Enhancing performance of an apparel manufacturing process in MSME through integrated quality management practices: a hybrid AHP-MICMAC model

Purpose This study aims to improve process performance in micro, small, and medium enterprises (MSMEs), particularly in apparel manufacturing, by identifying and prioritising the root causes of manufacturing critical defects. It integrates quality management practices (QMP) with multicriteria decision-making (MCDM) to support resource-constrained organisations in producing higher-quality outputs. The study is theoretically grounded in socio-technical systems (STS) theory, positioning defect reduction as dependent on both technical optimisation and social system alignment. The integrated framework was validated through a case study of an Indian MSME engaged in block-printed apparel manufacturing. Design/methodology/approach The study adopts the five-phased Six Sigma methodology of Define-Measure-Analyse-Improve-Control, combined with MCDM techniques to identify and prioritise critical defects and their causes. Data were collected through 100% inspection sampling over multiple monitoring cycles to ensure accuracy and reliability. Pareto analysis identified critical defect types, and cause and effect diagrams captured potential root causes. In addition, the Analytic Hierarchy Process (AHP) was employed to prioritise key causes, and MICMAC analysis determined the logical sequence of improvement initiatives for stable implementation. Findings Ten root causes contributing to critical defects, including wrong colour and incorrect placement, were identified using AHP. Improvement efforts were established to address the underlying problems, and the order of their implementation is determined through MICMAC analysis. A 72.6% reduction in defects and an increase in the sigma level from 3.97 to 4.65 in the printing process were achieved through standard operating procedures, 5S and kaizen. Practical implications This framework helps managers systematically prioritise process improvement initiatives, enabling quality improvement even with limited resources. It offers a replicable model for MSMEs to improve product quality, reduce rework, strengthen competitiveness, and achieve quality standards, thereby providing access to government policy benefits, including financial support and expert assistance. Originality/value The research presents a novel integration of QMP with AHP and MICMAC to prioritise root causes and sequence improvement initiatives to reduce defects in Indian MSME apparel manufacturing. It extends the existing literature by embedding STS into Lean Six Sigma implementation, demonstrating that sustainable quality improvement in resource-constrained MSMEs requires joint optimisation of technical tools (core QMPs) and social mechanisms (training, employee involvement, and visual communication). This research contributes a structured, scalable, and empirically validated socio-technical improvement framework.