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The Problem of High Yarn Waste in Weaving Unit MIKE Textiles is a leading manufacturer of sheet fabric that is used as raw material for
The Problem of High Yarn Waste in Weaving Unit
MIKE Textiles is a leading manufacturer of sheet fabric that is used as raw material for home and
personal textile products. The organization has always focused on high efficiency of operations,
which has led to increasing profitability year on year.
Over the past months, the cost of operations has been rising leading to plummeting profitability.
An initial investigation revealed that the quantity of Yarn Wastage in the Weaving Unit has been
increasing over this period and currently the percentage wastage of yarn is approximately of the
total yarn consumed. This is the highest percentage of yarn wastage recorded in the last years.
Yarn wastes have a direct negative impact on yield percentage of the process and increases the cost
of product manufacturing. Every percent of yarn waste led to loss of USD
In an industry sector where profit margins are thin, any escalation in manufacturing cost has
significant negative impact on profitability.
The management at MIKE Textiles want the team of Six Sigma experts to use the DMAIC methodology
of Lean Six Sigma to reduce the Yarn Wastage by at least without any capital expenditure.
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