Project Overview As the project lead, I spearheaded a company-wide extrusion scrap-reduction initiative to eliminate inefficiencies across engineering, purchasing, and operations. Extrusion scrap was one of the highest contributors to material waste and cost overruns. By addressing three major scrap sources using data-driven logic and structured continuous-improvement tools, I delivered annualized cost savings of approximatelyContinue reading “Extrusion Scrap Reduction Project – $1M Annual Cost Savings”
Author Archives: Keyur Dalal
Kaizen Event: Documentation Streamlining and Communication Improvement
Case Study: Kaizen Event in Window Wall Division for Documentation Streamlining and Communication Improvement 1. Problem Definition:The Window Wall Division of a construction company faced challenges related to inefficiencies and miscommunication in their documentation processes. Critical documents such as breakdown packages, packing slips, and cutlists were experiencing delays and errors, leading to disruptions in theContinue reading “Kaizen Event: Documentation Streamlining and Communication Improvement”
Strategic Capex Budget Proposal for New Equipment Purchase
Background: The manufacturing company needs to upgrade its production line to meet increasing demand and maintain a competitive edge. As a Process Improvement Specialist, I was tasked with developing a comprehensive CapEx budget proposal for the acquisition of new equipment. The proposal needed to outline the financial feasibility and expected benefits of the investment. Objective:Continue reading “Strategic Capex Budget Proposal for New Equipment Purchase”
PFMEA-Process Failure Mode and Effects Analysis
As a senior process engineer in a manufacturing company, I was responsible for designing and implementing a new production line for a new product. During the process mapping and design phase, we identified several potential failure modes that could occur during the production process. To mitigate these potential risks, we conducted a PFMEA (Process FailureContinue reading “PFMEA-Process Failure Mode and Effects Analysis”
New Product Line
As a senior process engineer, I had the opportunity to work on a new product line establishment project. The project involved setting up a new production line to accommodate a new product that required different processes and equipment than our existing product line. In this case study, I will detail the steps taken to establishContinue reading “New Product Line”
KANBAN
Introduction: As a Process Engineer in a manufacturing company, I was tasked with improving the production process and increasing efficiency in our assembly line. After researching various methodologies, I decided to implement the Kanban system, a lean manufacturing technique that helps improve production flow by reducing waste and improving communication. Project Goals: The primary goalContinue reading “KANBAN”
Process Development- R&D Mockups
Research and Development (R&D) is a crucial aspect of any industry that aims to stay competitive and ahead of its peers. In order to achieve this, companies invest in creating new products, processes, and technologies to improve their offerings and reduce costs. However, R&D can be a risky and expensive process, especially if the newContinue reading “Process Development- R&D Mockups”
KPI development and Implementation
As a process engineer, I have been tasked with improving the efficiency of the rolling and CNC cutting departments at my employer’s plant. To do this, I have developed a key performance indicator (KPI) that tracks each machine’s daily shift-wise production, scrap material, and downtime. This KPI is essential for driving productivity in the department,Continue reading “KPI development and Implementation”
Kaizen Event: Streamline the aluminum extrusion ordering process
As a Kaizen event facilitator, I had the opportunity to work with a team of 12 people from the purchasing and material departments of a manufacturing company. The purpose of the Kaizen event was to streamline the aluminum extrusion ordering process with production. In this case study, I will outline the problem statement, the stepsContinue reading “Kaizen Event: Streamline the aluminum extrusion ordering process”
Successful Implementation and Commissioning of Salvagnini P4+S4 Machine
Introduction: In this case study, we will discuss the successful implementation and commissioning of a Salvagnini P4+S4 machine at XYZ company. The company was looking to improve its production efficiency and product quality, and the Salvagnini P4+S4 machine was seen as the ideal solution. Problem Statement: The company was facing several challenges in its productionContinue reading “Successful Implementation and Commissioning of Salvagnini P4+S4 Machine”
DALAL'S 