Rasanga Rathnayaka

* Collaborate with Gap International Sourcing (GIS) Process Quality Auditors to implement and maintain Quality Management Systems (QMS), including the development and execution of SOPs across safety, mold prevention, fusing, labeling, sewing, washing, and packing processes. * Lead the creation and enforcement of Standard Operating Procedures (SOPs) to ensure consistency, compliance, and adherence to Gap Inc. quality standards throughout the production lifecycle. * Oversee a capable pool of Factory Key Representatives (FKRs), Designated Auditors (DAs), and Product Safety Officers (PSOs) to ensure effective inspection, quality control, and issue resolution aligned with GIS protocols. * Drive continuous improvement by implementing Corrective Action Plans (CAPs) and conducting Root Cause Analyses (RCA) for product safety concerns, ensuring compliance with Gap Inc.’s global standards. * Conduct pre-production meetings to address quality concerns, evaluate technical callouts, and establish preventive actions to maintain consistency in bulk production. * Monitor internal QA training programs and GIS Knowledge Runway courses to ensure yearly upskilling of all quality personnel and alignment with evolving compliance requirements. * Manage all in-factory testing operations, including laboratory accreditation, test reporting, and quality assurance protocols for both in-house and external assessments. * Ensure color accuracy and visual inspection capabilities by facilitating regular Mansell testing for FKRs, DAs, and factory colorists, while reviewing bulk fit, workmanship, and construction standards against approved samples and PPS.

* Established and led a factory-wide quality improvement culture by evaluating QMS effectiveness, implementing strategic action plans, and aligning initiatives with organizational objectives. * Conducted internal audits, including 3rd Eye QMS assessments, to identify process non-compliance, initiate corrective actions, and improve factory-specific performance and compliance levels. * Collaborated with top management through structured weekly and monthly performance reviews, delivering insights to drive quality assurance strategies and operational excellence. * Engaged with customer representatives to resolve quality issues promptly, instilled a problem- solving culture among teams, and enhanced client satisfaction through continuous improvement. * Applied lean principles to reduce operational waste, monitored daily/weekly/monthly KPIs, and drove ongoing improvements in product quality, process efficiency, and stakeholder communication.

* Managed the end-to-end process of requesting, reviewing, and approving development samples to ensure alignment with product quality and fit expectations. * Led the execution of fit, garment construction, and process optimization strategies to maintain high-quality standards from prototype to final production. * Established and maintained company-approved fit blocks, standard grading rules, and tolerances; developed new blocks as required to support evolving product categories. * Collaborated directly with factories to ensure precise execution of approved styles, fit corrections, and construction standards within established Time and Action (T&A) calendars. * Worked in close coordination with Designers, Product Managers, Sourcing teams, and external vendors to develop reproducible and production-ready garments. * Evaluated prototypes and samples for accuracy in size, fit, and construction to maintain consistency with brand standards and technical specifications. * Led fit sessions with cross-functional teams, ensuring technical and aesthetic alignment by adjusting fit, style, and functionality throughout the development process. Reviewed, documented, and amended technical specifications and construction details based on fit feedback and design modifications during the development lifecycle.

* Ensured the establishment, implementation, and maintenance of all processes required for an effective Quality Management System (QMS) across the organization. * Reported QMS performance metrics and areas for improvement to top management, facilitating strategic decision-making and continuous improvement initiatives. * Promoted awareness of customer-specific quality requirements throughout all departments to align operations with buyer expectations. * Liaised with external accreditation and assessment bodies to coordinate and maintain compliance with external quality standards and certifications. * Engaged directly with buyer representatives to understand their quality standards and implemented tailored quality systems across departments to meet or exceed expectations.

* Developed, implemented, and led cost reduction and quality improvement initiatives across the group to enhance operational efficiency and product excellence. * Identified critical cost and quality issues, conducted root cause analysis using structured problem- solving methods, and implemented sustainable solutions. * Initiated and promoted defect prevention strategies, integrating proactive quality assurance processes throughout the production cycle. * Ensured accurate and realistic specification of raw materials, manufacturing processes, and design methodologies to maintain consistency and reduce variation. * Performed risk analysis and re-engineered product styling to streamline operations, increase productivity, and optimize manufacturing outcomes.