Continuous Improvement Leader
Alumicor Ltd
Total years of experience :17 years, 8 Months
• Identified & facilitated process improvement projects (Kaizen, A3) to drive cultural change in coordination with the functional departments
• Recommended modification (automation) to the existing processes through research to optimize output
• Developed & planned operational excellence road map
• Designed, trained and implemented a 5S auditing system to improve workplace organization
• Conducted training and coaching on Lean tools to 2 supervisors and 6 lead hands
• SMED Kaizen project activity resulted in 35% improvement in rolling change over process
• Kaizen work shop (process flow) resulted in 34% reduction in product handling
• Worked very closely with the shop floor & management leadership in identifying lean projects to improve performance by reducing waste
• Conducted training and coaching on lean methodologies (5S, Types of waste, problem solving) to 4 supervisors, 25+ hourly workers and 15 office staff
• Developed & implemented standardized process using Toyota Production System concept
• Planned and led multiple Kaizen projects to improve throughput (VSM, 5S, SMED, A3)
• Reduced changeover time by 30%+ by developing a “changeover carts” that contained tools at the point of use
• Six Sigma project resulted in $196K savings on rework project
• Process improvement resulted in 20% reduction in recordable (H&S)
• Certified Crosby Canada Problem Solver (root cause analysis)
• Management representative for EMS and OHSAS
• PTMS (time study) to integrate new products into existing assembly
• Line balanced to minimize the impact of model mix
• Negotiated & resolved union grievances / disputes
• Successfully integrated multiple new models into current flex assembly line
• Extensive AutoCAD plant layout work for future expansions / projects
•Flex Line improvement project resulted in $2M annual savings
• Developed material handling system which resulted in 7% reduction in WIP
• Promoted lean culture by leading Kaizen workshops and trainings on continuous basis
• Led the project team to develop a project plan for the new product
• Monitored day to day project activities and provided weekly report to Director Operations
• Developed detailed MS-Project plan for the new products
• Successfully certified on ISO 14001 and ISO 9001
• Developed standard operating procedures (SOP) for multiple functions
• Overall responsibility for all aspects of the effective supervision, training & development
• Reduced waste by improving material presentation (lean material strategy)
• Extensive time & motion studies to line balance and to improve value added work
• Prepared multiple AutoCAD facility layout for the future projects
• Participated in throughput Kaizen workshops
• Successfully launched commercial truck at Flint Assembly
• Participated in the review & evaluation of new product designs & design changes
• Developed cell lay-out to maximize production requirements with best possible utilization of labor force directed at one piece flow
• Evaluated & prioritized process improvement opportunities for production operations
