Safety Engineer

Cipla; India; On-site; INR 1,200,000 - 1,800,000; Full time

Job summary

Cipla is seeking a Process Safety Engineer at its Formulation division to manage major hazards and maintain the process safety management system. You will lead trainings, MAH controls, and risk assessments across the site.

The role requires a degree in chemical engineering and 3+ years in chemical/pharma environments, with hands-on experience in PSM, CAPA, MOC, and QRA. On-site role with strong collaboration across EHS and operations.

Qualifications

• Degree in Chemical Engineering (B.Tech/B.E.).
• Minimum 3 years of experience in chemical/pharma industry as process/operations safety engineer.
• Experience with process safety management systems (PSM) and MAH controls.
• Knowledge of HAZOP, MOC, CAPA, QRA and related safety standards.

Responsibilities

• Implement and maintain Process Safety Management System at site.
• Deliver PSM trainings to operations teams and build competency.
• Monitor MAH assessments and control measures, ensuring ALARP compliance.
• Ensure data for HS1/HS2/HS3/HS4 is collected from process owners.
• Define and manage BPCS/IP/Reliefs as part of risk assessments.
• Lead site-level risk assessments and drive audits/inspections.

Skills

Hazard identification

PSM/PSI

HAZOP

CAPA

MOC

QRA

Process safety training

Education

Degree in Chemical Engineering

Tools

P&ID knowledge

HSE systems

Job description

Division

Manufacturing

Department

Formulation

Sub Department 1

Environment, Health and Safety - Formulation

Job Purpose

Be responsible for maintenance of the process safety (major hazards) management system including HAZOP process documentation, trainings, management of change, quality of process safety incident investigation, CAPA actions and ensure that the learnings are imparted site wide.

Key Accountabilities (1/6)

Process Safety Management System

Ensure implementation of PSM systems at site/unit inline with global EHS standards

Process Safety Standards Administration

• Surveillance of gap analysis against the PSM Global stds and plan for implementation.
• Be instrumental in delivering PSM trainings for each to build competency of operations team

Key Accountabilities (2/6)

Major Accident Hazard Assessment & Control

• Monitor compliance to risk assessments requirements and action completion and communicate compliance to management.
• Ensure driving the controls for raw risks in hierarchy of controls.
• Support as process safety team member for asset integrity programs.
• Monitor and demand for adequate HS1/HS2/HS3/HS4 data for all products handled at site/unit from process owners.
• Ensuring major accident hazard (MAH) risks are controlled to ALARP and involvement in decisions over the selection of the basis of safety for MAH control. This may involve input into the selection, installation and operation of equipment and inspection/maintenance considerations
• Ensure appropriate BPCS/IP/Reliefs are defined as part of controls in the risk assessment undertaken

Key Accountabilities (3/6)

Process Safety SME

• Drive site level systems inline with global standards and Site EHS Stds.
• Contribute to submission of required data in ONSEP plan.
• Coordinate with competent third party to be engaged to carry out studies such as QRA/PSM audits etc.

Key Accountabilities (4/6)

Process Safety Culture & Capability

• Help in gathering data for Process safety KPIs inline with global and Site KPIs.
• Drive PSM competency building at site/unit by defining appropriate trainings for workforce.

Key Accountabilities (5/6)

Investigations & CAPA

• Ensure CAPA actions for incident investigation is driven by hierarchy of controls.
• Track CAPA for closure & effectiveness
• Ensure compliance to recommendations from audits, Investigations etc

Key Accountabilities (6/6)

Operational Role “ Process Safety

• Conduct and lead recommended appropriate risk assessment tool for management of change.
• Escalate all high process risks to plant and EHS management immediately and help to define temporary controls in coordination with senior management.
• Conduct process safety internal audits to check availability of LIVE Process P&ID, LIVE HazOp completion of MoC actions, PSSR adequacy and other similar system adherence.
• Support the operations team on day to day on process safety issues.

Major Challenges

• Driving process safety assessments which will depict LIVE risk status of the plant.
• Handling ambiguity when data is unavailable.
• Building competency of existing employees

This will be overcome by

• Appropriate tools used for implementation such as RAM matrix to identify major hazards, KPI depiction of PSM Health.
• Empowering the PSM manager to elevate appropriate risk and work in consultation with Site Head. Site EHS Head and Functional head to arrive at appropriate acceptable risk.

Key Interactions (1/2)

• Process safety manager for regular updates and guidance
• Maintenance department heads for asset integrity related assignments.
• Production heads for driving PSM agenda and improvements
• Global Process Safey Lead for monthly review and seeking necessary guidance and support
• Vendors and service providers

Key Interactions (2/2)

ISO certification body- annually -for certification

Dimensions (1/2)

---1-Number of sites and “1-3---- number of units

--200-10000--Number of employees at site

--0---Number of direct and total reports

Key Decisions (1/2)

Decision to start the campaign/commission the Plant

Finalisation of PSM training calendar for site/unit employees

Key Decisions (2/2)

Be firm to ensure that all required recommendations are completed before starting of the operations.

Trainings to be conducted role based rather than general topic for all employees and further to ensure on the job training.

Education Qualification

Degree in Chemical Engineering with basic knowledge of powder safety hazards and chemical reactvity hazards

Relevant Work Experience

Minimum 3 years of experience in the industry out of which exposure to chemical / pharma industry for a minimum of 1-2 years as process engineer/operations engineer/process safety engineer