About this role
Objective:
Improve overall factory efficiency by proper line balancing, line layout improvement, building skills, Line Management.Improve Right the First Time (RFT) in terms of System Adherence and sustenance.Improve Quality at Source through effective implementation of Total Quality Management System (TQMS)Reduced SMV of permanent styles through Process Improvement, Re-Engineering, & Innovation.Cost OptimizationImprove material UtilizationProcess OptimizationEmpower Vendor & Factory by providing theoretical & practical training (Lean, TQM, Six Sigma, IE Tools, Innovation).Upgrade Factory to L3 or L4.Support Vendor/Factory based in creating culture of continuous improvement in the organization.Introduce the latest trend in machine innovation, Ai & digitalization to improve productivity, quality and reduce cost. Key Responsibilities:
C.I Playbook governance and deployment.
Act as the owner & subject matter expert of the Continuous Improvement Playbook.Leads the roll out of C.I Standards and requirements across Partner or KAS supplier factories.Ensure implementation of all C.I clauses, systems, methodologies, and minimum requirements defined in playbook.Develop roadmaps according to factory evaluation result levels.Ensure alignment between factory operations & corporate sourcing strategy.Review, maintain, and continuously improve ME Playbook standards based on emerging industry best practices.Factory Assessment & Evaluation:
Conduct ME Evaluation to Partner or KAS Supplier/Factories.Evaluate factories using the ME Scorecard & BRAG rating methodology.Determine the Factory’s ME Evaluation result Levels (L1, L2, L3, & L4)Identify gaps & Improvement opportunities.Prepare comprehensive assessment reports and executive summaries.Work with Partner or KAS Vendor/Factory to establish corrective action plan and implementation roadmaps.Monitor closure of assessment findings (NCs) and sustainment actions.Capability building and training.
Design and Deliver ME Training ModulesConduct Classroom & Practical Training workshopCoach Factory Management teams and Industrial EngineersBuild Lean and Continuous Improvement culture within the vendor & factory organization.Certify Factory ME champions & key users according to playbook standard.Training Modules to conduct to Vendor and Factory:
Critical Path ManagementProduction PlanningTotal Quality Management System (TQMS)Lean & Six SigmaSupermarket System (Cutting to Sewing)Industrial Engineering tools:
Sewing: Work Measurement (PMTS: GST/GSD); Operation Bulletin; Line Balancing Chart (SMV, Takt Time, Cycle Time); Operator hour Output & Efficiency Monitoring; Sewing End-line Kanban Board; Non-Productive Time Record & Analysis; Quick Changeover; Skill Matrix; Standard Worksheet; Zero Defect Operator Program; RFT/DHU/Reject/Rework % reports; Consolidated Daily, Weekly, Monthly & Yearly Sewing Line and Overall Sewing Department Production Output, Efficiency and Quality report. Cutting: Marker Optimization; Cut Plan Optimization; Daily Cutting Plan System; Spreading & Cutting Control System; Consolidated Daily, Weekly, Monthly, Yearly Output & Efficiency report for Spreading, Cutting, & Bundling & Loading Report (By Table/Team and overall).Finishing & Packing: Operator Hourly Target & Output report; Team Base & Department Output and Efficiency report;Cutting, Sewing, Finishing & Packing Consolidated Daily Production Report (DPR) summary.All department: Productivity Improvement; Workflow Optimization; Quality Improvement InitiativesContinuous Improvement Project Management:
Lead Kaizen, Lean, Six Sigma and Industrial Engineering Projects.Facilitate Value Stream mapping exercise.Conduct Root caused analysis (RCA): 5 Whys; Fishbone Diagram;Identify and eliminate waste across manufacturing process.Reduce: Cost, Lead time, Changeover, WIP, Defects and downtime.Improve: Productivity, Efficiency, Quality, Capacity Utilization;Digitalization, Industry 4.0 Deployment:
ERP SystemsMES Solutions such as Shop Floor Management system, Warehouse Management System; Quality Management System; Asset Management System; Planning System; RFID Application or Barcode/QR Code System; Shop Floor Tracking Solutions; GSD; AI & Data Analytics Application; AI Based Bots or Robotics Application (not really humamoid).Machine Innovation & Automation
Identify Automation opportunity in factory.Benchmark Best-in-class apparel technology.Provide and guide factories to invest in the latest trend on Machine Innovation to improve quality, efficiency, productivity, de-skill operation and reduce cost.Providing Cost Benefit Analysis, RROI and Payback Period analysis to justify if the investment is ideal.KPI Management & Reporting
Develop and Monitor Performance Indicator such as Efficiency%, Performance %, PPH, OEE, Capacity Utilization, RFT rate, DHU rate, Rework rate, Reject rate, Zero Defect, Cost Savings, Critical Path adherence performance, NPT Rate; SMV Reduction, OTD,Working Interface: Work closely with relevant department/team:
External: Vendor and Factory Leaders, Functional and Operational TeamInternal: Industrial Merch, Planning, Costing, P.E, GT, Strong knowledge of garment construction, material, and machines.Understand the end-to-end garment factory process.Capable of optimizing workflow.Garment Construction Re-Engineering.Project ManagementGood Interpersonal/Collaboration/Team Oriented.Proficient in MS Office Suite / PLM/Power-BiProficient in English; Mandarin is a plus.Data modeling and analyticsGSD Practitioner is a plusLean Certified or Lean Six Sigma green belt certified 5-10 years relevant work experience in Apparel Manufacturing, Industrial Engineering, Lean Manufacturing, Costing, or Operation Excellence.Experience in Quality Management System.Experience in work measurement (PMTS), line balancing and Methods Improvement.Minimum 3 years leading continuous improvement program with Vendor/Factory.Experience in Product Re-Engineering/Design to Cost/Eco Design & Process Innovation.Experience in Factory Assessment and Evaluation.Exposure in Cost Optimization ProjectsExposure in Project ManagementDiploma in Industrial Engineering/ Operation Management/ other Engineering Field/ Textile Engineering/Apparel Manufacturing Technology.