Digital technology is fundamentally reshaping modern manufacturing. As director of continuous improvement and industrial engineering, Onkar Nerkar is translating Industry 4.0's promise into tangible results, pioneering solutions that combine sustainability, resilience, and agility to meet the demands of next-generation manufacturing.
Industry 4.0, or the fourth industrial revolution, combines cyber-physical systems, the Internet of Things (IoT), and artificial intelligence (AI) to create smarter, more responsive production environments. This convergence is turning traditional manufacturing into intelligent, self-optimizing operations. For Onkar Nerkar, Industry 4.0 embodies a philosophy and a technology suite, fostering an adaptable framework for future growth.
"In manufacturing, resilience and agility are immensely crucial," he reflects. "Technology offers the tools, but we can lead change that brings those tools to life."
A Career Built on Transformation
Onkar Nerkar has decades of experience in industrial engineering and supply chain management, starting in India with a focus on manufacturing operations. His career includes leadership roles at Cummins Technologies and Alfa Laval India, and he currently works at Wieland Group in the U.S., where he is driving technological advancement and operational excellence.
His innovative work on greenfield supply chain projects and early-stage Industry 4.0 applications set new standards for digital integration in Operations. His tenure further refined his expertise through leading-edge manufacturing technology and process optimization projects, emphasizing business growth, profitability, and sustainability in a global setting.
Today, at Wieland Group, a multinational focused on copper and copper alloy products, Onkar Nerkar leads continuous improvement strategic initiatives and implementation of advanced industrial engineering methods. His comprehensive approach encompasses smart manufacturing, operations intelligence, and embedding a change-centric culture within the company. "Each position I've held has reinforced my belief in one thing: continuous improvement is not just a process; it's a mindset," he says.
A Holistic Approach
For Onkar Nerkar, Industry 4.0 involves a holistic approach to making manufacturing smarter and more sustainable. He focuses on integrating IoT and data analytics into predictive maintenance, using real-time monitoring to reduce downtime and enhance asset performance. This strategy anticipates equipment issues and supports decision-making throughout the supply chain.
"Data is powerful, but only if we know how to use it," he observes. By reducing unplanned disruptions and increasing equipment uptime, his team has cut costs and extended the machinery's life cycle. He also champions "footprint optimization," a strategy he uses to redesign production layouts to reduce waste and energy consumption.
"Efficiency and sustainability can go hand in hand," he asserts, emphasizing that operational savings align with environmental gains in his model.
Advancing Sustainability Through Operations Excellence
Today, sustainable practices are a hallmark of forward-thinking manufacturing. Onkar Nerkar has driven waste reduction, resource optimization, and eco-friendly processes that align with modern environmental standards through lean and agile operational methods. During his large span of career, he has implemented protocols that address quality issues early in the value stream to minimize customer claims and streamline the entire supply chain's carbon footprint.
"Sustainability is as much about the processes we create as it is about the products we deliver," he explains. This ethos permeates his work with a cultural shift toward continuous improvement that ensures environmental goals and operational benchmarks.
Thought Leadership in Industry 4.0
As an early adopter of Industry 4.0, Onkar Nerkar uniquely blends practical experience with thought leadership. He believes true digital transformation fosters a culture open to change and emphasizes the importance of training and change management in adapting to digital-first operations.
"Industry 4.0 is as much about people as technology," he says. Through initiatives at Wieland, he has applied tools like IoT and AI and cultivated a workforce capable of utilizing these technologies effectively.
Shaping the Future of Manufacturing
Onkar Nerkar's influence continues to expand as he leads the digital transformation journey. His cohesive approach to Industry 4.0 combines technical excellence with strategic vision, creating systems and developing talent that will define the future of manufacturing. Under his guidance, the team is building a manufacturing framework that emphasizes innovation and sustainability.
"Real progress means creating resilience and sustainability that lasts," he says, embodying his commitment to building a smarter, more responsible manufacturing industry. Through leadership, Onkar Nerkar is setting new standards for what modern manufacturing can achieve, proving that with the right vision, technology, and sustainability, they can work hand in hand to create lasting value.
