Continuous Improvement & Manufacturing2011 - 2019
Sinto Brasil — Operational Efficiency & Lean Manufacturing
Improving On-Time Delivery and Reducing Manufacturing Cycle Times
RoleProduction Coordinator (Progressed from Process Analyst and Process Coordinator)
Organization / ContextSinto Brasil Produtos Ltda
Overview
Worked across continuous improvement and industrial operations management, combining process analysis, Lean, Kaizen, and 5S to reduce waste, improve production flow, and increase operational predictability.
The Operational Challenge
The operation faced bottlenecks in critical manufacturing and assembly stages, with on-time parts delivery around 65%, requiring greater standardization, prioritization, and predictability across the production flow.
- Lack of standardized operating procedures in heavy machinery assembly.
- Excessive operator movement to fetch tools, consumables, and components.
- Absence of real-time visual management for manufacturing-order prioritization.
The Solution Blueprint
Implemented a practical Lean methodology focusing on shop-floor layout, ergonomic assembly tooling, and daily visual control.
- Reorganized factory floor layout, positioning tools, hardware, and benches directly adjacent to assembly points.
- Designed and standardized custom fixtures for precise component cutting and assembly.
- Deployed daily visual management boards to prioritize and balance work orders across teams.
- Structured preventive maintenance routines and station-by-station quality checklists.
Proven Results
65% → 85%On-Time DeliveryImprovement in on-time delivery
-50%Manufacturing timeOne of the largest gains achieved across different process improvements
-30%Impeller Assembly TimeProductivity gain on the main assembly line
Impact & Operational Outcomes
- Greater operational predictability through preventive maintenance routines and internal checklists.
- Improved manufacturing and assembly flow through layout changes, operating-sequence improvements, and custom fixtures.
- Standardized methods and routines through practical application of Lean, Kaizen, and 5S.
Applied Methods and Fundamentals
Industrial engineering rooted in time-and-motion studies and quality management.
Technologies & Methods
Lean ManufacturingKaizen5SVisual ManagementTime & Motion StudiesGreen Belt
Core Principles
- Identifying and eliminating waste directly where work occurs (Genba).
- Standardization precedes optimization.
- Direct operator participation in designing tooling and jigs.