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: Process Improvement
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”
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”
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 aContinue reading “Aligning Frame and Panel fabrication:”
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, theContinue reading “Sheet Metal Process improvement Plan:”
DALAL'S 