• Project: Customer First – Right First Time | Focus: Reducing wrong shipments of 5C spares (Camshafts, Connecting Rods, Cylinder Blocks, Cylinder Heads & Crankshafts)
• Identified root causes of shipment mismatches by mapping end-to-end packaging-to-dispatch processes; applied Fishbone Diagrams and Pareto Analysis to prioritize high-impact error categories and enable data-driven corrective actions.
• Standardized packaging operations through visual SOPs, engine-model-based checklists, and structured Documentation, reducing ambiguity for a rotating contract workforce (~6-month cycles).
• Gained comprehensive shop floor exposure across multiple plant zones to analyze spare part flow, packaging practices of look-alike parts, and quality checkpoints, improving Infrastructure layout efficiency.
• Enhanced packaging & inventory accuracy by proposing segregation layouts, QR-based labelling, and ASN updates to minimize wrong part selection during dispatch.
• Collaborated cross-functionally with logistics, operations, and dispatch teams to improve Teamwork, accountability, and inter-department coordination; presented findings using PowerPoint and Oracle data.
• Developed training content and awareness material for temporary workers to reinforce SOP adherence; recommended periodic refresher sessions to address workforce turnover and knowledge gaps.
• Analyzed error trends using MS Excel, pivot tables, and weekly dashboards to track deviations and quantify improvements; maintained daily part flow and error logs for effective Monitoring.
• Applied Lean principles, Analytical thinking, and BASIC process mapping to drive low-cost, high-impact Optimization initiatives supporting the company’s continuous improvement culture.