Key Responsibilities:

 Production Industrial Engineers of sewing floor are responsible for the following activities.

• Three days before the style starts in line, layout should be discussed with Change Over and Production Manager and get their signature to implement.
• If any changes in the layout is done, it must be updated and change accordingly with the approval of ME/MI – Head.
• Requesting machines, folders and attachment requirement well in advance based on scheduled production plan
• Conducting Method study and educate to follow the best method to operators
• Conducting capacity study of individuals and fix their target after 3 days from the style starts
• Follow-up study (operators who are all not achieving the Target/Capacity)
• Bundle system follow-up
• Bottle neck operation – identify and eradicate
• Fixing new tailors grade based on their performance and criteria.
• Developing multi-skill operators based on their individual interest and maintaining skill matrix record.
• List out low efficiency operator and monitor to improve their efficiency
• Measuring line lost hours due to various reasons in sewing floor
• Monitoring and Line balancing – Based on Capacity and WIP in the line
• Helping supervisors in line balancing during high operator absenteeism.

• Working for minimization of changeover time
• Preparation operation bulletin of new garment.
• Planning layout of machines in accordance to new garment stitching.
• Removing bottleneck in the process for smooth production
• Calculating SAM, establishing stitching targets, enhancing efficiency of sewing lines.
• Method improvement by keeping in view the best possible ergonomics.
• Implementation of principle of motion economy on operators.
• Designing sewing machine templates for better utilization of machines
• Prepared Process Flow Charts, SOPs, Manufacturing control plan
• Kaizen activity on monthly basis to improve manufacturing process
• Preparing and updating visual management board monthly basis.
• Preparing monthly reports of efficiency, forecast eff.%, changeover, kaizen, downtime.
• Prepared OB for new articles.


 Re Engineering Project
NTN Layout
• Change stitching line layout from Traditional to face to face layout (Reduce width of stitching line from 14 ft. to 8 ft.)
• Reduced WIP in the stitching line by 60%.

o 6S Implementation
 Conduct 6S Training for new inducted stitching Operator from Factory training school.
 Weekly 6S Audit and sharing score to everyone to create lean culture in the company