Job Purpose
To improve productivity, efficiency, manpower utilization, production flow, and manufacturing costs in the shirt production division through effective Industrial Engineering techniques, work measurement, line balancing, capacity planning, and continuous improvement.
Key Responsibilities
1. Method Study & Work Measurement
- Conduct method studies for shirt manufacturing operations from cutting to finishing.
- Analyze individual operations and develop the most efficient working methods.
- Conduct time studies and establish SAM (Standard Allowed Minutes) for each operation.
- Review and update operation breakdowns and standard times whenever there are changes in style, method, machine, or process.
- Identify and eliminate unnecessary motions, delays, and non-value-added activities.
2. Line Balancing
- Prepare operation breakdowns and production line layouts for different shirt styles.
- Balance sewing lines according to target production and available manpower.
- Identify bottleneck operations and implement corrective actions.
- Optimize manpower and machine allocation.
- Monitor line efficiency and take action to improve productivity.
3. Production Planning & Capacity
- Calculate production capacity based on available manpower, machines, working hours, and SAM.
- Support production planning by providing accurate capacity information.
- Analyze daily production requirements and determine required manpower and machine capacity.
- Monitor actual output against planned capacity.
4. Productivity & Efficiency Improvement
- Monitor hourly production, efficiency, utilization, and productivity.
- Analyze reasons for production losses and recommend corrective measures.
- Work closely with Production, Quality, Maintenance, PPC, and Cutting departments to improve overall efficiency.
- Implement continuous improvement initiatives using Lean Manufacturing, Kaizen, 5S, and waste-reduction techniques.
- Reduce unnecessary movement, waiting time, excess handling, rework, and other production losses.
5. Shirt Manufacturing Process Analysis
- Study and optimize operations such as:
- Collar preparation and attachment
- Cuff preparation and attachment
- Sleeve preparation and setting
- Placket preparation
- Pocket preparation and attachment
- Front and back joining
- Side seam
- Sleeve hem
- Buttonhole
- Button attaching
- Bartacking
- Final inspection and finishing
- Develop efficient operation sequences and workstation arrangements.
6. Manpower & Machine Utilization
- Analyze manpower requirements for each production line.
- Ensure optimum utilization of operators and helpers.
- Identify skill gaps and coordinate with Production/HR/Training teams for operator development.
- Analyze machine requirements and assist in machine allocation.
- Monitor machine utilization and identify underutilized resources.
7. Performance Monitoring & Reporting
- Prepare daily and weekly IE reports covering:
- Production efficiency
- Line efficiency
- Operator productivity
- Capacity utilization
- SAM performance
- Manpower utilization
- Bottleneck operations
- Production losses
- Maintain accurate IE records and production analysis.
- Present improvement opportunities and performance results to management.
8. New Style / New Product Development
- Study new shirt styles before production starts.
- Prepare operation breakdowns and estimated SAM.
- Conduct pre-production time studies.
- Support sample and pilot production.
- Develop line layout and manpower requirements for new styles.
- Identify potential production problems before bulk production.
9. Continuous Improvement
- Identify opportunities for productivity and cost improvement.
- Conduct root-cause analysis for production problems.
- Implement PDCA, Kaizen, Pareto, Fishbone, and other IE/Lean tools where appropriate.
- Track improvement projects and quantify productivity gains.
- Support management initiatives for reducing manufacturing cost.
Key Performance Indicators (KPIs)
- Line efficiency %
- Overall factory/section efficiency %
- Production output vs. target
- SAM accuracy
- Operator productivity
- Manpower utilization
- Machine utilization
- Bottleneck reduction
- Production loss reduction
- Improvement project savings
- On-time completion of IE activities
Required Qualifications
- Diploma/Bachelor's degree in Industrial Engineering, Production Engineering, Textile Engineering, Garment Technology, or a related field.
- Experience in garment manufacturing, preferably woven shirt manufacturing.
- Knowledge of garment production processes and sewing machines.
- Good understanding of Time Study, Method Study, SAM, Line Balancing, Capacity Planning, and Productivity Improvement.
- Proficiency in MS Excel and production/IE reporting.
- Knowledge of Lean Manufacturing and continuous improvement techniques is preferred.
Required Skills
- Strong analytical and problem-solving skills
- Good knowledge of garment manufacturing operations
- Time study and work measurement
- Line balancing
- Capacity calculation
- Manpower planning
- Production data analysis
- MS Excel and reporting
- Communication and coordination skills
- Ability to work under production pressure
- Continuous improvement mindset
Experience
Typical Requirement: 2–5 years of relevant experience in Industrial Engineering within a garment manufacturing environment.
For a Senior Industrial Engineer, 5–8+ years of relevant experience may be required.
Key Interfaces
The Industrial Engineer will work closely with:
- Production Department
- PPC Department
- Quality Department
- Cutting Department
- Finishing Department
- Maintenance Department
- HR / Training Department
- Merchandising Department
- Factory Management
Overall Responsibility
The Industrial Engineer is responsible for ensuring that shirt production processes are efficient, measurable, balanced, and cost-effective, while continuously improving productivity, manpower utilization, production capacity, and manufacturing performance.
Pay: ₹70,000.00 - ₹75,000.00 per month
Work Location: In person
