<p>The study aims to reduce the defect rates and reworking during the final inspection in an Indian apparel manufacturing unit, which will lead to better overall production quality. It explores the intervention project using lean six sigma DMAIC methodology to improve the sigma level and reduce wastage from production. The study applies DMAIC methodology, involving problem definition through SIPOC, current defect measurement using process capability analysis, root cause analysis via pareto charts and fishbone diagrams, followed by structured training programs and the development of standard inspection procedures. The impact of training on process capability and defect reduction was assessed. Applying the DMAIC method resulted in improved sigma levels from 3.66 to 3.88 (jackets) and 3.66 to 3.85 (trouser). Defect rates dropped from 1.55 to 0.87% for jacket and 1.55 to 0.94% for trouser and rework rates dropped dramatically. Inspection quality improved and fewer alterations were made in the final audit after checkers were trained on the basics of the inspection process. The research was confined to one production unit and the training took place for six days. Further studies may generalize the approach to cover multiple units and predefined motion and time system to achieve precise motion optimization. Research highlights the successful implementation of lean six sigma approaches in the Indian Garment sector, providing a valuable model for improving product quality, minimizing expenses, and maintaining competitive edge in international marketplace.</p>