Fractional COO · Quality Transformation Advisory

Turning factories into engines of profit.

Scaling throughput, slashing BOM costs, and building zero-defect, OEM-ready manufacturing plants for growth-stage EMS and automotive electronics suppliers. 30+ years on the shopfloor — not in slide decks.

Request a Shop Floor Diagnostic Audit See Case Studies
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Years leading operations
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Bottom line in 24 months
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Productivity uplift
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On-time delivery
Process Flow
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The Core Value Architecture

Three levers, one operating system.

Durable results come from disciplined systems on the shopfloor, not from reports written about it.

Operational Scale & P&L Governance

Stabilizing high-growth manufacturing through structured capacity planning, vendor development frameworks, and rigorous P&L turnarounds.

Zero-Defect Quality Systems

Embedding world-class PCBA manufacturing quality, SMT line control, and design-to-mass-production APQP/PPAP frameworks into the factory DNA.

Value Engineering (VAVE)

Maximizing bottom-line health through systemic E&E commodity cost optimization, yield enhancements, and localized strategic sourcing.

Waman Mhadeshwar at his desk
About

Three decades of operational leadership at industrial scale.

I've led plants and multi-site operations through some of the toughest transitions in EMS, automotive and electronics manufacturing — from cost-out and quality overhauls to full turnaround programs. My work sits at the intersection of P&L ownership, lean operating systems, and building the leadership bench that sustains change.

As a Lean Six Sigma Black Belt, I bring a hands-on, shopfloor-first approach. I now partner with promoters, CEOs and PE-backed boards as an advisor on manufacturing transformation — profit, productivity, and predictability.

  • P&L and site leadership
  • Turnaround & profit recovery
  • Lean, TPM & Six Sigma deployment
  • Cost, quality & delivery excellence
  • Leadership development at scale
  • Digital & Industry 4.0 readiness
Advisory Services

Where I create leverage.

Focused engagements for promoters, boards and CEOs who need manufacturing operations to deliver — reliably, profitably, at scale.

01 / DIAGNOSTIC

Manufacturing Turnaround

Rapid diagnostic and 90-day stabilization plans to restore profit, cash and delivery in underperforming plants.

02 / SYSTEM

Operational Excellence

Lean, TPM and Six Sigma deployed as a single operating system across cost, quality and delivery.

03 / STRUCTURE

Cost Transformation

Structural cost-out programs targeting materials, conversion, overheads and working capital — with a governance rhythm that sticks.

04 / LEADERSHIP

Plant Head / Interim Ops Leadership

Hands-on interim leadership for plants and multi-site operations during scale-up, transition or crisis.

05 / CAPABILITY

Leadership & Capability Building

Coaching Plant Heads, Ops leaders and shopfloor teams to run the business without you in the room.

06 / READINESS

Digital & Industry 4.0 Readiness

A practical roadmap for MES, OEE, analytics and connected shopfloor — starting from what actually moves the P&L.

Industries

Sectors I've operated in and led.

Deep, hands-on experience across regulated, high-mix and high-volume manufacturing environments.

Contract Manufacturing / EMS
Electronics & Semiconductors
Consumer Electronics
Automotive & Auto Components
Industrial & Engineering
Precision Manufacturing
Institutional Proof Points

The numbers behind the work.

Results from real plants — measured on the P&L, not on posters.

$100M
Apple iPhone 4 camera-module programme delivered at 100% OTIF, zero defects
45%
BOM and defect cost reductions engineered through structured VAVE and sourcing strategy
70 PPM
Quality levels consistently achieved across high-density SMT production lines
$20M
Portfolio turnaround, shifting an operational unit from 8% loss to 5% net profitability
Case Studies

Selected transformation outcomes.

Four engagements, four different levers — the same governance rhythm underneath.

EMS · Turnaround

Loss-making EMS plant to profit in 24 months

Rebuilt the operating rhythm, restructured the cost base and redesigned S&OP end-to-end.

2×
Bottom line
99%
OTD
Automotive · Cost-out

45% cost reduction across a multi-line plant

Deployed lean value-stream redesign, structured VA/VE, and supplier consolidation with a hard governance rhythm.

−45%
Cost base
+38%
Margin
Electronics · Productivity

150% productivity uplift on legacy lines

TPM, line balancing and Six Sigma projects on bottleneck cells unlocked capacity without capex.

+150%
Productivity
$0
Capex added
EV / BMS · Process Decoupling

Tripling BMS test throughput without buying new machines

Split a sequential flash-and-test cycle into two parallel stations — no new equipment, same single operator.

3×
Throughput
₹50L
Capex avoided

Full documentation for this engagement is available below in Case Study Downloads.

Case Study Downloads

Read the source documents.

The full, unabridged write-ups — open in your browser or download to keep.

Executive Slide Summary · PDF

Tripling BMS Testing Throughput Without Buying New Machines

A targeted case study in process decoupling and CapEx avoidance for EV component manufacturing.

View PDF Download
Full Written Report · PDF

BMS Testing Throughput Optimization — Case Study

Complete methodology, financial impact and ROI analysis behind the process-decoupling engagement.

View PDF Download
Experience

A career built on the shopfloor.

Three decades of progressive leadership — from engineer to plant head to trusted operations advisor.

Present
Manufacturing Transformation Advisor
Independent · Board & CEO Advisory

Advising promoters and PE-backed boards on turnaround, operational excellence and Industry 4.0 readiness.

Recent
Plant Head / Head of Operations
EMS & Electronics Manufacturing

Multi-site P&L leadership; doubled bottom line, took OTD to 99%, restructured the cost base.

Prior
Senior Operations Leadership
Automotive & Auto Components

Led lean and Six Sigma deployment across value streams; delivered 45% cost-out and 150% productivity gains.

Foundation
Engineering & Shopfloor Leadership
Manufacturing & Industrial

Built the hands-on operating foundation — quality systems, TPM, line management and team leadership.

Thought Leadership

Writing, speaking & masterclasses.

Keynotes, closed-door CEO roundtables and executive masterclasses on manufacturing transformation and leadership at scale.

Advisory Engagements

Let's talk about your operation.

“Let's identify the operational leaks hurting your margins. If your plant is preparing for an incoming Tier-1/OEM audit, or if scale is exposing quality vulnerabilities, let's schedule a brief introductory call.”

✉ waman.mhadeshwar@gmail.com
☎ +91 98700 26968
● Pune, India
🔗 linkedin.com/in/wamanmhadeshwar