Improving quality and efficiency: A Six Sigma approach to problem solving in the sewing unit of a garments manufacturer based in Pakistan

Garment sectors are a core component of Pakistan's industries. The escalating issues of productivity and quality, coupled with rising operational costs and time constraints, have had a significant adverse impact on garment manufacturing firms. Therefore, this research was conducted within a well-recognized garment industry in Karachi, Pakistan. The DMAIC approach of Six Sigma was chosen for this study to provide a structured framework for the identification, quantification, and elimination of sources of variation in operational procedures. Additionally, it focused on the optimization and improvement of operational variables, along with ensuring performance sustainability through the integration of multiple lean techniques. In conclusion, the results indicate a notable reduction in defect rates, enhanced cost-effectiveness, improved quality, reduced production time, and increased productivity following the implementation of problem-solving practices in the sewing (production) section. The study also highlights the evident relationship among the mentioned constraints.