Master Black Belt in Lean with 26 years running and transforming apparel factories across Asia for brands like Adidas, Victoria's Secret, M&S, H&M, Target and Next. Today I design Lean academies and learning systems so teams keep improving after the consultant leaves.
Most Lean trainers have never run a factory. Most plant heads have never designed a curriculum. I have done both, and the combination is what makes improvement stick.
Factory director, operational excellence director and Lean consultant across 13+ facilities. P&L ownership, lead-time cuts, line balancing and quality systems, delivered on the floor.
Designed MAS Holdings' Lean Practitioners Program and belt curriculum. Trained team leaders, group leaders and Built-In Quality champions with Lean Enterprise Institute and ex-Toyota mentors.
Lean academies, competency frameworks and on-site learning pathways matched to real authority and real work. The goal is internal capability, not consultant dependency.
A selection of results from the factories I have led or transformed.
Kaizen savings from 200+ shop-floor process owners I trained as Lean practitioners. The program was later adopted into MAS's corporate-wide belt curriculum.
Each box is a process step in my career, with its data box alongside. The most recent step is at the top.
Lead learning and capability strategy across Lean, Operational Excellence and Manufacturing Excellence, with competency frameworks and blended programmes.
End-to-end operations of an Adidas-dedicated facility, from planning and cutting to sewing, finishing and shipment.
Set up a new business venture and built AI literacy, applying it to Lean, operations and learning design.
Value stream mapping, workflow re-engineering and SAP ERP enhancements, with a KPI framework targeting 20% cost reduction.
Led the enterprise Lean transformation and designed the Vertical Production System, restructuring the cut-to-pack flow.
Transformation strategy for M&S, H&M, Target and Next. Launched a digital NPD centre; changeover cut from 15 to 7 days.
Capacity programme at the Indonesia plant (Victoria's Secret); cut 400+ manpower in six months and designed a central warehouse for Bangladesh and Indonesia.
Transformation across 13 facilities with 11 managers. Set up the first double-shift intimate apparel plant in Bangladesh.
Created the Lean Practitioners Program. Led Continuous Flow, Team Leader and Built-In Quality pilots across 5 plants.
Supplier integration and a material pull system; built a real-time SAP-integrated digital platform with digital Kanban.
Ran a milk-run air-cargo supply chain and SAP-based inventory control for 24-hour production.
34 moments from factory floors, Toyota study tours, classrooms and award stages across six countries. Tap any photo to view it full size.
Generic belt training teaches everyone the same thing. These three tiers match what each person can actually change, and about half the time is spent on-site at the gemba.
For operators and team members. Standard work, 5S and problem-solving at their own station.
For process owners and supervisors. Value stream thinking and kaizen across an end-to-end process.
For managers and executives. Lean strategy, governance and building a lasting improvement culture.
The same methods I used across six countries, packed into Excel toolkits with guides, AI prompt packs and a personal review. No macros, no subscription: download once and use them on your own line.
Log each shift and see where machine time goes: the six big losses, OEE by week and machine, and the top 3 losses on an action plan.
Turn an operation bulletin into a balanced line: takt, stations, bottleneck, Yamazumi chart and an hourly check.
Your first 90 days on the floor: 22 templates, conversation scripts, trackers, checklists and a playbook.
Measure, see and cut changeover and turnaround losses with live KPIs, charts and world benchmarks.
Current, running, trending and future maps with a week-by-week replay and kaizen bursts on the map.
Sector → issue → root cause → 3W plan. 120 ready issues with fishbone and 5 Whys pre-filled.
Type the problem once and the one-page A3 draws itself: narrow by impact, fishbone, 5 Whys, 3W plan.
A weekly series on the hidden side of well-known Lean tools: where they came from, the problem they were built to solve, and what most practitioners miss.
Follow the series ↗Quick explainers on the Lean ideas behind the toolkits. Tap play, no sound needed to follow along.
Level the mix and volume so the line runs steady instead of in waves. 40 seconds.
Prepare the ground quietly, one conversation at a time, so the decision is already shared before the meeting. 50 seconds.
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Open to Group Operational Excellence, Lean Academy and Head of L&D roles in manufacturing across South and Southeast Asia and Africa, and to on-site Lean programs through Valuecraft.