Sudharsan Sudhi

Manufacturing Operations Leader with 15+ years in Tier-1 automotive heat treatment. Expert in through & case hardening, induction hardening, and diaphragm spring processes. Proven track record in QCDM delivery, Lean & Kaizen, automation, and Industry 4.0 digitization using SAP ERP, FORCAM MES, and Power BI.

Senior Team Leader (Heat Treatment) - Schaeffler India Ltd - Hosur, Tamil Nadu

(2011-01)

• Lead end-to-end heat treatment operations including through hardening, case hardening, tempering, induction hardening, shot blasting, and phosphating.
• Provide expert process leadership for Diaphragm Spring heat treatment ensuring functional performance and consistency.
• Drive QCDM performance using Digital SFM dashboards, SAP BW production reports, and structured review mechanisms.
• Implemented Lean, Kaizen, SOP standardization, and waste elimination initiatives aligned with AIAG requirements.
• Created a stacker-free shop floor by introducing trolley-based material handling concept.
• Deployed small automation solutions eliminating 2 manpower per line.
• Develop Power BI dashboards for KPI visibility and management reviews.
• Ensure IATF 16949, CQI-9, and AIAG compliance during audits and customer requirements.
• Certified Six Sigma Green Belt with successful project completion delivering measurable improvement in quality and process stability.
• Eliminated 2 manpower per line through small automation and lean improvements.
• Reduced heat treatment rejection by more than 50% using PDCA and 8D methodology.
• Improved furnace utilization (OEE) through batch optimization, cycle-time reduction, and loss elimination.
• Implemented Digital SFM using Power BI, improving KPI transparency and decision-making speed.
• Established a stacker-free shop-floor layout, improving ergonomics, safety, and material flow.

B. Tech - Mechanical Engineering