SAI SHANKAR KARRA

· Spearheaded a Kaizen event, collaborating with cross-functional teams to streamline operations of new product manufacturing to identify bottlenecks and achieve a 10% cost reduction.

· Utilized root cause analysis (RCA) to troubleshoot recurring process issues, leading to a significant reduction in defects and rework.

· Developed and implemented centerlining techniques to standardize key process parameters and documented the procedures, parameters and tolerances for reference and training purposes of technicians.

· Developed and standardized work instructions and SOPs, enhancing consistency and reducing process variability by 25%.

· Led multiple Six Sigma and continuous improvement projects that optimized the manufacturing process that helped in reducing cycle time and increasing the output to meet increased production targets due to customer demand.

· Performed safety audits on equipments to identify hazards and conducted PHSR (Pre-Start Health and Safety review) with help of contractors to identify safety loopholes and suggested changes accordingly.

· Led process validation and verification activities, ensuring new processes met all performance and quality standards before full-scale implementation in collaboration with R&D and Quality control teams.

· Created and assigned over 500 work orders in the CMMS), ensuring timely and accurate distribution of maintenance tasks to technicians, resulting in a controlled reduction in equipment downtime.

· Coordinated with maintenance supervisors to prioritize work orders based on urgency and impact, effectively balancing workload and ensuring critical issues were addressed promptly.

· Monitored the progress and completion of work orders in the CMMS, providing regular status updates to management and ensuring adherence to maintenance schedules.

· Analyzed work order data to identify recurring issues and implement preventive maintenance strategies with a target in reducing the frequency of emergency repairs and later document them in SOPs for training purposes.

· Developed and maintained project schedules using MS Project, ensuring all milestones were met and delivering projects ahead of schedule.

· Led the team of 10 industrial electricians, 5 millwrights, 5 maintenance technicians and contractors for installation and commissioning of new production equipment in the process of upgradation of technology for new product change.

· Handled multiple product change projects by converting machines from 5 busbar to 9, 10 and 16 busbar production of solar modules by leading the mechanical, electrical and process changes and developing standards to meet quality requirements before large scale production.

· Trained technicians on the troubleshooting of equipment’s on day-to-day manufacturing issues and new product and process changes.

• Coached newly hired employees and interns while observing progress and delegating tasks.

• Ensured compliance with safety regulations and protocols during all maintenance activities
• Quickly responded to equipment malfunctions, performing troubleshooting to identify and resolve issues effectively
• Communicated effectively with supervisors and team members to provide updates on maintenance activities and equipment status
• Diagnosed and repaired mechanical issues in manufacturing equipment, ensuring minimal downtime and efficient operation
• Conducted routine inspections of systems and equipment to identify and resolve issues promptly
• Utilized Computerized Maintenance Management System (CMMS) for tracking work orders, maintenance schedules, and equipment history.