Lalith Kumar

Results-driven Engineering Leader with 12+ years of end-to-end ownership of complex manufacturing programs from greenfield plant design to global technology transfers. Combines deep PLM/simulation expertise with Agile project management and Six Sigma discipline to drive measurable operational impact at scale.

Assistant Lead Engineer – Manufacturing Layout & Design at Vestas Wind India (P) Ltd (2023-04 – Present)

• Led end-to-end execution of greenfield blade manufacturing projects (concept to commissioning), including layout design, capacity planning, and final handover.
• Drove brownfield expansion projects in Nakskov, Denmark, optimizing existing plant layouts and improving operational efficiency.
• Delivered cost reduction initiatives worth $9M+ across 2023–2024 through layout optimization, process improvements, and resource planning.
• Developed business case analyses and CAPEX budgeting for new manufacturing projects, supporting strategic investment decisions.
• Created and managed project timelines using Agile methodologies, ensuring cross-functional alignment and on-time delivery.
• Fronted New Product Introduction (NPI) for blade manufacturing in Poland and Scotland, enabling seamless product ramp-up.
• Executed Technology Transfer Projects (TTP) across Denmark and Taiwan, standardizing processes and ensuring knowledge transfer.
• Built digital factory models (2D → 3D) and performed process & product simulations using Tecnomatix, Teamcenter, Vis Mockup, and NX.
• Designed factory layouts and production line configurations, including process sequencing, cycle time optimization, and throughput improvement.
• Conducted logistics flow and material movement analysis, improving blade handling efficiency and reducing bottlenecks.
• Implemented JIT & FIFO strategies for raw material flow, improving inventory turnover and minimizing waste.
• Led virtual commissioning of blade manufacturing units, validating processes before physical deployment.
• Performed ergonomic and feasibility analysis to enhance operator safety and productivity.
• Collaborated with cross-functional teams and global stakeholders, managing international clients and ensuring alignment across regions.
• Grinding and finishing operation optimization of blade manufacturing through tool development, process optimization.
• Framed, monitored and reviewed yearly KPI objectives for team members.
• Architected a Scalable Training & Development Program, leveraging data-driven tracking to optimize team performance and build a high-competency talent pipeline capable of meeting aggressive scaling targets.
• Managed HSE compliance by coordinating mandatory safety training modules and maintaining a real-time tracking matrix to ensure 100% personnel certification across all fabrication teams.
• Campaigned a Lean Transformation Strategy by institutionalizing Value Stream Mapping (VSM) and Kaizen events, resulting in a 12% reduction in manufacturing lead time and a 9% improvement in First Pass Yield (FPY) through data-driven Root Cause Analysis.
• Supported a high-performance Preventive Maintenance (PM) strategy, leveraging Asset Criticality Analysis and CMMS-driven scheduling in unplanned downtime while governing a 100% safety compliance record.
• Collaboration with HSE team, REFM team, Project management team, tooling team, Process excellence team, installation and commissioning team to execute and implement NPI projects.
• Headed Layout design & sign off and official SAP document release for supplier plant facility take over.

Specialist – Digital Manufacturing at Ford Motor Company (2016-01 – 2023-04)

• Performed static and dynamic analysis of Trim, Chassis & Final (TCF) assembly systems for vehicle programs including Explorer, Fiesta, and Endeavour, improving assembly feasibility and process reliability
• Developed and validated 3D manufacturing simulations using Teamcenter Process Simulate, optimizing assembly sequences and reducing potential production issues
• Conducted ergonomic analysis (digital human simulation) to ensure operator safety, compliance, and improved workstation design
• Created and maintained Manufacturing Process Plans (MPP), ensuring alignment with production standards and engineering requirements
• Executed process planning using GSPAS, defining assembly workflows and standard operating procedures
• Managed Engineering Change Orders (ECO), ensuring smooth implementation of design and process updates without impacting production timelines
• Led project timeline tracking and coordination, ensuring milestone adherence across cross-functional teams
• Conducted GMR verification for interior and exterior trim components, ensuring quality and fitment standards
• Collaborated with cross-functional teams (CFT) including design, quality, and production to resolve manufacturing challenges

Senior Engineer at Madras Electroplaters (P) Ltd (2013-08 – 2015-11)

• Implemented S-shape electroplating process and motorized plating automation — reducing manpower and delivering $10M in cost savings.
• Managed supplier evaluation, raw material cost negotiation, and production planning for shift-based operations.
• Led Kaizen implementation on shop floor and authored ISO documentation for audit compliance.
• Process flow chart documentation and release & New tool procurement and implementation.

B.E. in Mechanical Engineering – Sri Sai Ram Engineering College, Chennai