Tushar Rawat

Operations Associate

Birmingham, England, United Kingdom2 yrs 6 mos experience

Key Highlights

Delivered over £1.2M in cost savings
Reduced cycle times by 18% in under 3 months
Improved efficiency by over 20% through practical changes

Stackforce AI infers this person is a Lean Transformation and Production Optimisation expert in high-volume manufacturing.

Contact

Skills

Core Skills

Lean TransformationProduction OptimisationQuality AssuranceSap Erp

Other Skills

Change managementCommunicationCost savingsCross-department projectsCycle time reductionData AnalysisDeviation reportsERP implementationEngineering ManagementGraduate LevelLean methodsPlant MaintenanceProcess improvementsProduct DesignProduct Management

About

I didn’t start out wanting to “save millions” or talk about Lean tools.I just hated seeing good people struggle with bad processes.Over the years, working on shop floors, production lines, and cross-department projects,I realised something simple:most problems aren’t because people don’t work hard, it’s because the system makes their job harder than it needs to be.I’m Tushar, a Production Optimisation & Continuous Improvement Engineer with 4+ years of experience in high-volume manufacturing environments.I’ve led and supported Lean transformations across multiple industrial sites,delivered over £1.2M in cost savings,reduced cycle times by 18% in under 3 months,and helped teams improve efficiency by over 20% through practical, on-ground process changes.My strength lies in bridging the gap between data, process, and people taking complex operational problems and breaking them down into systems that actually work on the shop floor.I enjoy working where change is real, not theoretical.Where improvements are seen in hours saved, defects reduced, and people less stressed.Currently exploring roles in:Production Optimisation | Continuous Improvement | Operational Excellence | Lean TransformationIf you’re building teams that care about real, measurable operational impact,I’d love to connect.

Experience

Gemba concepts

Lean Consultant

Jan 2025 – Jun 2025 · 5 mos · Sharjah, United Arab Emirates · On-site

● Delivered £1.2M in cost savings in one quarter by redesigning workflows across 5 production lines using Lean methods and shop floor engagement.
● Cut cycle time by 18.1% in 60 days, unlocking £300K in extra capacity through daily improvement workshops.
● Supported transformation across 5 industrial sites, tracking progress, documenting improvements, and reporting to leadership.
● Facilitated structured change workshops for 50+ engineers and operators, helping improve adoption of new work methods and standardised processes.
● Identified change resistance and improved workforce engagement by working closely with supervisors.
● Developed improvement documentation, case studies and performance reports for client transformation reviews, leading to £385K in project extensions.
● Supported ERP implementation projects, coordinating between operational teams and developers, resulting in 15.2% takt-time improvement through better production planning.

Lean methodsWorkflow redesignCost savingsCycle time reductionChange managementERP implementation+2

Dräxlmaier group

Quality Analyst

Jul 2023 – Sep 2023 · 2 mos · Solihull · On-site

● Maintained 99.7% quality compliance, preventing ~£150K in warranty risks through early defect detection.
● Supported process improvement meetings by preparing deviation reports and variation analysis, contributing to 12% reduction in quality deviations.
● Worked with production, quality and engineering teams to track defect trends and recommend corrective actions.
● Helped update SOPs and work instructions to improve consistency and operator understanding.

Quality complianceDeviation reportsVariation analysisSOP updatesQuality Assurance

Jbm group

SAP Consultant

Aug 2020 – Sep 2022 · 2 yrs 1 mo

● Identified production bottlenecks valued at $500K+ potential savings by analysing workflow data and machine utilisation.
● Implemented process improvements that increased production efficiency by 18% across multiple lines.
● Led cross-department improvement projects involving production, planning, maintenance and quality teams.
● Supported shop-floor digitalisation by improving SAP usage for production planning, defect tracking and performance reporting.
● Reduced material wastage by 17.4%, contributing to £650K annual savings.

SAP usageWorkflow analysisProcess improvementsCross-department projectsSAP ERPProduction Optimisation