Projects & Work in Action

Here’s a look at some of the real-world work I’ve been doing — solving friction-heavy problems, building operator ownership, and creating systems that actually stick.

Greenmill Uplift Project

Problem: Misalignment between scanner outputs and recovery KPIs. Operators didn’t trust the data, and team leads were flying blind during shifts.

Action: Conducted a full process audit across shifts. Ran live feedback sessions with operators to identify logic gaps. Built a real-time dashboard that translated recovery performance into something visible, relevant, and shift-specific.

Outcome:

• 12% reduction in rework

• Improved shift ownership over results

• Operators started flagging faults before they hit the numbers

Downtime Accountability Tracker

Problem: “Unknown cause” was the most common reason in downtime reports — which meant no one could fix anything.

Action: Designed a simplified daily downtime tracking form (with QR code), mapped downtime categories to real process issues, and coached team leads on how to use it live.

Outcome:

• 40% reduction in “unknown” tags within 3 weeks

• Clear data showing top 3 causes across shifts

• Actionable insights = faster resolution

Operator Capability Matrix + Reverification System

Problem: Training was informal and inconsistent. There was no way to tell who was actually competent on a given machine — especially after turnover.

Action: Built a digital capability matrix by workstation, shift, and individual. Created a re-verification cycle tied to annual reviews, audits, and shift changeovers.

Outcome:

• Training gaps became visible (and fixable)

• Managers could plan resourcing more effectively

• Operators had clear growth pathways, not guesswork

Fix-It Fast CI System

Problem: Improvement ideas were either stuck in meetings or lost in whiteboards. Nothing got actioned, and teams stopped suggesting anything new.

Action: Launched a “Fix-It Fast” system — QR code posters linked to a Microsoft Form that fed into a live Power BI tracker. Created a simple 3-status workflow: Not Started, In Progress, Complete.

Outcome:

• Over 45 CI ideas submitted in 2 months

• Staff could track their ideas publicly

• Management gained visibility into low-effort, high-impact wins

Training Reinforcement Model

Problem: SOPs were “read and signed” but not retained. Teams reverted under pressure, and no one knew who actually understood the process.

Action: Rebuilt training around real-world reps and shift-based refreshers. Added weekly quiz check-ins, live coaching sessions, and verification logs by workstation.

Outcome:

• 25% increase in SOP compliance

• Operator confidence improved on high-complexity stations

• Shift leads began using training data in weekly planning

Want to See More?

Screenshots, dashboards, visual workflows, and rollout templates available on request. Or better yet — let’s walk the floor together and talk about what’s working (and what’s not) in your world.

[Button: Let’s Connect]
[Button: View Insights Blog]