Project Overview

Role

Lead Operations Consultant

Client

Mid-sized plastic manufacturing facility (broom production)

Timeline

January 2018 - December 2019

Team

Cross-functional improvement team of 8 members

Client Context & Challenge

⚠️

Production Bottlenecks

Production capped at 2,000-3,000 units/day despite strong market demand

⏰

Poor Shift Utilization

Single-shift operation with only 33% facility utilization

🔧

Reactive Maintenance

No preventive maintenance program leading to unexpected downtime

📊

No KPI Tracking

Lack of data-driven decisions and performance visibility

📋

Missing SOPs

No standardized operating procedures for consistent quality

❌

Quality Issues

Reactive approach to quality control and defect management

Strategic Approach

1

Assessment & Analysis

Conducted comprehensive plant assessment and value stream mapping to identify bottlenecks

2

Shift Optimization

Implemented double-shift scheduling system to maximize facility utilization

3

Flow Rebalancing

Rebalanced assembly line flow and eliminated identified bottlenecks

4

Maintenance Program

Introduced comprehensive preventive maintenance program

5

KPI Dashboard

Established real-time KPI dashboard system for data-driven decisions

6

SOP Development

Created comprehensive SOP library for all critical processes

7

Training & Culture

Trained operators and supervisors while establishing continuous improvement culture

Results & Impact

+460%
Production Increase
From 2,500 to 14,000 units/day
60%
OEE Improvement
Overall Equipment Effectiveness
75%
Downtime Reduction
Unplanned downtime eliminated
40%
Quality Improvement
Defect reduction achieved
85%
Productivity Boost
Labor productivity increase
$2.3M
Annual Savings
450% ROI achieved

Proof of Work

Production Transformation

Before
2,500 units/day
After
14,000 units/day
+460% Increase

Real-Time KPI Dashboard

Daily Output
14,250
Target: 12,000
✅ Above Target
OEE
78%
Target: 70%
✅ Above Target
Downtime
3.2%
Target: <5%
✅ Within Target
Quality Rate
96.8%
Target: >95%
✅ Above Target

Optimized Shift Schedule

Before: Single Shift

Shift
Hours
Coverage
Utilization
Day Shift
8 hours
06:00-14:00
33%
Night Shift
-
Inactive
0%

After: Double Shift

Shift
Hours
Coverage
Utilization
Shift A
12 hours
06:00-18:00
85%
Shift B
12 hours
18:00-06:00
85%

Standard Operating Procedure Sample

Equipment Changeover Process
SOP-MFG-001 Version 2.1 Effective: Jan 2019
1

Safety Lockout

Engage LOTO procedure and verify zero energy state

⏱️ 5 minutes
2

Component Removal

Remove previous setup components using designated tools

⏱️ 15 minutes
3

New Setup Installation

Install new components per engineering specifications

⏱️ 20 minutes
4

Quality Verification

Run test batch and verify output meets quality standards

⏱️ 10 minutes
Total Standard Time: 50 minutes
Previous Time: 2.5 hours (-70% improvement)

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