Summary
Overview
Work History
Education
Skills
Websites
Accomplishments
Application
Core Responsibilities
Training Achievements
Core Training
References
Interests
Certification
Timeline
Generic
Md. Abdur Rahman

Md. Abdur Rahman

Lean Six Sigma Blackbelt
Dhaka

Summary

Strategic Lean Manufacturing & Manufacturing Excellence Leader with 16+ years of progressive experience in garment manufacturing, including 6 years leading Lean Manufacturing, Continuous Improvement, and Operational Excellence. Proven expertise in driving factory transformation through Lean systems, waste elimination, process optimization, productivity enhancement, cost reduction, and quality improvement. Demonstrated success in building high-performance teams, implementing sustainable continuous improvement cultures, and delivering measurable business results aligned with customer expectations and organizational growth.

Overview

17
17
years of professional experience

Work History

AGM (Industrial Eng.&Production)

Dekko Legacy Group
Savar Upazila
02.2024 - Current
  • Ensure the one-time shipment – Quality Standard to uplift profit and recognition.
  • Lead Lean Manufacturing, Industrial Engineering, Continuous Improvement (CI), and Manufacturing Excellence initiatives.
  • Drive Operational Excellence through productivity, quality, cost, and process optimization.
  • Develop and execute long-term manufacturing strategies aligned with business objectives.
  • Lead factory-wide Lean transformation using TPS, Kaizen, VSM, 5S, JIT, Kanban, and One-Piece Flow.
  • Optimize SMV, line balancing, PPH, capacity planning, and manpower utilization.
  • Improve factory efficiency through PMTS/GSD, Method Study, and process engineering.
  • Lead layout optimization, Cellular Manufacturing, Lean Supermarket, and material flow improvements.
  • Establish KPI dashboards and monitor operational performance to achieve business targets.
  • Reduce production costs through waste elimination, automation, and resource optimization.
  • Review sample development, style engineering, and risk assessment for production readiness.
  • Standardize processes through SOPs, Standard Work, and Lean best practices.
  • Lead Kaizen, Gemba Walks, and Root Cause Analysis to sustain Continuous Improvement.
  • Strengthen quality systems using PDCA, Fishbone, Pareto, and corrective action methodologies.
  • Partner with cross-functional teams to ensure on-time delivery and customer satisfaction.
  • Develop Lean capability through coaching, training, and performance-driven leadership.
  • 65-line largest Woven & Outerwear all kind Jacket, Formal Ware Factory

AGM (Industrial Engineering & Lean)

Debonair Group
Gazipur
11.2019 - 01.2024

Manager (Operational Excellence OPEX or C I)

AJ Super Garment Ltd.
Saver
05.2016 - 11.2021

Assistant Manager (Industrial Engineering)

Giant Group
Gazipur
01.2012 - 04.2015

Officer (Industrial Engineering)

Giant Group
Gazipur
10.2009 - 01.2012

Education

PGD - Supply Chain Management

Carrier Hub (BD)
01.2020

MBA - Textile Marketing, Operation Management

Primeasia University
01.2016

Bachelor of Science - Textile Engineering

Primeasia University
01.2010

Higher Secondary School Certificate (HSC) - Science Education

Sirajganj Govt College
01.2005

Secondary School Certificate (SSC) - Science Education

Sirajganj Govt College
01.2003

Skills

  • Operational Excellence
  • Method Improvement
  • Defect or Claim Reduction
  • Six Sigma Tools
  • Lean
  • Continuous Improvement
  • Customer Satisfaction
  • Team Development
  • Process Optimization
  • VSM

Websites

Accomplishments

  • Successfully led TPS (House of Lean) implementation across factory operations.
  • Delivered 5+ Continuous Improvement (CI) projects, driving sustainable operational excellence.
  • Reduced manufacturing waste using PMTS, GSD, and Method Study.
  • Implemented Lean Supermarket, Conveyor System, and Cellular Manufacturing.
  • Optimized SMV, line balancing, and layouts, achieving 90% balancing efficiency.
  • Established One-Piece Flow, JIT, 5S, and Kanban across 37 production lines.
  • Completed Value Stream Mapping (VSM) for end-to-end manufacturing processes.
  • Delivered 500+ Kaizen initiatives, strengthening the continuous improvement culture.
  • Achieved 64% OPEX Audit Score in the Decathlon France assessment.
  • Achieved 100% Technical Audit Level C and 25% Level B compliance.
  • Improved factory efficiency by 13% and cutting efficiency by 25%.
  • Reduced indirect manpower by 15% and overtime by 18% without impacting output.
  • Enhanced quality performance through Fishbone, Pareto, and Root Cause Analysis.
  • Implemented DHU and Visual Management Systems to improve quality control.
  • Applied global Lean best practices through Decathlon France technical training.

Application

2026-06-25, Lean Manager

Core Responsibilities

  • Ensure the one-time shipment – Quality Standard to uplift profit and recognition.
  • Lead Lean Manufacturing, Industrial Engineering, Continuous Improvement (CI), and Manufacturing Excellence initiatives.
  • Drive Operational Excellence through productivity, quality, cost, and process optimization.
  • Develop and execute long-term manufacturing strategies aligned with business objectives.
  • Lead factory-wide Lean transformation using TPS, Kaizen, VSM, 5S, JIT, Kanban, and One-Piece Flow.
  • Facilitate structured problem solving using RCA, A3, PDCA, CAPA, and Six Sigma methodologies.
  • Drive process optimization to improve productivity, quality, cost, delivery, and safety (PQCDSM).
  • Optimize SMV, line balancing, PPH, capacity planning, and manpower utilization.
  • Improve factory efficiency through PMTS/GSD, Method Study, and process engineering.
  • Lead layout optimization, Cellular Manufacturing, Lean Supermarket, and material flow improvements.
  • Establish KPI dashboards and monitor operational performance to achieve business targets.
  • Reduce production costs through waste elimination, automation, and resource optimization.
  • Review sample development, style engineering, and risk assessment for production readiness.
  • Standardize processes through SOPs, Standard Work, and Lean best practices.
  • Lead Kaizen, Gemba Walks, and Root Cause Analysis to sustain Continuous Improvement.
  • Strengthen quality systems using PDCA, Fishbone, Pareto, and corrective action methodologies.
  • Partner with cross-functional teams to ensure on-time delivery and customer satisfaction.
  • Develop Lean capability through coaching, training, and performance-driven leadership.

Training Achievements

  • Lean Six Sigma Black Belt, T
  • V S
  • D, India, 2023-01-01
  • PMTS / GSD (Method Study & SMV Improvement), Vector Times, 2022-01-01
  • Certified KPI Specialist (CKPISI), WARD, UK, 2021-01-01
  • Continuous Improvement (CI) & Lean Manufacturing, Decathlon Vietnam CI Team, 2019-01-01
  • Project Management (PM), PMaspire, Bangladesh, 2018-01-01
  • Total Quality Management (TQM), BD Job Training Centre, 2015-01-01
  • Toyota Production System (TPS) – Garment Manufacturing, BD Job Training Centre, 2015-01-01

Core Training

  • Operational Excellence (OPEX Book V10 Specialist)
  • 5 Core Continuous Improvement (CI) Program Training
  • KPI Implementation (CIPT)
  • Problem Solving Tools & Techniques (CIPTC)
  • Continuous Improvement Fundamentals (CIMF)
  • Stand-Up Meeting System (CICR)
  • 5S Workplace Organization (CI5S)
  • Toyota Production System (TPS) & Lean Leadership
  • Value Stream Mapping (VSM) & Process Optimization
  • Lean Six Sigma Overview
  • Lean Six Sigma Green Belt
  • Industrial Engineering & Production Improvement
  • Quick Changeover (SMED), JIT & 3P (Pre-Production Process)
  • Formal Kaizen & Improvement Management
  • Kanban System for Cutting Operations
  • 5S Workplace Organization & Visual Management

References

  • Md. Humayan Kabir, Ex-Executive Director, AJ Super Garments, Dhaka, Bangladesh, h2kn.perfect@gmail.com, +880 1763-672449
  • Md. Nasir Ullah, General Manager (Operations), Debonair Group, Unit-03, Gazipur, Bangladesh, ullahmdnasir@gmail.com, +880 1981-124501
  • Mr. Mick Farnardo, Ex-Plant Head, Dekko Legacy Group, +94 713 752321

Interests

Traveling

Certification

  • Lean sixsigma Blackbelt

Timeline

AGM (Industrial Eng.&Production)

Dekko Legacy Group
02.2024 - Current

AGM (Industrial Engineering & Lean)

Debonair Group
11.2019 - 01.2024

Manager (Operational Excellence OPEX or C I)

AJ Super Garment Ltd.
05.2016 - 11.2021

Assistant Manager (Industrial Engineering)

Giant Group
01.2012 - 04.2015

Officer (Industrial Engineering)

Giant Group
10.2009 - 01.2012

PGD - Supply Chain Management

Carrier Hub (BD)

MBA - Textile Marketing, Operation Management

Primeasia University

Bachelor of Science - Textile Engineering

Primeasia University

Higher Secondary School Certificate (HSC) - Science Education

Sirajganj Govt College

Secondary School Certificate (SSC) - Science Education

Sirajganj Govt College

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Md. Abdur RahmanLean Six Sigma Blackbelt