Transforming operations, in the manufacturing parlance, into sustainable growth engines by constant optimization, is a herculean task. Yet, that is the mission which Kapil Dev Singh Rawat took on himself. “I love it. The mission of ‘plant turnaround powered by manufacturing optimization.’ I have always been driven by the challenge of turning complex operational puzzles into well-oiled machines.” There’s something deeply satisfying about optimizing processes, boosting efficiency, and seeing tangible results in safety, quality, and cost, he says.
A plant and production operations leader, Kapil strives for manufacturing excellence and cost optimization by driving operational efficiency and growth. With over 21 years of solid experience in plant operations and manufacturing leadership at companies like Videocon, Samsung India, Eureka Forbes, IDEMIA, and Motherson Group, presently, Kapil is leading Elcon Banshu Wiring System as the General Manager of Operations – Plant Head. During all his positions, Kapil honed his skills by consistently focusing on strategic driving of manufacturing operations. What truly excites him is building high-performing teams and empowering them to drive continuous improvement and achieve ambitious goals.
His rich experience in managing large-scale manufacturing facilities, plant operations, and teams that streamline operations and deliver consistent business results sets an unmatched record in production management and supply chain optimization. Furthermore, he specializes in transforming crucial plant production operations into engines of efficiency, quality, and safety.
Over the years, Kapil has successfully led end-to-end plant operations, including production planning, capacity utilization, maintenance, quality assurance, and workforce management. His expertise lies in implementing lean manufacturing practices, Six Sigma methodologies, and automation-driven systems to improve throughput, reduce costs, and enhance product quality.
He adds, “I am deeply motivated by seeing the direct impact of improved cycle times, reduced rejection rates, and enhanced customer satisfaction. And I’m stubbornly dedicated to legal compliance and operational rigour.”
The Journey to Operational Excellence
Kapil’s professional journey is defined by a rigorous climb from a humble starting point to a position of executive leadership in high-stakes manufacturing.
From Small Town to Corporate Command
Kapil hails from a small town in Uttarakhand, where he completed his schooling before pursuing a B.Tech in Mechanical Engineering—the perfect foundation for a life dedicated to industrial mechanics and systems. His professional trajectory is a chronicle of success across diverse sectors, starting with Videocon and progressing through industry giants like Samsung, Eureka Forbes, Idemia, and Motherson.
Today, he serves as the General Manager – SBU Head at Elcon Banshu Wiring System (EBWS), managing two plants in the NCR region.
The Foundation of Support
His personal journey has been profoundly shaped by his family: a retired government employee father, a homemaker mother, and supportive siblings. Crucially, his wife, Renu, a software professional, provides an unwavering bedrock of belief and support. “My family has been my greatest strength throughout this journey. Their unwavering support and belief in me have been instrumental in my growth and success.” Currently based in Noida, Kapil is focused on driving continuous improvement both for the organization’s growth and his own personal development.
The Professional Mandate: Value-Adding Strategy
Kapil’s philosophy is rooted in converting experience into innovation. With over 21 years of success in Plant Operations, Manufacturing Excellence, and Cost Management, his core professional mandate is clear: to conceptualize and implement effective strategies that demonstrably add value to the organization. “I’m passionate about driving efficiency and contributing to the company’s long-term success. I see challenges as opportunities to innovate and add value.” He is an expert at driving operational excellence, skillfully managing P&L, and leveraging inspiring leadership to optimize productivity, reduce waste and costs, and achieve sustainable business growth.
The Balance: Prioritization and Boundaries
Leading two plants in a demanding industrial sector requires a meticulous approach to work-life balance. Kapil manages this complexity through disciplined prioritization. “I prioritize tasks based on urgency and importance, delegate when possible, and set clear boundaries for work and personal time.” While he ensures critical work goals are met without compromising family commitments, he remains agile. If urgent issues arise at work, he handles them promptly, but always makes sure to compensate by adjusting his personal schedule later, ensuring that both his family and his professional duties receive the attention they require.
The Passion: Value Through Efficiency
Kapil’s drive is singularly focused on the operational metrics that define industrial success. His passion is not merely managing a factory; it is about transformative change at the ground level. “My passion is driving operational excellence and creating value through efficiency and innovation. As a Plant Head, this passion helps me focus on optimizing processes, reducing costs, and ensuring quality, which directly impacts profitability and customer satisfaction.” This intense focus on the shop floor outcomes—cycle times, rejection rates, customer satisfaction—translates directly into a commitment to continuous improvement that forms the backbone of his operational strategy.
The Pandemic Test: From Crisis to Resilience
The COVID-19 pandemic presented a formidable test to his operational philosophy, bringing supply chain disruptions, fluctuating demand, and critical workforce safety concerns. Kapil’s first strategic move was anchored in human trust. “Our first priority was employee safety, so we implemented strict health protocols. The company remained highly supportive of its employees, even paying them during the lockdown period.” This loyalty was repaid with exceptional employee performance and fostered a strong sense of trust. Beyond safety, Kapil used the crisis as an opportunity for strategic redirection. Recognizing the vulnerability of being heavily reliant on one sector (automotive), the firm began exploring diversification to build a more resilient, future-proof business portfolio. These proactive measures ensured survival and positioned the company for sustained long-term growth.
The Strategic Mind: Strengths and Learnings
Three core strengths propel Kapil’s success. First, his strategic thinking allows him to analyze complex situations and consistently balance short-term needs with long-term goals. Second, his people management skills enable him to achieve high efficiency and loyalty through trust and motivation. Third, adaptability proved crucial during the volatile pandemic years.
He offers a valuable lesson from his professional weakness: being overly detail-oriented. “Earlier in my career, I spent too much time perfecting small things, which sometimes delayed decisions. I’ve learned to balance attention to detail with speed by delegating and focusing on priorities.”
The Credentials: Certified Excellence
Kapil’s commitment to operational rigor is documented through a portfolio of high-level certifications and executive education, underscoring his expertise in driving quality and efficiency. He is an internal auditor for multiple critical standards, including IATF 16949:2016 (Automotive Quality Management), ISO 45001:2018 (Occupational Health and Safety), and ISO 50001 (Energy Management).
Furthermore, he holds the prestigious Six Sigma Black Belt certification, confirming his mastery of process improvement methodologies. His continuous learning is evident in his completion of the Executive Program in Business Management from IIM Calcutta and the Senior Leadership Program from IIM Lucknow, solidifying his dual mastery of technical operations and executive strategy.
The Blueprint: Advice for Aspiring Leaders
Kapil’s philosophy for leadership is built on a tripod of core values that transcend any single industry, yet are crucial for the high-stakes environment of manufacturing: Integrity, Empathy, and Adaptability.
1. Lead by Example: Integrity and Trust
For Kapil, effective leadership starts with personal conduct. An ethical compass and unwavering commitment are non-negotiable. “Lead by example—your team will follow what you do, not just what you say. Integrity and consistency build trust.” He insists that in the complex, process-driven world of manufacturing, a leader’s actions speak louder than any manual or directive.
2. Emotional Intelligence: The Human Engine
A deep understanding of the human element in operational success balances Kapil’s technical expertise. He stresses that the most perfectly tuned machine is useless without a motivated team. “Develop emotional intelligence—understand your people, listen actively, and create an environment where they feel valued.” This focus on valuing the workforce is what translates into the loyalty and high performance that defined his response to the pandemic crisis.
3. Continuous Learning: Adaptability is Key
Finally, in a business landscape defined by rapid technological change—from automation to Industry 4.0—curiosity is a survival skill. “Embrace continuous learning—business landscapes change rapidly, so adaptability and curiosity are key.” This principle underpins his own pursuit of executive education from institutions like IIM and his mastery of methodologies like Six Sigma.
The Mantra: The Power of Incremental Gains
To those seeking their own path to growth and success, Kapil offers a simple, powerful mantra derived from his career of optimizing complex systems: Continuous Improvement. “Continuous improvement, even in small increments, builds a strong foundation for long-term success. So continuous improvement is the key mantra for growth and success.”
The Certified Legacy: A Foundation of Unending Growth
Kapil’s story is exceptional not just for the challenges he overcame but for his proactive pursuit of knowledge and certification at every stage of his career, ensuring his expertise never stagnated.
His journey began with the foundational Bachelor of Technology in Mechanical Engineering from Uttar Pradesh Technical University (UPTU) in 2004, providing the technical blueprint for his subsequent operational roles.
His dedication to quality management began early, earning his first Six Sigma Green Belt from Samsung India Electronics Ltd in 2006, followed by another Green Belt from SFRAN in 2012. He later achieved the highly sought-after Six Sigma Black Belt & Green Belt from IMC Abu Dhabi in 2025, marking his status as a master of process optimization.
Mid-career, Kapil strategically invested in executive business acumen: He completed the Executive Program in Business Management (EPBM) from the Indian Institute of Management (IIM), Calcutta, in 2013, bridging the gap between technical operations and high-level strategy.
He later secured a prestigious Senior Leadership Program from the Indian Institute of Management (IIM), Lucknow, in 2022, solidifying his preparedness for complex, multi-plant leadership roles.
Kapil Dev Singh Rawat’s story is a powerful narrative for aspiring leaders: that sustained growth in the demanding field of manufacturing requires a non-negotiable devotion to both hands-on experience and certified academic and professional excellence. He built his career on the principle that the pursuit of knowledge is the ultimate engine of professional and organizational turnaround. Kapil’s tale is the definitive story of a leader who found deep satisfaction in solving complex operational puzzles, who championed his teams through crisis, and who ultimately proved that disciplined execution, anchored by integrity and empathy, is the true engine of sustainable industrial growth.
