Implementation of Six Sigma Methodology to Reduce Knitted Fabric Defects: A Sustainable Approach for the Knitting Industry

The textile and ready-made garment industry has a significant global impact and plays an important role in human life. The increased demand from developed countries has led to higher production and employment in the sector, the growth of the agricultural sector, and the generation of foreign exchange for developing economies. The fabric manufacturing industries, which are part of this large sector, are divided into two main groups: woven and knitted fabrics. Knitted fabrics are produced by textile knitting industries.

Knitting is a method that emerged in the 16th century, where yarns are interwoven in a specific order to create fabric. Today, there are two main processes used: warp (horizontal) knitting and weft (vertical) knitting. This process offers significant advantages for efficient fabric production. However, errors encountered in knitting production can negatively impact productivity. At this point, minimizing errors in the production process and increasing efficiency becomes crucial.

Increasing Efficiency in Knitting Production with Six Sigma

The Six Sigma approach stands out as an effective method for reducing knitted fabric defects and increasing efficiency. Six Sigma is a quality management methodology introduced to the industry by Motorola in the 1980s. This approach aims to systematically eliminate errors in operational processes and enhance efficiency. By following the DMAIC (Define, Measure, Analyze, Improve, Control) steps, Six Sigma conducts data-driven analyses at each stage and minimizes defects.

Six Sigma and Its Applications in the Textile Industry

Six Sigma is frequently used in the textile industry, especially to improve production efficiency. Various studies have shown that Six Sigma is effective in reducing defect rates in fabric production, weaving, and knitting industries. For example, Six Sigma applications can significantly reduce yarn errors and fabric defects. Research has demonstrated that Lean Six Sigma (LSS) projects have yielded successful results in the textile and ready-made garment industries, leading to substantial improvements in production processes.

However, there are limited studies on the application of Six Sigma, particularly in knitting production. Research in this context has revealed that Six Sigma can be used not only in fabric production but also in various stages, from product design to assembly, to improve efficiency.

Contributions of Six Sigma to the Knitting Production Process

In knitting production, Six Sigma applications help reduce errors, improve fabric quality, and make the production process more efficient. The DMAIC approach enables a detailed analysis of each stage. For example, in the "Define" phase, it is determined where errors are most concentrated in production. In the "Measure" phase, the magnitude and frequency of these errors are measured. In the "Analyze" phase, the causes of errors are investigated, and in the "Improve" phase, solution proposals are made. Finally, in the "Control" phase, preventive measures are taken to ensure the improvements are sustainable.

At the end of this process, results such as reduced production costs, increased production speed, and quality improvements are achieved. As a result, a sustainable and cost-effective production model is established in knitting production.

Conclusion

The application of Six Sigma in the textile and knitting production sectors is a powerful tool for increasing efficiency and minimizing errors. Six Sigma applications in the textile industry offer an effective solution for improving quality and reducing costs. This approach provides textile manufacturers with the opportunity to achieve sustainable success not only in the short term but also in the long term.