Manager Manufacturing

BALDEV K. VOHRA

*** ******* ***** • Santa Rosa, CA 95404

Home: 248-***-**** • Cell: 248-***-**** • abntfq@r.postjobfree.com

To Whom It May Concern:

I understand that you are in need of an experienced Lean and operations expert with

international experience and a proven record of executing and transforming processes and

manufacturing operations by using lean strategies to improve productivity, efficiency and quality

while cutting costs. If so, I hope you will find the attached résumé interesting.

As a Lean expert with General Motors Corporation and Lean Consultant with Mercedes-Benz

Corporation, I led the implementation of Toyota Production System (TPS) type processes within

North American and international operations. Some of my accomplishments in this role include:

Improved resource planning in Mercedes-Benz to improve productivity and quality

using Lean tools

Led implementation of lean principles from planning to start-up phase of global

plants in Germany, Poland, China, Argentina, Thailand and Brazil

Implemented lean measurables globally, leading successful initiatives in Germany,

Spain, Belgium, UK, Portugal, Sweden and Australia – with savings of $50 million and

drove 30% increase in resource utilization (man, machine and material)

Led standardization of the vehicle design process resulting in 28% cost reduction and

a significant improvement in lead time.

Cut time-to-produce-vehicles from 48 to 31 months by implementing standardization

and value stream mapping.

Trained engineers and senior managers in lean principles resulting in implementation

and use of lean methods with minimal disruption.

Worked on major initiatives to standardize GM’s global processes.

These success stories are evidence of the value and results I can bring to an organization

seeking profitable business growth.

In brief, I am an accomplished lean expert with broad-based experience in Toyota Production

System, Lean processes (manufacturing & non manufacturing) and measurable

implementation, delivering multimillion-dollar profit gains, global standardization, waste

elimination/cost reduction, value stream mapping, process improvement and training.

In the current challenging business environment, I know that I can add great value to your team.

I would appreciate an opportunity to discuss the possibilities of contributing to your organization.

Sincerely,

Baldev K. Vohra

BALDEV K. VOHRA

505 Jenifer Court • Santa Rosa CA 95404

Home: 248-***-**** • Cell: 248-***-**** • abntfq@r.postjobfree.com

LEAN SYSTEM EXPERT / SENIOR OPERATIONS MANAGER

Drives Productivity, Efficiency, Quality and Cost Improvements, including Multimillion-Dollar

Savings, Within National and Global Operations of Fortune 5 Corporation

20+ years’ experience as a lean systems expert with ability to drive worldwide lean initiatives, deliver

multimillion-dollar profit gains and contribute to top-performing manufacturing operations. Recognized

by senior management for innovative, cost-conscious approach to production improvement. Skilled lean

change agent communicator and leader. Excellent strategic planning, implementation of lean and six

sigma strategies, value stream mapping, and project/program management skills, including leadership of

cross-cultural teams. Trained in Toyota Production System (TPS) at NUUMI plant in California and by

Japanese suppliers. M.S. from Rensselaer Polytechnic Institute with 4.0 GPA.

Specific Skill Areas:

PROFESSIONAL EXPERIENCE

MERCEDES-BENZ CORPORATION, Stuttgart, Germany (2006-2007)

Senior Lean Consultant

Improving shop floor lean management including internal processes, productivity, quality and logistics

between different plants and suppliers.

GENERAL MOTORS CORPORATION, Detroit, MI (1974 -2006)

Built distinguished record of achievement and advancement through increasingly responsible positions,

demonstrating excellence in lean manufacturing process design, development and implementation within

U.S. and global operations.

Senior Manager (2003-2006) – U.S.A

Developed and established standardized processes for existing programs; reviewed and facilitated

standards for future initiatives. Trained engineers and suppliers in lean principles

Challenges: Absence of lean principles within North American operations and existence of strong

“mass production” mindset resistant to change. Excessive waste and costs caused by lack of

standardization. Processes across various regions of GM lack commonality (Europe, Latin

America, Asia, North America).

Process Standardization – Guided standardization of processes, reducing layout budgets by 28%

(from $1.2 million+ to $880,000) and decreasing lead-time by several weeks.

Lean Measurement Implementation – Created lean measurables to monitor processes, resulting in

30% increase in both manpower and robot utilization

Shop Floor Transformation – Identified and implemented shop floors improvement in man, machine

and material aspects. Achieved higher productivity and quality on floor

Lead Time Reduction – Reduced time-to-produce-vehicle significantly using value stream mapping

Global Unification – Created common process across all regions of GM to be a global company

BALDEV K. VOHRA – PAGE 2

505 Jenifer Court • Santa Rosa, CA 95404

Home: 248-***-**** • Cell: 248-***-**** • abntfq@r.postjobfree.com

Manager, Lean Body Systems (1994-2003) - Germany

Directed Toyota Production System (TPS) type processes within 4 new worldwide plants (Poland,

Thailand, China and Argentina). Created and applied lean measurables, including

manpower/station/robot/space utilization, lead time, and automation ratio, to drive high-investment

efficiency goals. Oversaw 14-step standardized process for global planning engineers; trained engineers

in lean principles, lean measurables, and Kaizen workshops and thus changed their thinking.

Challenges: International, cross-functional teams presented cultural and technical challenges.

Lean Process Implementation – Implemented lean measurables in all future programs within

European plants including engine plants, leading to 30% resource utilization, 60% robot optimization,

and $50 million in overall savings.

Workforce Development – Created lean training program for engineers and workers in Russelsheim

plant, resulting in implementation and use of lean methods with minimal disruption.

Operations Leadership – Provided leadership for new worldwide GM plants in Argentina, Poland,

Thailand, and China involving design and processing within body shops.

Cross-Organizational Processes – Created processes to accommodate European design car in North

American facility at low investment.

Performance Recognition – Received commendation from CEO for improvement in investment

efficiency and cost reductions from implementation of lean manufacturing measurables in Europe.

Senior Project Consultant (1983-1994) - USA

Served as key member of several teams and initiatives, including Flex 2000 manufacturing team, GM

Manufacturing Technical Council, Japanese consortium and Power Train Group, to meet lean

manufacturing improvement goals.

Challenges: General Motors lacked common standardized practices and mfg. requirements.

Gained in-depth understanding from Japanese consortium of the Kaizen approach to product and

process improvement, leading to 15% increase in resource utilization.

Completed lean engine plant layout with emphasis to Quality, processing, studies of flexibility vs.

dedicated machinery systems, cost estimates for China Engine Plant, and engineering support for

overseas operations.

Manufacturing Planning Specialist (1974-1983) – General Motors do Brasil

Responsible for advance planning and implementation of Lean processes, engine programs and

improving efficiency in plants in Brasil.

EDUCATION & CREDENTIALS

Master of Science in Management of Technology - G.P.A 4.0

RENSSELAER POLYTECHNIC INSTITUTE – Rensselaer, NY

BS (Mechanical Engineering)

Languages: Speak Portuguese, Spanish, German and several Asian languages

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