Driving Operational Excellence through Digital Transformation.

Process & Industrial Engineering Professional with over 10 years of experience in Automotive and Heavy Machinery production.

Industrial Engineering | Automotive Process & Production Planning | Project Management | Lean Management | Operational Excellence | New Product Integration & Assembly Line Balancing | MTM C-Werte

10+ Years Experience
50+ Lean CI Workshops
7-Figure Annual Savings
Mairpady Adithya Rao

Professional Experience

Consultant Process & Industrial Engineering

Jan 2021 — Present

solvenext GmbH | Düsseldorf, Germany

Projects for Mercedes-Benz AG – Sprinter Vans

  • Cost Optimization: Delivered seven-figure annual savings through data-driven KPI frameworks and optimized workforce planning.
  • Process Expert: Subject Matter Expert for ILB & MTM, conducting 1000+ process validations.
  • Digital Transformation: Facilitated the shift to Digital SOPs, 3D Material Zone Plans, and GeoAP visualizations.
  • Line Balancing: Managed NPI & EOP integration, ensuring seamless transitions via Lean line-balancing.

MTM Process Engineer

Mar 2019 — Jan 2021

Mercedes-Benz AG (via Hays) | Düsseldorf, Germany

  • Assembly Optimization: Standardized workflows using MTM (C-Values), work sampling, and spaghetti diagrams.
  • Lean Leadership: Drove process improvements in 30+ New Lean Concept (NLC) workshops.
  • Efficiency: Reduced eHPV and Drift through mix-model analysis and workstation assessments.

Production Planner

May 2017 — Feb 2019

EDAG Production Solutions | Sindelfingen, Germany

  • New Model Launch: Led digital verification and manufacturability studies for the Mercedes-Benz SL R232.
  • Resource Planning: Evaluated module concepts for make-or-buy decisions and planned assembly resources.

Werkstudent & Intern

Oct 2015 — Mar 2017

Mercedes-Benz AG | Sindelfingen, Germany

  • IIoT & Data: Developed Industrial IoT architectures (OPC-UA, MQTT) and real-time dashboards using PowerBI.
  • Digital Validation: Performed CAD verification of joining sequences for Body-in-White using DELMIA.

Design Engineer

Jul 2012 — Aug 2014

Cyient Limited | Bengaluru, India

  • CAD Engineering: Spearheaded 3D modeling and 2D-3D conversion for heavy machinery using Siemens NX.
  • Quality Assurance: Applied FMEA and DVPSOR for Terex cranes and boom trucks.

Expertise & Skills

Lean Manufacturing
MTM / ILB
Line Balancing
Digital Transformation
Siemens NX / DELMIA
IIoT (MQTT, OPC-UA)
PowerBI / Data Analytics

Languages

English Native
German Professional
Hindi Fluent
Kannada Native

Driving License

EU Category B

Education & Credentials

M.Sc. Production Systems Engineering

2014 — 2016

RWTH Aachen University | Aachen, Germany

Dean's List 2014-2015

Named for Excellent Academic Performance (Top 5 percentile)

B.E. Mechanical Engineering

2008 — 2012

VTU | Bengaluru, India

Distinction

Projects

Master Thesis Project

Apr 2016 — Oct 2016

FIR an der RWTH Aachen

Theme: Application of control engineering principles to the Production Planning and Control for Industry 4.0

Derived concepts for production cells using real-time feedback data to obtain optimum production plans in Industry 4.0 environments.

Bachelor Thesis Project

Jan 2012 — July 2012

Visvesvaraya Technological University

Theme: Microstructure & Mechanical Properties of Friction Stir Welded Aluminum Alloy 6061 and Silicon Carbide Metal Matrix Composites

Certifications

Project Management Professional®
Lean Six-Sigma Green Belt
SAP ERP (TERP10)
Automobile Servicing and Maintenance Technology

Interests & Hobbies

🏃‍♂️ Running & Triathlon
🏏 Cricket
🏔️ Hiking
🌍 Travel
🍳 Culinary Enthusiast

Get in Touch