30 years inside manufacturing — across three continents.

I am Manoj Kumar Ahuja — a mechanical engineer, Six Sigma Black Belt, and Operational Intelligence consultant based in North India.

My career has been built at the intersection of three manufacturing worlds — India, Japan, and Europe — and that cross-cultural depth shapes everything I do.

Early in my career I was selected for Lean manufacturing training in Japan through AOTS, learning Toyota Production System tools not from textbooks but directly on Japanese shop floors. Later, as DGM Quality and Engineering at Spun Micro Processing, I built complete quality frameworks for European automotive customers and made multiple visits to Europe to resolve engineering and quality issues firsthand.

In 2004, while leading Quality and Engineering at Spun Micro, I was selected as Company Coordinator for a UNIDO cluster development programme under ACMA India — a 30-month UN-backed transformation roadmap. This programme took Spun Micro from a family-run small-scale operation to a company aligned with global automotive manufacturing standards. The experience of implementing 5S, Kaizen, Gemba, SMED, and formal employee engagement systems — and then watching them take root and sustain — is what convinced me that operational transformation is fundamentally a people challenge, not just a tools challenge. That belief is the foundation of everything I do today. 

For the past decade I have worked independently — consulting for Indian MSME manufacturers on Lean, Six Sigma, and increasingly on data. That last shift happened naturally: I kept finding that manufacturers had the right instincts but were making decisions without reliable information. This led me to Power BI and Business Intelligence — which I now combine with my operational frameworks to build dashboards that actually drive decisions.

I work with a small number of clients at a time. The work is always customised, always grounded in operational reality, and always focused on one outcome: improving your bottom line.