Lean & Six Sigma

Driving Efficiency and Quality in Your Organization

I can help your organization achieve operational excellence and drive continuous improvement through the implementation of Lean Six Sigma methodologies.

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Value Stream Mapping (VSM)

A process mapping technique used to identify areas of waste and inefficiency within a process or system.

Kaizen Events

Short-term, focused improvement events are designed to make rapid improvements to a specific process or area of the organization.

DMAIC

A structured problem-solving approach that consists of five phases: Define, Measure, Analyze, Improve, and Control.

5S

A set of workplace organization principles focused on creating a clean, organized, and efficient work environment.

FMEA

A technique used to identify potential failure modes in a process or system, and to develop preventive actions to avoid or minimize the impact of those failures.

SPC

A set of statistical techniques used to monitor and control process variation, ensuring that processes are performing within acceptable limits.

SIPOC

A tool used to understand and document the flow of a process by identifying its suppliers, inputs, process steps, outputs, and customers.

SQDCI

A continuous improvement framework consisting of five elements: Safety, Quality, Delivery, Cost, and Inventory.

GEMBA Walk

A practice of going to the “Gemba” (the place where work is done) to observe and identify opportunities for improvement.

Acquaintance with other Tools

Case Study

• Extrusion Scrap Reduction Project – $1M Annual Cost Savings
  by Keyur Dalal
  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”
• Kaizen Event: Documentation Streamlining and Communication Improvement
  by Keyur Dalal
  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
  by Keyur Dalal
  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”