Industrial Engineer Senior Manager
Resume:
MUHAMMAD ZUBAIR
Senior Industrial Engineer Specializing in
Apparel & Work wear Manufacturing
Excellence
Email: *****************@*****.***
Mob # +92-333-*******
Address: Zakria Town, Multan.
Professional Summary
Result-oriented Industrial Engineer with 12+ years of experience in denim and apparel manufacturing. Proven expertise in capacity enhancement, lean implementation, cost control, and setting up new production units. Skilled in layout designing, SMV/GSD, ERP integration, manpower optimization, and productivity improvement. Adept at bridging interdepartmental communication and driving continuous process improvements to deliver bottom-line impact. Core Competencies
Apparel & Work wear Production Engineering
Lean Manufacturing (Kaizen, 6S, Gemba Walks)
Time & Motion Study SMV GSD
Line Balancing & Layout Optimization
Garment Costing & Cost Control
ERP Systems Implementation
KPI Monitoring & Dashboard Creation
Training & Skill Development Programs
New Plant Setup & Expansion
Cross-Functional Team Leadership
Professional Experience
Senior Manager – Industrial Engineering
FIRHAJ APPAREL (Umar Group), Lahore
Sep 2023 – Present
Established a new denim production unit (12,000 pcs/day): from layout, machinery selection to quality SOPs.
Increased monthly production capacity from 300K to 500K pcs via line optimization.
Implemented hanger system
Introduced lean projects (Gemba Walk, Kaizen, and Visual Management).
Replaced ticketing with stamp numbering: saved PKR 600K/month.
Installed auto thread trimmers: reduced 50% manual labor in finishing. Manager – Industrial Engineering
MK SONS LTD, Faisalabad
Apr 2019 – Aug 2023
Led 15,000 pcs/day production project; optimized machinery, layout, and space.
Shifted manual to barcode-based payroll system.
Developed skill training center: trained 25 individuals/month.
Designed cost sheet framework for accurate wage/operation costing.
Managed new denim expansion unit (5,000 pcs/day): layout & hierarchy setup.
Initiated thread and stitching method changes: saved PKR 200K/month.
Assessed operation KPIs to drive performance-based annual bonuses.
Identified product mix based on 1-year analysis to optimize bookings. Deputy Manager – Industrial Engineering
AZGARD-9 Ltd, Lahore
Feb 2013 – Nov 2018
Led product development and production scheduling for sampling.
Implemented lean tools (6S, Kaizen, VSM, PDCA, Takt Time).
Eliminated non-value-added activities; introduced automation.
Created performance dashboards (efficiency, absenteeism, DHU).
Led Continuous Skill Development (CSD) training programs.
Delivered weekly KPI reviews and man-to-machine ratio analysis. Key Skills & Strengths
Production Line Setup & Optimization
Lean Manufacturing & 6S / Kaizen Implementation
SMV/GSD / Time & Motion Study
Line Balancing & Skill Matrix Deployment
Cost Reduction & Garment Costing
Performance KPI Tracking & ERP Systems
Team Training & Cross-Functional Collaboration
Facility & Machinery Planning
Achievements
Boosted line efficiency by 25% through layout & method improvement.
Reduced operational costs by 15% via lean initiatives.
Lowered labor costs by 10% using standardized SMV via GSD.
Reduced learning curve by 30% with skill matrix implementation.
Cut WIP inventory by 25% and floor space by 15% with new layouts.
Balanced over 200+ styles/season with >85% daily efficiency.
Increased first-pass yield by 12 %through feedback and audits.
Reduced manual report errors by 95% via ERP/IE module implementation.
Eliminated 22% of material waste via analytic root-cause strategies.
Reduced lead time from weeks to days
Led lean transformations on multiple lines.
Redesigned plant layout to cut material handling by 30 %.
Trained operators in time-study and lean methodology.
Established floor KPI dashboards for transparency. Education
B.Sc. Textile Engineering (Garment Manufacturing) BZU Multan 2009 – 2013
Certifications
IE in Apparel Manufacturing (Line Balancing, Work Study, Time Study)
Lean Six Sigma – Quality & Process Improvement
GSD (General Sewing Data)
Kaizen & 5S Productivity Training
Lean Manufacturing in Apparel
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