Engineer - Instrumentation

DivisionManufacturingDepartmentActive Pharmaceutical IngredientSub Department 1Engineering - APIJob PurposeThe incumbent is a team member of Unit Engineering Maintenance & Reliability Team and carries overall responsibility to:1.Execute the maintenance activities in the plant & ensure the minimum Instrumentation & Automation breakdown with maximum efficiency by following safety & GMP Standards 2.Support EM & R Senior Instrumentation 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; Instrumentation Engineer is responsible for executing maintenance tasks as assigned by Senior Engineer for his function in the Manufacturing & Packing Area.Where outsourced, 3rd Party Instrumentation Engineer is accountable for the Service Floor / Technical Floor maintenance executionKey Accountabilities (1/6)I.    Shift Maintenance Activity: Execute maintenance activities in a shift by managing available resources to achieve shift maintenance plan.¢    Execute assigned tasks as per planned Instrumentation & Automation maintenance activity to meet maintenance targets for a shift¢    Cater to machine maintenance requirements of Unit as a responsible member of the team with overall ownership of Unit Operations.¢    Increase the efficiency of area by ensuring better utilization of equipment and by reducing downtime in manufacturing area¢    Prepare and submit Instrumentation shift engineer report to ensure smooth shift handover 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.¢    Schedule shift activities in line with the CMP including PM, Calibration, and condition monitoring activities.¢    Execute planned Instrumentation & Automation maintenance and update related documentationo    Preventive Maintenance o    Calibrationo    Condition Monitoringo    Planned Corrective Actions¢    Follow good Engineering practices during planned preventive activity.    ¢    Perform validation, qualification and calibration as per schedule and update output of all activities in the systems¢    Prepare new documents and update existing documents as per GMP requirement¢    Update Metrics on Schedule complianceIII.    Breakdown Maintenance: Handle breakdown maintenance to avoid recurrence and maintain continuous process operations¢    Execute Instrumentation & Automation breakdown work expeditiously but safely and in compliance with cGMP. ¢    Receipt and tracking the job card for the break down activity ¢    Maintain critical Instrumentation & Automation spares inventory of all machines to reduce resolution timeKey Accountabilities (2/6)IV.    Efficient Equipment Operation: Operate the equipment efficiently without error and deviation as per SOP to meet shift targets    ¢    Operate an equipment only when trained and authorized to do it.¢    Perform unit operations as per SOP & unit processes as per work instructions¢    Maintain equipment, facility and block premises as per SOP for audit readiness. Ensure equipment, facility and block premises are maintained as per regulatory compliance¢    Ensure all operations are performed as per GMP & Safety norms by reviewing all processes and documents for compliance ¢    Maintain system integrity by updating documentations and deviations on CipDox while performing operationsV.    New Technology / Capex: Use new technologies initiated by Management while adhering to CAPEX and OPEX targets to improve Machine/system performance¢    Implement new technologies in the plant initiated by management¢    Attend planned trainings and incorporate the learnings on the floor for improving machine performance¢    Implement and close ideas generated through internal audits / Idea generation sessions ¢    Monitor present energy use of the plants to identify and report areas for energy conservation¢    Implement Energy Conservation activities to improve the equipment efficiency, reduce error and reduce production cost¢    Identify areas of improvement in instrumentation functoin for waste & work simplification¢    Manage activities to operate within budget and to reduce operating expenses¢    Verification of the contract invoices and making of the job orders as per estimatesVI.    Spares Management: Perform Material and Spare management and issue Consumables, spares, materials, log books etc. to avoid delays due to unavailability of materials¢    Issue required Instrumentation & Automation materials (spares and consumables) to the contractors from stores and make SAP entries for the receipts and issuance¢    Maintain the inventory of critical spares and consumables by tracking consumption and monitoring of stocks¢    Assess log book requirements, raise the request to QA and issue them within required timelines¢    Classify the unused / spare / usable scrap materials or components and reuse the same where ever possibleKey Accountabilities (3/6)VII.    EHS Compliance: maintain high level of Safety during maintenance to avoid major breakdown and report accidents/ incidences¢    Complete preplacement Safety Training before starting the work in any area.¢    Monitor safe operations of the machine as per SOP and timely report any safety deviations¢    Maintain proper procedures for safety permits in plant Ensure safety systems and procedures followed by the operators in the shift¢    Issue work permits to contractual staff after verifying the safety aspects, monitoring and communicating safety hazards and safety near miss to the concern.¢    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¢    Report any safety incident to the Shift In charge as well as the Senior Engineer for the followingo    Near Misso    Safety Incidento    Work Place Inspectiono    Unsafe Acto    Unsafe Condition¢    Attend safety meetings and ensure implementation of actions planned during departmental safety meeting at shop floor¢    Ensure compliances to safety training targets by monthly reconciling attendance recordsVIII.    cGMP Compliance: Execute and update online documentation to meet cGMP requirements¢    Complete preplacement cGMP Training before starting the work in any area.¢    Monitor cGMP compliance in the impact domain and report any incident / cGMP deviation to the Shift In charge as well as the Senior Engineer.¢    Maintain online instrumentation documentation and timely entries in all documents in cGMP environment and their supporting documents¢    Check documentation before submission to ensure data integrity. In case of any deficiency or errors in documents and rectify them as per SOP¢    Conduct training related to cGMP, equipment operation, safety and housekeeping for workmen¢    Optimize the use of resources in housekeeping; Ensure good housekeeping and sanitisation as per the guidelines¢    Operate software such as SAP, CipDox and QMS as required and basis training & certification.¢    Execute CAPA as guided by the Instrumentation Senior Engineer.¢    Prepare and maintain engineering documents wrt cGMP and Good Engineering PracticesKey Accountabilities (4/6)IX.    Continuous Improvements: Provide suggestions for optimization of processes to manufacture quality product¢    Propose and implement new idea to enhance production, optimise the use of consumable goods and maximum utilization of resources¢    Provide new ideas and simplify processes to reduce process cycle time and achieve new targets¢    Participate in internal audits / Idea generation sessions to improve on deficiencies to verify GEP and GMP. ¢    Implement action plans for improving on deficiencies observed through internal / external audits X.    [E] Self Development on functional & leadership aspects ¢    Keep self-updated on regulatory guidelines and product regulatory requirements of all markets to which product manufactured by the Site is exported. ¢    Undergo training on Functional & Leadership capability building as per guidance from HR function and the Global Operations Team.Key Accountabilities (5/6)Key Accountabilities (6/6)Major ChallengesCapEx and OpEx Adherence to the budgetCost vs performance trade off in equipmentAgeing Asset leading to escalating OpEx CostChallenges around capability & competence of personnel and service providersKey Interactions (1/2)Internal¢    Central Engineering for technical standards and guidance¢    EHS for safe operations and near-misses ¢    Site head & Unit heads for Proposals, breakdowns and developments ¢    Indirect purchase for Spares, scope, insurance and new vendors¢    Central purchase for provide Technical inputs and clarifications for CAPEX ¢    Global Leadership Team Guidance & Updates in TLT, Focus Calls & Reviews¢    Corporate Affairs & Legal Team Guidance & Updates on Compliance mattersExternal¢    OEMs for projects , automations, alternate vendor development , quality issues and maintenance ¢    Facility maintenance contractors for Improve maintenance and quality standards ¢    Industry Bodies Connect on external benchmarking & information on technology evolution¢    Statutory Bodies Connect for Regulatory complianceKey Interactions (2/2)Dimensions (1/2)Direct Reports: 0, Team Size 9-12Unit Maintenance + Utility Budget: 15-20 CR [ Functional ~ 33% of this]Capex Budget: Sustenance 10 CR [ Functional ~ 33% of this]Revenue of Goa I: CRCurrent Replacement value of Assets Maintained: Net Block > 50 CR; CRV > 200 CRDimensions (2/2)Key Decisions (1/2)Decisions¢    Spends within Approved Budget Capex & Opx¢    Maintenance & Reliability Strategies¢    Engineering & Project Vendors & service Providers as per EA¢    Technology for Manufacturing¢    Resource Conservation initiatives¢    Capability ProgramsRecommendations¢    Opex & Project costs Proposal¢    New vendor addition ¢    Facility audits ¢    Hiring consultants ¢    New equipment & TechnologyKey Decisions (2/2)Education QualificationBE / B Tech (Mechanical / Electrical / Instrumentation)Relevant Work Experience2-5 years of experience in manufacturing (Maintenance and Projects).Ability to implement new techniques, deep understanding of manufacturing process, planning and organizational skills, prioritization multi-tasking, understanding of financial conceptsGood technical knowledge of Pharma / API machinery and utility requirementsGood knowledge and experience in execution of green field / brown field projectKnowledge of GMP and various regulatory requirementsGood leadership skills and experience in industrial automation