Opinions expressed by Digital Journal contributors are their own.
Onkar Nerkar demonstrates that automation can be both effective and affordable. His methodical approach shows that meaningful improvements are possible without substantial investments. With over 25 years in operations management and industrial engineering, he has enhanced manufacturing processes through practical, cost-effective solutions. His systematic approach to automation has improved operations while challenging common assumptions about the relationship between cost and efficiency.
As the director for continuous improvement and industrial engineering, Onkar Nerkar has shown how targeted automation can deliver solid results without excessive spending. His focus on low-cost automation (LCA)—an approach that identifies and implements precise process adjustments—has enabled manufacturers to improve efficiency while maintaining financial stability.
The philosophy of low-cost automation
“Automation doesn’t always need to break the bank,” Onkar explains. “In many cases, it’s about understanding your existing processes and identifying the smallest, most impactful changes that can streamline operations.” This approach offers an alternative to the traditional view that automation requires substantial capital investment and complex technologies.
Onkar has demonstrated the effectiveness of LCA. By implementing specific digital tools and process adjustments in assembly lines and operational workflows, he has improved equipment reliability, reduced downtime, and increased productivity while maintaining cost controls.
Leading the path to automation
Onkar’s development as a manufacturing specialist stems from his extensive education and experience. With a Master’s in Industrial Engineering and an MBA in Supply Chain Management, he combines technical knowledge with practical business understanding. One of his key achievements was designing and implementing system automation & digitization in the warehouse environment. He was successful in developing IT solutions with use of RFID to reduce capex requirements. In another project he integrated the Automated Storage & Retrieval system to the Oracle for order picking.
“I’ve always believed that every challenge is an opportunity to innovate,” he shares. This mindset has informed his approach to problem-solving throughout his career, leading to practical solutions that have improved industry practices.
The need for accessible low-cost automation
Manufacturing in 2025 will have ongoing challenges—from rising raw material costs to increasing demand for rapid delivery. While many companies recognize the value of automation, implementation costs often create barriers, especially for smaller and mid-sized manufacturers. It requires a complete echo system and not the mere solution in isolation.
“Technology is changing at an incredible pace, and companies need to adapt quickly,” Onkar Nerkar observes. “The goal is to use technology effectively while maintaining financial stability—this is where low-cost automation provides value.”
Assessing the activities critically with new paradigms
Onkar’s contributions include both technical improvements and cultural changes. He thinks the objective of automation is not mere cost saving through productivity improvement but has a larger context with people safety, preventing mistakes and making tasks less stressful. Organizations need to look at technology with a new paradigm, he emphasizes.
“A great process means nothing if people don’t believe in it,” he states. This perspective has helped create an engaged workforce that understands the value of continuous improvement.
Building a robust ecosystem
Onkar Nerkar has developed a comprehensive strategy that includes seamless integration of tools, processes, and technologies. He is a strong advocate of security, monitoring, and maintenance to ensure resilience and success in automation initiatives.
“A well-designed ecosystem not only streamlines processes but also allows for scalability and adaptability” he states. Without a robust ecosystem, automations are likely to hit multiple obstacles and lose trust of the employees. “Automation shall make life of operators safe and easy, not the other way round” he reiterates.
Aligning productivity with sustainability
Onkar has integrated environmental considerations into his automation strategies, showing how efficiency and sustainability can complement each other. His focus on resource optimization and waste reduction demonstrates how low-cost automation can support operational and environmental objectives. “Sustainability and productivity aren’t mutually exclusive,” he notes. “With careful planning, we can design efficient and responsible processes.”
Setting industry standards
Onkar’s work in manufacturing extends beyond his role as a Director. His approach to low-cost automation has helped establish practical benchmarks for operational efficiency, showing that improvements are possible without excessive spending. “I’m driven by the idea that there’s always a better way to do things,” he reflects. “Effective manufacturing solutions should be accessible to companies of all sizes.”
Through his work, Onkar has helped develop a practical approach to modern manufacturing—one that balances productivity, sustainability, and fiscal responsibility. He has an ambition to help & demonstrate how thoughtful automation can improve operations while maintaining financial discipline, providing a useful model for the small and medium manufacturing industry in a competitive market.
