LEAN SIX SIGMA APPLICATIONS ON LEVIS

PRESENTED BY GROUP-6

Souvik Dutta 20PGDM075

Rahul Raj 20PGDM105
Mohit Kumar Mahato 20PGDM018
Anushka Paul 20PGDM049
 INTRODUCTION
Levi's Strauss & Company, the world's largest trouser maker, is
best known for its blue denim jeans called Levi's®. Other
products include bespoke trousers, jackets, hats, shirts, skirts,
belts, as well as novelty manufacturing licenses. Headquartered
in San Francisco. Levi Strauss & Co (Levi`s), a leading
international premium denim wear maker, started its activities
in India in 1994 by establishing a wholly owned subsidiary
under the name Levi`s Strauss India Ltd
The Levi's brand is symbolic because consumers rely on
innovation, quality, performance, durability, style and fit. Levi's
listens to buyers and empowers them to run the company. Levi's
has been killing it for several years, and the latest IPO allows
Levi's to publicly see what went wrong. Levi's is killing it not
only in the denim segment, but also as a manufacturer and
retailer.
DEFINE PHASE
D
CONTD. TRANSLATING VOC INTO CTQ

CTQs are the measurable data that is needed on a product or service

that your customers have specified as being a very important
requirement. Keeping the following drivers in mind, the metrics would
be:

Special preferences should be given to design and looks of the

jeans.

The tenacity and the residual elongation after rope dyeing is the
vital factor that is the main source of the material.

The stitching around a jeans' hems, pockets, and side seams are
telling of its quality.

Premium features must be incorporated stretch factor, bright

colors, under thigh support, design details, quality stitches,
pockets, smooth fabric and luxury material feel.

After sales service experience with proper durability, service

availability and knowledgeable service staff will enhance the
 MEASURE PHASE M
The sources of variation that are represented in the graph are:

1. Total Gage R&R: This measuring system of the variation

included multiple operators using the same gage. The value
is 7.76%.
2. Repeatability – A measure of the effectiveness of the tool
being used; the variation of measurements obtained by a
single operator using the same tool to measure the same
part.
3. Reproducibility – A measure of the operator variation; the
variation in a set of data collected by different operators
using the same tool to measure the same part.
4. Part-to-Part: This is the variability that measures across
different parts. (92.24%)

% Contribution: Gage R&R Variance should be less than the Part-

to-Part Variance. In the table Gage R&R is 7.76% where Part to
Part Variance is 92.24%.
ANALYZE PHASE A
CONTD.
CONTROL PHASE
 IMPROVEMENTS AND SUGGESTIONS I
Improvements (Defects)
The defect in a garment is not intended. But somehow defects are generated during the processing
of the garment. To make a quality garment, all the defects must be rectified through the checking
process. Further action is taken for eliminating garment defects from the process and from the raw
materials or avoid using the defective raw materials.

SOME COMMON QUALITY DEFECTS

UNCUT/LOOSE THREAD - Extra threads or loose

threads on seam line.
SUGGESTIONS- UBT/thread trimmer should be used, Operator
training and Garments finishing should be checked properly
 CONTD.
STICHING ERRORS- It appears due to improper trimming or
machine usage. 
SUGGESTIONS-
 Needle plate, presser foot and feed dog should be checked
periodically for damages.
 Tension and threading should not be fiddled with much.
 Proper trimming

FABRIC FLAWS: SEAM PUCKERING - Seam puckering

refers to the gathering of a seam either just after sewing or after laundering
causing an unacceptable seam appearance.

SUGGESTIONS-
 Feed dog, eyelets and thread guides should be checked periodically for
damages.
 Machine feed mechanism must be better quality
 CONTD.
DISORTED KNITTING- These defects can be identified by
looking at the surface area; they usually appear as irregular on the fabric 

SUGGESTIONS-
 Better inspection of fabric and cut piece.
 Ensure that fabric and cut pieces that are not up to standard are not put
into line and production is wasted.

NEEDLE THREAD BREAKAGE- Thread gets trapped at the

thread guide. Irregularities or damages in needle guard, throat plate, bobbin
case and needle eye

SUGGESTIONS-
 Ensure that the re-threading is done correctly.
 Replace the needle with one of better quality.
THANK YOU