Process improvement
Slow, error-prone planning work measured, redesigned and made standard.
Day to day
Most of my improvements started with a daily or monthly task that took too long or kept going wrong. I measured it first, changed the process, then handed it over as the new standard.
- 01
Automated the daily multi-source shortage report: about 60 minutes to 5–10 minutes per run.
- 02
Rebuilt the monthly export plan around one input, with error-proofing that flags lot-size mismatches: 6–7 hours to about 1 hour, adopted as standard.
- 03
Helped build an SAP framework for CKD/SKD export packing, raising packing capacity from 450 to 540 units a day.
- 04
Reviewed safety stock across 3,000+ components, identifying ~PKR 50M of inventory that could be released.
- 05
Modelled shift, overtime and solar-timing scenarios and took them to plant leadership.
How it runs
- Find the wasteWhere the same work repeats, waits or gets corrected.
- Measure the baselineTime, errors or stock, before anything changes.
- Change the processOne input, error-proofing, automation or a new SAP setup.
- Hold the gainTest, train, document, and make it the standard.
What I know
Find & measure
- Where the waste iswork that repeats, waits or gets corrected
- Baseline before changetime, errors or stock, measured first
Redesign
- One validated inputentry in one place, with drop-downs and rules
- Error-proofing (poka-yoke)lot-size mismatches flagged in the export plan
- AutomationExcel, VBA and Power Query: shortage report 60 → 5–10 min
- SAP setup changesexport packing framework: 450 → 540 units a day
Analyse
- Scenario analysisshift, overtime and solar-timing options for plant leadership
- Cost-benefitdisplaced energy valued with Finance
- Inventory review~PKR 50M of safety stock identified for release
Hold the gain
- Standard workexport plan adopted as the standard
- Handovertested, trained and documented, known limits included
What I improved
Planning should turn complexity into action.
Open to Production Planner, Materials Planner, Production Controller and Supply Chain Planning roles in the UK.