S Prabhu

Production & Operations Manager with 10+ years in high-volume manufacturing (rail and industrial). Expert in lean, TPM, Kaizen, SMED, and takt time reduction. Known for cutting cycle time and rework, improving first-time quality, and driving on-time delivery through robust idea systems, stage-wise quality, and KPI management.

Manager – Elementary Production Unit - Alstom Transport India Ltd - Sricity, India

(2025-01)

• Launched a QR code–based Lean Champions League; generated 250+ ideas in two months with 180 implemented, delivering ~200 hours method time reduction per train set.
• Built a stage-wise quality culture via mandated in-process inspections and regular audits, reducing defect carryover and rework while improving first-time quality.
• Optimized MIG welding on aluminium–MS underframes (toe angle, weld end merge), eliminating TIG touch-up and removing ~40 hours of rework per train set.
• Introduced welding templates for bush/clamp fitment, eliminating marking/measurement errors and improving process consistency and waste reduction.
• Improved shop-floor utilization and productivity by managing KPI 1 (Manufacturing Utilization Ratio) and KPI 2 (Efficiency Ratio) in AOS; daily reviews and visible KPI boards drove accountability.
• Operational leadership: schedule adherence, self-inspection before handover, weekly cross-station safety inspections, and daily 5-minute SPQCDME stand-ups.

Assistant Manager, Production - SCHWING Stetter India Pvt Ltd

(2016-01 - 2025-01)

• Led batching plant assembly operations, consistently achieving 100% production targets.
• Implemented lean practices to reduce lead time and improve workflow.
• Designed and optimized jigs and fixtures to enhance productivity and ergonomics.
• Managed line balancing and shift manpower planning to maximize throughput.

MBA - Logistics & Supply Chain Management - University of Madras (2021-01 - 2023-01)

B.E. - Mechanical Engineering - Agni College of Technology (2012-01 - 2016-01)