The Study Of Dyeing First-Time-Yield Rate Improvement In A Company By Six Sigma Approaches

As the challenge to environment situation has been getting more serious,the Chinese government launched a serial of regulations and policies on environmental protection,which forced many small and medium sized dyeing companies to be phased out from the industry.With the new challenges,dyeing companies must squeeze all the potentials to improve product quality,delivery service and cost control for survival in the fierce competition.A company is a global well-known industrial sewing thread manufacturer.The main manufacturing processes are constituted of spinning and twisting,dyeing and finishing.The current outstanding problem in A company is the low dyeing first time yield(FTY)performance.It brings many negative impact,including the largely increased manufacturing cost and the poor delivery service.and it turned out to be fatal for A company to find an effective approach to improve dyeing FTY performance.This essay studies the above outstanding and critical problem in A company by applying Six Sigma methodology.First of all,to define the problem and focus on the processes that are in scope;secondly,to collect the related data from A company for better understanding the current performance,and to identify a few potential causes and the related standards;thirdly,to conduct Measurement System Analysis(MSA)and to use Six Sigma tools to run analysis on the identified few critical factors for proving the correlations between the factors and dyeing FTY.The tools include Design of Experiments(DOE),Hypothesis Test and Response Optimization.an optimal solution was applied in the manufacturing process for trial.The related performance data and financial data were also collected for evaluating the optimal solution.At the same time,the control plan was also provided.At the end,to draw a conclusion for the improvement based on the achievement of dyeing first time yield rate and financial returns.Based on the realistic outstanding problems in A company,this essay studied the problems and applied Six Sigma methodology to provide effective and feasible solutions.With the implementation in A company,it improved the dyeing first time yield rate by fixing the critical problems and achieved the pre-set objective,which brought profound positive impact on cost saving and service improvement in A company.