To drive Manufacturing Excellence across the API business by improving productivity, process efficiency, equipment effectiveness, manufacturing cost, yield, quality, reliability and overall operational performance.
The role will act as a central excellence function, working closely with Site Heads, Production, Engineering, Quality, EHS, Supply Chain and Finance teams to identify performance gaps and implement sustainable improvement initiatives across API manufacturing sites.
- Key Responsibilities
A.
Manufacturing Excellence
Strategy
- Develop and implement the Manufacturing Excellence roadmap for the API business.
- Establish common manufacturing standards, performance benchmarks and operating practices across sites.
- Identify opportunities for productivity enhancement, capacity improvement and cost optimization.
- Drive a culture of continuous improvement and data-driven decision making.
- Benchmark manufacturing performance across plants and identify best practices for replication.
- Identify bottlenecks and develop structured improvement plans.
- Lead cross-functional projects for debottlenecking and productivity enhancement.
- Review production losses and establish corrective actions.
C. OEE & Asset Utilization
- Establish a robust OEE measurement and review mechanism.
- Analyze availability, performance and quality losses.
- Identify major equipment losses and coordinate with Engineering and Production for corrective actions.
- Improve utilization of critical API manufacturing assets.
- Drive reduction in equipment-related production losses and idle capacity.
D.
Process
Optimization
- Analyze manufacturing processes to identify opportunities for:
- - Cycle-time reduction
- Yield improvement
- Reduction in process losses
- Reduction in solvent consumption
- Reduction in energy consumption
- Reduction in reprocessing
- Improvement in batch consistency
- Work with Technical, Production and Quality teams for process optimization.
- Support scale-up, technology transfer and process improvement initiatives.
E. Cost Optimization
- Lead manufacturing cost-reduction initiatives across API sites.
- Identify opportunities for reduction in:
- - Conversion cost
- Energy cost
- Solvent consumption
- Manpower cost
- Maintenance cost
- Material losses
- Waste generation
- Develop measurable business cases for improvement projects.
- Track financial perks and ensure savings are sustainable.
F. Lean & Continuous Improvement
- Implement Lean Manufacturing principles across API operations.