Key Responsibilities
1. Wastage Monitoring & Data Control
- Track daily wastage at each process stage: yarn breakage, knitting defects, cutting wastage, stitching rework, washing shrinkage, finishing defects.
- Implement systems to capture real-time wastage data and link it with production reports.
- Maintain wastage dashboards and issue variance reports.
2. Process Control & Improvement
- Identify root causes of excessive wastage and lead problem-solving meetings.
- Conduct process audits to verify actual consumption vs standard consumption.
- Optimize machine parameters, knitting settings, handling procedures, and material flows to reduce wastage.
3. Inventory & Material Control
- Ensure accurate issuance and consumption of yarn and trims.
- Monitor yarn-to-garment ratio and highlight variances.
- Work with Stores and Costing to reconcile material consumption.
4. Quality & Rework Reduction
- Collaborate with QA to reduce defects stemming from knitting, linking, sewing, and washing.
- Analyze rework trends and take corrective actions.
5. Reporting & Cost Impact Analysis
- Prepare daily/weekly/monthly wastage reports by department/shift.
- Quantify wastage-cost impact and share with management.
- Track improvements and savings from corrective actions.
6. SOP Development & Training
- Develop and implement wastage control SOPs.
- Train supervisors, operators, and quality staff on wastage standards and efficient handling.
7. Compliance & Production Discipline
- Ensure adherence to production standards, machine calibration, and operating procedures.
- Conduct internal audits to enforce compliance.
Education
- Bachelor’s degree in Textile Engineering, Industrial Engineering, Quality Management, or related field.
Experience
- 5+ years of experience in knitwear production, wastage control, quality, or industrial engineering.
- Strong understanding of knitting, linking, stitching, washing, and finishing processes.
- Knowledge of wastage control tools (Pareto, RCA, Fishbone, 5 Why).
- Understanding of shrinkage control, fabric behavior, and consumption norms.
- Familiarity with ERP systems and production data recording.