Built machine-sensor analytics using SQL and Power BI to identify which machines, styles, and colors generated the highest defect rates. The insights drove a process-optimization project that reduced defects by 48% and was later replicated across an additional Company site. 

Led the redesign of the Daily Management System for a key manufacturing area, improving KPI alignment and operator engagement. Efficiency loss dropped from 19.36% to 12.55%, and the DMS score rose from 1.6 to 5.0, surpassing the original target of 4.0. 

Increased production speed by 50% through structured trials, heat‑history analysis, and controlled parameter optimization, delivering $170K in annual savings while maintaining medical‑grade product integrity. The improvement doubled daily output and was recognized by leadership. 

Reduced scrap on a high cost style by 37% through a full DMAIC project involving MSA, regression analysis, and a 7‑factor DOE. Improved weight consistency to a 94.6% success rate and delivered more than $35K in annual savings through recipe optimization and process stabilization.