Bhavesh Shah

Senior Operations Manager | Lean Six Sigma

Salary / Daily rate

Amsterdam, Netherlands

Freelance, open to permanent contract

Can come onsite

Skills

Project Management (PMO)ERPSAP ERP

Languages

English (Native)Gujarati (Native)Hindi (Native)DutchLithuanian

About me

Intro

Strategic Operations & Transformation Leader | Supply Chain Architect | Lean Specialist | Consultant I am a globally experienced operations executive with 25+ years leading transformation across supply chain, manufacturing, and business operations in high-stakes environments — from Fortune 100 companies like Caterpillar and Johnson Controls to innovation-driven leaders like Cummins and Hiab. Armed with a Master’s in Industrial Engg and a Six Sigma Green Belt. I turn complexity into clarity.

Links

Work experience

Global Operations Manager

Hiab

May 2021 - Oct 2024

3 years 6 months

Meppel, Netherlands

Hiab employs over 2,000. Leader in truck mounted crane and hook attachments. Installation is one of the biggest services divisions. Key Accomplishments: • Global P&L (10M) responsibility for Hiab Crane and Demountables installations in services department. Turn around installation in to profit making model. Transform from service organization to operations organization with focus on working capital and leadtime reduction. Standardize operations across different operating models. • Design and implement order to invoice process for installations. Integrated process industrialized order creation, order and resource planning as well as execution. Pilot in Meppel site, cascade methods, tools to other CSCs. Transition to SAP PP module with production manufacturing structure. Generated 7.5% GM impact with cost out worth 450K. Lead time from equipment arrival to invoice improved by 38%. • E2E order visibility to improve communication, decision making among various supply chain functions. Reduce inventory by 5M. Change required from optimizing capacity at the manufacturing plants to optimizing order flow.

New Product Launch Manager

TMC (for Cummins Inc)

May 2020 - May 2021

1 year 1 month

Roermond, Netherlands

CES employs over 2,000. Center of innovation in clean technology development. Key Project Accomplishments: • Industrialization of New Catalytic Converter: Facilitated launch and industrialization process of catalytic converter for key customer DAF trucks. Lead liaison between tier 2 supplier Faurecia and CES. Led cross functional team of quality, engineering, product management, materials and procurement to ensure material flow was established, quality plans and processes were documented and maintained, production processes were established and documented. Follow continuous improvement methodology to drive production improvements and ramp up production. Reduced scrap from 10% to 1%. Improved Right First Time (RFT) from 0% to 90% on key processes and ramped up production from 10 units per week to 200 per week with capability to meet future demand of 200 units per day.

Johnson Controls

Nov 2014 - Mar 2020

5 years 5 months

Enschede, Netherlands

Continuous Improvement Manager

Jul 2018 - Mar 2020

1 year 9 months

Enschede, Netherlands

Business Partner for EMEA Distribution Centers. Part of Site Management Team. Promoted and transferred to Netherlands to lead JCMS continuous improvement system deployment, conduct training and promote best business practices across global operation. Conduct network foot print analysis. Develop business case for consolidation, sourcing or expansion Key Project Accomplishments: • CI System Deployment and Initiatives: As a business partner and change agent led teams at different locations across Europe. Coach and train on key principles of lean methodology as well as CI culture (Kaizen, VSM, Simple Problem Solving, 5S, Gemba Walk, Root Cause Analysis, Visual Factory, TPM) to sustain improvements over years. Led the team that won Chairman’s Merit Award. One of the highest acknowledgements of achievements. Standardized KPI measurements across warehouses in the region. Set cadence for CI projects tracking and measurement. Each site generated 100-150K USD first year of implementation. Implement CI project to conduct freight rate shopping using software ProShip. Resulting in €700K savings per year.

Senior Manager Supply Chain Management

Nov 2014 - Jul 2018

3 years 9 months

Lansdale, PA 19446, USA

Changed industry to broaden experience and have exposure to highly regulated product requirements. As company evolving from holding company to strategic company, led collaborative efforts for critical future Foot Print Consolidation as well as Supply Chain Optimization efforts in China, Europe, Middle East and US. Key Project Accomplishments: • Supply Chain Optimization: Led collaboration across crossfunctional team to standardize and optimize supply chain for Fire Suppression Products. Team size varied from 6 members to 22 members. Followed Total Cost of Ownership model in SC to show need for investment in new site/equipment vs strategic placement of inventory in various regions. Analysis included End to End (E2E) demand and supply analysis (S&OP), Make/Buy considerations, options compared on strategy, timeline, cost and risk assessment. • VA/VE Projects (NPI): Savings ranged from 300K to 1.2M in annual operating cost. Sites involved were in US, EME and China. Led multi-function team to upgrade China Certification Center for Fire (CCCF) & Tianjin Fire Research Institute (TFRI) certification for pressurized fire suppression product systems. 2yr effort to setup complex supply chain between US and China. Collaborate with local advisor, engineering team in UK as well as US and operations in China to successfully pass documentation and testing requirements. Operationalize new supply chain with Supplier Lifecycle Management, Demand Planning, Materials Mgmt as well as Production Phase. This project enabled revenue growth by 40% in first year.

Global Implementation Manager

Caterpillar Parts Department

Jun 2008 - Oct 2014

6 years 5 months

Morton, IL, USA

Promoted to Logistics Division to preside over business-critical projects and act as strategic thinker in planning future developments. Led 3rd party logistics (3PL) efforts for companies such as Manitowoc, Baker Hughes in UAE, Mazda and AutoZone in Brazil. Key Project Accomplishments: • M&A and Divestiture Project: Supplied leadership and oversight of 42 cross-functional team members preparing the 3rd party logistics business to stand up independently and be sold. Enabled sale of company at high value in 15 months. • Mentoring and Training: Mentored and trained new Program Managers on key aspects of LNPI program launch as well as stakeholder expectation management. Coached on preventative methods to keep program on time and to the budget (Scope, Resource, Timeline, Budget, Risk Management). Proactively understand and manage implementation risks. How to be effective change agent and manage change during transitions. Criticality of scope management with customer relationship. Sensitivity with presentation and communication of reporting. • Ocean Freight Consolidation-Deconsolidation Center: Led team comprised of IT system administrators, the Ocean Transportation Group, DHL, CEVA and other freight forwarders to set up this key client center, projected to realize $4.5MM savings in supply chain network optimization due to consolidation of ocean containers and a reduction in the overall # of containers. Stepped up to complete operation on time, despite challenges of creating a system where none had existed and ensuring the client’s global location requirements were supported. • Core and Common Warehouse Processes: Developed a material flow Value Stream Map (VSM) for fabrication, assembly and warehouse processes and identified quality/cost savings in material flow and warehousing. Increased location accuracy to 95%, emergency order fill to 98%, reduced IB to storage time by 50%

Caterpillar Inc.

Jul 2000 - May 2008

7 years 11 months

Joliet, IL, USA

Manufacturing Engineering Supervisor

Oct 2006 - May 2008

1 year 8 months

Joliet, IL, USA

Promoted to oversee team of 11 manufacturing engineers, consultants and onsite/offsite technical support service engineers managing various Value Streams for hydraulic system division. Supervisory Role Accomplishments: - Empowered and mentored manufacturing engineers, improving engagement from 63% to 87%. Achieved accountability by setting realistic but challenging goals and checkpoints to measure progress. - Provided guidance on succession planning as well as performance evaluation. Conducted business requirement analysis for staffing needs and determine skill set needs.

Sr Manufacturing Engineer / Project Manager

Jul 2000 - Oct 2006

6 years 4 months

Joliet, IL, USA

Six Sigma Project Accomplishments: • New Product Introductions: Led team of product engg, manufacturing engg, quality engg, Metlab spcl, Purchasing and Procurement Spcl, Supply chain Spcl and Bus Resources to develop program plan for new product introduction. Successfully launched more than four completely new product line, more than 50 product improvement initiatives. Most of the initiatives were concurrent and at various stages of product launch. Deliverables were detailed PFMEA, Quality Plan, Process Plan, Demand Plan, Training and KPI Measurement Plan. • Hydraulic Cylinder Area Transformation: Took initiative to streamline the fabrication and assembly area, increasing daily throughput from 245 cylinders to 305 cylinders. Performed a detailed analysis of processes and material movement (VSM). Developed business case for capital requirement in justification with IRR and ROI targets. Procured, tested & installed new equipment and automated the material handling system. CMI Team Project Leader Accomplishments: • Directed team in capacity planning and system efficiency analysis. Proposed change of separating high volume standard size parts and grouping them to reduce changeover on the bottleneck machine. Worked with operations team to standardize Key Performance Indicators in People, Quality, Velocity and Cost. • Lean Manufacturing Implementation: Introduced use of Lean Manufacturing concepts in the Hydraulic Cylinder area, reducing in-process inventory from $933K to $279K & improving delivery from 60% to 100%. Process Planning Accomplishments: • Drove safety optimization efforts by performing safety audits, implementing OSHA & ANSI-RIA guidelines. • Teamed with Supplier Development Group to rapidly bring new suppliers online using APQP-PPAP.


Education

ROC van Twente

Certification

2025 - 2026

1 year 3 months

Oklahoma State University

Master of Science - MS

1998 - 2000

2 years 1 month

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