Vamsi Srinivas Ailavarapu
Program Management Professional from NIT Warangal, specializing in automation, lean manufacturing, and process optimization. Spearheaded strategic projects in component standardization and quality system enhancements, achieving significant cost savings and operational flexibility. Proficient in Excel, Python, and data visualization tools, driving data-driven decision-making and process excellence.
Work Experience:
5.7 Years
Industry:
Aviation & Automotive | Manufacturing & Engineering
Function:
General Management | Operations & Supply Chain | Project & Program Management
Work Experience
Maruti Suzuki India Limited (India's leading automobile manufacturer) | Gurgaon
- Deputy Manager
- Developed an in-house prototype for real-time engine monitoring, saving INR 50 lakhs by collaborating with production teams, enhancing operational efficiency.
- Designed a 0.02mm precision manipulator for transmission assembly, cutting errors by 30%. Saved INR 40 lakhs across three models, ensuring quality for assembly teams.
- Optimized engine and transmission processes using lean principles, cutting cycle times by 10 seconds. Increased capacity by 12%, streamlining production workflows.
- Standardized assembly line components, saving INR 40 lakhs via supplier negotiations thereby improving product consistency.
- Mentored 3 junior trainees with a structured program, delivering Advanced Excel and GD&T training to bridge skill gaps and boost automotive project efficiency.
- Authored 10 KAIZEN/PDCA documents, reducing process variability by 10%. Enabled 5 new initiatives, standardizing processes for project teams.
- Assistant Manager
- Automated four assembly lines, improving tact time by 4 seconds with robotics teams. Boosted daily production capacity by 5%, advancing factory automation.
- Replaced compressed air systems with electric actuators, cutting energy by 12%. Reduced carbon footprint by 8% and costs by 10% for facility management.
- Built a needle bearing inspection machine, reducing defect rates by 20%. Saved INR 50 lakhs for quality teams, improving production reliability.
- Collaborated with Procurement to replace bottleneck components, shortening lead times by 2 months. Enhanced supply chain efficiency for project teams, meeting tight deadlines.
- Implemented a biogas-to-bio-CNG system for the canteen thereby reducing operating expenses by 5%, supporting plant sustainability goals.
- Developed 8 standardized Excel-based tools to optimize project lead times, improving operational efficiency and enabling seamless knowledge transfer for engineering teams.
- Graduate Engineer Trainee
- Improved paint shop quality by reducing the rejection rate by 5%. Saved INR 10 lakhs in rework costs, enhancing output for production teams.
- Built an Excel tool to auto-correct CNC errors for five machines, reducing breakdowns by 8%. Increased uptime by 10%, supporting maintenance teams with scalable solutions.
Accomplishments
- Promoted to Deputy Manager in FY 22-23 and mentored 3 members with an emphasis on adaptability and commitment to continuous improvement.
- Awarded Best Performer for FY 21-22 for the successful delivery of 3 projects focused on improving tact time and reducing energy consumption and carbon footprint.
- Gained admission to NIT Warangal by ranking in the top 0.5 percentile among 12 Lakh candidates in JEE Mains 2015.
Education
- B-Tech (Mechanical Engineering), National Institute of Technology, Warangal
Certification
- Business Writing, University of Colorado Builder
- Excel Skills for Business: Advanced, Macquarie University
- Crash Course on Python by Google, Coursera
- Design of Electric Vehicle Batteries, Alison Education Company
Extra-curricular
- Member of Gurgaon Toastmasters club with an aim to improve my public speaking and leadership skills (2025).
- Actively volunteered with the Youth Red Cross Club at college, successfully organizing various activities such as blood donation camps and essay writing events in my role as General Secretary (2019).
- Served as technical lead for the Society of Automotive Engineers (SAE) team, representing our college in the MEGA-All-terrain Vehicle (ATV) Championship (2018).