Abdullah Usmani

Industrial Engineering manager

Stylewise Direct Limited • Full-time

Nov 2021 - Present • 4 yrs 6 mos

Lead 10+ Lean Six Sigma (DMAIC) projects across production lines, targeting waste elimination and process variation reduction ▸ Developed Power BI and Excel dashboards adopted by senior leadership to monitor OEE, line efficiency, and cost deployment KPIs in real time ▸ Implemented SMED programs, reducing changeover time by 10% across 78 production lines, directly improving machine utilization ▸ Drove TPM and 6S rollout across departments, improving equipment reliability and reducing unplanned downtime ▸ Conducted Gemba walks and Root Cause Analysis (RCA) sessions to identify systemic losses — translating findings into sustainable countermeasures with measurable results ▸ Trained and coached 78 supervisors and 2,200 operators on Lean principles, standard work, and autonomous maintenance — building internal capability for continuous improvement ▸ Managed cross-functional improvement projects using PMP principles, ensuring on-time delivery, stakeholder alignment, and scope control ▸ Redesigned production floor layouts to enable linear workflow, reducing material travel distance and improving throughput rate ▸ Implemented 5S + Audit systems across departments, achieving sustained workplace organization standards ▸ Led process digitalization initiatives, replacing manual tracking with automated data collection tools — reducing reporting time significantly ▸ Conducted SAM/SMV calculations and line balancing studies to optimize workforce deployment and eliminate bottlenecks ▸ Executed Quick Changeover (SMED) and TPM programs to reduce downtime and improve Overall Equipment Effectiveness (OEE)