Hello, I'm

Mehul Wadhavekar

Trainer | Operational Excellence

Lean Six Sigma practitioner driving continuous improvement through training, process engineering, and data-driven problem solving.

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About Me

I'm an Operational Excellence Trainer with a focus on Lean Six Sigma and internal training programs in production environments. Currently at Tesla in Berlin, I design and deliver LSS training programs, facilitate problem-solving workshops, and drive measurable improvements on the shop floor.

With a background in process engineering at companies like Medtronic and W. L. Gore, I bring hands-on experience in automation, root cause analysis, and continuous improvement. I hold a Master's in Engineering Management and am passionate about empowering teams to work smarter.

3+ Years Experience
136+ Trainees
40+ Improvement Projects
M

Experience

Trainer — Operational Excellence (Lean Six Sigma)

Mar 2025 — Present

Tesla, Berlin

Built and delivered the internal Lean Six Sigma White-Yellow Belt program (17 sessions, 136 participants) resulting in 40+ completed improvement projects and 170+ ideas from Gemba exercises. Insourced Excel training (Basics & Advanced), saving €139,000/year in external costs. Co-trained 4 Yellow Belt and 2 Green Belt cohorts, delivering 350+ hours of Lean training including 5S workshops, problem-solving sessions, and shopfloor management. Developed and launched a Root Cause Analysis training offered twice per quarter.

Process Engineer

Oct 2024 — Feb 2025

PanTrac GmbH, Berlin

Introduced a new cutting technology to fully eliminate accident risk in the manual cutting of carbon parts. Redesigned production processes through IT infrastructure updates, saving 30 minutes of daily setup time. Evaluated machine performance and cost-effectiveness to improve safety, throughput, and costs in series production.

Process Engineer

Aug 2023 — Aug 2024

Medtronic, Deggendorf

Led automation projects for capacity increase and cost reduction. Analyzed process performance and derived improvement measures. Built and optimized material and information flows to reduce lead times. Created Power BI dashboards for performance monitoring and supported project portfolio management.

Footwear R&D Intern

Oct 2022 — Mar 2023

W. L. Gore & Associates, Feldkirchen-Westerham

Conducted 3D prototyping and user studies to optimize new shoe designs. Determined process windows and optimized production processes for waterproof footwear. Developed and implemented test procedures to ensure product quality.

Education

M. Eng. Engineering Management

IU International University of Applied Science

Mar 2021 — Jul 2023

Focus: Product Development, Industry 4.0, Performance Management, Quality Management

B. Eng. Mechanical Engineering

University of Mumbai

Aug 2016 — Feb 2021

Focus: Production Planning, Industrial Automation, Design, PLM

Projects

Project PACE

Achieved 65% reduction in packaging area downtime (2.5 h → 50 min) through root cause analysis and targeted technical measures, significantly increasing capacity and efficiency.

Root Cause AnalysisDMAICLeanApr 2024

Project AME

Planned and evaluated a $1.2M pilot project for automating packaging with collaborative robots (cobots), enabling the transition from manual to autonomous systems.

AutomationCobotsFeasibility StudyMar 2024

SMED / VSM / Kanban Implementation

Introduced SMED, Value Stream Mapping, and Kanban in injection molding production, driving a 33% improvement in quality and significant efficiency gains.

SMEDVSMKanbanJun 2023

Automated Testing Method

Developed a test method for automating machines in shoe production, leveraging statistical analyses to optimize process efficiency and ensure consistent quality.

Statistical AnalysisProcess OptimizationJan 2023

Skills

Methods

Lean Six Sigma (Green Belt) DMAIC A3 5S SMED

Tools

Excel PowerPoint Power BI Visio SharePoint MS Forms

Software

SolidWorks CREO MS Office 365

Languages

German English Marathi Hindi

Get In Touch

I'm currently open to new opportunities and always happy to connect. Whether you have a question, a project idea, or just want to say hello — my inbox is open.

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