Team Member - Engineering (Process Instrumentation)

Dr. Reddy's Laboratories; Andhra Pradesh; On-site; INR 600,000 - 900,000; Full time

Job summary

Dr. Reddy's Laboratories in Andhra Pradesh seeks a skilled instrument maintenance engineer to oversee maintenance, calibration, and installation of sensors, IPC, HMI, PLCs, and control panels to ensure reliable plant operations.

You will plan preventive, predictive, and shutdown maintenance, support automation upgrades, coordinate with engineering teams, and drive TPM activities including RCA for instrumentation issues.

Responsibilities

• Recognizing potential hazards during maintenance and coordinating safety requirements through work permits, LOTO procedures, and JSA reviews.
• Maintenance, calibration, and installation of sensors and instruments (Temperature, pressure, flow, level, humidity, Load cells, speed sensors, encoders, Proximity, photoelectric, IR) including IPC, HMI, PLC and control panels.
• Identify and rectify instrument issues (signal fluctuation, false alarms, interlock failures, sensor misalignment) and ensure mechanical health and proper mounting.
• Plan and execute preventive, predictive, and shutdown maintenance; maintain housekeeping and critical spare availability.
• Support automation systems to minimize downtime; implement control system backups and explore new automation opportunities.
• Manage Preventive Maintenance per schedule; maintain records; ensure ISO, cGMP, and statutory compliance.
• Troubleshoot instrumentation issues; coordinate with engineering and issue new instruments to user departments for seamless operations.
• Handle process equipment like RMG, FBD, blenders, Octagonal mixers, tablet presses, coating, packing equipment; support production during operation, changeovers, and breakdowns.
• Plan, execute, and support PLC and SCADA upgrades for manufacturing equipment.
• Participate in TPM activities; identify abnormalities and perform RCA for instrumentation failures with corrective actions.
• Initiate purchase requisitions; inspect spares; oversee contractor work related to fabrication and insulation; execute annual maintenance plans.
• Identify process abnormalities; implement lean tools (5S, Kaizen, Autonomous Maintenance); coordinate small project modifications with plant leads.

Job description

• You will be responsible for recognizing potential hazards during critical maintenance and coordinating safety requirements through work permits, LOTO procedures, and JSA reviews to ensure 100% compliance.
• You will be responsible for handling the maintenance, calibration, and installation of instruments like, Temperature, pressure, flow, level, humidity sensors, Load cells, speed sensors, encoders, Proximity, photoelectric, and IR sensors, IPC, HMI, PLC and control panels, ensuring accuracy and reliability in plant operations.
• Identify and rectify instrument‑related issues such as signal fluctuation, false alarms, interlock failures, and sensor misalignment and Ensure all instruments are mechanically healthy, properly mounted, protected, and operational.
• You will be responsible for planning and executing preventive, predictive, and shutdown maintenance activities, maintaining good housekeeping, and managing critical spare availability efficiently.
• You will be responsible for supporting automation systems to minimize downtime, implementing control system backups, and identifying opportunities for new areas of automation.
• You will be responsible for managing Preventive Maintenance activities as per schedule, maintaining accurate records, identifying discrepancies, and ensuring compliance with ISO, cGMP, and statutory requirements.
• You will be responsible for troubleshooting instrumentation issues, coordinating with engineering teams, and issuing new instruments to user departments for seamless operations.
• You Will be responsible to handle and Idea About Process Equipment like, RMG, FBD, Blenders, Octagonal mixers, Tablet compression machines, Capsule filling machines, Coating machines, Packing equipment and Support production during routine operation, changeovers, and breakdown conditions to avoid process interruptions.
• Responsible for planning, executing, and supporting PLC and SCADA upgradation activities for manufacturing equipment.
• Responsible for participating in TPM activities by identifying, reporting, and supporting closure of instrumentation‑related abnormalities and Responsible for performing root cause analysis (RCA) for instrumentation failures and implementing corrective actions.
• You will be responsible for initiating purchase requisitions, inspecting received spares, and overseeing contractor work related to fabrication and insulation, while executing annual maintenance plans.
• You will be responsible for identifying process abnormalities, implementing lean tools such as 5S, Kaizen, and Autonomous Maintenance, and coordinating small project modifications with plant leads.