Unit Engineering Maintenance & Reliability Head
Location
Anekal | India
Job description
Division
Manufacturing
Department Active Pharmaceutical Ingredient
Sub Department 1 Engineering - API
Job Purpose The incumbent provides leadership to the' Unit Engineering Maintenance & Reliability Team and carries overall responsibility to:
- Manage Unit Engineering Maintenance & Reliability Operations with strict adherence to statutory & legal requirements and Cipla Global Standards & Procedures to meet the Unit Annual Operating Plan:
- Maintenance Execution: Lead the multidiscipline maintenance execution team assigned to the Unit EM&R ' Mechanical, Electrical, Instrumentation & Planning- responsible and accountable for delivering results on Safety & cGMP + Quality, Technical Availability, Maintenance Cost & œBest in Class ME with ˜Zero™ rework.
- Service Floor Utility Operations: ensure that utilities are operated at standard efficiencies and enable achievement of standard capacity by plant & equipment with agreed levels of plant availability;
- Asset Integrity & Reliability: drive the Reliability Engineering, Asset integrity and Process safety processes for Unit operations leveraging the support of the Site AI&R Team
- Turn Around Management: Ensure that Unit turnaround / shutdown are managed effectively with œzero rework. Support the delivery of the Unit Capex Program.
- Reliability Analytics & Planning: Leverage and support the Site reliability analytics & planning team to drive continual improvement in Unit EM&R Function.
- Procurement & Engineering Stores: Maintain interface with, review and ensure availability of critical spares.
- Develop, Obtain approval of & Execute the Comprehensive Maintenance Program to comply with Cipla Global E&P Technical Standards & Procedures, cGMP Standards & Procedures [ Cipla QMS] , OHS & Environment Sustainability Standards & Procedures ; Support deployment of the strategic Initiatives in the Unit Operations
Key Accountabilities (1/6)- Develop & Maintain a Interdependent Safety Culture [ This is a multidisciplinary line job and hence safety takes first priority] ¢ Provide œVisible Felt Leadership™ and Ensure Compliance to Cipla EHS Policies, Standards & Procedures and ensure ' Zero Harm' through periodic institutionalized reviews / audits and Gemba Walks ¢ Develop and Maintain a safety culture with zero reportable and LTA (Loss Time Accident) ¢ Ensure ME Priority standards are implemented
- Permit to Work [ Including LOTOTO]
- Chemicals Handling [ Incl. Health & Hygiene]
- Contractor Safety
- Critical & Controlled Elements
- PPE
- Incident Reporting & Investigations
¢ Review all near misses, incidents, accidents, WPI, deviations and audit observations for appropriateness of CAPA to meet EHS standards. Track & drive closure as per agreed SLA. Ensure reporting as per standard.
¢ Drive BOS as a behaviour Modification Tool to improve towards œZERO HARM.
¢ Ensure systems are in place to comply with national and international statutory and regulatory requirements. Review compliance at defined frequency [Quarterly] and deviations if any are escalated as per the procedure and CAPA completed as per agreed timelines.
¢ Drive Resource Conservation Initiatives in the Unit.
II. [D] [E] Unit Operations Leadership ' EM&R Functional Leader Role
¢ Participates in Unit Head™s meeting; Reports functional updates; Asserts technical judgments whenever necessary to optimize the Unit performance with an open and professional communication.
¢ Develop and schedule long-term and short-term maintenance plans (routine and shutdown), working with Unit Head Operations to achieve standard capacity; meet production requirements and targets for Site Operations while adhering to cost targets.
¢ Unit cGMP & EHS Requirement in the Manufacturing & Packing Area; Support Unit Operations Team as required.
¢ Ensure optimum balance on asset utilisation, cost control, reliability, maintenance planning, maintenance execution, knowledge / skill deployment and staff development, stock inventory management and spares availability for the Unit EM&R Operations
¢ Ensure delivery of best in class services to the stakeholders
¢ Maintain excellent and accurate communications with the stakeholders.
Key Accountabilities (2/6) III. [D] [E]Maintenance Execution
¢ Interface and coordinate with the different maintenance teams and service providers to ensure the reliability and sustainability of the equipment repairs is guaranteed; Considers the long-term cost of ownership and risk management when outsourcing certain services to support the maintenance group.
¢ Leads in discussing with other sections of the maintenance department concerning reliability, spare parts management and Asset Integrity to maximize the quality of the maintenance execution and Technical Availability.
¢ Drive implementation and maintain oversight to achieve Best Practice Standards in terms of Maintenance Execution and Maintenance Productivity KPMs such as
- Wrench Time
- PM to CM Ratio
- CM due to PM
- Open Notification past Due dates
- Asset Hierarchy & Register Completeness
- SAP CMMS Usage
- Tier-1 Leaks per month
- Tier-2 Leaks per month per unit
- Average Time to repair leaks (hrs)
- Temporary repairs per unit
¢ Ensure that maintenance execution work processes are fully implemented and followed
¢ Ensure the proper, timely and safe implementation of preventive and corrective maintenance activities
¢ Develop a ˜Zero™ Rework culture on preventive and corrective maintenance activities
¢ Ensure that breakdown maintenance is done in expeditious manner.
¢ Ensure Fault & Breakdown Diagnosis and drive corrective and preventive actions to minimize breakdowns. Review learning from other sites and include them in the improvement ideas.
¢ Ensure critical spares of critical m/c are maintained to reduce resolution time by predicting demand and reviewing availability
¢ Maintenance execution is documented as per the Cipla Global Standards & Procedures.
¢ Implement Minor Capital Program and Improvement Initiatives for the Unit operations as per agreed SLAs
IV. [D] [E]Service Area Utility Operations
¢ Maintain oversight of the Utility Operations at Unit Service / Technical floors
- administer the Master Services Agreement
- ensure technical availability meet production need
- adhere to cost targets
¢ Drive compliance to cGMP, QMS, EHS and Tech. workplace standards for the Utilities / Technical Floor including Good House Keeping.
¢ Drive Cipla Global strategic initiatives in Technical Floor
- Decluttering of idle equipment
- Filter cleaning & management
- INTEGRATED PEST MANAGEMENT PROGRAM
Key Accountabilities (3/6)- Comprehensive Maintenance Program Execution ¢ Develop a Comprehensive Maintenance Program [Condition Monitoring, Predictive Maintenance, Preventive Maintenance, Breakdown Maintenance, Calibration Schedule and Turn Around Maintenance] for the Unit Operations and obtain approval of Site E&P Head, Unit Head & Unit Quality. ¢ Drive & ensure implementation thereof [including review of critical spares & personnel] and delivered agreed performance standards
- Plan, budget, and schedule facility maintenance activities including estimates on equipment, labor, materials and other related costs
- Define CMP execution budget and control the cost within the budget
- Provide input on the quality and implementation of service contracts
- Ensures company standard processes and procedures are utilized by deployed groups
- Design, evaluates and approves CMP Maintenance reports, documents and revisions, and resource performance before submission to Unit Head and Site Engineering & Projects heads.
- Monitors and contributes to management of institutional maintenance issues and oversees subcontracted and/or in-house facility maintenance services
- Provide inputs for improvement of the comprehensive maintenance program to the Global Engineering & Projects Team.
¢ Ensure reliability of the assets at the highest level by by driving the following KPMs
- %Plant Availability
- %Breakdown hours
- %PM hours
- %Reduction of Failures from last year
- %Reduction of Repeat Incidents
- %Implemented recommendations from RCA
- %Implemented recommendations from RCM
- %Implemented recommendations from RBI
- % Missing barriers restoration - Bowtie Studies
- %Implemented recommendations from IPF
VI. Turn Around & Capex Program for the Unit Operations
¢ Develop, Document, Obtain Approval Of And Drive The Execution Of The Unit Turn Around Program To Ensure Delivery Of The Following KPMs
- TA Program Stage Gate Review Compliance
- TA Program Scope Delivery
- TA Program Timelines Delivery
- TA Program Cost Delivery
- Zero LTA in TA Execution
- Zero cGMP Incidents in TA Execution
- Zero Rework on Start Up
¢ Drive the Technology for Manufacturing Agenda for SIte Operations ' Manufacturing Automation, Engineering Automation and Digital Transformation.
¢ Develop, Document, Obtain Approval Of And Drive The Execution Of The Unit Capex Program To Ensure Delivery Of The Following KPMs
- Project Stage Gate Review Compliance
- Project Scope Delivery
- Project Timelines Delivery
- Project Cost Delivery
- Zero LTA in Project Execution
- Zero cGMP Incidents in Project Execution
- Zero Rework on Start Up
Key Accountabilities (4/6) VII. [E] Implement the Site Engineering & Projects processes & systems
¢ Support & Drive the implementation of Site Engineering & Projects processes & systems for Unit Operations
- Plan for Implementation of E&P P&S
- Support the Implementation of E&P P&S:
- Operationalize the E&P P&S in EM&R Operations:
- Evaluate Performance of E&P P&S for Unit Ops
- Drive Improvement through E&P P&S:
- Conduct Internal Audit to ensure adherence
VIII. [E] Global Operations and Global Engineering & Projects Strategy Deployment at Goa I Site
¢ Provide inputs to finalize priorities for the function in the Site Operations Strategic Capacity & Capability Plan.
¢ Provide support to implement the key priorities
- Resource Conservation
- Capacity Debottlenecking
- RCM Strategy
- New Technology / Asset Retiral Strategy
- MRO Strategy [Vendor, Spare Parts]
- cGMP Compliance Strategy
- Statutory Compliance Strategy
¢ Support implementation the following in Unit EM&R Operations for the Unit
- Pegasus
- Asset Management System
- Reliability Centred Maintenance
- Reliability Engineering & Analytics
- Asset Integrity
- Technical Process Safety
- Maintenance Execution
- Turnaround Management
- Project Management
- Group Technical Standards
- Critical & Controlled Equipment Standards
- Strategic MRTA Technologies
- SAP CMMS
- ESP (w/PTM)
- MTO
- MRO
- MSC
- Utility Automation
- AR & MR Based Training
- Professional Certifications
- AI ML based Maintenance Planning & Analytics
- Contracting and Procurement
- Competence Framework
- Site Management System
- Asset Information Management
IX. [E] Compliance to Cipla Global Standards & Procedures: cGMP & QMS Standards
¢ Ensure that facility is maintained as per CGMP, CGMP requirements of country where product is being exported and strict adherence of Good Engineering practices during task execution.
¢ Ensure validation & calibration is done as per the Master Validation & Calibration Schedule and that personnel are trained for validation and qualification
¢ Review and evaluate the risk assessment along with risk management team i.e. Failure mode effect criticality analysis (FMECA) & draw necessary CAPA.
¢ Evaluate change controls related to system, facility and document and study of impact related to changes and to ensure implementation of change.
¢ Review major deviations as per standard procedure and necessary CAPA in relation to deviation system.
Key Accountabilities (5/6)- [E] Functional Capability |Employee Connect | Rewards & Recognition ¢ Recruit, train and develop team for sustainable and more effective operation, and to ensure the expertise level required to meet current and future needs of the department; ¢ Recommends appropriate developmental program for potential areas of improvement ¢ Structured Connect within the framework of Cipla People Processes.
- Chai pe Charcha
- Monthly Communication
- Quarterly Connect with Third Party Service Providers
- Annual connect with Service Partners
¢ Promote & drive adherence to the Rewards & Recognition Program. Recognise disciplined execution & excellence, innovation & going beyond the call of duty
XI. [E] Operations Excellence in EM&Rs
¢ MIS Report ' Ensure timely reporting of agreed metrics. Drive a Continual Improvement Program on priority metrics.
¢ Embed Lean Six Sigma Capability in the team. Build and sustain a 16% penetration on D+ level.
XII. [D] & [E] Site Cost Performance:
¢ Ensure compliance to the Annual Budget on
through periodic reviews with the Site Engineering & Projects Head.
¢ Drive Productivity Improvement Plans to have a war chest to mitigate any deviations from the Budget.
¢ Ensure adherence to Cipla Financial Control Polices, Standards & Procedures and ensure 'EFFECTIVE' status on Control Environment and 'NO CRITICAL OBSERVATIONS' in Internal Audits through periodic institutionalized reviews / audits with the Unit Heads / Functional Heads and the Site Finance Head.
XIII. [E] Other Execution
Accountabilities
¢ Approval of requisition in SAP system.
¢ Maintain oversight of the Master Services Agreement SLAs
¢ Development, approval and monitoring of suppliers of engineering materials and services for the Site
¢ Any other job allocated by Senior Factory Management.
XIV. [E] Self Development on functional & 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 Functional & Leadership capability building as per guidance from HR function and the Global Operations Team.
Key Accountabilities (6/6) Major Challenges - CapEx and OpEx ' Adherence to the budget
- Cost vs performance trade off in equipment
- Supply of critical utility resources like water
- Increasing energy tariffs and Fuel rates leading to escalated product cost
- 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
¢ Finance for Capex & Opex proposal approvals, analytics & MIS
¢ EHS for safe operations and near-misses
¢ HR for Attrition, Recruitment, Training
¢ Site head & Unit heads for Proposals, breakdowns and developments
¢ Engineering DR for Guidance & Updates
¢ 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: 6-7, Team Size ' 24-30
- Unit Maintenance + Utility Budget: 15-20 CR
- Capex Budget: Sustenance 10 CR
- 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 / Electrical / Instrumentation)
Relevant Work Experience ¢ 10-12 years of experience in manufacturing (Maintenance and Projects). At least 3 years in senior management role
¢ 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
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