Lean/6s Specialist (Manager or Above for Knit Garments)

Job Description

Title: Lean/6s Specialist (Manager or Above for Knit Garments)

Company Name: A Largest Knit Garments Company

Vacancy: --

Age: 32 to 42 years

Job Location: Gazipur

Salary: Negotiable

Experience:

• 7 to 14 years
• The applicants should have experience in the following business area(s): Garments

• Bachelor of Science (BSc) in Textile Engineering, Industrial Eng & Production

Certifications (Preferred):Certified 5S / 6S/ Lean Practitioner / Kaizen Leader.

Six Sigma Green Belt or Lean Manufacturing Certification. 

• 7 to 14 years
• The applicants should have experience in the following business area(s): Garments

• Age 32 to 42 years
• Only Male

7 to 14 years of direct experience driving Lean, 5S, and continuous improvement initiatives in large-scale RMG / apparel manufacturing factories.

Technical & Functional Competencies

Deep functional knowledge of garment production flows:Yarn/Fabric Store → Cutting → Sewing Line Balancing → Washing → Finishing → Packing/Shipment.

Hands-on proficiency in Lean tools:

Value Stream Mapping (VSM), Kanban, Kaizen, SMED (Single-Minute Exchange of Die for line changeover), Poka-Yoke (Error Proofing), and Root Cause Analysis (5-Why, Fishbone). 

Strong audit capability and familiarity with digital audit apps/software.

Sound knowledge of local workplace safety regulations (DIFE standards) and international apparel buyer compliance frameworks.

loor-level Kaizen ideas generated by workers/supervisors.

Job Purpose

The Lean 5S/6S Specialist is responsible for establishing, driving, and sustaining workplace organization, visual management, and shop floor safety protocols across cutting, sewing, finishing, and warehousing units in Ready-Made Garments (RMG) manufacturing. The specialist acts as a change agent to eliminate waste (Muda), streamline throughput times, reduce defect/rework rates, and cultivate a safety-first culture on the floor. 

Key Responsibilities

1. 5S/6S Implementation & Visual Management

Execute and sustain all 6 pillars, Sort (Seiri), Set in Order (Seiton), Shine (Seiso), Standardize (Seiketsu), Sustain (Shitsuke), and Safety, across all departments (Cutting, Sewing, Finishing, Stores, and Packing). 

Create visual management systems on the floor, including shadow boards for tools/mechanic supplies, line side inventory/Kanban racks, aisle demarcations, color-coded floor markings, and Andon visual cues. 

Standardize machine maintenance layout, worktable arrangements, pattern storage, trim store organization, and WIP (Work-in-Progress) trolley movement.

2. Process Audit & Compliance

Formulate department-specific 5S/6S audit checklists and standard operating procedures (SOPs) tailored to apparel manufacturing.

Conduct weekly/monthly 5S/6S floor audits, score departments, publish scorecard dashboards, and track corrective action plans (CAPA).

Coordinate with buyer audit teams to align workplace standards with international buyer compliance requirements.

3. Waste Elimination & Kaizen Facilitation

Identify and eliminate 8 Lean Wastes, specifically unnecessary motion, waiting time, searching time for trims/patterns, and over-processing on sewing lines. 

Lead shop floor Kaizen events and Rapid Improvement Events (RIE) with line supervisors, mechanics, and operators.

Establish visual Red Tagging zones to identify, remove, or recycle obsolete fabrics, defective trims, damaged machine parts, and unwanted materials.

4. Shop Floor Safety (6th S)

Identify ergonomic and structural safety risks in cutting and sewing floors (e.g., loose wiring, blocked fire exits, unmonitored needle guard policies, chemical storage in spot-cleaning areas).

Partner with the EHS (Environment, Health & Safety) department to ensure strict compliance with Personal Protective Equipment (PPE) usage (e.g., chainmail metal gloves in cutting, dust masks, eye guards).

5. Capacity Building & Culture Transformation

Develop training materials in Bengali and conduct regular shift-level 5S/6S awareness workshops, toolbox talks, and operator orientation sessions. 

Mentor and train floor champions, line supervisors, and quality controllers to embed 5S/6S into daily operational routines.

Organize monthly internal 5S competitions, recognition awards, and incentive programs to maintain long-term engagement.