Pratik Sonavane

Industry 4.0 consultant with hands-on plant operations experience, specializing in MES-based traceability, manufacturing KPI dashboards, and process optimization for quality and efficiency. I combine an M.Sc. in Industry 4.0 & Management with real-world production leadership to deliver fast, practical results: cleaner data flows, clearer KPIs, tighter compliance, and measurable performance gains on the shop floor.

Background and results

Production executive experience in high-volume manufacturing: improved First-Time-Right by 5%, reduced rejection by 7%, cut cycle time by 10s through time studies and bottleneck fixes, and increased OEE by 4% via KPI cadences and corrective actions. Implemented MES (SATO) for traceability and standardized SOPs/WIs, cutting NCRs by 10%. Led planning across mechanical/hydraulic presses and injection molding with cross-functional alignment (QA, Maintenance).

Operations leadership in logistics: managed shifts of up to 30 staff, standardized inspections, booking, inventory control, and hygiene checks to stabilize service and ensure HACCP compliance. Built team training and daily KPI huddles for faster corrective action.

Thesis: designed a real-time OT/IIoT KPI dashboard concept integrating IoT/MES/enterprise data (SQL/Python/Power BI; OPC UA/MQTT concepts). Features included asset/device baselines, OEE/FPY trends, failure-risk forecasts, and energy/ESG KPIs with threshold alerts, plus adaptive KPI weighting to reduce decision latency. I can adapt this framework to your context pragmatically, even without full IIoT in place.

Tools and skills

Power BI, SQL, Excel, Python

MES traceability (SATO), SOP/WI creation, change control basics.

KPI design (OEE, FPY, scrap, downtime), time studies, bottleneck analysis.

ISO 9001/14001/45001, HACCP (experience); IEC 62443 concepts (familiarity).

English C1; German A1 (improving). Based in Essen; remote or onsite across Germany.