Engineer - Mechanical

Division

Department

Sub Department 1

Job Purpose

• The incumbent is a team member of Engineering Maintenance & Reliability Team and carries overall responsibility to:
• 1.    Execute the maintenance activities in the plant & ensure the minimum breakdown with maximum efficiency by following safety & GMP Standards
• 2.    Support Senior 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;
• Functional Engineer is responsible for executing maintenance tasks as assigned by Senior Engineer for his function in the Manufacturing, Packing and utility areas.
• Where outsourced, 3rd Party Functional Engineer is accountable for the Service Floor / Technical Floor maintenance execution

Key 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 maintenance activity to meet maintenance targets for a shift
• ¢    Cater to machine and facility 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 Shift Engineer report to ensure smooth shift handover
• ¢    Analyse breakdowns, diagnose faults and supervise time critical equipment repairs.
• ¢    Offer technical expertise to maintenance people like supervisor, foreman, fitters and technicians.
• ¢    Function as project development member to maintain new equipment.
• ¢    Work with reliability engineers to extend equipment life cycle.
• 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 maintenance and update related documentation
• o    Preventive Maintenance
• o    Calibration
• o    Condition Monitoring
• o    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 compliance

Key Accountabilities (2/6)

• III.    Breakdown Maintenance: Handle breakdown maintenance to avoid recurrence and maintain continuous process operations
• ¢    Execute breakdown work expeditiously but safely and in compliance with cGMP.
• ¢    Receipt and tracking the job card for the break down activity
• ¢    Maintain critical spares inventory of all machines to reduce resolution time
• 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 operations
• V.    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 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 estimates.

Key Accountabilities (3/6)

• VI.    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 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 possible
• 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 following
• o    Near Miss
• o    Safety Incident
• o    Work Place Inspection
• o    Unsafe Act
• o    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 records

Key Accountabilities (4/6)

• VIII.    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 documentation and timely entries in all document 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 Senior Engineer.
• ¢    Prepare and maintain engineering documents wrt cGMP and Good Engineering Practices
• 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 mechanical engineering & 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 mechanical engineering & Leadership capability building as per guidance from HR function and the Global Operations Team.

Key Accountabilities (5/6)

Key Accountabilities (6/6)

Major Challenges

• CapEx and OpEx “ Adherence to the budget
• Cost vs performance trade off in equipment
• Ageing Asset leading to escalating OpEx Cost
• Challenges around capability & competence of personnel and service providers

Key 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 matters
• External
• ¢    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 compliance

Key Interactions (2/2)

Dimensions (1/2)

• ¢    Direct Reports: 0, Team Size “ 9-12
• ¢    Unit Maintenance + Utility Budget: 15-20 CR [ Functional ~ 33% of this]
• ¢    Capex Budget: Sustenance 10 CR [ Functional ~ 33% of this]
• ¢    Revenue of Goa I: 300-400 CR
• ¢    Current Replacement value of Assets Maintained: Net Block > 50 CR; CRV > 200 CR

Dimensions (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 Programs
• Recommendations
• ¢    Opex & Project costs Proposal
• ¢    New vendor addition
• ¢    Facility audits
• ¢    Hiring consultants
• ¢    New equipment & Technology

Key Decisions (2/2)

Education Qualification

BE / B Tech (Mechanical)

Relevant Work Experience

• 2-5 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 concepts
• Good technical knowledge of Pharma / API machinery and utility requirements
• Good knowledge and experience in execution of green field / brown field projects
• Knowledge of GMP and various regulatory requirements
• Good leadership skills and experience in mechanical engineering activities