Application of Total Quality Management Principles in Textile Finishing Operations in Kaduna State Textile Mills

Total quality management represents a structured philosophy for achieving consistent product quality and operational efficiency, with broad applicability in textile finishing operations where process variability directly impacts product market acceptance. This study examines the application of total quality management principles in textile finishing departments of three selected mills in Kaduna State, North West Nigeria, assessing the relationship between quality management practice adoption and product defect rates. Data were collected through structured interviews with quality managers and process supervisors, complemented by analysis of production records including defect logs, customer return data, and process control charts maintained over a 24-month period. Quality management practice indices were developed and correlated with operational outcome metrics using Spearman rank correlation analysis. Results indicate that the mill with the highest total quality management practice index score demonstrated a defect rate of 1.8 percent compared to an industry average of 4.7 percent among comparable operations. Statistical analysis confirmed a significant negative correlation between total quality management practice adoption and defect incidence. Implementation gaps identified include inadequate statistical process control usage, inconsistent supplier quality auditing, and limited employee quality training programmes. The study recommends structured total quality management implementation roadmaps tailored to the resource constraints of North West Nigerian textile operations, including priority interventions in process monitoring, supplier evaluation, and workforce competency development. Findings support the business case for systematic quality management investment among Kaduna textile manufacturers seeking to improve competitiveness and reduce production waste. Keywords: total quality management, textile finishing, Kaduna mills, defect rate, process control