Swamy Prasad Varanasi
Plant Manager Cummins Clean Fuel Technologies, Roanoke, Tx @Cummins Inc.
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WORK HISTORY
Plant Manager Cummins Clean Fuel Technologies, Roanoke, Tx @Cummins Inc.
Roanoke, TX, US
CNG Fuel Systems Manufacturer |$100M+ Revenue | 150+ EmployeesRole Summary:Lead full-plant operations for a complex CNG fuel systems manufacturing facility, overseeing Assembly, Fabrication, Manufacturing Engineering, Quality, Supply Chain, and Logistics. Drive strategic growth, digital transformation, and continuous improvement to position the plant for a 2.5X revenue expansion by 2027.Key Achievements:Capacity Expansion & Flow Optimization: Transformed plant from batch builds to 4 streamlined assembly flow lines, boosting throughput without additional headcount.5X Fabrication Capacity Increase: Led $10M investment in automation—including laser cutters, press brakes, robotic welders, and tube bending cells.Strategic Supply Chain Resilience: Reduced risk through dual sourcing, vertical integration, and a $23M tech transfer project from Germany.Productivity & Innovation: Cut assembly time for key new product by 50%(31 to 15 hours) using advanced DFM principles.Cost Savings: Delivered over $1.0M in material cost savings via direct sourcing and continuous improvement projects (2023–2024).Margin Improvement: Led product cost reduction initiatives that increased net margin by 10% through cross-functional collaboration.Plant Growth & Expansion: Spearheaded sq. ft. facility expansion; planning further sq. ft. growth by 2026.Workforce & Culture Development: Built and mentored high-performing teams across engineering and operations, increasing hourly retention by 30%.Safety & Morale: Elevated plant safety culture and employee engagement through transparent leadership and on-floor mentoring.Quality & Compliance: Successfully achieved ISO 9001 certification in 2023 and led follow-up Surveillance Audit in 2024.Digital Transformation Roadmap: Designed and implemented comprehensive Manufacturing IT strategy including ERP overhaul, MES, SCADA, and 3DX MPP.
EDUCATION
Dayalbagh Educational Institute
B. Sc. Engineering, Mechanical Engineering
Harvard Business School Online
Certificate, Accounting and Finance
ABOUT SWAMY PRASAD VARANASI
I’m a manufacturing and operations leader with 27+ years of experience driving transformation across global industrial, automotive, and clean energy sectors. From launching greenfield facilities across Asia and North America to leading full-plant turnarounds in high-stakes environments, I specialize in building systems, teams, and strategies that scale.Currently, I serve as Plant Manager at Cummins Clean Fuel Technologies, leading a $100M+ CNG systems facility positioned for rapid growth to $250M+. I’ve delivered record-breaking outcomes by transforming batch production into lean flow lines, expanding fabrication capacity 5X, implementing digital manufacturing systems (ERP, MES, SCADA), and leading cross-functional teams through complex supply chain, quality, and product cost challenges.Previously, I’ve held global and corporate roles in Manufacturing Engineering, Program Direction, and Digital Transformation—leading teams that executed over $250M in capital projects, authored corporate standards, and rolled out innovations adopted enterprise-wide.What I bring is an engineer’s rigor, a builder’s mindset, and a leader’s perspective—the ability to bridge shop-floor realities with strategic goals, whether that\'s improving net margin by 10%, cutting WIP by 38%, or helping develop fuel cell and electrolyzer technologies from prototype to mass production.I thrive in environments where technology, people, and process intersect—and I’m always looking to connect with others who are shaping the future of smart, sustainable manufacturing.
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