Prashanth Sudhakar
San Antonio,TX
Summary
Industrial engineer with a proven track record of improving production efficiency and implementing lean manufacturing. Skilled in capacity planning, process optimization, and leading teams to achieve operational goals. Experienced in automation, cost reduction and continuous improvement leading to increased productivity and cost savings. Committed to delivering quality results through data-driven decision-making and strategic planning.
Overview
12
12
years of professional experience
1
1
Certification
Work History
Senior Industrial Engineer
INDO-MIM
07.2021 - Current
- Oversee daily production operations and resource allocation based on monthly forecasts to ensure production targets are met efficiently.
- Spearheaded capacity expansion and automation projects, increasing throughput by 2.6M units annually and reducing labor costs by 20%.
- Enhanced inventory management through Kanban implementation, improving operational performance by 15% and increasing inventory accuracy from 70% to 96%.
- Developed and rolled out a comprehensive training program for production staff, alongside implementing error-proofing techniques (poka-yoke), cutting monthly COPQ by $65,000.
- Led multiple kaizen events as part of the company’s lean and just-in-time transformation, improving space utilization, productivity and ergonomics.
- Managed the procurement and commissioning of new machinery with a total capital investment of $5 million.
Industrial Engineer
Indo-MIM.Inc
09.2017 - 07.2021
- Led machine qualification and process capability studies for new production introductions, ensuring compliance with IQ and OQ protocols.
- Conducted Design of Experiments (DOE) to establish optimal process parameters for injection molding operations achieving 95% FPY.
- Designed End of Arm Tooling and conveyor systems, while programming robots to streamline work cell layouts.
- Successfully transferred products between facilities, developing efficient work cells and standard operating procedures to ensure seamless transitions.
Graduate Research Assistant
Wichita State University
01.2016 - 01.2017
- Conducted comprehensive energy audits across five industries, identifying opportunities to reduce energy consumption and achieve annual savings of $50,000.
- Collaborated with plant personnel to collect key process data and make recommendations for energy efficiency improvements.
- Compiled detailed reports outlining potential savings, costs, and payback periods for energy-saving initiatives.
Process Associate
Amazon
09.2013 - 08.2015
- Designed and optimized vendor processes and workflows, focusing on automating tasks to streamline operations and enhance efficiency.
- Strengthened product lifecycle management by providing data-driven insights on new product introductions and SKU rationalization decisions.
- Spearheaded a major process automation initiative, improving workflow accuracy to 98% and increasing individual productivity by 70%.
Service Engineer
Aggreko
01.2013 - 09.2013
- Inspected equipment quality and collaborated with cross-functional teams to implement corrective actions using root-cause analysis techniques.
- Conducted site assessments and installed generators (ranging from 125KVA) and chillers at various customer locations.
- Managed inventory using ERP systems to track fleet details, ensuring preventative maintenance, and document repair activities.
- Tracking and analyzing customer service metrics, using process failure mode and effects analysis (FMEA) to improve reliability and customer satisfaction.
- Led the implementation of the 5S methodology across the plant, enhancing operational efficiency safety, and standardization of daily processes.
Education
Master of Science - Industrial Engineering
Wichita State University
Wichita, KS01.2017
Bachelor of Science - Mechanical Engineering
Sathyabama Institute of Science And Technology
Chennai, India05-2012
Skills
- Lean Manufacturing & Six Sigma
- Value stream mapping
- Product Development & Process Engineering
- Minitab & Data Analytics
- ISO 9001 & ISO 13485
- Internal Audits
- Process Improvement & Production Planning
- ERP Systems (Microsoft Dynamics 365)
Certification
- Lean Systems - Wichita State University
- Foundations of Six Sigma and Quality Improvement - Wichita State University
- Certified Six Sigma Green Belt - ASQ World Headquarters (Credential ID 17068)
Additional Information
Green card holder; no visa sponsorship required.
Languages
English
Timeline
Senior Industrial Engineer
INDO-MIM
07.2021 - Current
Industrial Engineer
Indo-MIM.Inc
09.2017 - 07.2021
Graduate Research Assistant
Wichita State University
01.2016 - 01.2017
Process Associate
Amazon
09.2013 - 08.2015
Service Engineer
Aggreko
01.2013 - 09.2013
- Lean Systems - Wichita State University
- Foundations of Six Sigma and Quality Improvement - Wichita State University
- Certified Six Sigma Green Belt - ASQ World Headquarters (Credential ID 17068)
Master of Science - Industrial Engineering
Wichita State University
Bachelor of Science - Mechanical Engineering
Sathyabama Institute of Science And Technology
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