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General Dynamics Land Systems

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One Piece Flow Implementation

Industrial Engineering Intern @ GDLS

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Skills Applied

LEAN Manufacturing
Process Optimization
Value Stream Mapping

    Inspiration and Objective:

    The existing workflow relied heavily on batch processing, resulting in long wait times, excessive WIP, inconsistent quality checks, and significant operator idle time. Material routing was unclear, changeovers caused bottlenecks, and the process lacked clear flow or standardization, all of which limited capacity and created unnecessary variation.

    Process and Results:

  • Conducted a detailed process observation using time studies, spaghetti diagrams, and value stream analysis.
  • Identified major sources of waste: transportation, inventory buildup, defects, and overprocessing.
  • Mapped the current state and designed a future-state flow model centered around one-piece movement.
  • Collaborated with operators and engineers to reorganize workstations into a logical, linear sequence.
  • Measured a 12% efficiency improvement by eliminating batch queues.
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VBA Reporting Automation

Industrial Engineering Intern @ GDLS

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Skills Applied

VBA Programming
Data Processing
Excel Automation

    Inspiration and Objective:

    The goal of this project was to eliminate the manual, time-intensive reporting process used to track operational performance metrics. I set out to build an automated VBA tool that could pull raw data, validate it, generate visual performance charts, and export professional reports with minimal user input. The objective was to improve accuracy, consistency, and speed, enabling supervisors and engineering teams to make data-driven decisions without the burden of repetitive administrative work.

    Process and Results:

  • Improved consistency and accuracy by eliminating manual data entry and formatting errors.
  • Reduced report creation time by 80–90%, turning a repetitive process into a near-instant automated task.
  • Mapped the current state and designed a future-state flow model centered around one-piece movement.
  • Positive adoption from supervisors and engineers due to reduced workload and clearer analytics.
  • Measured a 12% efficiency improvement by eliminating batch queues.
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