Vikram A R

Operations Associate

Mettuppalaiyam, Tamil Nadu, India15 yrs 8 mos experience

Highly Stable

Key Highlights

Increased project execution capacity by 2.5x.
Achieved over 30% improvement in machining efficiency.
Led Lean initiatives reducing material waste by 20%.

Stackforce AI infers this person is a Manufacturing Operations Expert with a strong focus on Lean and Six Sigma methodologies.

Contact

Skills

Core Skills

Cad/camProcess EngineeringNpi/npdProject EngineeringManufacturing EngineeringLean ManufacturingIndustrial EngineeringManufacturing OperationsProject ManagementTool Manufacturing

Other Skills

CAD/CAM Process EngineeringSOP DevelopmentCycle Time ValidationContinuous ImprovementResource PlanningCross-functional CoordinationManufacturing WorkflowsLean Six SigmaValue Stream MappingVendor DevelopmentProcess OptimisationTime and Motion StudiesTraining ProgrammesPoka-Yoke SolutionsLean Methodologies

About

Over the past 15+ years, I have progressed from hands-on machining and tooling operations to leading process engineering, sourcing, and large-scale manufacturing initiatives. Early exposure to complex machining environments helped me build a strong foundation in process planning, tooling, and quality control, while my later roles expanded my responsibilities across Lean transformation, vendor development, and new product introduction. A consistent challenge I have faced is improving productivity without compromising quality or cost. I addressed this by re-engineering workflows, introducing standardised machining practices, and applying Lean and Six Sigma principles to remove inefficiencies. I have increased concurrent project capacity by over twofold and reduced setup times and material waste, ensuring measurable operational gains. I currently drive CAD/CAM process standardisation and manage high-value project deliveries, focusing on improving throughput, consistency, and cross-functional coordination. I identify gaps, implement structured solutions, and align teams towards clear outcomes, enabling organisations to strengthen manufacturing performance, improve delivery reliability, and sustain long-term growth.

Experience

15 yrs 8 mos

Total Experience

3 yrs 8 mos

Average Tenure

11 mos

Current Experience

Bharat fritz werner ltd. (bfw)

Deputy Manager – CAD / CAM Process Engineering

Jul 2025 – Present · 11 mos · Hosur · On-site

Oversee CAD/CAM process planning and standardisation for machining operations, ensuring alignment across multiple production lines
Develop and maintain SOPs and work instructions, improving shop floor adherence and reducing process deviations by approximately 25%
Support CAM programming, tool list preparation, and cycle time validation, contributing to improved machining efficiency by nearly 30%
Coordinate with Production, Quality, Design, and Process Engineering teams to resolve technical issues, reducing rework instances by around 25%
Ensure adherence to standard machining practices, strengthening process discipline across projects and improving audit compliance outcomes
Identify and drive continuous improvement initiatives focused on productivity, quality, and process stability, contributing to measurable gains in throughput
Lead heavy parts supply for NPD and SPM projects, increasing concurrent project execution capacity from 3–4 to 9–12 projects, a 2.5x improvement
Plan and align resources across high-value projects, improving delivery throughput by over 30%
Re-engineer SQA process sequences, reducing bottlenecks and improving process flow efficiency by approximately 30%
Employ a common work offset methodology, enhancing machining consistency and reducing setup variability by 25%
Introduce one-touch clamping solutions, ZPS clamping, decreasing setup time by nearly 40% and improving machine utilisation
Serve as a key technical interface across CAD/CAM, Production, SQA, and Process Engineering teams, ensuring seamless project execution

CAD/CAM Process EngineeringSOP DevelopmentCycle Time ValidationContinuous ImprovementProject ManagementCAD/CAM+1

Macreq manufacturing services pvt ltd

Manager - Manufacturing / Process Engineering, Sourcing, and Vendor Development

Oct 2023 – Jun 2025 · 1 yr 8 mos · Coimbatore · On-site

Designed manufacturing workflows that improved production output by approximately 30% while reducing cycle times by 25%
Led Lean, Six Sigma, and Value Stream Mapping (VSM) initiatives, lowering material waste by nearly 20% and improving On-Time Delivery by 15%
Developed SOPs aligned with ISO and AS standards, strengthening process consistency and audit readiness
Optimised equipment utilisation and process flow, generating cost savings of around 15%
Supported new product introduction through process trials and tooling strategies, reducing ramp-up time by 30%
Identified and onboarded high-performing vendors through structured audits, improving supply reliability by 20%
Negotiated contracts that balanced cost and quality, contributing to sustained cost reductions without delivery delays
Tracked vendor KPIs, reducing lead times by approximately 25% through continuous improvement initiatives
Aligned vendor capabilities with production needs, minimising downtime by nearly 20%
Executed strategic sourcing initiatives that delivered 20% cost savings over 20 months
Ensured adherence to environmental and regulatory standards across the supply base

Manufacturing WorkflowsLean Six SigmaValue Stream MappingSOP DevelopmentVendor DevelopmentManufacturing Engineering+1

Lgb forge limited - india

Assistant Manager – Industrial Engineering & Technical Services

Oct 2019 – Sep 2023 · 3 yrs 11 mos · Coimbatore · On-site

Improved production efficiency by over 30% through Lean-driven process optimisation and waste elimination
Designed layouts and workflows that enhanced throughput and resource utilisation by approximately 25%
Conducted time and motion studies, establishing labour standards and improving operational efficiency by 20%
Supported installation and commissioning activities, reducing machine downtime during ramp-up phases
Delivered operator training programmes that improved process adherence and reduced handling errors
Bridged engineering and production teams, enabling smooth implementation of product changes with minimal disruption
Reduced tooling costs by approximately 20% through next-generation cutting tool adoption
Met production KPIs consistently while reducing cycle time by 25% and improving product quality metrics
Eliminated non-value-added activities, lowering operational costs by nearly 15%
Implemented Poka-Yoke solutions that reduced rejection rates by approximately 30%
Resolved fixture and tooling issues to maintain uninterrupted production flow
Led hydraulic fixture validation, ensuring reliability prior to full-scale deployment
Established robust processes for new product development, improving first-time-right rates by 35%
Maintained ISO/TS compliance, supporting successful audits and quality assurance benchmarks

Process OptimisationTime and Motion StudiesTraining ProgrammesPoka-Yoke SolutionsIndustrial EngineeringProcess Engineering

Gkditr-tooling centre

Senior Engineer / Head – Planning & Production

Sep 2017 – Oct 2019 · 2 yrs 1 mo · Coimbatore · On-site

Ensured timely sample submissions and first-off approvals, improving project acceptance rates by 30%
Established production tracking systems that enhanced visibility and improved performance monitoring accuracy
Validated supplier control plans and approved vendors, improving incoming quality levels by approximately 25%
Planned and controlled tooling schedules, achieving on-time project delivery improvements of nearly 30%
Maximised utilisation of manpower and machinery, increasing operational efficiency by 25%
Led cross-functional teams from Machine Shop, Process, and Tool Engineering for tooling development and product launches, reducing lead time by 30%
Managed inventory and routing processes, ensuring uninterrupted production flow
Collaborated with suppliers and internal teams for tooling and raw material coordination
Acted as the engineering interface for key customers, improving communication and reducing escalation instances
Prepared tooling cost estimates and controlled budgets, achieving cost adherence within ±5% variance
Reduced material waste through reuse initiatives, supporting sustainability and lowering costs
Led TQM and ACME initiatives, contributing to reductions in the cost of poor quality by approximately 20%

Production Tracking SystemsTooling SchedulesCross-functional Team LeadershipManufacturing OperationsProject Management

Larsen & toubro

Junior Engineer – Tool Manufacturing Shop (TMS)

Aug 2010 – Sep 2017 · 7 yrs 1 mo · Coimbatore · On-site

Managed machining operations across CNC, EDM, WEDM, and special processes, improving operational reliability
Developed process plans and setup strategies for complex components, improving machining accuracy by 25%
Optimised cutting tool selection through trials, reducing tooling costs by approximately 20%
Monitored tool life and introduced SOPs, improving consistency in new product introductions
Designed fixtures and gauges, enhancing manufacturability and reducing inspection errors
Prepared inspection control plans based on GD&T and CTQ parameters, incorporating PQCDSM metrics aligned with AS9100 Rev. C standards
Conducted gap analysis between planned and actual performance, improving cost and time accuracy by 20%
Facilitated daily production reviews, enabling quicker issue resolution and improved team alignment
Investigated Non-Conformance Reports (NCRs) and implemented corrective and preventive actions, reducing recurrence rates by 30%
Led 5S and industrial engineering initiatives, improving workplace organisation and efficiency