American Journal of Industrial and Business Management, 2017, 7, 1320-1329 http://www.scirp.org/journal/ajibm ISSN Online: 2164-5175 ISSN Print: 2164-5167 DOI: 10.4236/ajibm.2017.712093 Dec. 20, 2017 1320 American Journal of Industrial and Business Management Applying DMAIC Methodology to Reduce Defects of Sewing Section in RMG: A Case Study Dewan Maisha Zaman * , Nusrat Hossain Zerin Department of Industrial Engineering and Management (IEM), Khulna University of Engineering & Technology (KUET), Khulna, Bangladesh Abstract Global competition, crying off profit margin, customer requirement for high quality product at near to the ground cost and other economic factors set in motion the manufacturer to reduce their production cost without concession of quality in order to stand up in business area. Defect or wastages reduction is the initial step to reduce production cost as well as improve the quality. Higher quality comes with the reduced cycle time by reducing alternation. Apprehensive this issue, this work walks around the use of DMAIC metho- dology of six sigma to lessen the defect rate in sewing section of FCI (BD) LTD. Throughout five phases of DMAIC methodology, named Define, Meas- ure, Analyze, Improve and Control, this approach minimizes defects analyti- cally. In different phases, different types of six sigma tools were exercised. Pa- reto analysis was acted to identify the top defects and root causes of those de- fects were sensed. These were done for Ladies’ tops and trousers. Brainstorm- ing and literature review helped to endow with some potential solutions to overcome the problem. With the remedial action and implementation in pilot run, the result found is very noteworthy. The defect percentage has been re- duced from 11.67 to 9.672 and as a result, the sigma level has been upgraded from 2.69 to 2.8. Keywords DMAIC, Sewing Defects, Six Sigma, Sigma Level 1. Introduction and Literature Review In Bangladesh economy, RMG sector plays a vital role. From the last decade, RMG sector becomes popular in Bangladesh and it contributes to the national economy in considerable rate. It is necessary to focus on quality control of gar- How to cite this paper: Zaman, D.M. and Zerin, N.H. (2017) Applying DMAIC Me- thodology to Reduce Defects of Sewing Section in RMG: A Case Study. American Journal of Industrial and Business Man- agement, 7, 1320-1329. https://doi.org/10.4236/ajibm.2017.712093 Received: November 2, 2017 Accepted: December 17, 2017 Published: December 20, 2017 Copyright © 2017 by authors and Scientific Research Publishing Inc. This work is licensed under the Creative Commons Attribution International License (CC BY 4.0). http://creativecommons.org/licenses/by/4.0/ Open Access