Mahesh Kumar Bommani
Perrysburg,USA
Summary
Senior Technical Lead with 18 years of experience in industrial and manufacturing engineering. Skilled in driving operational excellence through strategic initiatives, process optimization, and new product launches. Expert in assembly process design, material logistics, and supply chain efficiency to reduce costs and improve performance. Proven leader of cross-functional teams delivering measurable gains in quality, productivity, and cost management.
Overview
19
19
years of professional experience
Work History
Senior Technical Lead
HCLTECH
09.2014 - Current
- WPI Specialist and Launch Lead for JEEP Wrangler and Gladiator Internal logistics at Toledo Assembly Complex.
- Led PDCA process, maintaining records (issue lists, PFEP data, Kaizen journals) to ensure zero open issues.
- Designed and executed delivery strategies (POS to POI) following World Class Logistics principles.
- Ensured 100% production station readiness with sign-offs before VPA, SOF, and SOP milestones.
- Conducted EBOM analysis to support product launches; generated actionable reports.
- Led daily and weekly status meetings with cross-functional teams and management.
- Drove cost reduction and material flow improvements through continuous improvement initiatives.
- Maintained accurate PFEP data for production support.
- Proposed and executed projects with KPIs, milestones, and ROI assessments.
- Verified CAD layouts and equipment for efficient material flow and packaging per WCM standards.
- Consulted on Value Chain Simulation project integrating CAD/PLM and MES for a wind turbine client.
- Applied Line of Consideration Analysis for ergonomic optimization.
- Developed benchmarking, best practices, and Value Stream Maps to eliminate waste and boost efficiency.
- Saved $320K in assembly costs through process improvements in medical devices.
- Achieved $790K cost savings by switching from wooden to hybrid packaging.
- Boosted dock utilization by 15% via replacement of racks with wheeled trolleys.
- Saved $30K annually by implementing Common Loop Kitting Trolleys.
- Freed up 1,800 sq. meters of warehouse space with JIS/JIT supply and milk run setups.
Senior Industrial Engineer
Aiscades Limited
07.2010 - 08.2014
- Led process improvement and RCA initiatives to enhance manufacturing efficiency.
- Developed assembly work instructions, PFMEA, and control plans using VPPA PLM.
- Managed Manufacturing BOM and product changes through Teamcenter; ensured accurate model structure.
- Supervised a team of 8 engineers, overseeing workload planning, forecasting, and project delivery.
- Executed end-to-end DFMA activities including virtual builds, static assembly validation, work instructions, line balancing, and BIQ checks.
- Reviewed engineering change notices and updated BOM/routing structures.
- Conducted training for new associates and created Standard Work Element Sheets (SWES) to document best practices.
Design Engineer
Bharat Dynamics Limited
07.2009 - 06.2010
- Worked on a project based on improvement of mechanical properties by changing the process parameters.
- Project Lead for Assembly Planning activities & relocation of production facilities between plants.
- Design Parts and Assembly and develop 2D drawings using Autodesk Inventor.
- Design for Manufacturability, assembly validation, interface checks to eliminate design errors.
- Upgrading/Enhancement of facilities to meet the requirement as per DEFENCE Standards.
- Realign Supplier Material delivery strategy accordingly to Defence Facility requirements by updating packaging and delivery modes.
- Developed Quality check after assembly.
Engineer – Engineering Services
Satyam BPO Limited
10.2007 - 05.2009
- Setting time standards using MTM and basic most and use the data for manpower projections.
- Provide visual aids as a resource to minimize defects & time for the assembler on the floor.
- Conduct time studies & validate the bill of material for the assembly operations.
- Creating MBOM from EBOM for manufacturing assembly line planning procedures and validation.
- Create SWES (Standard Work Element sheet) for New Products.
- Worked on Time standards and torque audits.
- Develop Manufacturing Process Planning Instructions.
- Engineering change management Validate BOM accountability.
Design Engineer
EO2 Systems
05.2007 - 10.2007
- Design Periscope Parts and Assembly and develop 2D drawings using CATIA V5 R15.
- Design to Manufacturability assembly validation interface checks to eliminate design errors.
- Upgrading/Enhancement of facilities to meet the requirement as per DEFENCE Standards.
- Realign Supplier Material delivery strategy accordingly to Defence Facility requirements by updating packaging and delivery modes.
Education
Bachelor's - Mechanical Engineering
Jawaharlal Nehru Technological University
Hyderabad, India05.2007
Skills
- Material Logistics Management
- NPI Launch
- Lean Manufacturing
- World Class Manufacturing
- PFEP
- Continuous Improvement
- Factory Layout Design
- ERP Systems
- Project Planning
- PFMEA & Control Plans
- Data Analytics
- Line Balancing
Declaration
I declare that the above details are accurate and true to the best of my knowledge.
TOOLS & SOFTWARE
- AutoCAD
- Autodesk Inventor
- Navisworks
- Solid works
- Catia V5
- Teamcenter (Vismockup, Vispro2, MPP)
- Microsoft Office (Outlook, Excel, Word, PowerPoint, Project)
- PMTS (Basic MOST, MTM-UAS)
Timeline
Senior Technical Lead
HCLTECH
09.2014 - Current
Senior Industrial Engineer
Aiscades Limited
07.2010 - 08.2014
Design Engineer
Bharat Dynamics Limited
07.2009 - 06.2010
Engineer – Engineering Services
Satyam BPO Limited
10.2007 - 05.2009
Design Engineer
EO2 Systems
05.2007 - 10.2007
Bachelor's - Mechanical Engineering
Jawaharlal Nehru Technological University