Megapack 2 XL - General Assembly

Megapack 2 XL

Multimodal Manufacturing Environment focused on R&D Manufacturing and a variety of sustainment Production:• Developed and maintained multiple exception-based dashboards using PL SQL and Power BI service to support data-driven decisions.• Maintained focus on MMAS initiatives and sustainment of MES/SAP to support on-time delivery of IRAD RPA prototypes and production.- Master route standards, work center capacity parameters, Heijunka, and process development.• Devised functional architecture for an internal tool to aid in IRAD estimation based on DFM insights, analogous, and historical data.

• Partnered with the lamination team to address process variation with targeted ply kit & tool adjustments, this resulted in a 23% reduction for the Ground Control Station (GCS) and 16% reduction for the Plenum’s in-tool time. • Implemented a low-cost solution that adapted a shipping & receiving dock area and stockroom utilizing Systematic Layout Planning principles.• Launched a Foreign Object Debris (FOD) prevention and 7S program that has supported 3 years of continued industry leading safety rates and OSHA recordable mitigation.

• Mapped the Fuel Pod assembly process, identified non-value-added activities, and collaborated with the team to remove wastes while transitioning to the future state system.- Simulated material flow in Proplanner with two primary objectives; eliminating unnecessary motion and minimizing aisle congestion.- The team sustained a 52% improvement in cycle time and supported a 30% decrease in Fuel Pod manufacturing throughput time.

• Established the foundations for an insert-parts dashboard.• Collaborated on multiple workstation redesigns to reduce ergonomic risk and increase throughput

• Defined project scope and evaluated current state of the pressure decay test equipment• Increased oil leak detection by 28% through our sensor device addition• Probable cost avoidance of $1,304,000 total over three years with minimal capital investment

• Integrated a Manufacturing Execution System (MES), developed corresponding training material, and led training across three shifts for over 300 technicians and several supporting engineers• Applied Lean principles to reduce wastes relating to unnecessary transport and overproduction• Queried data and formulated multiple reports utilizing SAP Crystal Reports

• Evaluated and stress tested various commercial golf course and industrial prototypes• Devised practical solutions to weaknesses in designs relating to ergonomics• Assisted Toro engineers with 4 and 10 meter sound tests to comply with European regulations