CONTINUOUS IMPROVEMENT MANAGER

* Vertical Process Optimization & Bottleneck Resolution
- Analyze the end-to-end production flow (Spinning -> Knitting/Weaving -> Dyeing -> Sewing) to identify bottlenecks, constraints, and process disconnects.
- Design and implement solutions to synchronize production schedules across different factories, significantly reducing lead times and WIP inventory.
- Map complex value streams (Value Stream Mapping - VSM) to identify and eliminate non-value-added activities (Muda) in material handling, quality handovers, and transition phases between facilities.
* Lean Six Sigma Implementation
- Lead and execute high-impact CI projects using Lean, Six Sigma, Kaizen, 5S, and PDCA methodologies.
- Establish and track key performance indicators (KPIs) for manufacturing excellence, including Overall Equipment Effectiveness (OEE), Cycle Time, Defect Rate, and Yield across all plants.
- Partner closely with the Dyeing and Sewing Plant Managers to optimize chemical usage, reduce energy consumption, and minimize fabric wastage/fallout.
* Cross-Functional Coordination & Change Management
- Act as a central mediator to resolve operational conflicts and align priorities between standalone factory units (e.g., balancing the output of the Dyeing factory with the input needs of the Sewing factory).
- Collaborate with the Sales, Planning, Supply Chain, and Quality Assurance (QA) departments to ensure smooth material flow and prevent production standstills.
- Drive a top-down and bottom-up continuous improvement mindset. Train, coach, and mentor production staff, supervisors, and middle management on Lean tools and problem-solving techniques.
* Data-Driven System Enhancement
- Leverage ERP and Manufacturing Execution Systems (MES) to extract production data, analyze variance, and provide actionable insights to the Board of Management.
- Standardize Standard Operating Procedures (SOPs) across all manufacturing units to ensure consistency and compliance.