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General Presentation
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2. Methods of Reducing Waste 5S - Sort, Store, Sweep, Standardize and Sustain. Led the 5S initiative . SMED - The SMED system is a set of techniques that make it possible to reduce equipment setup and changeover operations. Led Kaizen Events which reduced 1D, 2D and 3D change over times by up to 25 minutes. RCA - Root Cause Analysis Step 1 - Background Information Step 2 - Determine the Chain of Events or Describe the Process Involved Step 3 - Tool Selection Step 4 - Analyze for Potential Cause Step 5 - Identify and List Root Causes Step 6 - Audit and Follow-up (Short term and Long term corrective actions) Created, implemented, and sustained the network Root Cause Analysis culture shift. Quality Improvements Designed and Implemented Missing Lid Detector for Sour Cream and Cottage Cheese Cups Led design changes, for filling machines, to reduce variation in fill weight Led projects for reducing packaging NIS’s related to valve, seal and print issues. Reduced the total units NIS’ed by 65%. Processing Improvements Installation of 5 lb case packer for CC & SC; which led to increasing line speed and reducing labor Modified Ammonia refrigeration system; which reduced energy consumption by 12% and increased cooling capacity for product storage warehouse Modified CC packaging lines to produce “Hot Pack” product vs. “Cold Pack” product Modified Box Conveyor system to increase utilization for packaging lines Modified packaging line layouts to maximize space and increase efficiencies Modified 5 lb bagger sealing assembly; which allowed the line speed to increases from 35 to 40 bpm. Add nothing but value - reduce waste The 7 Wastes Over Production Inventory Transportation Processing Idle Time Operator Motion Bad Quality Lean Manufacturing Highlights