Manager Lean Six
Resume:
Priyabrat Kumar
Head of Production
COMPANY - CROWN NATURE – LAGOS, NIGERIA
NIFT - New Delhi, India, (B.F.Tech- Apparel Production )
adge41@r.postjobfree.com
SUMMARY
Collaborate with Core Team in defining & implementing operational strategies for smooth functioning of 300 m/c
factory. Focus on maintaining compliance to delivery schedules as well as managing administrative aspects related
to optimizing floor cost, cut to Ship / Order to Ship / wastages, Man Machine Ratio (MMR).
I have set the factory having 300 m/c with specialized machinery achieving the production and printing of 6K to 8K
pcs of garment every day at 65% efficiency. Also Implement the end-to-end QMS to reduce the DHU from 40% to
12%.
Rated high for reducing factory budget to 15% within first 3 months of joining the organization, reducing Man
Machine Ratio through LEAN and Enhanced the First-time Final Inspection pass of 95%, On time shipment of 90%
I can very well deal with all the pros & cons of the garment manufacturing process, like grey fabric, dyeing, printing,
embroidery, machinery required for line setting, cutting, stitching, finishing packing & shipment.
Being an Independent handling authority, certain reporting system were developed by me & have been able to
implement all those on the shop floor with the help of concerned management, which yielded better results for the
organization to mapping controlling & improvement in productivity, efficiency and Quality of products.
Highlight critical internal/ external issues with potential business impact to the Board of Directors for effective
resolution. Render consultancy to the Board of Directors pertaining to day to day activities of the organization.
CURRENT JOB PROFILE
Planning with Business Head Labor Management
Priorities the Product Delivery Cross Communication
Fabric Plan and Dyeing Plan Outsourcing Daily Factory Costing
BOM & Costing & SAP Processing Factory Overheads Controlling
Coordination with Design & Merchandisers Production target for timely shipment
Forecasting future production requirements Factory Auditing & Compliance
Initiate Product Engineering Idea to PD Using latest production technologies
Re-planning and corrective action. Monthly budgeting
Planning for learning & Developments. Monthly MIS Report & P/L presentation.
IN PLANT: TECHNIQUIES USING FOR QUALITY IMPROVEMENT
Lean Manufacturing System In-line Quality Control
Time Motion Study, Cycle Time Study Critical path and Critical Operation
Productivity Improvement. Hourly Production Target update
Continuous Improvement Control DHU to minimum Level
Wastage Reduction Shipment Follow-ups
WIP Control Control MMR / OT
Lean Six Sigma training to staff Cost Reduction Activities
Improving 5s activities Productivity & Efficiency Report
Responsibility for kaizen, improvement Machine & Equipment Report
Implement FTR across the Operations Rejection & Alteration Control.
WORK EXPERIENCE
HEAD – PRODUCTION & QUALITY May 2019 TO December
COMPANY - CROWN NATURE – LAGOS, NIGERIA
PLANNING PART
Trend Analysis & forecasting: Getting updated with latest trends & Competitors analysis for season planning.
Range Selection & Product development: Working Closely with Designers to create an excellent product
Responsible for Identifying, Developing the prospective vendors / Negotiation & Closures
Taking Immediate action on Fast moving / Slow moving product for higher sell thru.
Product wise performance analysis. Periodically reviewing the merchandise performance to monitor the target.
Planning Category Mix: Helping in Style Selection & Range Development to create most favorable Category mix.
WITH ALL ABOVE ACTIVITY, I AM INVOLVE RIGHT FROM BIGNING TILL FINAL STYLE SHEET FOR THE MONTH.
PRODUCTION PART
End to end operations for smooth functioning of the Sourcing / Vendor Management / SCM & Production Unit.
Monthly production & new launch planning with category Head / Product Development Team
Make the Knitting Plan / Fabric Plan / Dyeing Plan/ Stitching Plan/ Printing Plan / Dispatch Plan.
Ensure all the Outsourcing article should be In-House on Time.
Setting up quality check points & assigning quality checkers according to the critical operation.
Closely monitoring & Controlling the TNA for All category.
Fabric Testing before In-House / MIGO/ MIRO/ GRN
Line Setting, operation Breakdown, m/c & folder requirement in coordination with IE team.
Planning and setting up TARGET for different garment styles as per Delivery Schedule.
Master TNA & Plan v/s Actual, for each style, starting from material procurement till Dispatch.
Costing & Consumption of Fabrics / Trims & other materials & Follow ups
Separate Plan for all PRINTING for All categories. (Screen Print, Digital Print, M&R Print)
Throughout production planning & Control (PPC) @ SAP ERP.
Monitoring hourly production and dispatch to finishing.
Factory problem analysis - Weekly meetings / Implementation / Result / Reporting.
Conducting Buyer’s factory audit (Industry Certification Compliance/ ICTI).
Factory Costing / Cost per Pcs, Monthly budgeting / Cost per machine analysis.
HEAD – PRODUCTION March 2016 TO April 2019
II INSPECTION & EXPORT PVT LTD. (FOR - JAPNEASE GARMENT EXPORTS COMPANY)
Communicate with team regularly to ensure on-time delivery of goods
Do planning, costing, product development, quality control and delivery scheduling.
Track shipments in coordination with factories and brokers.
Follow up shipments and update day-to-day warehouse stock and shipment, quality and deliveries.
Communicate effectively with design, sales, accounting, and logistics staff.
Allocate styles to factory for production. Negotiate prices with Product Development.
Issue and maintain purchase orders. Troubleshoot production issues.
Manage all delivery related issues, including tracking, confirmation and extension negotiations.
Day to day communicating with vendors, buyers and merchandising, planning and SCM
Manage exception to Time & Action calendar and work-in-process reports received from sourcing.
Facilitate weekly production update with cross-functional team
Review reports prepared by the Production Manager prior to the meeting.
SR. PRODUCTION MANAGER JUNE 2013 TO FEB 2016
RAW MANGO – High Fashion. New Delhi
Setting Factory for apparel manufacturing with300 machines in-plant, and 200 machines at job work factor
Responsibility included: R & D Department: Supervise Sample Room Manager Sample development, consumption,
marker, production pattern, costing and price negotiation with vendor.
Centralized Cutting department: Supervise Cutting Room Manager, lay marker with minimum wastage plaid & stripe
matching and balancing, numbering and bundling the cut parts etc.
Manufacturing department: Supervise Sewing Plant and Production Managers to improve productivity with minimum
cost and without affecting the quality and delivery.
PRODUCTION & IE EXECUTIVE MAY 2007 TO JUNE 2008
GINNY AND JONY APPARELS LIM
Developing sewing & handling methods & training to workers
Calculations thread consumption
Work Study, Make Operation Bulletin, Machine Layouts, Line Plan
Line Efficiency making with Cost per pcs
Give target to operation with GSD
Mention and arrange what kind of machine will be used & folders
Co-ordinate with marketing department for costing (of garments)
Coordinate with PPC department / Making layouts & form line setting
BUYER HANDLED
KIABI (FRANCE)(Dress) ANTHROPOLOGY (USA)(Top)
LINDEX (SWEDEN)(Dress) ARMANI (ITALY)(Hi-Fashion)
GARCONNE (JAPAN)(Bottom) KOIZUMI APPARELS (JAPAN)(Top/Bottom)
LEVI’S (USA) Bottom LCW (JAPAN)(Hi-Fashion)
KAPPA (ITALY)(kids) NEW LOOK (BRITISH) (Top)
BEWAKOOF BRANDS (Knits)
AREA OF EXPERTIES
Production Planning & Control / Garment Manufacturing /Cutting-Stitching-Finishing-Printing-Dispatch.
Target Setting and Analysis – PLAN Vs. ACTUAL. / Fabrics Consumption /Gross/Trims Av.
Vendor Development / Outsourcing / Rate Negotiation with Vendors
Garment Fitting & Construction / Pattern / Product Development / Sampling / Graphic Design
Trend Analysis & Forecasting / Planning Category mix/ Style Selection/ Range Development.
Seasonal merchandise Planning / Launch of Sale events / Product wise performance analysis.
DECLARATION
I hereby affirm that the information in this document is accurate and true to the best of my knowledge.
Regards
PRIYABRAT Kumar
Mob: +91-991*******
adge41@r.postjobfree.com
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