About the role
Only from GARMENTS industry experience
Budget - 4L to 5.5L
PRODUCTION DEPARTMENT
Job Description for
SENIOR INDUSTRIAL ENGINEER
Job Title : Industrial Engineer- Senior Executive Department: Production Reports To : Production Manager
Key Responsibilities:
1. Advanced Production Process Optimization & Work-Study
· Conduct method studies and process mapping to streamline workflows and eliminate non-value-added activities (NVAA).
· Perform detailed time and motion studies (TMS) and establish Standard Minute Values (SMV) using GSD (General Sewing Data) technique.
· Implement ECRS (Eliminate, Combine, Rearrange, and Simplify) methodology to refine process efficiency.
· Develop and implement Work aids, jigs, fixtures, and attachments to improve operator productivity.
· Conduct Value Stream Mapping (VSM) to analyse current production flow and redesign for optimal efficiency.
· Ensure ergonomically designed workstations to enhance operator comfort and efficiency.
2. Line Balancing & Throughput Optimization
· Conduct Line Balancing using Yamazumi to ensure smooth workflow and optimized manpower allocation.
· Implement Takt Time, Cycle Time analysis, and Bottleneck Identification to balance production lines dynamically.
· Develop QCO Strategy to adapt to style changes with minimal downtime.
· Implement Theory of Constraints (TOC) to improve throughput and reduce Work-in-Process (WIP).
· Utilize Heijunka (Production Levelling) methodology for better scheduling and reduced fluctuations.
3. Performance Monitoring & Continuous Improvement (Kaizen, Six Sigma, PDCA)
· Establish Key Performance Indicators (KPIs) such as OEE (Overall Equipment Effectiveness), RFT (Right First Time) and Operator Efficiency Tracking.
· Use DMAIC (Define, Measure, Analyse, Improve, Control) methodology to drive defect reduction and process improvements.
· Conduct A3 problem-solving and Kaizen events to eliminate waste and improve production flow.
· Utilize Pareto Analysis (80/20 Rule) for defect identification and prioritization of improvements.
4. Quality Improvement & Rework Reduction
· Implement Zero Defect Approach (ZDA) & Poka-Yoke (Error Proofing) techniques for defect prevention.
· Collaborate with the Quality Assurance team to drive Six Sigma defect reduction projects.
· Implement Failure Mode and Effects Analysis (FMEA) to identify potential defects and risks in production.
· Optimize Standard Work Procedures (SWP) and SOPs to ensure consistent quality.
· Utilize 5Y and Ishikawa (Fishbone) Diagrams for in-depth problem analysis in rework reduction.
5. Cost Control & Waste Elimination (Lean Manufacturing Focus)
· Apply Lean Principles – 8 Wastes (TIMWOOD: Transportation, Inventory, Motion, Waiting, Overproduction, Overprocessing, Defects, Skills underutilization) to eliminate waste.
· Implement Kanban pull system and JIT (Just-in-Time) manufacturing for inventory control.
· Conduct cost-benefit analysis for process improvements, automation, and new technology implementation.
· Develop Value Engineering (VE) strategies to reduce material consumption while maintaining quality.
6. Training & Skill Development
· Develop competency matrices and training roadmaps for operators, supervisors, and junior IE staff.
· Conduct Lean Six Sigma Green Belt training for cross-functional teams.
· Conduct Knowledge sharing for cross-functional teams
· Lead work-study and ergonomics training programs to improve operator efficiency and well-being.
7. Conducting 6S Audits & Workplace Organization
· Lead 6S (Sort, Set in order, Shine, Standardize, Sustain, Safety) audits and ensure adherence.
· Implement 5-Why Analysis & Gemba Walks to identify and solve workplace inefficiencies.
· Conduct Visual Management and Standardized Work initiatives to improve shop floor discipline.
Skills & Competencies Required:
✔ Expertise in Lean Manufacturing, Six Sigma, 6S, Work-Study, and Industrial Engineering tools. ✔ Proficiency in ERP, SAP and digital tracking solutions.
✔ Factory Layout Planning and Execution skills ✔ Advanced problem-solving skills using RCA, PDCA, DMAIC, and Ishikawa models. ✔ Strong statistical analysis and data visualization skills
✔ Knowledge of automation technologies, smart factories, and Industry 4.0. ✔ Excellent leadership, project management, and stakeholder management skills.
Process Owner
Head Of Department
Factory Manager
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