Industrial Engineer- Senior Executive

Job Title: Industrial Engineer - Senior Executive

Department: Production
Reports To: Production Manager
Job Location: Coimbatore
No of Openings: 1
Qualification: Diploma/Degree in Textile Technology, Garment Manufacturing, or a related field.
Experience: 5-8 years of experience.
Salary: 40 60K / Month (Negotiable for the right candidate)

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.

• 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.

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Job Category: Industrial Engineer - Senior Executive
Job Type: Full Time
Job Location: Coimbatore
Industry: Garment