Vaibhav Khanna

Results-driven SAP Digital Manufacturing (SAP DM) Senior developer with 9 years of experience delivering digital manufacturing transformations across Automotive, EV Manufacturing, Consumer Products, and Industrial domains. Proven expertise in SAP DM Production Process Designer (PPD), POD Development, Non Conformances, Shop-Floor Automation, and MES Solution Design. Currently spearheading SAP DM implementation for Bentley Motors next-generation EV Factory program.

Strategic contributor to SAP DM CoE team, driving technical solutioning, client demos, PoCs to support client acquisition. Strong background in PTC ThingWorx, FactoryTalk Production Centre, Industry 4.0, IIoT, and Smart Factory initiatives as well.

SAP Digital Manufacturing Lead Consultant at Capgemini Pvt Ltd. (2024-08 – Present)

• Lead SAP DM development for Bentley Motors next-generation EV manufacturing facility.
• Designed, configured, and developed production processes for equipment's like VIN Etching, Glazing, Gap & Rad Gun, and AR HUD manufacturing stations.
• Developed plant automation capability by eliminating manual Start/Complete operations by automatically identifying the next operation and Tool ID from routing information post receiving initialization from PLC.
• Developed production execution processes for tool interaction with Kepware and created asset, resource and asset connectivity. Actively contributed in shop floor integration as well.
• Collaborated with Manufacturing Engineers, SAP Architects, Functional Consultants, and Business Stakeholders to define future-state production processes.
• Created functional and technical design documents, test cases, test scripts, and validation artifacts; executed SIT, supported UAT cycles and lead cutover activities.
• Provided defect analysis, issue resolution, deployment support, and hypercare activities for production go-live.
• Developed complex production process for quality systems allowing user to communicate bi-directionally with third party legacy quality sytem of client for Nonconformance data.

MES Product Developer – PTC ThingWorx at Capgemini Pvt Ltd. (2021-07 – 2024-07)

• Core team member for enterprise-wide PTC ThingWorx MES product development serving global manufacturing facilities for Kimberly-Clark.
• Designed and developed ThingWorx mashups for Monitoring, Quality, Production, and Efficiency modules; delivered optimised solutions to increase shop-floor efficiency.
• Built complex ThingWorx services, localization tokens, functions, and collection widgets to meet diverse business scenarios across global mills.
• Gathered requirements by closely partnering with Business teams in an Agile/Scrum environment; developed new mashups and TWX entities including Widgets, Localization Tokens, and Functions.
• Conducted Technical PoCs to assess feasibility of functional and non-functional requirements; worked with solution architects to design and enhance platform capabilities.
• Performed bug fixing and dashboard screen improvements ranging from new feature development to debugging stored procedures and resolving data unavailability issues.
• Provided expedited production support ensuring consistent template changes across environments; documented changes in FDS and site-specific documentation.

MES Implementation Engineer at Tata Technologies Ltd. (2018-03 – 2021-06)

• Delivered MES implementations using PTC ThingWorx, Siemens Opcenter, and FactoryTalk ProductionCentre across Automotive and Industrial sectors.
• Implemented genealogy, electronic work instructions, order execution, material consumption, OEE dashboards, and production reporting solutions.
• Worked on Tata Motors (Make to Order & Make to Stock) scenarios using Rockwell FTPC; developed Quality and VIN Generation apps for passenger vehicle manufacturing.
• Delivered Berkeley Modular Housing UK MES using Siemens Opcenter Discrete for production tracking and quality management.
• Developed custom integrations, SQL procedures, plant reporting, and conducted end-to-end testing, deployment, and production support.

Bachelor of Engineering in Computer Science – Chitkara University (2013 – 2017)