Cost-loss analysis and roadmap
In integrated plants we quantify losses separately for each process step, from spinning to garment making, and rank them by money value. The result is a roadmap that shows which project will close which loss.
International
Lean Six Sigma and Operational Excellence Consulting in Pakistan
Yes, we have delivered Lean Six Sigma projects in Pakistan and we provide consulting to manufacturing sites there. Consulting and belt training are delivered in English, with on-site visits and online coaching in between. We start by putting a money value on energy, material and capacity losses and work on the largest items first.
- 7
- countries with projects
- 500+
- projects across Türkiye, Pakistan, Iran and Ethiopia
- 1,000+
- improvement projects
Manufacturing in Pakistan and where improvement matters
Textiles and apparel are the backbone of Pakistan's industry and exports, with many integrated plants running from spinning and weaving through dyeing and finishing to garment making. FMCG and food and beverage production form another large sector serving a big domestic market.
In integrated textile plants, losses accumulate along the chain: variation in yarn becomes breaks in weaving, reprocessing in the dye house and seconds in garment making. In energy- and water-intensive processes, every reprocess is a direct cost. That is why work in Pakistan usually starts with a cost-loss analysis, and improvement projects are selected from that list.
Services most relevant to plants in Pakistan
DMAIC for dyeing, finishing and process quality
For shade variation, re-dyeing and seconds we open DMAIC projects and, where needed, optimise process parameters with design of experiments (DoE). We coach the project leader through every phase.
OEE and TPM
On weaving, knitting and filling-and-packing lines we break losses down with OEE into availability, speed and quality. For recurring breakdowns we set up autonomous and planned maintenance on the shop floor.
Green Belt and Black Belt training
Green Belt and Black Belt programmes are delivered in English, face to face and alongside a real project. Training can be held in-house at your plant; a Black Belt Upgrade is available for existing Green Belts.
What we have done in Pakistan and how we work
Part of the more than 500 Lean Six Sigma projects delivered across Türkiye, Pakistan, Iran and Ethiopia between 2013 and 2021 took place in Pakistan. New engagements start on the shop floor with the current state and the data, and we select the projects and project leaders together with you. Because English is widely used in Pakistani business, consulting and training run directly in English; we do not work in Urdu. Coaching between visits is online; belt training is delivered face to face and can be held in-house at your plant.
How an international programme runs.
- 1
Introductory call
We discuss the plant, the targets and the team structure in an online call. The working language (English or Turkish) and the scope of the first site visit are agreed at this stage.
- 2
Diagnosis on site
On the first visit we walk the lines, review the data and identify the largest losses together with the management team. Programme priorities are based on what we see on the shop floor.
- 3
Programme plan
We put into writing which projects run with which teams and in what order, so that headquarters and plant management work from the same plan.
- 4
Site visits and remote coaching
Projects move forward through regular site visits. Between visits we hold online coaching sessions with project leaders and review analyses and milestones together.
- 5
Training and sustainability
Belt training is delivered face to face, ideally at the plant itself. The goal is to build internal experts who keep the programme running without a consultant.
Frequently asked questions
Common questions.
Do you provide Lean Six Sigma consulting in Pakistan?
Yes. We have delivered Lean Six Sigma projects in Pakistan before and provide consulting to textile, apparel and FMCG plants there, on site and in a hybrid model. The scope is agreed in an introductory call based on the plant's priorities.
Do you offer Lean Six Sigma Green Belt and Black Belt training in Pakistan?
Yes. White/Yellow Belt, Green Belt and Black Belt training is delivered face to face in English and can be organised in-house at your plant. Participants work on a project selected from their own operation during the programme.
Where do you start in a textile plant in Pakistan?
We start with a cost-loss analysis. Scrap, reprocessing, energy and downtime losses are measured at every step from yarn to garment, and projects are selected according to the largest items.
Can you support operational excellence across several plants in Pakistan?
Yes. Operational excellence consulting covers a common roadmap, Hoshin Kanri to align targets and a daily management system, so that several plants work to the same priorities and report losses the same way.
Led by
Abbas Erdenal
Lean Six Sigma Master Black Belt · Founder of Fega Partner
More than 25 years on the shop floor, over 1,000 improvement projects and programmes delivered in seven countries. Abbas Erdenal personally leads every consulting engagement and training.
About Abbas Erdenal