Rajesh Khanna
Greater Noida,UP
Summary
Results-driven manufacturing and operations leader with 24 years of experience in the professional and industrial manufacturing sector, supported by a strong engineering foundation and an MBA in Operations. Expertise includes operations management, strategic planning, large-scale manufacturing leadership, continuous improvement, and cross-functional team development. Recognized for exceptional communication, analytical thinking, and problem-solving skills, alongside a proactive leadership style. Committed to fostering high-performance teams, driving operational excellence, and achieving measurable improvements in productivity, quality, cost efficiency, and delivery performance.
Overview
24
24
years of professional experience
1
1
Certification
Work History
General Manager (Operations)
ITP Electronics Pvt. Ltd.
04.2024 - 01.2025
- Developed and executed long-term manufacturing strategies that improved operational efficiency, enhanced scalability, and supported sustainable business growth.
- Achieved ₹30M in production output while reducing operating costs by 15% through performance management, process control, and optimized resource utilization.
- Implemented VSM, line balancing, and WIP inventory controls to reduce bottlenecks, minimize waste, and strengthen end-to-end process flow.
- Improved plant productivity and equipment reliability by identifying inefficiencies and leading strategic upgrades to facilities, machines, and supporting systems.
- Drove innovation and continuous improvement culture, integrating automation and advanced technologies while maintaining strict QCDS compliance.
- Owned and managed manufacturing budgets, conducting detailed cost-per-unit and ROI analyses to drive cost savings and improve bottom-line performance.
- Ensured full compliance with safety regulations, environmental laws, and internal SOPs, fostering a safe and legally compliant workplace.
- Championed Lean Manufacturing and Six Sigma practices, reducing waste, improving productivity, and elevating product quality across key production lines.
- Led 475+ cross-functional team members, improving coordination, problem-solving, and performance to consistently meet QOTIF targets, reduce OOBF, and support ROCE goals.
- Analysed and reported KPIs to identify performance gaps and implement timely corrective actions for improved efficiency and output quality.
- Enhanced on-time delivery by ensuring seamless coordination between production, warehouse, and logistics teams for smooth finished goods flow.
- Tape Wound-Toroid Electrical LV Transformers-Telecom & Energy meter CT, Cable & Wire Harness-EV, Li-Ion Battery, EMS Electronics SMT Lines from NPD to high volume production.
Plant Manager-Operations
Hayakawa Electronics India Pvt. Ltd.
09.2018 - 03.2024
- Directed and mentored high-performing teams, providing ongoing coaching, training, and competency development to enhance skill levels and build future-ready talent.
- Achieved up to 8% cost reduction by implementing process improvements, cycle-time optimization, and Lean–Six Sigma (DMAIC) methodologies, eliminating MURA, MURI, and MUDA waste and strengthening operational efficiency.
- Led 5S and safety initiatives, driving 100% compliance with comprehensive safety programs and resulting in a 30% reduction in workplace accidents while improving employee morale and fulfilling CSR safety commitments.
- Developed and managed positive employee relations, ensuring proper talent placement, fostering continuous learning, and building a strong leadership bench to meet future organizational needs, including succession planning.
- Championed forward-thinking operational excellence, leading, teaching, and implementing enterprise-wide Lean, Kaizen, and performance improvement programs to enhance productivity and process stability.
- Headed QC/QA and cross-functional teams (CFT), ensuring full compliance with IATF 16949, ISO 9001, ISO 14001, and ISO 45001 certifications while strengthening audit readiness and quality system performance.
- Led business development initiatives with new clients, and identified domestic and international vendors (Philippines, Vietnam, and Thailand) to achieve cost reductions, secure approvals, and ensure supplier capability for production requirements.
- Japanese Company-Wire Harness-Automobile 2W/4W & Electronic Sensor, SMT.
Senior Manager Manufacturing & Assembly
C&S Electric Limited
09.2008 - 08.2018
- Accomplished senior management professional with hands-on expertise in in-house manufacturing of electrical sheet metal LT/HT panels, switchgears, bus ducts, bus trunking, transformers, distribution boards (DBs) for starters & motors, MCB switches, and LED lighting systems.
- Experienced in CNC machine operations and maintenance. Oversee end-to-end plant operations, including production, quality control, and maintenance, receiving, and shipping, while driving productivity, efficiency, and profitability through optimized resource utilization, continuous process improvement, and implementation of best practices.
- Bus Ducts, Electrical Sheet Metal Panels & DB Boxes.
Sr. Engineer -Manufacturing
SIDWAL Air-Conditioning & Refrigeration Pvt. Ltd.
09.2000 - 08.2008
- Ensuring highest level of Utilization and productivity in the assigned production area of sheet metal on CNC AMADA TURRET PRESS-AP-100, FANUC P-16 series and MURATEC MOTORUM-54LT JAPAN. CAM Programming & software to machine language.
- SS, GI, Aluminium sheet metal linear TIG-MIG and spot welding, surface finishing process electroplating, powder coating paint.
- Consumer Durable Equipment’s and Air-Conditioning
Education
MBA/PGDBA - Operations Management
Symbiosis Centre for Distance Learning
PUNE01.2006
B. Tech /B.E. - Mechanical
M.I.E.T - GONDIA, NAGPUR UNIVERSITY
01.2000
Skills
- Efficient Plant Operations
- Manufacturing Proficiency
- Sustainable Innovation Strategies
- Strategic Leadership
- Kaizen Methodology Implementation
- Lean Six Sigma Practices
- Cross-Function Team collaboration
- Efficiency Enhancement Initiatives
- Operational Expenses Optimization
- Quality Assurance Compliances
- Supply Chain Management
- Safety Management Framework
- Data Driven Performance Reporting
- Business Growth Strategies, Budgeting P&L
- Stakeholder Collaboration & Customer Retention
- Team Leadership & Accountability
- Transparency & Adaptability
- Skilled in MS Office & ERP Integration
Certification
- IATF Internal Auditor
- Lean Six Sigma-Yellow Belt
- Six Sigma Assessment
- Pursuing Lean Six Sigma-Green & Black belt.
Disclaimer
Thank you for taking the time to review my professional resume. I truly appreciate your consideration and hope to have the chance to prove through my profession. Rajesh Khanna
Industrial Domain Expertise
- 1. Automotive Industry (Japanese Manufacturing Standards, System & Organization Operational Culture):
- Extensive hands-on experience in manufacturing wire harnesses, electronic sensor assemblies, and lighting components for 2-wheeler and 4-wheeler applications.
- Strong exposure to Japanese industrial work culture with deep emphasis on quality, precision, process discipline, and Lean manufacturing practices.
- Skilled in implementing Clean Room operations, ESD controls, Value Stream Mapping (VSM) with 3M analysis, Takt time analysis, and Total Productive Maintenance (TPM).
- Proven ability to optimize flow, eliminate waste, and enhance efficiency in high-volume, automotive-grade production environments.
- Well-versed in establishing, implementing, and auditing world-class quality systems, including:
- IATF 16949 – Automotive Quality Management System.
- ISO 9001 – Quality Management System.
- 2. Electrical & Power Systems Manufacturing:
- Hands-on expertise in manufacturing low-voltage (LV) tape-wound transformers, UPS components, MCB switches, and LED lighting systems.
- Strong background in plant operations, facility management, and resource planning for electrical manufacturing units.
- Experience in building robust quality assurance frameworks to ensure compliance, traceability, and process reliability.
- 3. Sheet Metal Fabrication (SS/GI/AL) & HVAC Systems:
- Skilled in the fabrication and assembly of sheet metal electrical panels, LED profiles, spot lighting systems, home appliances, and distribution boxes (DBs).
- Strong command of end-to-end fabrication processes, assembly line design, quality controls, and testing procedures for complex HVAC and sheet metal products.
- Proven expertise in designing and assembling HVAC solutions, including
- Air conditioners Water coolers
- Visible coolers Cold Rooms
- Roof-mounted AC units for railway and bus coaches.
Internship
Steel Authority of India Limited (SAIL) RSP Learning experience-manufacturing process of Steel Coils & Hot Plate from Iron Ore; Process flow and Plant Safety.
HOBBIES AND INTERESTS
Online learnings., To attend webinars of tech. guru’s and reading technical articles., Reading technical articles.
Languages
English
Bilingual or Proficient (C2)
Hindi
Bilingual or Proficient (C2)
Timeline
General Manager (Operations)
ITP Electronics Pvt. Ltd.
04.2024 - 01.2025
Plant Manager-Operations
Hayakawa Electronics India Pvt. Ltd.
09.2018 - 03.2024
Senior Manager Manufacturing & Assembly
C&S Electric Limited
09.2008 - 08.2018
Sr. Engineer -Manufacturing
SIDWAL Air-Conditioning & Refrigeration Pvt. Ltd.
09.2000 - 08.2008
B. Tech /B.E. - Mechanical
M.I.E.T - GONDIA, NAGPUR UNIVERSITY
MBA/PGDBA - Operations Management
Symbiosis Centre for Distance Learning