Production Manager

Reports To: General Manager / Directors

Direct Reports: Production Supervisors, Line Chiefs, IE Officers, Quality Auditors

Job Summary

The Production Manager is the linchpin of the garment factory floor, responsible for transforming raw materials (fabrics, trims) into finished garments efficiently, on time, within budget, and to the required quality standards. This role is the critical link between planning (merchandising) and execution, overseeing the entire production process from cutting to finishing and packing. The Production Manager is ultimately accountable for the output, efficiency, and workforce of the production department.

Key Responsibilities

1. Production Planning & Scheduling:

2. Collaborate with the Planning/Merchandising department to understand order requirements, deadlines, and specifications.

3. Develop detailed master production schedules and allocate resources (machines, manpower) accordingly.
4. Break down the production plan into daily and hourly targets for each production line.

5. Ensure a smooth flow of materials from the cutting room to the sewing lines and finishing section.

6. Execution & Floor Management:

7. Oversee the entire production process: Cutting, Sewing, Finishing (ironing, checking), and Packing.

8. Monitor production lines in real-time to ensure they are meeting daily targets and efficiency standards.
9. Identify and resolve bottlenecks in the production process promptly.

10. Ensure the factory floor is organized, adhering to 5S principles (Sort, Set in order, Shine, Standardize, Sustain).

11. Efficiency & Productivity Management:

12. Work closely with the Industrial Engineering (IE) department to implement standard minute values (SMV) and set realistic targets.

13. Monitor key performance indicators (KPIs) like Line Efficiency, Production Capacity Utilization, and On-Time Delivery.
14. Drive initiatives to improve productivity through method improvements, line balancing, and operator skill development.

15. Control and reduce production waste (fabric, thread, time).

16. Quality Control & Assurance:

17. Work with the Quality Control (QC) Manager to establish and maintain quality standards for each order.

18. Ensure in-line quality checks are being conducted effectively to catch defects early (Right First Time approach).
19. Analyze quality reports and end-line inspection data to identify recurring defects and implement corrective actions on the floor.

20. Promote a culture of quality consciousness among all production staff.

21. Cost Control & Budget Management:

22. Manage the production budget, controlling costs related to labor, overtime, and consumables.

23. Strive to reduce the Cost of Making (CM) per garment.

24. Minimize rework and rejection rates to reduce cost and improve yield.

25. Team Management & Development:

26. Lead, motivate, and manage a large team of production supervisors, line chiefs, and operators.

27. Conduct performance reviews and identify training needs for supervisory staff and workers.
28. Resolve personnel issues and maintain a positive, productive, and safe working environment.

29. Foster a culture of continuous improvement and teamwork.

30. Reporting & Communication:

31. Prepare and present daily, weekly, and monthly production reports to senior management.

32. Liaise with other departments (Merchandising, Sourcing, Store, Maintenance) to ensure alignment and resolve cross-functional issues.

Key Performance Indicators (KPIs)

• On-Time Delivery: Percentage of orders shipped as per the original schedule.
• Line Efficiency: (Total Output in SMV / Total Man-Minutes Worked) x 100.
• Production Target Achievement: Percentage of daily/weekly production targets met.
• Quality: First Pass Yield (FPY), Rejection Rate, Return Rate from customer.
• Cost Per Unit: Adherence to the planned Cost of Making (CM).
• Absenteeism & Attrition Rate: Workforce stability.

Qualifications & Experience

• Education: Bachelor's degree in Textile Engineering, Apparel Manufacturing, Industrial Engineering, or a related field.
• Experience: Minimum of 8-12 years of experience in garment production, with at least 5 years in a managerial role overseeing multiple production lines.
• Technical Knowledge:
• In-depth understanding of garment construction, sewing operations, and production processes.
• Strong knowledge of IE concepts: SMV, line balancing, method study, and workflow analysis.
• Familiarity with a wide range of fabrics, machines, and garment types (e.g., woven shirts, knitwear, denim, trousers).
• System Skills: Proficiency in MS Office (especially Excel) and experience with production management software or ERP systems.

Required Skills & Competencies

• Strong Leadership & People Management: Ability to lead a large, diverse team.
• Problem-Solving & Decision-Making: Quick and effective at troubleshooting production issues.
• Communication & Interpersonal Skills: Must communicate clearly with operators, peers, and senior management.
• Pressure Handling: Ability to perform under tight deadlines in a fast-paced, dynamic environment.
• Analytical Mindset: Data-driven approach to managing efficiency and quality.
• Technical Acumen: A solid grasp of the technical aspects of garment manufacturing.