Aswin Sahayarajan

• Designed, developed, and implemented manufacturing processes, equipment configurations, and automated
production/testing systems for a high-volume electronics line, applying a Lean Manufacturinapproach to optimise production
efficiency across multi-shift operations.
• Delivered 20%+ line efficiency gain by re-engineering PLC logic and robotic assembly sequences, reducing cycle time, eliminating
non-value-added process steps, and driving a cost-efficient production setup without sacrificing throughput.
• Supported design for manufacturability (DFM) during NPI and ramp-up — reviewing new product designs against equipment
and process capability, running equipment readiness checks and trial builds, and coordinating the orderly transition and
installation of new processes/methods in line with product specifications, enabling smooth pilot-to-mass-production
changeover with minimal stoppages.
• Acted as first point of escalation for complex technical problems on the production floor — provided guidance and hands-on
support to production and quality teams, led RCA on process losses and yield defects, implemented CAPA, and validated fixes on
the line before they were locked into standard work, eliminating repeat failures and reducing unplanned downtime.
• Maintained 100% audit and quality compliance across SOPs, process control plans, breakdown logs, and equipment/spare-part
records through every process change; coordinated with procurement on equipment/component specifications and supplier
evaluation for spares and tooling.
• Enforced safe equipment and process design practices (LOTO/PTW) and held stop-work authority over non-conforming
activities; trained and mentored technicians and junior engineers, reducing external contractor dependency by ~15-20% while
building sustainable in-house process capability.

• Designed and stabilised process parameters on key production lines as part of a Lean cycle-time reduction initiative, cuting
cycle time by 15% and lifting productivity by 20% while holding product quality within spec.
• Diagnosed and resolved complex equipment and automation faults on automated electrical production lines — PLC logic,
sensors, actuators, and LV control systems — to minimise production loss and keep the line running to specification.
• Reduced breakdown frequency by 10-15% by redesigning preventive maintenance schedules for LV panels, control systems,
and production equipment, feeding equipment reliability data back into process design decisions.
• Coordinated the transition and installation of new/modified equipment during machinery installation and commissioning
projects — verified electrical connections, wiring practices, and safety interlocks met product and safety specifications before
handover to production.
• Reduced workplace incidents by 30% by building safer process and equipment layouts alongside LOTO enforcement and
electrical safety training; maintained full documentation for audits and continuous improvement.

• Operated and maintained electrical infrastructure and systems — transformers, HV/LV switchgear, LV panels, DBs, bus bars, and
circuit breakers — across a major multi-building complex, applying systematic fault-diagnosis and preventive maintenance
practices.
• Monitored transformer load, temperature, and protection systems; coordinated oil testing, servicing, and planned shutdowns to
keep equipment within specification and ensure uninterrupted power supply.
• Led technician teams through the transition and installation of upgraded switchgear and control panel components under
PTW/LOTO, proposing design improvements as continuous-improvement initiatives.
• Maintained daily logs, maintenance records, and test reports to support quality, audit, and compliance requirements.