Applying the Ishikawa Diagram and Pareto Chart for Defect Reduction in the Manufacturing Industry. A Case Study from a Textile-Producing Company

The most difficult aspect of production is consistently generating high-quality products. Improving product quality is critical to satisfy consumers, minimize production costs, and conserve energy. Improving product quality requires intentional and ongoing attention and devotion from every individual inside the production organization. Producing a high-quality product is essential for survival in this globally competitive sector. In this paper, the application of two TQM techniques in a garment factory will show an important role in preserving garment quality. Stitching is a critical process in the garment and textile industries. As a result, any defects must be avoided when stitching. This research looks at many faults or defects that can occur when sewing and potential tactics for re-solving these concerns. According to the Pareto Chart, three problems accounted for more than 80% of all errors in the DBS garment factory’s sewing area for an item. Following identifying major defects, a brainstorming tool was utilized to generate possible explanations, and probable root causes were identified using online inspections and root cause analysis. The Taguchi approach is extremely effective in defect reduction. Using these strategies regularly will help the company reduce defect rates while enhancing productivity. While this study focuses just on sewing, an integrated evaluation of other production processes like knitting, dyeing, cutting, and finishing may be more beneficial in reducing errors. Many Albanian textile firms should be better aware of Six Sigma concepts, and this study will trigger a good surge throughout the garment sector, making them more competitive.