1Project overview
A Quick Response Manufacturing (QRM) redesign of an injection molding operation, modeled before any rollout.
2Objective
Redesign an injection molding operation to reduce lead time from 18 to 10 business days.
3My role
- Led system design and current-state capacity analysis.
- Mapped queue, setup, and inspection delays and touch time.
- Designed the future-state shop floor layout.
- Compared smaller batches, point-of-use staging, and a focused cell (QROC).
- Used QRM capacity analysis and MPX to model options before rollout.
4Engineering approach
Current state
Mapped where lead time goes: queues, setups, inspection delays, and actual touch time.
Options
Compared smaller batches, point-of-use staging, and a focused QRM cell (QROC).
Modeling
Used QRM capacity analysis and MPX to test each option before any change on the floor.
Future state
Designed the future-state shop floor layout around the selected option.
5Analysis and visuals
Image to add: Current-state vs. future-state layout
Side-by-side shop floor layouts showing the focused cell.
Image to add: MPX model output
Lead time and utilization for each option you compared.
6Results and impact
- −44%lead time, 18 → 10 business days (target)
- 38→71%share of time spent on actual work (target)
These are proposed future-state targets from the model, not completed operational results.