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Pushpendra Goyal

22 Years
Not available
B.Tech. (Mechanical)
Training & Consulting on 5S, TPM, QMS, EMS, OHSAS
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Management Consultant



    ·         An engineering professional having 22 years of industrial exposure in different business sectors such as FMCG, Chemicals, Textile, Steel, MSMEs & PSU.

    ·         Hands on experience in Coordination, Facilitating, Training & Implementation of Manufacturing Excellence concepts such as 5S, Lean Manufacturing, TPM, WCM, AIB, M&W, QMS, EMS, OHSAS & ZED in addition to handling of Production, Maintenance, Commercial, Safety & HR functions.



    Core Competencies

    Asset Reliability Management                              Process optimization

    Zero Defect Strategy                                          Skill Transformation                                           Early Management                                                Assessment / Auditing                                      


    Professional Experience

    Management Consultant  (Oct’17-Present)


    ·         Sr. Consultant (ISO 9001:2015, ISO 14001:2015, OHSAS 18001:2007, Manufacturing Excellence) under Here Quality Excellence Private Limited

    ·         Lean Consultant for 2 MSME (Medium Small & Micro Enterprises) clusters at Aurangabad (Maharashtra). Total comprising of 13 Units under Margadarshan Management & Measurement Pvt. Ltd.

    ·         TQM Consultant for GAIL (Gas Authority of India Limited) under Margadarshan Management & Measurement Pvt. Ltd..

    ·         EHS Consultant for Ami Life Sciences, a pharma Company in Bharuch (Gujarat) under GK Engineering.

    ·         Conducting pre audit for Deksons Castings, Aurangabad as part of preparation for audit by Japanese customers from Showa. The audit was based on ISO 9001:9008.

    ·         Providing trainings on 5S, Lean, TPM, TQM, WCM, QMS, EMS & OHSAS.

    ·         Assisting in setting approach, deployment, assessment & review of above systems.

    ·         Preparing the organization for challenging relevant awards / certifications.

    ·         Providing guidance to students who are pursuing Manufacturing Excellence as academic interest.  

    ·         Home based HR Recruiter under 3D India Group.


    Manager (TPM) – UPL Ltd., Unit#3, Ankleshwar (2011 – 2017)


    ·         ISO Coordinator (2011 – 2017)

    o    Management Representative for EMS 14001 & OHSAS 18001 standards for 6 years.

    o    Successfully completed Lead Auditor Course for EMS 14001 2004 & 2015 version conducted by Bureau Veritas.

    o    Successfully completed Internal Auditor Course for QMS 9001: 2008, EMS 14001:2004 & OHSAS 18001:2007 conducted by Bureau Veritas.

    o    Handled recertification audits & Surveillance Audits (frequency 6 monthly / yearly) for EMS & OHSAS.

    o    Trained & assisted the process owners / internal auditors on the documentation & requirements of QMS, EMS & OHSAS standards.

    ·         5S & Lean Coordinator (2011 – 2017)

    o    To drive companywide 5S program under mentorship of Kimura San, a Japanese consultant.

    o    Sustained 5S practices became a big enabler for the Unit to achieve Silver Award for Manufacturing Excellence by Frost & Sullivan and Best Unit Award out of 12 Units in year 2011.

    o    Developed Unit Gallery depicting trends of PQCDSM & related success stories. The same was appreciated at the Group level including 5S coordinators from Brazil, Argentina, France and Vietnam and also by critical suppliers.

    o    Liquidation of non-moving inventory to the tune of INR 7 million as a result of 5S in production area. Systems developed to prevent further generation.

    o    Reduction of SAP transactions by 75% through SAP hygiene in Production system. It resulted in speedier delivery to internal customers as well as accurate MIS data to Management. Also there was saving of precious resource ‘manpower’ by approx. 1200 man-hours per year.

    o    Adoption of lean led to reduction in packing material storage space by 25% from 1840 pallet positions to 1400 pallet positions. Enabled storage of raw material & finished goods without development of extra stores. This has led to reduction in inventory by INR 10 million& creation of 600 sq. mtrs. Extra floor space.

    ·         Incharge for Liquid Formulation Production (2013-2015)

    o    To implement 5S & lean practices in addition to managing day to day operations for Insecticide & Herbicide liquid formulation plant with capacity 2400 KL / month

    o    Handled around manpower strength of 100 nos including company shift supervisors / operators, Contractual (Addecco) workmen & other unskilled workmen for 3 shift operations

    o    Key operations included batch charging, packaging of bottles, carbouys drums & IBC,  box printing & label printing. All records maintained in SAP.

    ·         Incharge for Packing Materials Warehouse (2015-2017)

    o    To implement 5S & lean practices in addition to managing day to day operations for Packing Materials Warehouse catering to 3 Units as well as 22 tolling sites.

    o    Handled around manpower strength of 20 nos including company supervisor, Contractual (Addecco) data entry operator, utility operators & other unskilled workmen for 2 shift operations

    o    Key operations included receipt, storage & distribution of packing materials. All records maintained in SAP.


    Assistant Manager (Manufacturing) - Pepsico India Holdings Private Ltd. Paithan (Aurangabad) (2007– 2011)


    ·         To drive companywide 5S program independently.

    ·         Production In-charge of Returnable Glass Line.

    ·         Manufacturing Excellence Coordinator - to drive M&W (Manufacturing & Warehousing) System companywide and to manage data warehouse.


    ·         Extensive usage of visuals led to easing of day to day operations on the shopfloor.

    ·         Adoption of 5S led to creation of extra space, digging out of hidden items, reduction in searching time which overall led to net saving of INR 5 million.

    ·         As a result of 5S, Unit achieved 2nd position out of 64 units in National Summer League in 2007. The best practices adopted in the Unit were shared to other plants across India and were well appreciated.

    ·         Adoption of JH,  PM and E&T concepts led to

    o    Increase in line productivity by 50%(8000 to 12000 cases per shift)

    o    Increase in yield from 99.0 to 99.5 % primarily due to reduction in rejection and interruptions. This in turn resulted into increased profit by INR 17 million per year.


    Assistant Manager (TPM)-Ispat Industries, Kalmeshwar, Nagpur (2004-2007)


    ·         Coordinated TPM in entire complex under guidance of Egami San (a JIPM consultant) for implementation of key TPM Pillars –Focused Improvement, Quality Maintenance & Office TPM.

    ·         Coordinated TPM in Colour Coating Line for all pillar activities.

    ·         Single-handedly managed TPM data for entire complex & prepared documentation (Activity Report etc.) for successfully challenging Award for TPM Excellence in 2006.


    ·         Development of unique Kaizens leading to reduction of human effort saving 600 man-hours per year.

    ·         Changeovers time reduced from 2 hours to 5 minutes.

    ·         Cost saving in Color coating line to tune of INR 1 million per year.


    Coordinator WCM - Grasim SFD, Nagda, Ujjain (1999 – 2004).


    ·         To coordinate activities as per CWCM Road Map for following pillars – Focused Improvement, Information Technology, Market Orientation & Customer Driven and custodian of entire WCM data

    ·         To coordinate activities in Viscose Plant


    ·         Campaign based approach led to speedier implementation of WCM concepts

    ·         Systematic compilation of WCM data from start to finish led to formulation of effective Application which was one of the key factors for the Unit to be awarded Chairman’s Silver Medal for Manufacturing Excellence in 2003.


    Mechanical Engineer - Grasim SFD, Nagda, Ujjain (1995 - 1999)


    ·         To handle preventive, predictive & breakdown maintenance of Viscose Plant.


    ·         Recodification of Engineering Spares for easier inventory management

    ·         Reduction in MTTR / Increase in MTBF achieved by Multiskilling of fitters & helpers, Min-Max system for maintaining inventory of critical spares & Zero Abnormality Movement


    Trainings Attended & Certifications

    ·         2011           : Internal Auditor Training Course for ISO 9001:2008, ISO 14001: 2004 & OHSAS

       18001:2007 by Bureau Veritas

    ·         2011           : Management Development Programme on Lean Manufacturing by Baroda Management


    ·         2012           : Lead Auditor Course for ISO 14001:2004 by Bureau Veritas

    ·         2014           : Advanced TPM Master Class by JMA Consultants

    ·         2016           : Advanced Logistics & Material Handling by Global Business Conference

    ·         2016           : Lead Auditor Course for ISO 14001:2015 by Bureau Veritas

    ·         2017           : ZED Assessor by Quality Council of India

    ·         2018           : Six Sigma White Belt by Udemi


    Personal Information

    Qualification       :           B.Tech (Mech) in 1993 from NIT Warangal

    M.Tech (Hydro) Hons in 1996 from NIT Bhopal


    Date of Birth      :           3rd Nov, 1971


    Address             :           37, Sanskar Villa, Behind Yogi Petrol Pump,

    Zadeshwar, Bharuch, Gujarat, India 392011