Saurabh Pandey

Results-driven operational excellence professional with over 6 years of experience in spearheading Lean transformations, digitalization, and automation initiatives within the automotive and process industries. Expertise in leading large-scale automation and MES programs (₹28 Cr), achieving significant productivity improvements, manpower optimization, and cost reductions through TPS, Lean methodologies, and data-driven decision-making. Strong customer-facing leader adept at managing Tier-1 programs (BOSCH, HERO VIDA) while fostering a culture of change for sustainable performance. Proven track record of successfully implementing Lean manufacturing tools, 4M Optimization, TPM, and continuous improvement strategies, complemented by the development of comprehensive Lean Roadmaps focused on process optimization, JIT, 5S, TPM, Industry 4.0, and new product line installations.

• Implemented Lean Manufacturing tools in 8 different plants of MAT group which includes (Moulding and assembly, Sheet metal Blanking, Forming, Welding, Foundry, Rotor Machining) and Hindalco Industries Ltd. Automotive division deals in extrusion & value addition process of aluminum profile.

• Delivered 15% productivity improvement (3000 → 3450 sets/day) and deferred capex.

• Led 25+ engineers & operators for Lean deployment and TPM pillar ownership.

• Improved OEE by 8%, generating ~₹25 lakh annual capacity gain.

• Implemented CLIT sheet, TPM boards, and PLMS system for PM tracking, MTTR & MTBF monitoring.

• Reduced rejection by 0.8% and rework by 1.2% in painting via root cause analysis and SOP standardization.

• Conducted cycle time & motion studies, line balancing, and material flow improvements.

• Digitized training modules, SOPs, checklists, and quality documents for real-time monitoring.

• Implemented digital check sheets, MES, and IoT solutions on older machines to capture real-time OEE data.

· Led end-to-end execution of BOSCH ABS Pump Housing project involving design, costing, and implementation of a fully automated robotic manufacturing line with total project investment of ₹28 Cr and annual capacity of 4 million components.

· Owned complete Operational Excellence scope including Value Stream Mapping (current & future state), machine finalization, process flow design, takt-based capacity planning, and line balancing aligned with BOSCH demand ramp-up.

· Spearheaded MES implementation for real-time production monitoring, downtime analysis, quality traceability, and KPI dashboards to meet BOSCH audit and compliance requirements.

· Applied Toyota 14 Principles (TPS) and Lean Manufacturing concepts to design a high-throughput, low-waste automated production system with built-in quality and poka-yoke mechanisms.

· Led cross-functional teams (Production, Quality, Maintenance, Automation, IT, SCM) for APQP documentation, PFMEA, Control Plan, SOPs, and Standard Work development.

·  Developed complete capex justification, cost-per-piece analysis, ROI and automation costing for robotics, machining centers, material handling, and inspection systems.

· Acted as single-point interface with BOSCH for technical reviews, readiness audits, and project milestone tracking.

• Operational & Manufacturing Excellence
• Time & Motion Study, Line Balancing
• Lean Manufacturing Tools (VSM, SMED, Kaizen)
• Toyota Production System / 14 Principles (14Q)
• 4M Optimisation (Man, Machine, Material, Method)
• Capacity Planning & Resource Optimisation
• Layout Design & Material Flow Engineering
• TPM & 5S Implementation
• Digital Manufacturing & Industry 4. O
• Process & Productivity Improvement

• Implemented Lean Manufacturing tools in 8 different plants of MAT group which includes (Moulding and assembly, Sheet metal Blanking, Forming, Welding, Foundry, Rotor Machining) and Hindalco Industries Ltd. Automotive division deals in extrusion & value addition process of aluminum profile.

• Delivered 15% productivity improvement (3000 → 3450 sets/day) and deferred capex.

• Led 25+ engineers & operators for Lean deployment and TPM pillar ownership.

• Improved OEE by 8%, generating ~₹25 lakh annual capacity gain.

• Implemented CLIT sheet, TPM boards, and PLMS system for PM tracking, MTTR & MTBF monitoring.

• Reduced rejection by 0.8% and rework by 1.2% in painting via root cause analysis and SOP standardization.

• Conducted cycle time & motion studies, line balancing, and material flow improvements.

• Digitized training modules, SOPs, checklists, and quality documents for real-time monitoring.

• Implemented digital check sheets, MES, and IoT solutions on older machines to capture real-time OEE data.

· Led end-to-end execution of BOSCH ABS Pump Housing project involving design, costing, and implementation of a fully automated robotic manufacturing line with total project investment of ₹28 Cr and annual capacity of 4 million components.

· Owned complete Operational Excellence scope including Value Stream Mapping (current & future state), machine finalization, process flow design, takt-based capacity planning, and line balancing aligned with BOSCH demand ramp-up.

· Spearheaded MES implementation for real-time production monitoring, downtime analysis, quality traceability, and KPI dashboards to meet BOSCH audit and compliance requirements.

· Applied Toyota 14 Principles (TPS) and Lean Manufacturing concepts to design a high-throughput, low-waste automated production system with built-in quality and poka-yoke mechanisms.

· Led cross-functional teams (Production, Quality, Maintenance, Automation, IT, SCM) for APQP documentation, PFMEA, Control Plan, SOPs, and Standard Work development.

·  Developed complete capex justification, cost-per-piece analysis, ROI and automation costing for robotics, machining centers, material handling, and inspection systems.

· Acted as single-point interface with BOSCH for technical reviews, readiness audits, and project milestone tracking.