Mahesh Rajamani
Plant Operations and Manufacturing Excellence
New Panvel
Summary
Experienced Operations Leader with a proven track record of managing end-to-end plant operations in continuous process manufacturing environments. Known for ensuring seamless production, developing high-performing teams, and driving continuous improvement through TPM methodologies. Champion of safety, consistently enforcing compliance with regulatory standards and cultivating a zero-incident safety culture.
Expert in analyzing production metrics and implementing strategies to boost efficiency, optimize resources, and enhance equipment reliability. Skilled in streamlining manufacturing processes to improve productivity and maintain strict quality standards, while fostering a culture of quality and accountability.
A collaborative leader who works closely with cross-functional teams to align operations with business goals. Strong financial acumen in managing budgets, controlling operational costs, and supporting capacity enhancement initiatives. Recognized for adaptability, strategic problem-solving, and exceptional communication skills in dynamic manufacturing settings.
Overview
30
30
years of professional experience
4
4
Certifications
5
5
Languages
Work History
Operations Leader – Technical Fabrics & Plant TPM
Owens Corning India Pvt. Ltd.
04.1998 - Current
- Spearhead end-to-end operations of a continuous process manufacturing plant, leading a workforce of 340+ employees to drive productivity, safety, and operational excellence.
- Participate in Behavior-Based Safety (BBS) audits and presently serving as Program Leader for Powered Industrial Vehicles (PIV) under the Safety Critical Six initiative, resulting in a 70% reduction in workplace PIV incidents through proactive safety measures aligned with OSHA standards.
- Led implementation and employee engagement in TPM methodologies—focusing on the Autonomous Maintenance (AM) pillar—to drive operational excellence. Achieved a 9% reduction in manufacturing costs y-o-y, improved OEE gap closure by 5% y-o-y, extended equipment life, and enhanced people productivity from 88 to 100 man-hr/MT by eliminating process inefficiencies and streamlining operations.
- Led budgeting, resource deployment, and financial oversight to deliver sustained cost savings and optimize plant profitability.
- Instrumental in driving three major organizational restructurings, aligning plant operations with evolving corporate transformation strategies to enhance agility and performance.
- Built a strong leadership pipeline by facilitating Leadership development workshops across plants in India and Singapore, covering 120 leaders and strengthening next-generation plant and operations capability.
- Formed and led a customer-centric improvement team, leveraging LPA-based coaching and process enhancements to achieve consistent 15% year-on-year decline in customer complaints.
- Drove end-to-end quality enhancements and customer engagement initiatives, achieving a 2% reduction in downstream waste at the customer end.
- Partnered cross-functionally with Product Managers and CTSO to resolve complex process issues, standardize process capability, translate FFU into actionable parameters, and institutionalize NPI and commercialization systems.
- Drove cross-functional participation in employee engagement initiatives—sports committees, health campaigns, and physical fitness challenges—strengthening team cohesion and workplace energy.
- Currently leading a $6 million Greenfield expansion project at a new site to support growing demand in the Indian wind energy market, ensuring timely execution, cost control, and operational readiness.
Production Engineer
CG Glass Ltd.
11.1995 - 04.1998
- Led process engineering initiatives in a high-volume glass container manufacturing setup.
- Implemented lean manufacturing practices, improving productivity by 15%.
- Managed equipment trials, production line upgrades, and packaging installations.
- Delivered quality improvements through root cause analysis and preventive maintenance programs.
Engineer
Avasarala Automation Ltd.
06.1995 - 11.1995
- Designed and executed automation solutions for production lines (e.g., coating lines, TV tube conveyors).
- Managed project documentation, equipment performance tests, and quality control.
Education
Executive MBA - undefined
ITM
Graduation - Industrial Engineering
IIIE
Post-Graduation - Production & Materials Management
IIMM
Diploma - Mechanical Engineering
Board of Technical Education
Skills
- Plant Operations & Manufacturing Excellence
- TPM & Safety Compliance
- Production Planning & Process Optimization
- Cost Control & CAPEX Project Leadership
Certification
Lean Manufacturing (SME)
Accomplishments
- Developer of Talent Award, Owens Corning
- Led People Leadership training programs for India and Singapore leadership teams
- Short term assignments in OC USA manufacturing facility
Leadership Capabilities
A strategic and people-oriented leader with a Maximizer mindset, I consistently focus on amplifying strengths within teams and operations to achieve exceptional results. Known for agility in navigating complex manufacturing environments, I quickly adapt to evolving business needs while driving continuous improvement through Lean and TPM methodologies. I thrive in building high-performance teams, fostering collaboration, and developing talent — aligning individual potential with organizational goals to create sustainable impact.
Timeline
Operations Leader – Technical Fabrics & Plant TPM
Owens Corning India Pvt. Ltd.
04.1998 - Current
Production Engineer
CG Glass Ltd.
11.1995 - 04.1998
Engineer
Avasarala Automation Ltd.
06.1995 - 11.1995
Executive MBA - undefined
ITM
Graduation - Industrial Engineering
IIIE
Post-Graduation - Production & Materials Management
IIMM
Diploma - Mechanical Engineering
Board of Technical Education
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