The IUP Journal of Operations Management
Lean Six Sigma for the Process Improvement of Yarn Package Dyeing in Textile Industry

Article Details
Pub. Date :Feb, 2021
Product Name : The IUP Journal of Operations Management
Product Type : Article
Product Code : IJOM10221
Author Name : A S M Touhidul Islam
Availability : YES
Subject/Domain : Management
Download Format : PDF Format
No. of Pages : 27



Yarn dyeing, a big area in textile industry, has been overlooked in the extant Lean management literature. With a decade's practical experience in four renowned knit composite apparel industries in Bangladesh, the author has identified the scope to apply Lean Six Sigma (LSS) in this area. Standard time for different processes is derived with detailed practical observations in some companies, which has helped to measure the lead time of yarn dyeing using Value stream mapping. Business excellence professionals will find these outcomes readily applicable to improve the capacity and efficiency of yarn dyeing in any textile industry. This study also inspires academicians to further explore opportunities to apply LSS in the vast textile industry. Different data requirements for further application of LSS have also been recommended along with scope and ideas of improvement per process, per function.


Bangladesh, previously known as East Bengal, was self-sufficient in textiles (Islam et al., 2013) for centuries. Now, Bangladesh, a developing market economy (Riaz and Rahman, 2016), is ranked 39th largest in the world in nominal terms (nominal terms is measured in terms of money, not against goods or services, and not adjusted for inflation). In the first quarter of 2019, Bangladesh was the world's seventh fastest growing economy with 7.3% real Gross Domestic Product (GDP) annual growth (Real GDP Growth, 2019). The main source of this rapid growth was the textile and clothing industries. Bangladesh has become the world's second biggest exporter of clothing (Latifee et al., 2017) with $28.14 bn in the financial year 2016-2017, which was 80.7% of the country's total export earnings and 12.36% of the GDP (Latifee et al., 2017).

Companies are adopting Lean to build "manufacturing systems characterized by having high-velocity order-to-delivery and flexible processes which improve the overall business performance" to face "global competition, uncertain demand environment