Kshitij Rai
Operations Excellence Intern @ Halo Industries, Inc.
About
I’m a mechanical engineer and engineering management graduate student at Johns Hopkins, passionate about solving problems at the intersection of engineering, operations, and strategic decision-making. My motivation is simple: to apply mechanical intuition and systems thinking to enhance the performance of processes, products, and organizations. Mechanical & Engineering Work: I have a strong foundation in mechanical design, simulation, and systems engineering, and I enjoy building hardware that is reliable, efficient, and scalable. My strengths include SolidWorks, ANSYS, MATLAB, mechanical redesign, manufacturing workflows, and fundamentals of robotics and automation. -> Developed a low-friction wheel collar at Bhilai Steel Plant, improving equipment reliability, cutting downtime by 7%, and saving $75K+ annually. -> Led the design and manufacturing of full-scale RC aircraft with 550+ CAD components as Captain of Team Albatross. -> Managed procurement, CAD workflows, structural analysis, fabrication, and global logistics, achieving: 1st in Asia | 13th globally – SAE Aero Design East 2nd in India – SAEISS DDC 2023 & 2024 Consulting, Strategy & Operations Work: Parallel to my engineering work, I’ve built strong experience in operations strategy, process improvement, supply chain, and AI readiness consulting. I thrive in roles where I can use data, dashboards, structured problem-solving, and continuous improvement to drive measurable outcomes. -> At Johns Hopkins Hospital, led a Lean/Kaizen initiative that delivered: 90% reduction in cycle time 35% increase in compliance $17K+ annual savings -> With the Catalyst Community, conducted global market research across the U.S., APAC & Europe (25+ manufacturers) and built a custom GPT-based Predictive AI readiness model for small-scale manufacturing. -> Developed phased AI adoption strategies grounded in Lean, feasibility analysis, and operational maturity assessment. What I’m Looking For I'm exploring opportunities in: Mechanical Engineering | Robotics & Automation | Manufacturing Engineering | Operations Strategy | Supply Chain Optimization | Industrial Engineering | Engineering Consulting I’m especially drawn to roles where I can combine hands-on engineering with data-driven operational thinking to build scalable, real-world impact. If you’re solving meaningful problems in engineering or operations, I’d love to connect.
United States
San Francisco Bay Area
Management Consulting
Business Strategy, Enterprise Consulting, Supply Chain Management, Robotics, Data Analysis, Lean Process Improvement, Project Management, Management Consulting, Healthcare Consulting, Operations Process Improvement, Stakeholder Communication , Interdisciplinary Team Coordination, Teamwork, Industrial Engineering, Six Sigma, 3D Printing, Mechanical Engineering, Process Optimization (Manufacturing), Computer-Aided Design (CAD), Static Analysis
Experience

Operations Strategy Consultant (Student)
Cuenca, Castile-La Mancha, Spain
>Conducted market sizing, competitor benchmarking, and customer segmentation for Spain’s prefabricated timber housing sector to support the company’s commercialization and geographic expansion strategy. >Built an operational scaling plan by analyzing production capacity, throughput constraints, and process standardization required to transition from project-based construction to repeatable manufacturing. >Mapped supplier network and material flows (CLT panels, structural components, and on-site assembly inputs), identifying lead-time drivers and recommending sourcing and coordination improvements to reduce schedule risk.

Student Strategy Consultant
Baltimore, Maryland, United States
>Researched 25+ small-scale manufacturers to assess Predictive AI readiness. >Benchmarked 15 AI tools for predictive maintenance, demand forecasting, and supply chain ops. >Designed a custom GPT-based evaluation framework with 10+ AI-readiness criteria. >Built a strategic roadmap covering 5 AI integration stages over 12–18 months. >Conducted SWOT analysis of 7 predictive-AI platforms for business impact. >Addressed 3 core barriers: data quality, interoperability, and cybersecurity. >Proposed a phased adoption plan using Lean and Kaizen for cost-efficiency. >Created 2 executive presentations and 1 strategic report for leadership. Note: This project was part of the “Strategies for Innovation and Growth” course at Johns Hopkins University.

Student Strategy Consultant
Baltimore, Maryland, United States
>Led an operations improvement project in the Pediatric Operating Room (OR) focused on reducing Surgical Site Infection (SSI) risks caused by observer movement and noncompliance. >Designed a two-phase implementation plan introducing colour-coded gown zoning, digital QR code sign-in systems, and preoperative training modules to standardize onboarding and observer management. >Developed and implemented updated SOPs and visual signage aligned with hospital infection-control policies. >Predicted measurable outcomes, including ≥90% compliance in digital observer tracking, ≥50% reduction in sterile-field breaches, and ≥25% decrease in nurse oversight time through automation and visible ID systems. >Created KPI frameworks and cost-time analysis showing an estimated 203 staff hours saved per member annually and a $17,000+ reduction in accessory waste (caps, gowns, and badges). >Collaborated cross-functionally with nursing leadership, infection control teams, and OR management to build a sustainable, evidence-based framework for observer monitoring and infection prevention. Note: This project was part of the “Strategies for Innovation and Growth” course at Johns Hopkins University.

Team Captain
Vellore, Tamil Nadu, India
In my role as Team Captain, I am responsible for guiding a team consisting of over 40 team members in pursuit of our collective objective to construct and produce remotely controlled aircraft models that exhibit desired aerodynamic efficiency. Additionally, I am committed to cultivating a culture of creativity within the team, with the ultimate goal of efficiently executing aircraft fabrication. This vision and aim serve as the driving force behind my leadership. Additionally, I oversee the team's administration. The process of formulating efficient action plans to fulfill crucial deadlines and offering technical expertise to enhance the efficiency of design and analysis.

CAD and Structures Engineer
Vellore, Tamil Nadu, India
> Engineered the structure of lightweight UAVs with the primary goal of lifting the maximum payload with a given constraint on the wingspan. > Designing and developing models and drawings of various structures, mechanisms, and other components of a system using CAD software. > Conducted simulations and tests to verify the designed structures and components' stability, strength, and durability. > Successfully manufactured our flagship aircraft “KOLOSSOS” for SAE Aero Design East 2023 (Florida, USA). >Successfully manufactured our national flagship "ALB 23" for SAEISS DDC 2023 (Chennai,India).

Project Intern
Bhilai, Chhattisgarh, India
Topic: Investigating the Impact of Elevated Friction on the Drive Wheel Collar of EOT Cranes: Mitigation Strategies for Enhanced Performance >Led a comprehensive study into the consequences of increased friction on the drive wheel collar of Electric Overhead Travel (EOT) cranes operating in the dynamic steel melting process environment. >Utilized modern data acquisition tools to collect real-time operational data, enabling the detection of performance bottlenecks caused by friction. Utilized statistical analysis techniques to establish correlations between friction levels and wear and tear, facilitating data-driven decision-making processes. >Worked closely with maintenance engineers, metallurgists, and technical employees to validate findings and incorporate varied perspectives into mitigation techniques. >Thrived in a rapid industrial environment, contributing to the enhancement of EOT crane operations through the development of a comprehensive project that focused on friction reduction. Utilized technical expertise, worked together with other people, and analyzed data to create measurable improvements in the efficiency and longevity of cranes.
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