Risk/Quality/Performance Assurance senior consultant ll
PwC
Total years of experience :12 years, 1 Months
Policies and procedures development
Supply chain process re-engineering
Enterprise risk management implementation
• ISO 9001:2015 Quality Management System implementation % maintenance
• Process improvement & lean transformation
* Design lean customer journeys
• QMS Internal Auditing
• Stakeholder management and analysis
• KPI and risk identification for core business process
• Generation of QMR reports
• Study existing processes, identity areas of improvement, improve capacities, reduce costs and reduce lead time.
• Design new processes, re-engineer existing processes, improve service levels, efficiencies & reduce operational risks.
• Evaluate existing system and recommend technological enhancements.
• Document and assess current value stream maps, remove non value adding operations and propose future VSM.
• Design lean warehouse layouts and material handling systems.
• Define processes using SIPOC and conduct Kaizen/5s events.
• Lead continuous improvement initiatives in the manufacturing, packaging, supply chain and quality.
• Act as a change agent along side McKinsey consultants to implement lean six sigma methodologies throughout the plant, focusing on reducing waste using the DMAIC approach.
• Develop manufacturing excellence plans and support the delivery of improvement targets across multiple sites.
• Lead process improvement projects selection, management, planning and execution.
• Generate reports and presentations for each project.
Major Achievements:
Manufacturing and packaging:
*Generate a weekly production review report to discuss production output, sources of shortfalls, production schedule and deviations from standard hours.
*Improve MTBF and reduce the downtime on the packaging lines by 52%
*Implement OEE system to identify and attack the six big losses of TPM.
*Increase the OEE in the manufacturing and packaging area by standardizing the work, increasing the output, enhancing process input and reducing the rejection.
*Design and implement performance boards in the machine cells and introduced a problem solving (A3) and root cause analysis (CAPA) system.
*Reduce machine change over time by 40% using 5s and SMED.
*Optimize labor by performing VA/NVA analysis on all the manual packing operations.
*Design work station layouts for efficient process map, machine allocation and material handling.
*Conduct feasibility studies & gap analysis of operating systems.
*Design financial modules and report ROI to capture the saving from each lean six sigma initiative.
*Prepare and audit lean initiative SOPs in order to comply with GMP regulations.
*Facilitated with the creating and monitoring of KPIs.
*Support new product launches (product costing, capacity and resources).
*Reduce the manual operations and propose automated solutions.
Supply chain:
*Analyze and study the design of packaging material, arrangement of products inside the shipper and the weight & dimension of pallets to reduce the cost of logistics, labor and holding cost.
*Reduce the cost of logistics by using paper based pallets and standardizing the pallet height.
*Study and improve the flow of inventory in the warehouse by rearranging the location of inventory in order to save time, space and enhance the kitting process.
*Implement a visual management system (Kanban) by designing a FIFO (pull) system to control, optimize the material flow, reduce the inactive inventory and line balance the operations.
*Use Kanban cards to level the production and generate a weekly production schedule in order to achieve a (JIT) Just-In-Time production system.
*Design a capacity model to maximize the utilization of resources.
*Negotiate new contracts with transportation companies.
*Reduce the cost of logistics by changing the design of the racking and shipping cartoon to utilize a full pallet.
*Design a spreadsheet to evaluate and monitor the supplier performance.
*Design cages and tools to enhance the flow of material and utilize space in production.
Quality:
*Design a new sampling procedure for packaging material.
*Scale up the batches to reduce cycle time and reduce quality testing.
*Design a system to track the yield for all the products from material dispensing to final packaging, find the root causes behind low throughput and utilize CAPA tools to improve it.
Organization performance development and change management:
*Prepare training material and conduct workshops on lean topics.
*Designed a skill matrix and estimated manpower requirements for the whole plant.
*Monitor the performance of the employees and set criteria to award top performers
*Reduce the overtime cost by 29% by setting rules and ceilings, linking the overtime with output and forecasting the overtime requirements using the capacity model.
* Provide direction and build awareness & desire for change management competency within the organization.
*Lead the production planning and scheduling of heavy industrial equipment (Heat exchangers, pressure vessels and tanks).
*Review drawings and bill of materials, determine appropriate manufacturing process and sequence and prepare for the quality testing.
*Responsible for issuing the raw material, logistics planning and raising purchase requests using Oracle ERP software.
*Identify inventory requirements needed for production and expedite advanced shipments of orders to satisfy plant production requirements.
*Implement lean manufacturing techniques to reduce cost and idle time and increase yield.
*Perform time studies on several metal fabrication process and material handling.
*Improve manufacturing process and efficiency, and optimize the existing production flow.
*Provide project updates and forecast completion date by tracking the production progress.
*Help production with problem solving and developing standardized work for production operators.
*Visit different hotels and advertise all the features of the communicator.
*Assisted to develop marketing strategies for new product launched.
*Show interested customers how to connect to the internet using the communicator
*Customer service
Transcript and other documents can be provided upon request