SURIBABU BODASAKURTHI
Aurangabad
Summary
Seasoned manufacturing leader with 31+ years of experience across plant operations, supply chain optimization, and vendor development, backed by over 25 years of hands-on expertise in TPM and lean manufacturing tools, driving sustainable operational excellence and productivity improvements. Currently heading the Plant Head at Varroc Engineering Limited, driving production efficiency in a high-volume and high precision transmission Gears manufacturing setup. Expert in CNC machining, Lean manufacturing, and process reengineering—instrumental in reducing cycle times, boosting OEE, and optimizing resource utilization. Demonstrated expertise in low-cost auto machining solutions to optimize manpower and enhance equipment efficiency, successfully deployed robotics and smart automation in line with Industry 4.0 standards to improve takt time, throughput, and overall productivity. Drove significant profitability improvements by minimizing downtime, reducing waste, and enhancing cost-to-output ratios through KPI-focused strategies. Built high-performing cross-functional teams and maintained strong industrial relations by leading proactive union negotiations and fostering a collaborative work culture. Recognized for driving continuous improvement programs that led to substantial reductions in operational waste and improved sustainability metrics. Proven track record in managing end-to-end supply chain efficiency through strategic vendor partnerships, cost-effective sourcing, and rigorous performance monitoring. Acknowledged for exceptional leadership in embedding a culture of innovation, adaptability, and excellence, aligned with long-term business transformation goals.
Overview
32
32
years of professional experience
Work History
Plant Head
Varroc Engineering Ltd.
12.2025 - Current
- Responsible for supporting sales by ensuring consistent quality, on-time delivery, and capacity readiness to meet customer requirements.
- Accountable for plant profitability through cost control, productivity improvement, and efficient use of resources.
- Establishes and sustains robust systems in quality, safety, and operations to ensure stable and scalable performance.
General Manager – Manufacturing
Mahle Engine Components India Pvt. Ltd.
04.2007 - 11.2025
- Proven track record as General Manager – Manufacturing (Operations Machining Unit), overseeing comprehensive plant operations including production, quality, maintenance, safety, and logistics.
- Strategically implemented lean principles, MAHLE Production System, and low-cost automation for significant cycle time reductions.
- Optimized equipment layout and material flow through value stream mapping, resulting in measurable productivity gains.
- Upgraded production systems with robotics, gantry automation, and smart manufacturing tools.
- Collaborated cross-functionally to drive quality assurance initiatives and enhance compliance.
- Managed labor relations, including union negotiations and workforce development.
- Held full P&L accountability, with strong expertise in cost control, budgeting, and optimizing operational expenditure to maximize profitability.
- Successfully aligned strategic decisions with long-term business goals, resulting in improved plant efficiency and market responsiveness.
- Championed continuous improvement initiatives that enhanced production throughput, reduced waste, and strengthened bottom-line performance.
- Led critical programs such as plant expansions, ERP implementations, and new product launches, ensuring seamless execution within timeline and budget.
- Effectively collaborated with top management, vendors, customers, and cross-functional internal teams to drive cohesive operational excellence.
- Achieved significant reductions in cycle time, downtime, and operational waste.
- Boosted profit margins through cost-control programs and strategic sourcing.
- Engineered greenfield execution of Toyota camshaft line, establishing a benchmark for project execution excellence.
- Spearheaded transformative initiatives in manufacturing operations, achieving substantial improvements in productivity, cost efficiency, and sustainability, while fostering a skilled workforce and ensuring compliance with industry standards.
Senior Engineer – Railway Brake Block Division
Rane Brake Linings Ltd.
04.2006 - 04.2007
- Spearheaded vendor development and procurement strategies to enhance material availability.
- Ensured rigorous quality compliance with industry and regulatory standards.
- Improved operational efficiency by deploying lean manufacturing techniques.
- Established a robust supplier performance evaluation system, leading to a XX% improvement in on-time delivery rates.
- Conducted comprehensive training sessions on lean methodologies for team members, resulting in enhanced operational efficiency and a culture of continuous improvement.
- Strengthened supplier quality assurance through enhanced material availability.
- Implemented root cause analysis and corrective action systems for quality compliance.
- Drove operational excellence through strategic vendor management and team training initiatives, significantly enhancing material availability and quality compliance within the Railway Brake Block Division.
Senior Engineer – Assembly and Machine Shop
Usha International Ltd.
02.2005 - 03.2006
- Streamlined assembly line operations using lean manufacturing principles.
- Led shop-floor supervision initiatives to ensure daily production targets were met.
- Initiated a kaizen program that led to a XX% reduction in assembly line cycle time, showcasing a commitment to continuous improvement.
- Collaborated with quality assurance teams to implement a new inspection protocol, resulting in a XX% decrease in defect rates.
- Enhanced product quality and process reliability through ISO-compliant quality systems.
- Utilized continuous improvement strategies to increase output consistency.
- Enhanced assembly line efficiency and product quality through innovative process improvements and collaborative quality assurance initiatives, contributing to the overall success of the manufacturing operations.
Production Engineer – Machine Shop Division
Rane Engine Valves Ltd.
07.1994 - 02.2005
- Directed precision machining operations and implemented process optimization techniques.
- Oversaw maintenance planning and execution to ensure maximum equipment uptime.
- Streamlined CNC programming processes, achieving a XX% increase in machining accuracy and reducing scrap rates.
- Led a cross-departmental project to optimize maintenance schedules, resulting in a XX% increase in equipment uptime.
- Leveraged CNC programming and lean manufacturing to enhance manufacturing efficiency.
- Promoted cross-functional collaboration to meet stringent quality and delivery targets.
- Championed precision machining and maintenance optimization initiatives, significantly enhancing operational efficiency and product quality within the Machine Shop Division.
Education
PG certificate - Lean Manufacturing Management & Analytics
IIM Vishakhapatnam
01-2026
B.Tech. - Mechanical Engineering
KSOU
01-2015
Diploma - Mechanical Engineering
State Board of Technical Education & Training
01-1992
Skills
CNC Machining
Lean tools (VSM, Layouts, )
Low-Cost Automation (LCA)
Robotics and Automation Integration
JIT Integration
Timeline
Plant Head
Varroc Engineering Ltd.
12.2025 - Current
General Manager – Manufacturing
Mahle Engine Components India Pvt. Ltd.
04.2007 - 11.2025
Senior Engineer – Railway Brake Block Division
Rane Brake Linings Ltd.
04.2006 - 04.2007
Senior Engineer – Assembly and Machine Shop
Usha International Ltd.
02.2005 - 03.2006
Production Engineer – Machine Shop Division
Rane Engine Valves Ltd.
07.1994 - 02.2005
B.Tech. - Mechanical Engineering
KSOU
Diploma - Mechanical Engineering
State Board of Technical Education & Training
PG certificate - Lean Manufacturing Management & Analytics
IIM Vishakhapatnam