Achieving a 45% Cost Reduction and 300% Space Efficiency for a Leading Medical Device Manufacturer

• Conducted a current state assessment including a detailed analysis of current manufacturing operation, identifying bottlenecks, inefficiencies, and areas for improvement.
• Assembled a multidisciplinary team from R&D, quality, program management, and continuous improvement to tackle challenges collaboratively.
• Led a two-week value stream mapping exercise to visualize the entire production process, pinpointing inefficiencies such as inventory buildup, quality gaps, and equipment downtime.
• Developed a comprehensive project plan, targeting space optimizations, cost reduction, and quality improvement. The plan included:
  • Transitioning from four manual production lines to one automated line.
  • Moving from paper-based documentation to a fully electronic system.
  • Designing and validating an automated manufacturing machine in partnership with external vendors.
• Implemented lean manufacturing principles, automation, and advanced documentation systems to achieve targeted improvements

Heerain's leadership and expertise in lean manufacturing, automation, and cross-functional collaboration enabled the company to scale operations effectively while reducing costs and improving quality. This project demonstrated the transformative power of lean principles and automation in the medical device industry.

MetaExpert skills needed:

• Lean Manufacturing
• Project Management
• Automation and Machine Design
• Value Stream Mapping
• Financial Modeling
• Negotiation and Stakeholder Management
• Quality Systems Implementation

Contract Length:

• Three and a half years, full-time commitment. The project was part of a broader 16-year tenure with the company.