Operations & Manufacturing Leader with Lean Six Sigma expertise

GANESH SUNDARARAJ

Madison, WI, USA +1-608-***-**** ******.**********@*****.*** linkedin.com/in/ganesh-sundararaj

Professional Summary

Engineer & Entrepreneur with 10+ years of international experience in aerospace system, product design and manufacturing, driving process optimization, system integration, and operational excellence. Proven success in production system design, cost modelling, leading cross-functional engineering teams, and implementing digital transformation initiatives. Skilled in Lean Six Sigma, NPI, manufacturing operations, supply chain systems, and decision analytics. Highly motivated, curious and determined to solve complex challenges in industrial settings creatively optimizing processes and improving operational efficiency.

Education

University of Wisconsin–Madison, USA,

MS Industrial Engineering Systems Engineering & Analytics (2025) GPA: 3.65

Relevant Coursework: Quality & SPC, Facilities Planning, Production Planning & Control, Operations Research, Supply Chain Management, Decision Analysis, Logistics Management, Human Factors

University of Salford, UK,

MSc Robotics and Automation (2008) First Class GPA: 3.4

Anna University, India,

BEng Electronics and Instrumentation (2005) GPA: 3.5

Work Experience

MANAGER Engineering, Manufacturing & Supply Chain Operations 03/2015 to 08/2024

GESAR Displays Pvt Ltd, Chennai, India

Co-founded and scaled electronics display manufacturing startup; grew the team from 3 to 30+ and achieved 300% revenue growth in 3 years, demonstrating strong leadership and cross-functional coordination.

Established the company’s first indigenous production facility, reducing capital expenditure (CAPEX) by 35% through optimized process flow design, equipment selection, material planning, facility planning and layout design.

Led three NPI programs delivering full ePLC deliverable sets including manufacturing line design and setup, material flow design, new tooling and fixture development, standard work packages, and capacity validation — ensuring cost targets and production readiness requirements were met at each gate.

Led manufacturing methods engineering projects including standard work, BOMs, routing sheets. Developed jigs and fixtures (SolidWorks) improving process efficiency, 3D printed prototypes validating manufacturing processes.

Led Industrial Engineering functions including methods engineering, time studies, ergonomic evaluations and workstation redesign, facility layout, capacity planning, supply chain, logistics planning and VSM; provided ROI analysis for project prioritization and delivered 18% productivity improvement across the facility.

Directed Lean Six Sigma continuous improvement programs across the production floor, applying lean methodologies and using statistical SPC tools to eliminate waste and resolve chronic quality and throughput issues improving First Pass Yield; delivered measurable improvements in OEE (61% to 76%), cycle time, takt time adherence, on-time delivery, and per-unit labor cost by 20%. Conducted Kaizen structured problem-solving workshops for process improvements (PFMEA).

Concurrently managed multidisciplinary engineering projects across electronics (PCB design), embedded software, mechanical design (SolidWorks), and industrial automation systems.

Standardized ERP/MES configuration across manufacturing processes, improving data integrity, production tracking accuracy, cost visibility, and process control while reducing IT system costs by 60%.

Built end-to-end business systems across manufacturing, supply chain, and product development (NPD/CPD), developed business cases, operating procedures, and process documentation. Managed 200+ client projects end-to-end, leading design, production, and installation within SLA and cost targets.

SYSTEMS ENGINEER Avionics Software 03/2013 to 02/2015

Airbus Group, Toulouse, France

Developed the A350 Aircraft Battery Management Unit (BMU) software, executing the full SDLC and delivering the project in a record 18 months.

Reviewed software requirements, design documents, and source code to ensure compliance with aviation certification standards.

Led software verification on both target hardware and simulated environments, achieving 90% test coverage through automated testing aligned with DO-178C, DAL-B assurance requirements.

Contributed to product requirements and specifications, participating in design reviews and cross-functional technical discussions. Collaborated with suppliers, performing technical reviews and providing support for tool development work packages.

SYSTEMS ENGINEER Fuel Systems and HMI Level 2 10/2008 to 02/2013

Airbus Group, Bristol, UK

Contributed to multiple A380 Fuel Management System (DAL-B) continuous product development projects, applying the V-model systems engineering lifecycle, MBSE practices, and supplier coordination.

Led model-based systems requirements management and traceability work packages, ensuring alignment across engineering, certification, and operational needs.

Coordinated aircraft-level system integration, including safety and reliability reviews (PFMEA, FTA), maintenance systems, manufacturing engineering/production inputs, and system-level test readiness.

Led Verification & Validation (V&V) activities across simulators, ground tests, and flight test campaigns, ensuring compliance with system performance and certification requirements.

Served 2 years on the Reactive Support Team, resolving global aircraft issues on a 24/7 rotational basis; contributed to significant downtime reduction, preventing airline losses of $20,000 per hour.

Proposed three patentable concepts and dedicated 30% of workload to Airbus Future Projects (R&T), advancing next-generation system innovations.

Selected for the Airbus Future Leaders Initiative, a 21-day interdisciplinary innovation and leadership development program.

Mentored and coached 6 interns and apprentices in systems thinking and engineering best practices.

Other Experience

TECHNICAL SPECIALIST FUTURE CARS LAB Bentley Motors Ltd, UK 05/2008 to 08/2008

Designed and tested real time simulations for future car concepts – cruise control & ABS

RESEARCH ASSISTANT ROBOTICS & ARTIFICIAL INTELLIGENCE LAB University of Salford, UK 01/2008 to 04/2008

BAE Systems Autonomous Unmanned Aerial Vehicle (UAV) system simulation project – ASTREA

Certifications:

Airbus A380 BASE Maintenance Certifying Engineer (T4) Lean Six Sigma Green Belt (Expected by 20 Mar 2026 Project Management Professional (PMP) – In progress

Skills & Competencies

Industrial & Operations Engineering

Process Design & optimization Process Mapping Facility Layout Space Planning Capacity Planning Work Design & Measurement Time Studies (MOST / MODAPTS) Statistical tools (SPC) Control charts Design of Experiments (DOE) ANOVA Root Cause Analysis Value Stream Mapping Value Analysis (VA/VE) Production Planning & Control (PPC) Lean Manufacturing Six Sigma Kanban Kaizen 8D 5S 5 Whys Inventory Management Supply Chain Management Logistics Planning ROI analysis

Systems Engineering

MBSE Requirements Management System Integration Verification & Validation (V&V) SDLC Risk Analysis Supplier Management Cross functional team co-ordination Engineering Analysis

Software & Tools

Python SQL C++ Arena MS Project MS Visio Odoo ERP MS office, Excel, PowerPoint MATLAB, Simulink, Stateflow SolidWorks CAD KiCAD Power BI

Leadership, Business & Interpersonal

Entrepreneurship & Business acumen Leadership Project Management Stakeholder Engagement Budgeting Client Relations Coaching Communication Organizational Analytical Problem-solving Presentation

Additional Information

Languages: English (fluent), Tamil (native), Hindi (fluent)

Extracurricular & Interests:

Active member – Lion’s Club (5 yrs): blood donation, flood relief, girl child education initiatives.

Captain – College and District Cricket Teams (3 yrs); State-level award winner.

Former Department General Secretary – Anna University (2 yrs).

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