Design and Implementation of Lean Six Sigma in The Garment Industry

Authors

  • Awais Ahmad Khan Department of Mechanical Engineering, University of Engineering & Technology, Lahore, Pakistan
  • Naseer Ahmad Department of Mechanical Engineering, University of Engineering & Technology, Lahore, Pakistan https://orcid.org/0000-0001-7773-2830
  • Jawad Sarwar Department of Mechanical Engineering, University of Engineering & Technology, Lahore, Pakistan
  • Qazi Zohaib Ahsan Department of Mechanical Engineering, University of Engineering & Technology, Lahore, Pakistan
  • Zain Ul Hassan Department of Mechanical Engineering, University of Engineering & Technology, Lahore, Pakistan

DOI:

https://doi.org/10.23055/ijietap.2025.32.3.10555

Abstract

Lean Six Sigma (LSS) is widely adopted in manufacturing industries to optimize production efficiency and minimize defects. However, its application in the garment industry, particularly in sewing line balancing, remains underexplored. The study integrates LSS methodologies with the Ranked Positional Weight (RPW) method to enhance line balancing efficiency in a sewing line. The Define, Measure, Analyze, Improve, and Control (DMAIC) framework was applied to identify the root causes of defects, optimize workstation balancing, and evaluate process improvements. Data was gathered from a single sewing line to evaluate the existing sigma level and identify critical inefficiencies. Statistical tools such as Process Capability Indices (Cp, Cpk) and short-term vs. long-term sigma level analysis were used to assess process variations. The findings indicate that implementing RPW resulted in a reduction of workstations from 27 to 22, an increase in line balancing efficiency from 53% to 70.3%, and a decrease in the defect rate from 8.34% to 4.6%. The process sigma level improved from 2.9 to 3.19, demonstrating a significant enhancement in quality performance. This research demonstrates practical value by integrating Lean Six Sigma (LSS) with the Ranked Positional Weight (RPW) method for line balancing in the garment industry. It offers valuable insights into critical challenges, identifies root causes, and presents a scalable approach for defect reduction in textile manufacturing.

Author Biographies

Awais Ahmad Khan, Department of Mechanical Engineering, University of Engineering & Technology, Lahore, Pakistan

Dr. Awais Ahmad Khan has completed his PhD in 2015 from King Saud University, Riyadh, Saudi Arabia. His research interests are manufacturing systems, fixture design, die design, lean six sigma and production optimisation.

Naseer Ahmad, Department of Mechanical Engineering, University of Engineering & Technology, Lahore, Pakistan

Dr. Naseer Ahmad, serving as an Assistant Professor at the Department of Mechanical Engineering, University of Engineering and Technology, Lahore, Pakistan; He holds PhD degree in Mechanical engineering (Multidisciplinary system modeling and control) from King Fahd University of Petroleum and Minerals, Saudi Arabia, MSc in Mechatronics and BSc in Mechanical Engineering from the University of Engineering and Technology, Lahore, Pakistan. His field of interest are modeling & simulation, dynamical systems, embedded control, and computational mechanics.

Jawad Sarwar, Department of Mechanical Engineering, University of Engineering & Technology, Lahore, Pakistan

Jawad Sarwar earned his Ph.D. in 2013 from Dublin Institute of Technology, Ireland and the focus of his current research is solar thermal applications and photovoltaics to improve their conversion efficiencies.  Dr. Sarwar has a research portfolio of around $300k and contributed to a patent, published numerous peer reviewed leading journal and conference papers. He has supervised several undergraduate and graduate level students and has taught various courses in Dublin Institute of Technology, Texas A&M University at Qatar, and at University of Engineering & Technology, Lahore, Pakistan. He has contributed in the teaching innovation at Texas A&M University at Qatar and Research Symposiums. He is also contributing towards developing and achieving Outcome Based Education accreditation in University of Engineering & Technology, Lahore. He has presented in various leading conferences around the globe and a member of American Society of Mechanical Engineers and International Solar Energy Society, in addition to a reviewer to some leading journals such as Applied Energy, Solar Energy and Energy Conversion and Management.

Zain Ul Hassan, Department of Mechanical Engineering, University of Engineering & Technology, Lahore, Pakistan

Zain Ul Hassan    received the B.Eng. degree in Mechanical Engineering from University of Engineering and Technology, Lahore, in 2015. Currenlty, he is studying M.Eng. in Automotive from the UET, Lahore and working as a team lead to teach Digital Engineering Tools of AutoCAD and 3D designing at a Project of Virtual University of Pakistan. His research interests are in Digital Twin Technology, Artificial Nueral Networking in Auomotive, Autonomous Vehicles and Safe AI in Automotive Control System. He has won an award of best paper in International Conference on Mechanical Engieering in the catogary of Mechanical Design in 2020. Currently he is keenly working on design and development of Bio-hybird cargo vehicle for short range commute and cargo within city to cater the cargo and delivery issues in the urban cities of Pakistan. He can be contacted at email: zuh426@gmail.com

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Published

2025-06-02

How to Cite

Khan, A. A., Ahmad, N., Sarwar, J., Ahsan, Q. Z., & Hassan, Z. U. (2025). Design and Implementation of Lean Six Sigma in The Garment Industry. International Journal of Industrial Engineering: Theory, Applications and Practice, 32(3). https://doi.org/10.23055/ijietap.2025.32.3.10555

Issue

Vol. 32 No. 3 (2025)

Section

Production Planning and Control

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