Block printing process performance evaluation and improvement using FMEA and Taguchi loss function for selecting print paste suppliers in apparel industry

Block printed fabrics are a choice of many, both in India and abroad. Block printing is a time-consuming process requiring expertise of traditional artisans. But with the current fast urbanisation, technological advances, the opportunities seem minimal for these artisans. Setting up of micro, small and medium enterprises (MSMEs) ensures jobs for many such artisans. Even these MSMEs need to strive for overall operational and service excellence. Hence, the focus of this study is on minimisation of defects to enhance block printing process in an Indian apparel manufacturing MSME. For this Six Sigma is implemented through define, measure, analyse, improve and control. Root causes for occurrence of defects were uncovered through current reality tree (CRT). The large number of root causes, are prioritised in two-folds using analytic hierarchy process (AHP) and failure mode and effect analysis (FMEA). Root causes obtained were then eliminated in two phases of improvement. Using Taguchi loss function (TLF) and AHP for evaluating and selection of best suppliers of print paste. In second phase, FMEA is performed to ensure the feasibility of all improvement initiatives taken against each root cause. Improvement in the process is established in terms of sigma level.