Process Optimization & Layout: Analyzes machine capacity (CNC routers, edge-banders, boring machines) and designs efficient plant layouts to maximize material flow and eliminate production bottlenecks.
Line Balancing: Balances assembly and upholstery lines to optimize operator utilization and eliminate idle time.
Time & Motion Studies: Conducts time and motion studies to establish standard time (SAM/SMV) for cutting, sizing, routing, sanding, polishing, upholstery, and packaging operations.
SOP Development: Creates detailed Standard Operating Procedures (SOPs) to ensure production consistency and standardize worker training.
Method Engineering: Analyzes production workflows to eliminate non-value-added (NVA) activities and implement safer, faster manufacturing techniques.
Material Yield Management: Works with design teams to optimize cutting patterns for solid wood, plywood, MDF, and particle board to maximize material yield and minimize scrap.
Lean Manufacturing: Leads continuous improvement initiatives using Lean tools like 5S, Kaizen, Kanban, Value Stream Mapping (VSM), and SMED (Single-Minute Exchange of Die) for quick machine setups.
Costing Assistance: Provides accurate labor and process cost estimations based on standard time data for new furniture designs during prototyping.
KPI Tracking: Monitors and reports critical metrics including Overall Equipment Effectiveness (OEE), line efficiency, labor productivity, and rework percentages.
Automation: Identifies opportunities for low-cost automation in repetitive processes such as sanding, polishing preparation, or hardware sorting.