Mr.Sanjaya Athapttu

Overall responsible for Manufacturing excellence and Industrial engineering duties, including machine maintenance, for six manufacturing units (1300 Directs) in the organization.

Key highlights for the changes made in the current organization.

• Started GSD standardization for the POLO T-shirt and structured the organization's SMV calculation process, as well as the involvement of the sample development process of front-end IE teams.
• In Build, the process is to the sample room to make sure the product is stitched based on the customer's requirements and the method/operation given by the IE teams for costing based on the GSD values.
• Process set up to use all the bulk stitching method in the sample room to make sure there cannot be unnecessary sewing operations in the bulk.
• Training conducted for all the IE, Quality, and Technical teams on the industrial engineering concept for the garment industry. Special training is given to IE teams for GSD at a very detailed level.
• Started GSD data-based Video Library and common operation standardization for polo, and set up follow-up mechanism to make sure units are using GSD methods in production.
• Set up a world-class automation unit in the organization and make the process of utilizing the machines to get real ROI.
• Working directly with Tommy Europe (PVH) PIT team (Product Improvement Team) for the global product standardization project.
• Started with Tommy Europe team (PVH) for product clustering to get vendor efficiency improvements.
• Directly working with PVH manufacturing excellence teams for quality, automation, and process improvement activities.
• Reduced POLO T-Shirt SMV by 18% using GSD values.
• Working with the product risk analysis process and merging with units to understand and prepare for the bulk, to avoid unnecessary drop in the learning curves.
• Working to apply digital skill matrix and correct balancing process to manufacturing units, IEs.
• Preventive maintenance process alignment.

Hold the responsibility for the industrial engineering function of the Brandix apparel solutions India cluster, which has four (4) double shift plants in Andhra Pradesh, with a sewing machine operators' capacity of 6700 directs.

• Make sure higher productivity by analyzing products and capabilities based on the skills, and allocate the right product for right modules.
• Driving KPIs for business needs from industrial engineering function.
• Looking after all training and development of industrial engineering teams, as well as being a lead member of TED team to enhance IE skills of other departments.
• Maintain product plant matrix and product categorization with planning teams for strategic efficiency improvements.
• Working with customers such as PVH Inc., Victoria's Secret, Uniqlo, H&M, Walmart, and Warner's.
• Handled SMV improvement projects with customers (Victoria's Secret and PVH).
• Leading major boxer automation project in one of PVH plants at Brandix India plant.
• Connect with front-end development teams (Technical/Industrial engineering) for business growth and smooth execution of products for manufacturing locations.
• Sewing machine requirements budgeting, generation, and optimizing throughout plants.
• Management information flow monitoring (SAH, downtime, efficiencies)

Projects carried out in Brandix India cluster.

• Introduce mini module concept to reduce balancing losses and lead project to convert conventional modules to mini module concept in PVH product plant.
• Uniqlo product efficiency enhancing project with zero defects.
• Project leader of automation for boxer and panty products.
• PVH Zero defect project member from IE side to do method improvement and calculations of the cost of quality.
• New plant expansion for Uniqlo with T-Shirt, Pants, and Underwear.
• Product re-engineering to reduce cost – Sew at low cost to higher quality products.
• Lead empower Kaizen culture project in India cluster

Hold the responsibilities for the industrial engineering function of the Brandix essentials cluster (Sri Lanka) and handled IE teams in five plants in Sri Lanka.

• Driving KPIs for business needs from industrial engineering function.
• Maintain product plant matrix and product categorization with planning teams for strategic efficiency improvements.
• Handled customers such as PVH inc.coop /Victoria Secret/ Uniqlo/Amazon/Tommy John/ Under amour/ LIDL /Kauflands/ Haddad.
• Handled Automation and innovation function from industrial engineering side.
• Involving plant expansion projects overseas and Sri Lanka.
• Visited USA, Dominican Republic, and Haiti for new plant evaluation, process setup, product transferring, layout preparation, and skill identification for PVH Calvin Klein (CK) underwear products.
• Sewing machine requirements budgeting, generation, and optimizing throughout the plants.
• Management information flow monitoring (SAH, downtime, efficiencies)
• Involved in doubling company turnover within seven years by doing product re-engineering, method improvement projects, customer productivity projects, and new layout implementation

Projects handled in Brandix's essential Sri Lanka cluster.

• Sewing method GSD standardizing.
• Men underwear automation projects, Women underwear automation projects.
• Bucket loss reduction project.
• Skill development project.
• Efficiency ladder improvement project.
• Cut to box concept installation project.
• Downtime on-time capturing project.
• Operator training and skill-improving project.
• Packing automation project.
• Uniqlo product transformation project.
• Plant layout change projects.

Project that was carried out with customer teams.

PVH

• PVH Product clustering.
• Men's Molding underwear project.
• CK men's Off-Price cost reduction project
• CK Women's bonding project.
• Region strategy manufacturing project (Haiti, DR).

Worked as an Industrial Engineering Executive at MAS Design Center.

• Done all of garment re-engineering/method engineering and labor costing for MAS Intimates cluster, and also calculate final production SMV (GSD).
• Handled product development meeting, facilitated all technical inputs, and performed garment engineering, construction, and method engineering functions to reduce labor costs and material consumption.
• Well experience in various types of costing, such as sample costing, tech pack costing, and sketch costing, especially for Mark & Spencer, BHS, Lasenza, Tesco, H&M, Chico's, Victoria's Secret, Gap, Sans, Fila, Dim, Playtex, Nike, Triumph, and Walmart.

Following projects carried out in MAS intimate.

• Sewing method standardizing.
• Bonding SMV database creation and setup, SMV calculation method.
• Efficiency improvement projects.

• Total industrial engineering responsibilities for the manufacturing floor.