
• Put emphasis on co-operation and collaboration in the organization to make environment friendly.
• Provide incentives and allowances to satisfy employees.• Appreciate employees to increase motivation