Pankaj Sharma
Senior Manager – Plant Operations | Manufacturing Transformation
Panchkula
Summary
Operations and Manufacturing Excellence Leader with 12+ years of hands-on experience leading factory transformation projects across pharmaceuticals, automotive, and FMCG sectors. Proven track record in optimizing supply chain efficiency, driving end-to-end plant improvement initiatives, and delivering measurable impact on productivity, cost, and quality KPIs. Adept at deploying Lean, TPM, and digitalization strategies to streamline processes, reduce waste, and scale performance across multi-site operations
Overview
13
13
years of professional experience
2
2
Languages
3
3
Certificates
Work History
Principal Consultant – Strategy & Operations
EFESO Consulting
01.2023 - Current
- Spearheading multiple factory transformation engagements focused on throughput enhancement, cost reduction, and process digitalization for manufacturing clients.
- Built strong relationships with clients, fostering long-term partnerships and repeat business.
- Facilitated change management initiatives, helping organizations adapt smoothly to new systems and processes.
- Led cross-functional teams to deliver high-quality results on complex assignments.
- Designed and implemented comprehensive plant improvement roadmaps, optimizing line balancing, OEE, and resource utilization using Lean and TPM frameworks.
- Executed plant floor diagnostics and hands-on Gemba walks to identify and resolve critical operational bottlenecks.
- Deployed visual management, real-time dashboards, and data-driven performance governance to track KPIs and enhance operational decision-making.
Sr. Manager – Operational Excellence
Zydus Lifesciences Ltd
09.2021 - 12.2022
- Directed cross-functional TPM rollout and operational excellence programs across plant units, improving asset utilization and workforce productivity.
- Increased manpower productivity by 10% YoY through capacity rebalancing and line reengineering on packing lines.
- Implemented Lean Six Sigma (LSS) methodologies, leading Kaizen events and SMED projects for reduction in changeover times.
- Digitized performance monitoring and reporting, contributing to agile and responsive plant floor management.
- Mentored in-house SMEs and trained >50 Green/Black Belt participants on Lean, TPM, and Six Sigma tools.
Sr. Manager – Operations
Minda Corporation Ltd
05.2016 - 08.2021
- Led end-to-end operations of the manufacturing plant with focus on timely delivery, production planning, and operational efficiency.
- Delivered 30% productivity increase on the Hero Line through strategic reengineering and automation support.
- Reduced rejection rates of die casting components by 25% by streamlining quality assurance protocols.
- Developed risk mitigation strategies and contingency plans for supply disruptions, improving OTIF delivery metrics.
- Championed workplace safety initiatives and drove continuous improvement through 5S, Poka-Yoke, and employee involvement programs.
- Collaborated closely with peers from other departments to drive organizational success jointly as one cohesive unit.
- Reduced costs, optimized resource allocation, and improved efficiency in managing projects.
- Demonstrated exceptional adaptability in navigating complex situations or rapidly changing environments with ease.
- Increased customer satisfaction with timely project deliveries and seamless communication.
UAP FES Engineer
Faurecia Automotive Seating India Pvt Ltd
07.2012 - 05.2016
- Managed daily production operations and assembly process optimization of starter motor lines, ensuring adherence to volume and quality targets.
- Led process engineering initiatives to improve assembly line cycle times and reduce production scrap.
- Used FMEA, PDCA, and GEMBA practices to resolve non-conformities and implement proactive quality improvements.
- Delivered operator upskilling programs focused on safety, productivity, and compliance.
Education
Post Graduate Executive Diploma in Operations Mgt - Operations Management
04.2001 -
Bachelor of Science - Mechanical Engineering
04.2001 -
Skills
Digital transformation
Certification
Lean Six Sigma Black belt
Accomplishments
EFESO Consulting – Principal Consultant
- Drove cost savings of over ₹2 Cr annually by optimizing supplier terms, inventory turns, and material flow.
- Enabled 15–20% throughput increase for Tier-1 client using Lean Line Design and bottleneck analysis.
- Conducted over 40+ Gemba workshops across 5 sites to drive factory-floor performance alignment.
- Deployed real-time KPI dashboards, reducing decision-making lead time from 24 hours to
- Achieved a 10% increase in manpower productivity via multi-skilling and layout redesign.
- Reduced changeover time by 35% through SMED implementation on blister and bottle lines.
- Coached and certified 20+ in-house Green Belts, strengthening internal CI capability.
- Digitized daily performance management boards across 3 lines, improving visibility and response time
Work Availability
monday
tuesday
wednesday
thursday
friday
saturday
sunday
morning
afternoon
evening
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Languages
English
Advanced (C1)
Hindi
Advanced (C1)
Work Preference
Work Type
Full TimeWork Location
On-SiteRemoteImportant To Me
Personal development programsTeam Building / Company RetreatsCompany CultureCareer advancementSoftware
AI Tools
POWER BI
Timeline
Principal Consultant – Strategy & Operations - EFESO Consulting
01.2023 - Current
Sr. Manager – Operational Excellence - Zydus Lifesciences Ltd
09.2021 - 12.2022
TPM
07-2016
Sr. Manager – Operations - Minda Corporation Ltd
05.2016 - 08.2021
Lean Six Sigma Black belt
09-2015
MTM- Rober Bosch
05-2014
UAP FES Engineer - Faurecia Automotive Seating India Pvt Ltd
07.2012 - 05.2016
IMT Ghaziabad - Post Graduate Executive Diploma in Operations Mgt, Operations Management
04.2001 -
Lingaya’s Institute of Management & Technology - Bachelor of Science, Mechanical Engineering
04.2001 -
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