The incumbent provides leadership to theâ Unit Engineering Maintenance & Reliability Team and carries overall responsibility to:
1. Manage Unit utility operations with strict adherence to statutory & legal requirements and Cipla Global Standards & Procedures to meet the Unit Annual Operating Plan:
a. Maintenance Execution: Lead the multidiscipline maintenance execution team assigned to the utility EM&R â Mechanical, Electrical, Instrumentation & Planning- responsible and accountable for delivering results on Safety & cGMP + Quality, Technical Availability, Maintenance Cost & ÅBest in Class ME with ËZero⢠rework.
b. Utility block Operations: ensure that utilities are operated at standard efficiencies and enable achievement of standard capacity by plant & equipment with agreed levels of plant availability;
c. Asset Integrity & Reliability: drive the Reliability Engineering, Asset integrity and Process safety processes for Utility operations leveraging the support of the Site AI&R Team
d. Turn Around Management: Ensure that Unit turnaround / shutdown are managed effectively with Åzero reworkÂ. Support the delivery of the Unit Capex Program.
e. Reliability Analytics & Planning: Leverage and support the Site reliability analytics & planning team to drive continual improvement in Unit EM&R Function.
f. Procurement & Engineering Stores: Maintain interface with, review and ensure availability of critical spares.
2. Develop, Obtain approval of & Execute the Comprehensive Utility 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
I. Develop & Maintain a Interdependent Safety Culture [ This is a multidisciplinary line job and hence safety takes first priority]
¢ Provide ÅVisible 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
o Permit to Work [ Including LOTOTO]
o Chemicals Handling [ Incl. Health & Hygiene]
o Contractor Safety
o Critical & Controlled Elements
o PPE
o 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 ÅZERO HARMÂ.
¢ 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] Utility Operations Leadership â EM&R Functional Leader Role
¢ Participates in Site Engineering Headâ¢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.
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
o Wrench Time
o PM to CM Ratio
o CM due to PM
o Open Notification past Due dates
o Asset Hierarchy & Register Completeness
o SAP CMMS Usage
o Tier-1 Leaks per month
o Tier-2 Leaks per month per unit
o Average Time to repair leaks (hrs)
o 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 ËZero⢠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] Utility Operations
¢ Maintain oversight of the Utility Operations at Utility block
o administer the Master Services Agreement
o ensure utilities availability to meet production need
o adhere to cost targets
¢ Drive compliance to cGMP, QMS, EHS and Tech. workplace standards for the Utilities including Good House Keeping.
¢ To minimize down time production plant due to Utility services / operations
¢ No utility contingency
¢ Provision of Uninterrupted and consistent services of Power & Utilities to entire complex with reliability
V. [E] 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 Utility 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 Site Engineering & Projects head.
¢ 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
o %Plant Availability
o %Breakdown hours
o %PM hours
o %Reduction of Failures from last year
o %Reduction of Repeat Incidents
o %Implemented recommendations from RCA
o %Implemented recommendations from RCM
o %Implemented recommendations from RBI
o % Missing barriers restoration - Bowtie Studies
o %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:
o TA Program Stage Gate Review Compliance
o TA Program Scope Delivery
o TA Program Timelines Delivery
o TA Program Cost Delivery
o Zero LTA in TA Execution
o Zero cGMP Incidents in TA Execution
o Zero Rework on Start Up
¢ Drive the Technology for Utilities Agenda for Site Operations â Utilities 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:
o Project Stage Gate Review Compliance
o Project Scope Delivery
o Project Timelines Delivery
o Project Cost Delivery
o Zero LTA in Project Execution
o Zero cGMP Incidents in Project Execution
o Zero Rework on Start Up
VII. [E] Implement the Site Engineering & Projects processes & systems
¢ Support & Drive the implementation of Site Engineering & Projects processes & systems for Utility Operations
o Plan for Implementation of E&P P&S
o Support the Implementation of E&P P&S:
o Operationalize the E&P P&S in EM&R Operations:
o Evaluate Performance of E&P P&S for Unit Ops
o Drive Improvement through E&P P&S:
o 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
o Resource Conservation
o Capacity Debottlenecking
o RCM Strategy
o New Technology / Asset Retiral Strategy
o MRO Strategy [Vendor, Spare Parts]
o cGMP Compliance Strategy
o Statutory Compliance Strategy
¢ Support implementation the following in Utilities Operations for the Unit
o Pegasus
o Asset Management System
o Reliability Centred Maintenance
o Reliability Engineering & Analytics
o Asset Integrity
o Technical Process Safety
o Maintenance Execution
o Turnaround Management
o Project Management
o Group Technical Standards
o Critical & Controlled Equipment Standards
o Strategic MRTA Technologies
o SAP CMMS
o ESP (w/PTM)
o MTO
o MRO
o MSC
o Utility Automation
o AR & MR Based Training
o Professional Certifications
o AI ML based Maintenance Planning & Analytics
o Contracting and Procurement
o Competence Framework
o Site Management System
o Asset Information Management
IX. [E] Compliance to Cipla Global Standards & Procedures: cGMP & QMS Standards
¢ Ensure that utility equipment and distribution systems are maintained as per 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.
X. [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.
o Chai pe Charcha
o Monthly Communication
o Quarterly Connect with Third Party Service Providers
o 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 â 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
o OPEX
o CAPEX
o MANPOWER COST
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.
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 â Guidance & Updates in TLT, Focus Calls & Reviews
¢ Corporate Affairs & Legal Team â 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 â Connect on external benchmarking & information on technology evolution
¢ Statutory Bodies â Connect for Regulatory compliance
Decisions
¢ Spends within Approved Budget â Capex & Opx
¢ Maintenance & Reliability Strategies
¢ Engineering & Project Vendors & service Providers as per EA
¢ Technology for Utility generation and distribution.
¢ Power and fuel Conservation initiatives
¢ Capability Programs
Recommendations
¢ Opex & Project costs Proposal
¢ New vendor addition
¢ Utility audits
¢ Hiring consultants
¢ New equipment & Technology
BE / B Tech (Mechanical / Electrical)
¢ 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
¢ Good leadership skills and experience in industrial automation
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