API Unit Engineering Head - Sr. Manager

Cipla; Kurkumb; On-site; INR 1,000,000 - 1,500,000; Full time

Job summary

Cipla is seeking a Mechanical Engineer with 10 to 15 years of experience to oversee maintenance and project activities at their Kurkumb facility. The ideal candidate should have strong technical knowledge in pharma equipment and proven leadership skills.

You will be responsible for maintaining compliance with GMP standards while implementing energy-saving projects. This role also involves managing breakdown maintenance, vendor relations, and continuous improvement initiatives.

Qualifications

• 10 to 15 years of experience in API manufacturing (Maintenance and Projects).
• 5-7 years experience at Section head/engineering head level preferable.

Responsibilities

• Finalise planner for preventive maintenance & instrument calibrations.
• Oversee breakdown maintenance to ensure continuous operations.
• Seek and recommend new vendors and technologies for improvement.
• Implement energy savings initiatives to optimise resources.
• Monitor adherence to safety and quality standards.
• Identify scopes for energy saving projects.

Skills

Technical knowledge of Pharma / machinery and utility equipment / HVAC

Planning and execution Skills

Experience in industrial automation

Knowledge of GMP requirements

Leadership skills

Education

B.Tech/B.E. in Mechanical engineering

Job description

Preferred candidate profile

• B.Tech/B.E. Mechanical engineer with 10 to 15 years of experience in API manufacturing (Maintenance and Projects). 5-7 Years experience at Section head/engineering head level preferable.
• Technical knowledge of Pharma / machinery and utility equipment / HVAC.
• Planning and execution Skills.
• Experience in industrial automation.
• Knowledge of GMP requirements.
• Good leadership skills.

Role & responsibilities

• I. Finalise unique planner and monitor its implementation for planned preventive maintenance & instrument calibrations to achieve effective maintenance and adherence to standards
  • Supervise the PPM/Calibration planner process by giving inputs to Section Heads, collating to prepare a common Unit plan and approve the planner for the Unit
  • Oversee adherence to PPM Schedule by periodic reviews with section heads
  • Monitor Good Engineering Practices are followed during Planned preventive activity, and at all other times, across Unit
  • Understand QA and User feedback on Unit maintenance procedures and improve on the same across Unit
  • Review all Engineering Procedures for being compliant as to cGMP and GEP guidelines, and modify the non-compliant procedures
• II. Oversee breakdown maintenance to avoid recurrence and maintain continuous process operations by checking critical parts availability and adherence to PPM schedule
  • Review availability of critical spares of machines as per plan to reduce resolution time
  • Review PPM being conducted as per schedule to avoid breakdown along with Section heads by checking their schedule adherence
  • Ensure that breakdown of machines are attended timely to minimise impact on quality and production through daily review of breakdown, scheduling work and assessing its completion.
• III. Seek out and recommend new vendors and technologies and recommend capability building initiatives for the Unit Engineering Team to improve the Machine performance
  • Ensure training needs of the unit engineering team are met by assessing training needs, collecting user feedback, overseeing training calendar preparation and reviewing its implementation
  • Recommend and arrange internal and external training/seminars to stay updated with contemporary techniques used in maintenance
  • Recommend implementation opportunities of new technologies available in the market through external interactions and conferences
• IV. Implement energy savings initiatives and draft facility improvements proposals for optimum utilisation of resources to have cost effective operations
  • Govern idea generation sessions and review participation in idea evaluation and implementation of energy savings proposals
  • Schedule internal/external agency audits/checks to receive energy saving, improvement proposals and monitor its implementation
  • Review and follow-up on implementation of action plans for improving deficiencies through internal/ external audits to verify GEP and GMP
• V. Execute, monitor and control CAPEX and OPEX across Unit to reduce cost
  • Review cost heads within Section Heads and provide inputs to Site Engineering Head to take corrective actions for keeping cost heads under control
  • Seek opportunities for reducing operating cost through process and utility automations, propose the same to Site Engineering Head and lead their implementation
  • Evaluate and propose better costing options during brown field projects execution by evaluating options of alternate machinery available at lower costs
  • Explore and implement alternate economical option during execution
• VI. Monitor adherence to safety /quality standards along with HSE/QA to achieve high level of Safety/quality during routine work.
  • Check all safety interlocks of critical machines are checked as per SOP
  • Review all safety meetings and follow-up on implementation of actions planned during departmental safety meeting across unit
  • Ensure proper procedures for safety permits are followed through random checks and reviews with section heads
  • Ensure compliance from government authorities during routine and new project implementation to ensure plant safety
  • Review, approve and track of QMS tools to maintain quality matrix
  • Plan, execute and submit to QA compliances related to regulatory audits
• VII. Identify scope and implement electrical, thermal, energy saving & water saving projects by evaluating its returns, saving and implementation feasibility to reduce cost and make the plant energy sustainable
  • Monitor internal and external energy audits at the Unit Level and formulate action plans for improving on deficiencies identified
  • Lead energy saving projects with respect to renewable energy and green fuel systems at the Unit Level

Major Challenges

Control on OPEX considering rate revisions and variations in product planning. Trade-off between OpEx Management and Quality of services.

Difficulty in upgrading systems / equipment and implementing new ideas due to CAPEX constraints.

Economical option of facility services lead to inconsistent -standard quality services. Trade‑off between OpEx Management and Quality of services.

Deterioration of facility with time leading to higher OpEx requirement. Seek opportunities for temporary patch‑up work to increase life of facility.

Lack of uniformity in Engineering documents due to absence of clear corporate guidelines. Decisions taken at Unit level after discussions.

Increased workload due to Project responsibilities in addition to routine work post dissolving of core project teams. Reschedule and prioritize routing activities.