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”
Category Archives: Lean and CI
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”
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”
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”
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 improveContinue reading “SQDCI Boards:”
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 toContinue reading “Gemba Walk”
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 accurateContinue reading “Value Steam Mapping”
DALAL'S 