CASE STUDIES

Manufacturing automation projects I've completed

Confidentiality Notice
Client confidentiality and proprietary business information are strictly protected. The following case studies present project outcomes and methodologies while adhering to non-disclosure agreements. Specific client names and proprietary processes have been generalized to maintain confidentiality while accurately representing the scope and results of the solutions delivered.
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Aerospace Manufacturing Scheduling Automation

Eliminated manual scheduling for precision component manufacturer
Aerospace Manufacturing
Precision Components
Multi-Cell Operations
Project Summary
I built a custom scheduling automation system for an aerospace manufacturer that reduced their daily scheduling work from 4 hours to minutes. The solution automated manufacturing cell assignments and autoclave scheduling, eliminating manual coordination while optimizing resource utilization.

The Situation

The aerospace facility was spending 4+ hours daily on manual scheduling. Multiple production personnel had to coordinate manufacturing cell assignments, autoclave scheduling, and resolve resource conflicts manually. This created bottlenecks, suboptimal resource utilization, and production delays.

The manual process involved spreadsheets, phone calls, and constant adjustments throughout the day. When conflicts arose or priorities changed, the entire schedule often needed to be rebuilt from scratch.

My Approach

1. Analyzed Current Workflow
I spent time on-site mapping their existing scheduling process, understanding constraints, priorities, and decision-making rules.
2. Designed Custom Logic
I created optimization algorithms specific to their equipment setup, processing requirements, and business rules.
3. Built Automation System
I developed a system that automatically assigns jobs to manufacturing cells and optimizes autoclave utilization based on their specific constraints.
4. Integrated with Existing Systems
I connected the new system to their current production management tools to ensure seamless data flow.

The Results

4 Hours to Minutes
Daily scheduling time reduced from 4+ hours to under 30 minutes
100% Automation
Complete elimination of manual cell assignment decisions
Optimized Utilization
Maximized autoclave and manufacturing cell efficiency
6 Week Implementation
From initial analysis to full deployment
Technical Implementation
Custom Optimization Algorithms Constraint Programming Real-Time Processing System Integration User Interface Design Load Balancing
Total Project Duration
6 Weeks - Analysis to Deployment

Warehouse Capacity Optimization

Inventory management system for agricultural retailer
Regional Retail
11,000+ SKUs
Multi-Location
Project Summary
I designed and implemented a custom inventory optimization system that reduced warehouse capacity from 130% to 80% while saving over $10,000 annually in carrying costs. The system automated purchasing decisions and improved communication between departments.

The Situation

The agricultural retailer was operating at 130% warehouse capacity with over 11,000 SKUs. Poor communication between purchasing and operations led to systematic over-purchasing and substantial dead stock accumulation.

My Approach

1. Data Analysis
I analyzed their enterprise WMS data to identify purchasing patterns and inventory inefficiencies.
2. Pilot Program Design
I selected the top 300 products for optimization to demonstrate ROI before full implementation.
3. Custom Inventory Model
I built min-max optimization models integrated with their existing systems.
4. Process Improvement
I established new communication protocols between purchasing and operations teams.

The Results

130% to 80%
Warehouse capacity reduced to optimal levels
$10,000+ Savings
Annual cost reduction in carrying costs
Automated Purchasing
Systematic inventory management for priority items
3 Month Timeline
Analysis through full implementation
Technical Implementation
SQL Data Analysis VBA Automation Excel Integration WMS Connectivity Statistical Modeling Process Design

Interested in Similar Results?

If you're facing similar operational challenges, I'd be happy to discuss how a custom solution could work for your specific situation.

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