Roshan Mani Rao R

Roshan founded TvastrOps to bring the engineering discipline of US manufacturing to Indian warehouses and factory stores. Hyderabad is his home and a fast-developing industrial hub; he started TvastrOps here to help the city's warehouses and factories develop, and to grow along with them. He holds an MS in Industrial Engineering (Operations Research) from Purdue University with a 4.0 GPA, and is a certified Lean Six Sigma Black Belt.

As implementation engineer and operations consultant with Quantumlytix at a Fortune 500 manufacturer's largest engineer-to-order site, he redesigned a warehouse that had to feed three business lines with different pace, product mix and ways of working. He designed the 31,000 sq ft, $2.5M layout in AutoCAD, with racking customized and standardized to hold active stock, excess and obsolete stock and WIP in a confined footprint, very narrow aisles and high racking cleared with EHS, aisle clearances negotiated down with vendors, and vertical carousels for job-specific parts that had been going missing. Tested in AnyLogic simulation, the construction-ready concept needs 40% less projected space. He built the business case and stage-gate plan to move a $20M product line to another facility to free the floor, and on the same program labor utilization rose from 24% to 40%, average daily material shortages fell from 52 to 15, and defects per unit dropped 30% in two months.

Before that, at Lowe's, he automated the analysis of $110M in stagnant inventory and supported an improvement in inventory turns from 3.7 to 4.0. At Tredence he built 21 predictive analytics use cases that supported more than $13M in lost-sales recovery for a major retailer.

His approach is straightforward: walk the floor, measure the constraint, test the options before money is spent, and stay with the team until the change holds on live shifts.