Summary
Overview
Work History
Education
Skills
Websites
Awards
Timeline
Generic

KUCHIMANCHI VEERABHADRA

Production Manager | BIW & Paint Shop Operations | ₹13 Cr+ Cost Savings | Lean Manufacturing Expert
Pune

Summary

Strategic and agile Production Manager with 6+ years of hands-on leadership in BIW and Paint Shop operations within top automotive OEMs. Proven ability to lead with integrity, accountability, and collaboration, while delivering high-impact outcomes in fast-paced, quality-focused environments. Expert in Lean Manufacturing, digital transformation, and cost optimization — driving ₹13 Cr+ in savings through process reengineering and waste reduction. Adept at building empowered teams, embracing change, and taking calculated risks to accelerate performance. Committed to continuous improvement and ready to take on broader strategic responsibilities in a digitally evolving manufacturing landscape.

Overview

7
7
years of professional experience
7
7
years of post-secondary education
3
3
Languages

Work History

Manager, Bodyshop

Mercedes-Benz India Pvt. Ltd.
09.2023 - Current
  • Led BIW operations for six models across three weld lines and two finish lines, delivering approximately 70 units per day with full safety, quality, and takt-time adherence.
  • Reduced weld spatter injuries by 80% through cost-effective welding glove innovation.
  • Conducted 200+ HSE briefings and 50+ safety walks per month, eliminating 35+ unsafe conditions, and boosting near-miss reporting by 60%.
  • Achieved 100% CS1 process adherence through layered training, audits, and operator certification.
  • Resolved ultrasonic and stud breakage defects using 8D methodology, reducing rework by 90%.
  • Eliminated dents and damages by 70% with FRP protective covers, and resolved customer-end leakage issues.
  • Maintained 100% shift adherence with dynamic planning for model mix, layout changes, and volume ramps.
  • Improved manpower flexibility across six lines; supported E-Class ramp-up to 24 per shift.
  • Maintained over 98% equipment uptime through TPM routines and autonomous maintenance.
  • Delivered over 98% on-time body delivery to the Paint Shop, with full FIFO and sequence discipline.
  • Reduced consumable costs through usage optimization, and eliminated DIP part damage.
  • Digitized barcode/job card printing in SAP, removing NVA steps.
  • Recognized shop floor suggestions and handled IR issues during ramp-ups.
  • Built Power BI dashboards for KPI, energy, Red Table, and aging; developed a PowerApps-based heatmap tool.
  • Coordinated with Maintenance and Planning CFT; received international recognition for replacing NVA with digital systems.

Senior Manager (BIW & Paint Shop)

Tata Motors Ltd.
08.2018 - 09.2023
  • Led operations across BIW and Paint Shop, handling new product launches, cost-saving, and digital initiatives.
  • Implemented RDE Signa and Marcus packages; led 1, 5, and 25 prototype builds; resolved BIT issues.
  • Achieved ₹12.5 Cr/year cost savings through DMCR ideas in 1,516 Cowl and Signa platforms.
  • Improved BIW quality through the alignment of design, process, and supplier interfaces.
  • Deployed real-time cabin tracking in the paint shop, increasing productivity by 20%.
  • Salvaged ₹26 lakh in non-moving inventory, and recovered ₹1 crore from obsolete parts.
  • Automated tracking, inventory salvage, and escalation workflows.
  • Projects and Recognitions:
  • Led 8D problem-solving across quality and material topics.
  • Awarded multiple Certificates of Appreciation (Driving Execution, Customer Centricity, Agility).
  • Received a Bronze Certificate of Achievement for exceeding divisional targets.
  • Commended for 150% dispatch performance and spare cabin salvage worth ₹30 lakh.

Education

Mechanical Engineering

National Institute of Technology Raipur
Raipur, India
04.2014 - 01.2018

Intermediate - MPC

Sri Chaitanya Junior College
Kakinada, India
01.2012 - 01.2014

SSC - 10th

Little Buds School
01.2011 - 01.2012

Skills

  • Operations management expertise
  • Body-in-white and paint shop proficiency
  • Lean production techniques
  • TPM
  • Digital Transformation (Power BI, PowerApps, SAP)
  • Cost Optimization
  • Quality Systems (CS1, 8D, BIT)
  • Team Leadership
  • IR Handling
  • SQPDCME
  • Layered Audits
  • Cross-functional Collaboration
  • Automation
  • Collaborative team management
  • Operations management
  • Strategic planning
  • Decision-making

Awards

Certificate of Appreciation – Customer Centricity, 

Certificate of Appreciation – Driving Execution (Cab/Cowl Tracking Project), 

Bronze Certificate of Achievement – For exceeding divisional targets,

 Certificate of Appreciation – 150% dispatch performance (4 consecutive months), 

Certificate of Appreciation – Agility in salvaging non-moving spare cabins worth ₹30 lakh, 

International Recognition – For identifying and digitalizing NVA processes (Mercedes-Benz)

Timeline

Manager, Bodyshop

Mercedes-Benz India Pvt. Ltd.
09.2023 - Current

Senior Manager (BIW & Paint Shop)

Tata Motors Ltd.
08.2018 - 09.2023

Mechanical Engineering

National Institute of Technology Raipur
04.2014 - 01.2018

Intermediate - MPC

Sri Chaitanya Junior College
01.2012 - 01.2014

SSC - 10th

Little Buds School
01.2011 - 01.2012

Similar Profiles

CREATE PROFILE
KUCHIMANCHI VEERABHADRAProduction Manager | BIW & Paint Shop Operations | ₹13 Cr+ Cost Savings | Lean Manufacturing Expert