PDCA applied to printing sector of ghanaian textile industry

Abstract

Ghanaian textile industry has been collapsing since late 1980s. In addition, there has been a decline in most textile products in Ghana due to competition with Chinese products, known for their lower prices compared to home-made textile products. In order to provide engineering-based solutions this research aims to apply the PDCA method to reduce the 6,5% of rejected finished products at the printing sector of Akosombo Textile Limited of Ghana. The work intends to apply the first stage of the PDCA which is P (plan), with the support of quality tools like Brainstorming, Flowchart, Checklist, Sequential graphics, Pareto chart, Cause and Effect diagram, GUT Matrix, BASICO solutions and 5W2H. This work was able to bring out Action Plan, which whether applied it may reduce the 6,5% to 1,95% reducing about 70% of the 10.833,33 yards rejected monthly with an estimated gaining of US $17.062,42 out of losing of US $24.374,89 monthly. This method applies to all processes to control the production quality, and to reduce and eliminate waste. Moreover, this could also deliver a better reliability and confidence before the clients, elimination of rework, economize energy, time and resources.