Extrusion Scrap Reduction Project – $1M Annual Cost Savings
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 approximately…
Keep reading
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 the…
Keep reading
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:…
Keep reading
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 Failure…
Keep reading
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 establish…
Keep reading
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 goal…
Keep reading
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 new…
Keep reading
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,…
Keep reading
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 steps…
Keep reading
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 production…
Keep reading
Accommodating New Machinery through Layout Modification
Problem Statement: A sheet metal fabrication company was facing the challenge of outdated equipment limiting their production capacity and efficiency. The company sought to upgrade its machinery to increase production and improve product quality. Approach: Result: The layout modification project was a success and the company was able to successfully integrate the new machinery into…
Keep reading
Streamlining Production through Layout Optimization
Problem Statement: An XYZ company was struggling to meet the growing demands for its products, as its current layout was causing inefficiencies in material handling, machine utilization, and workflow. The company sought to improve its layout to increase production and meet the growing demands for its products, while also reducing waste and improving product quality.…
Keep reading
SQDCI Boards:
As a process engineer, I carried out a continuous improvement project in the company, where I prepared SQDCI (Safety, Quality, Delivery, Cost, and Inventory) boards in all departments of the company, including the Warehouse, Cutting, Assembly, Glazing, Awning, Patio Door, Shipping, Railing, and Sheet Metal Fabrication departments. The goal of this project was to improve…
Keep reading
Gemba Walk
As a process engineer, I carried out a Gemba Walk in the window wall manufacturing department. Gemba Walk is a lean management technique where you go to the actual place of work to observe and understand the current processes, identify areas for improvement and eliminate waste. I started by creating a checklist of areas to…
Keep reading
Value Steam Mapping
Value Stream Mapping (VSM) is a process analysis tool used to understand and improve the flow of materials and information within a manufacturing process. As a Process Engineer, I carried out a time study as a part of the VSM in the Patio Door department. The purpose of the time study was to gather accurate…
Keep reading
Aligning Frame and Panel fabrication:
The problem statement for the project is to improve the current process of fabricating windows and panels in the company. The current process involves the assembly of frames, placement of spacers, IGUs and glazing, followed by loading the windows in a trailer, all based on the production schedule. Meanwhile, the panels are fabricated in a…
Keep reading
Sheet Metal Process improvement Plan:
Problem Statement: The sheet metal fabrication company was facing challenges in meeting customer demand due to inefficiencies in its production processes. The production line was not operating at full capacity, leading to long lead times and frequent bottlenecks in the process. This resulted in decreased customer satisfaction and a loss of potential revenue. Additionally, the…
Keep reading
Subscribe for more posts like this
Get in touch
Don’t hesitate to reach out with the contact information below, or send a message using the form.
Contact: +12267593770
Email: kurdalal08@gmail.com
DALAL'S 