Francis Chopsi

• Implemented control planning, embedded process controls, and inline checkpoints to enhance First Pass Yield (FPY) at feeding stage to over 90% on new styles.
• Implemented Statistical Process Control to assess CTQ performance, achieving 35% within ±1σ, 63% near mean, 1% near limit, and less than 1% outliers.
• Conducted root cause analysis on production defects, leading to a 25% improvement in product quality.
• Evaluated quality of staff work and performance against objectives to assess need for improvements.
• Supervised technical work according to applicable best practices and regulatory requirements.
• Analyzed process flow data to identify bottlenecks and implemented solutions to enhance throughput.
• Coordinated cross-functional teams to troubleshoot critical process issues, minimizing downtime by 30%.

• Increased operational efficiency by 80% through strategic process calibration and waste reduction.
• Achieved 20% cost savings in supply chain management while maintaining production integrity.
• Improved delivery speed by 12%, optimizing production flow across 150+ apparel categories.
• Implemented Lean methodologies and GSD Macro Motion Economy, enhancing factory-wide efficiency.
• Developed factory capacity planning, ensuring optimized material loading and production execution.
• Led workforce training and development programs, establishing structured skill matrices to enhance employee capabilities.
• Designed tension-free operator layouts, improving workplace ergonomics and fostering a more motivated and productive workforce.
• Strengthened compliance enforcement, maintaining health, safety, and regulatory standards.
• Managed budget forecasting and overhead expenditure, achieving cost-effective resource allocation.
• Oversaw SOP development and execution, ensuring structured workflows and maximum efficiency.

• Optimized operational workflows, driving a 15% profitability increase and 10% cost reduction through lean execution strategies.
• Developed a revised 3-year business plan, projecting a 20% revenue growth and 15% expense reduction via cost control and investment strategies.
• Led market expansion, introducing three new products and securing two successful collaborations, driving a 10% increase in customer retention.
• Redefined organizational structure, reducing staff turnover by 30% while boosting employee satisfaction (25%) and overall productivity (20%).

• Scaled multi-brand production, driving efficiency improvements from 300K to 1.5M units/month across categories.
• Reduced development lead time by 30% through full deployment of process automation and workflow optimization.
• Led Lean and GSD Macro implementation, standardizing production workflows and optimizing labor allocation.
• Optimized factory floor layouts, increasing productivity through modular automation and streamlined motion economy.
• Improved material utilization by 20%, reducing waste via strategic marker, spreading, and auto-cutting enhancements.
• Led cross-functional process automation, integrating real-time decision-making tools for production performance tracking.
• Developed strategic qualification systems, ensuring seamless bulk transitions and operational scalability.
• Drove efficiency improvements in operator training, creating incentive-driven skill development programs.
• Strengthened compliance and quality assurance, embedding inline quality controls for First Pass Yield (FPY) above 99.5%.
• Championed continuous improvement initiatives, enabling strategic partnerships and cross-team innovation for sustainable growth.

• Oversaw Speedo's complete procurement cycle, encompassing greige booking, consumption validation, MOQs, supplier scorecards, CBD submission, and labdip processing.
• Founded swimwear-focused technical design department for brands like Speedo, Victoria's Secret, CK, Lands' End, and M&S.
• Created bra cups, molded features, and implemented 3D digital prototyping to expedite design approval.
• Introduced cutting-edge nylon/polyester digital print systems, featuring innovations like GRIPPER screen prints and rubberized transfers.

• Achieved shipment tolerances of +/- 3% by ordering fabrics for 100% on-time performance and 80% efficiency through strategic planning with Critical Path.
• Developed SAP-based cutting room operations and a cutting priority plan, applying JIT and FIFO to maintain production input/output demand, with delivery schedules, achieving zero downtime due to waiting for cut parts.
• Planned 40 production modules, ensuring daily output of 1,000–1,500 pieces per line.
• Implemented first bulk consumption validation for bulk orders, enhancing order accuracy, and reducing excess stock. Saved 10% from the regular estimate.
• Led a 5S programme to national recognition, winning first place among 500+ factories in the Akimoto 5S Award in 2001, and first place in the Sri Lanka National Productivity Award in 2001.