Production Technician (Bfs Manufacturing)

Adcock Ingram Holdings Ltd; Johannesburg; On-site; ZAR 350,000 - 600,000; Full time

Job summary

Adcock Ingram Holdings Limited is seeking a skilled operator to manage Rommelag BFS machines in a busy manufacturing environment. The role focuses on safe operation, process control, and quality adherence within GMP guidelines.

You will monitor critical parameters, perform start-ups and line changes, and contribute to continuous improvement while ensuring documentation is accurate and compliant. Johannesburg-based, full-time position with healthcare and related benefits.

Qualifications

• Operate and monitor Rommelag BFS machines during production runs.
• Perform line opening and line clearance activities in accordance with approved procedures.
• Report production outputs and equipment issues accurately and timeously.

Responsibilities

• Operate BFS machines and monitor production runs to meet targets.
• Perform start-ups, shutdowns, and mould changes as required.
• Control BFS process parameters and ensure product quality and process stability.
• Maintain GMP and QMS compliant documentation and deviation reporting.
• Assist with routine maintenance and support root cause investigations.

Skills

BFS machine operation

Process monitoring

Troubleshooting

Quality documentation

GMP compliance

Tools

HMI

PLC

Calibration tools

Job description

Adcock Ingram Holdings Limited and its Subsidiaries(“we”, “us”) is committed to protecting and respecting your privacy. Our Privacy Notice sets out the basis on which personal information collected inter alia from you, social media, recruitment agencies and our website, will be processed by us. The Privacy notice is available on our website www.adcock.co.za.

One of the conditions under the Protection of Personal Information Act 4 of 2013 (POPIA) provides that candidates have the right to be informed about the collection and use of their personal information,

In the course of your application: we may

• collect personal information that may be used to identify potential professional opportunities other than the job you have applied for but of which we think might be of interest to you.
• use your Personal Information to confirm references or background checks you have provided us.
• request your consent to participate in aptitude tests or recruitment assessments.

We also use your personal information to respond to your inquiries, to verify your information and to share information with you.

Your personal information will be securely stored by the Human Capital Department and it will be retained for a period of up to 12 months as of the closure of the application procedure if your application is unsuccessful, and in case of a successful application and you are hired, your data will be transferred to your personal employee file.

By applying for this position, you consent to us processing your personal information.

We reserve the right to make an appointment. If you have not heard from us within 30 (thirty) days of the closing date, please accept that your application was unsuccessful. Correspondence will be entered into only with shortlisted candidates.

Please note that this appointment will be made in line with company’s employment equity policy and divisional employment equity targets

JOB PURPOSE:

To operate, monitor, maintain, troubleshoot, and optimise Rommelag Blow-Fill-Seal (BFS) filling equipment and associated production processes to ensure the safe, efficient, and compliant manufacture of sterile pharmaceutical products. The incumbent is expected to apply practical expertise in BFS technology, polymer behaviour, plastics extrusion and moulding principles, machine process control, electronic and mechanical fault finding, and PLC-controlled automated systems. The role is responsible for machine operation, first-line maintenance, line clearance, line opening activities, process monitoring, quality assurance, GMP and QMS compliance, deviation support, root cause analysis, and accurate technical report writing.

MAIN TASKS / RESPONSIBILITIES:

Production Operations

• Operate and monitor Rommelag BFS machines during production runs.
• Ensure production targets are achieved while maintaining product quality standards.
• Perform machine start-ups, shutdowns, product changeovers, and mould changes.
• Set up and control BFS process parameters relating to polymer extrusion, parison control, mould temperature, cooling, cutting, sealing, and container formation.
• Conduct line opening and line clearance activities in accordance with approved procedures.
• Monitor critical process parameters, including:
  • Temperature
  • Pressure
  • Fill volume
  • Bottle weight
  • Cycle times
• Polymer melt condition and extrusion stability
• Sealing integrity
• PLC alarms, interlocks, sensor feedback, and automated control status
• Ensure correct machine setup and operational readiness before production commencement.
• Report production outputs, process deviations, and equipment issues accurately and timeously.

Equipment Maintenance & Troubleshooting

• Perform first-line maintenance on BFS equipment and associated systems.
• Use machine HMI and PLC feedback to identify alarms, abnormal operating conditions, process deviations, and equipment interlock issues.
• Conduct routine machine inspections and preventive maintenance activities.
• Troubleshoot mechanical, electrical, pneumatic, hydraulic, and process-related faults.
• Diagnose BFS-related process issues linked to polymer flow, extrusion instability, mould alignment, trimming, sealing defects, container formation, and plastic material performance.
• Identify and elevate equipment abnormalities for further technical intervention when required.
• Assist Engineering and Maintenance teams during major maintenance and breakdown investigations.
• Ensure equipment remains in optimal operational condition to minimize downtime.

Quality Assurance

• Perform in-process quality inspections according to SOPs, GMP requirements, and batch documentation.
• Monitor and inspect products for:
  • Leaks
  • Bottle weight compliance
  • Fill volume accuracy
  • Seal integrity
  • Flashing defects
  • Cosmetic defects
  • Particulate contamination
  • Print quality and traceability
• Complete all production and quality documentation accurately and legibly.
• Participate in deviation investigations, root cause analyses, and corrective action implementation.
• Assist with batch reconciliation and release-related activities.
• Support root cause analysis investigations by gathering process information, reviewing machine trends or events, identifying contributing factors, and documenting investigation outcomes.
• Prepare clear, factual, and GMP-compliant deviation, investigation, and technical reports where required.

Cleaning & Housekeeping

• Clean and sanitize BFS machines and production equipment according to approved procedures.
• Maintain housekeeping standards within manufacturing and cleanroom areas.
• Ensure adherence to contamination-control procedures and sterile gowning requirements.
• Participate in scheduled cleaning and sanitization programs.

Safety, GMP & Compliance

• Adhere to all Occupational Health and Safety regulations and company safety procedures.
• Always wear and maintain required PPE.
• Comply with GMP, SOPs, work instructions, and regulatory requirements.
• Participate in audits, inspections, training programs, and compliance initiatives.
• Apply pharmaceutical, GMP, and QMS training in daily operations, documentation practices, deviation handling, and compliance activities.
• Identify and report safety hazards, near misses, and unsafe conditions.

Continuous Improvement

• Contribute to process improvement initiatives aimed at increasing machine efficiency and reducing waste.
• Participate in root cause investigations and problem-solving activities.
• Use structured problem-solving tools to support root cause analysis, CAPA development, and documented effectiveness follow-up.
• Support implementation of corrective and preventive actions (CAPA).
• Assist in achieving departmental productivity, efficiency, and quality objectives.