Division

Manufacturing

Department

Formulation

Sub Department 1

Engineering - Formulation

Job Purpose

The incumbent is a team member of Engineering Maintenance & Reliability Team and carries overall responsibility to:
1. Execute the maintenance activities in the plant & ensure the minimum breakdown with maximum efficiency by following safety & GMP Standards
2. Support Senior Engineer in carrying out Functional EM&R Planning, Detailed Scheduling and Execution of CMP to- ensure continuity of availability of plant & equipment at optimal cost; achieve standard capacity; ensure overall plant & equipment integrity & reliability - in compliance with Cipla Policies, Standards & Procedures; Reporting of EM&R MIS, Incidents & Deviations @ SOP;
Functional Engineer is responsible for executing maintenance tasks as assigned by Senior Engineer for his function in the Manufacturing, Packing and utility areas.
Where outsourced, 3rd Party Functional Engineer is accountable for the Service Floor / Technical Floor maintenance execution

Key Accountabilities (1/6)

I. Shift Maintenance Activity: Execute maintenance activities in a shift by managing available resources to achieve shift maintenance plan.
\xc3\x82\xc2\xa2 Execute assigned tasks as per planned maintenance activity to meet maintenance targets for a shift
\xc3\x82\xc2\xa2 Cater to machine and facility maintenance requirements of Unit as a responsible member of the team with overall ownership of Unit Operations.
\xc3\x82\xc2\xa2 Increase the efficiency of area by ensuring better utilization of equipment and by reducing downtime in manufacturing area
\xc3\x82\xc2\xa2 Prepare and submit Shift Engineer report to ensure smooth shift handover
\xc3\x82\xc2\xa2 Analyse breakdowns, diagnose faults and supervise time critical equipment repairs.
\xc3\x82\xc2\xa2 Offer technical expertise to maintenance people like supervisor, foreman, fitters and technicians.
\xc3\x82\xc2\xa2 Function as project development member to maintain new equipment.
\xc3\x82\xc2\xa2 Work with reliability engineers to extend equipment life cycle. II. Comprehensive Maintenance Plan Execution: Give inputs for preparing & adhere to unique planner for planned preventive maintenance & instrument calibrations for effective maintenance and adherence to standards.
\xc3\x82\xc2\xa2 Schedule shift activities in line with the CMP including PM, Calibration, and condition monitoring activities.
\xc3\x82\xc2\xa2 Execute planned maintenance and update related documentation
o Preventive Maintenance
o Calibration
o Condition Monitoring
o Planned Corrective Actions
\xc3\x82\xc2\xa2 Follow good Engineering practices during planned preventive activity.
\xc3\x82\xc2\xa2 Perform validation, qualification and calibration as per schedule and update output of all activities in the systems
\xc3\x82\xc2\xa2 Prepare new documents and update existing documents as per GMP requirement
\xc3\x82\xc2\xa2 Update Metrics on Schedule compliance

Key Accountabilities (2/6)

III. Breakdown Maintenance: Handle breakdown maintenance to avoid recurrence and maintain continuous process operations
\xc3\x82\xc2\xa2 Execute breakdown work expeditiously but safely and in compliance with cGMP.
\xc3\x82\xc2\xa2 Receipt and tracking the job card for the break down activity
\xc3\x82\xc2\xa2 Maintain critical spares inventory of all machines to reduce resolution time IV. Efficient Equipment Operation: Operate the equipment efficiently without error and deviation as per SOP to meet shift targets
\xc3\x82\xc2\xa2 Operate an equipment only when trained and authorized to do it.
\xc3\x82\xc2\xa2 Perform unit operations as per SOP & unit processes as per work instructions
\xc3\x82\xc2\xa2 Maintain equipment, facility and block premises as per SOP for audit readiness. Ensure equipment, facility and block premises are maintained as per regulatory compliance
\xc3\x82\xc2\xa2 Ensure all operations are performed as per GMP & Safety norms by reviewing all processes and documents for compliance
\xc3\x82\xc2\xa2 Maintain system integrity by updating documentations and deviations on CipDox while performing operations V. New Technology / Capex: Use new technologies initiated by Management while adhering to CAPEX and OPEX targets to improve Machine/system performance
\xc3\x82\xc2\xa2 Implement new technologies in the plant initiated by management
\xc3\x82\xc2\xa2 Attend planned trainings and incorporate the learnings on the floor for improving machine performance
\xc3\x82\xc2\xa2 Implement and close ideas generated through internal audits / Idea generation sessions
\xc3\x82\xc2\xa2 Monitor present energy use of the plants to identify and report areas for energy conservation
\xc3\x82\xc2\xa2 Implement Energy Conservation activities to improve the equipment efficiency, reduce error and reduce production cost
\xc3\x82\xc2\xa2 Identify areas of improvement for waste & work simplification
\xc3\x82\xc2\xa2 Manage activities to operate within budget and to reduce operating expenses
\xc3\x82\xc2\xa2 Verification of the contract invoices and making of the job orders as per estimates.

Key Accountabilities (3/6)

VI. Spares Management: Perform Material and Spare management and issue Consumables, spares, materials, log books etc. to avoid delays due to unavailability of materials
\xc3\x82\xc2\xa2 Issue required materials (spares and consumables) to the contractors from stores and make SAP entries for the receipts and issuance
\xc3\x82\xc2\xa2 Maintain the inventory of critical spares and consumables by tracking consumption and monitoring of stocks
\xc3\x82\xc2\xa2 Assess log book requirements, raise the request to QA and issue them within required timelines
\xc3\x82\xc2\xa2 Classify the unused / spare / usable scrap materials or components and reuse the same where ever possible VII. EHS Compliance: maintain high level of Safety during maintenance to avoid major breakdown and report accidents/ incidences
\xc3\x82\xc2\xa2 Complete preplacement Safety Training before starting the work in any area.
\xc3\x82\xc2\xa2 Monitor safe operations of the machine as per SOP and timely report any safety deviations
\xc3\x82\xc2\xa2 Maintain proper procedures for safety permits in plant Ensure safety systems and procedures followed by the operators in the shift
\xc3\x82\xc2\xa2 Issue work permits to contractual staff after verifying the safety aspects, monitoring and communicating safety hazards and safety near miss to the concern.
\xc3\x82\xc2\xa2 Ensure availability and usage of PPEs in the shift by coordinating with EHS department for requirements and shift schedule; Ensure usage and maintenance of PPEs by self & other workmen during shifts
\xc3\x82\xc2\xa2 Report any safety incident to the Shift In charge as well as the Senior Engineer for the following
o Near Miss
o Safety Incident
o Work Place Inspection
o Unsafe Act
o Unsafe Condition
\xc3\x82\xc2\xa2 Attend safety meetings and ensure implementation of actions planned during departmental safety meeting at shop floor
\xc3\x82\xc2\xa2 Ensure compliances to safety training targets by monthly reconciling attendance records

Key Accountabilities (4/6)

VIII. cGMP Compliance: Execute and update online documentation to meet cGMP requirements
\xc3\x82\xc2\xa2 Complete preplacement cGMP Training before starting the work in any area.
\xc3\x82\xc2\xa2 Monitor cGMP compliance in the impact domain and report any incident / cGMP deviation to the Shift In charge as well as the Senior Engineer.
\xc3\x82\xc2\xa2 Maintain online documentation and timely entries in all document in cGMP environment and their supporting documents
\xc3\x82\xc2\xa2 Check documentation before submission to ensure data integrity. In case of any deficiency or errors in documents and rectify them as per SOP
\xc3\x82\xc2\xa2 Conduct training related to cGMP, equipment operation, safety and housekeeping for workmen
\xc3\x82\xc2\xa2 Optimize the use of resources in housekeeping; Ensure good housekeeping and sanitisation as per the guidelines
\xc3\x82\xc2\xa2 Operate software such as SAP, CipDox and QMS as required and basis training & certification.
\xc3\x82\xc2\xa2 Execute CAPA as guided by the Senior Engineer.
\xc3\x82\xc2\xa2 Prepare and maintain engineering documents wrt cGMP and Good Engineering Practices IX. Continuous Improvements: Provide suggestions for optimization of processes to manufacture quality product
\xc3\x82\xc2\xa2 Propose and implement new idea to enhance production, optimise the use of consumable goods and maximum utilization of resources
\xc3\x82\xc2\xa2 Provide new ideas and simplify processes to reduce process cycle time and achieve new targets
\xc3\x82\xc2\xa2 Participate in internal audits / Idea generation sessions to improve on deficiencies to verify GEP and GMP.
\xc3\x82\xc2\xa2 Implement action plans for improving on deficiencies observed through internal / external audits X. [E] Self Development on Electrical engineering & leadership aspects
\xc3\x82\xc2\xa2 Keep self-updated on regulatory guidelines and product regulatory requirements of all markets to which product manufactured by the Site is exported.
\xc3\x82\xc2\xa2 Undergo training on Electrical engineering & Leadership capability building as per guidance from HR function and the Global Operations Team.

Key Accountabilities (5/6)

Key Accountabilities (6/6)

Major Challenges

• CapEx and OpEx \xc3\xa2\xe2\x82\xac\xc5\x93 Adherence to the budget
• Cost vs performance trade off in equipment
• Ageing Asset leading to escalating OpEx Cost
• Challenges around capability & competence of personnel and service providers

Key Interactions (1/2)

Internal
\xc3\x82\xc2\xa2 Central Engineering for technical standards and guidance
\xc3\x82\xc2\xa2 EHS for safe operations and near-misses
\xc3\x82\xc2\xa2 Site head & Unit heads for Proposals, breakdowns and developments
\xc3\x82\xc2\xa2 Indirect purchase for Spares, scope, insurance and new vendors
\xc3\x82\xc2\xa2 Central purchase for provide Technical inputs and clarifications for CAPEX
\xc3\x82\xc2\xa2 Global Leadership Team \xc3\xa2\xe2\x82\xac\xc5\x93 Guidance & Updates in TLT, Focus Calls & Reviews
\xc3\x82\xc2\xa2 Corporate Affairs & Legal Team \xc3\xa2\xe2\x82\xac\xc5\x93 Guidance & Updates on Compliance matters
External
\xc3\x82\xc2\xa2 OEMs for projects , automations, alternate vendor development , quality issues and maintenance
\xc3\x82\xc2\xa2 Facility maintenance contractors for Improve maintenance and quality standards
\xc3\x82\xc2\xa2 Industry Bodies \xc3\xa2\xe2\x82\xac\xc5\x93 Connect on external benchmarking & information on technology evolution
\xc3\x82\xc2\xa2 Statutory Bodies \xc3\xa2\xe2\x82\xac\xc5\x93 Connect for Regulatory compliance

Key Interactions (2/2)

Dimensions (1/2)

• Direct Reports: 0, Team Size \xc3\xa2\xe2\x82\xac\xc5\x93 9-12
• Unit Maintenance + Utility Budget: 15-20 CR [ Functional ~ 33% of this]
• Capex Budget: Sustenance 10 CR [ Functional ~ 33% of this]
• Revenue of Goa I: 300-400 CR
• Current Replacement value of Assets Maintained: Net Block > 50 CR; CRV > 200 CR

Dimensions (2/2)

Key Decisions (1/2)

Decisions
\xc3\x82\xc2\xa2 Spends within Approved Budget \xc3\xa2\xe2\x82\xac\xc5\x93 Capex & Opx
\xc3\x82\xc2\xa2 Maintenance & Reliability Strategies
\xc3\x82\xc2\xa2 Engineering & Project Vendors & service Providers as per EA
\xc3\x82\xc2\xa2 Technology for Manufacturing
\xc3\x82\xc2\xa2 Resource Conservation initiatives
\xc3\x82\xc2\xa2 Capability Programs
Recommendations
\xc3\x82\xc2\xa2 Opex & Project costs Proposal
\xc3\x82\xc2\xa2 New vendor addition
\xc3\x82\xc2\xa2 Facility audits
\xc3\x82\xc2\xa2 Hiring consultants
\xc3\x82\xc2\xa2 New equipment & Technology

Key Decisions (2/2)

Education Qualification

BE / B Tech (Electrical)

Relevant Work Experience

\xc3\x82\xc2\xa2 2-5 years of experience in manufacturing (Maintenance and Projects).
\xc3\x82\xc2\xa2 Ability to implement new techniques, deep understanding of manufacturing process, planning and organizational skills, prioritization multi-tasking, understanding of financial concepts
\xc3\x82\xc2\xa2 Good technical knowledge of Pharma / API machinery and utility requirements
\xc3\x82\xc2\xa2 Good knowledge and experience in execution of green field / brown field projects
\xc3\x82\xc2\xa2 Knowledge of GMP and various regulatory requirements
\xc3\x82\xc2\xa2 Good leadership skills and experience in Electrical engineering activities.