1. Role PurposeTo lead and manage External Manufacturing (EM) operations by ensuring successful technology transfer, process scale-up, manufacturing readiness, commercial production execution, process optimization, and cost-effective operations at toll manufacturing locations. The role acts as the key interface between R&D;, Technology & Development (T&D;), Supply Chain, Quality, EHS, and EM partners to ensure seamless product commercialization and reliable supply while maintaining safety, quality, delivery, and cost objectives.2. Key Responsibilities 1. External Manufacturing Strategy & PlanningDevelop and execute External Manufacturing (EM) plans in consultation with business and functional stakeholders.Identify manufacturing capacities and capabilities available at toll manufacturing partners.Support sourcing and evaluation of potential External Manufacturing partners.Drive commercialization and scale-up projects through a structured execution framework.Monitor production plans and align output with business demand forecasts.Ensure optimum utilization of approved EM capacities.2. Process Engineering & Technology TransferEngineering DocumentationPrepare, review, and approve:Block Flow Diagrams (BFD)Process Flow Diagrams (PFD)Piping & Instrumentation Diagrams (P&ID;)Process DatasheetsUtility Requirement SpecificationsEquipment ListsEnsure process engineering documentation complies with company standards.Review process modifications and maintain engineering document control.Technology TransferWitness demonstration batches at R&D; and Pilot Plant facilities.Understand reaction chemistry, critical process parameters, process hazards, and operating windows.Lead technology transfer from laboratory/pilot scale to commercial manufacturing.Independently implement and commercialize products at EM sites.Ensure successful execution of first-time commercial batches.3. Material & Energy Balance ManagementPrepare detailed material balance and energy balance calculations.Establish raw material consumption norms for products.Determine utility requirements including (If required. As per current practice for existing product, Operation/T&D; has to provide):SteamChilling WaterCooling WaterElectricityNitrogenCompressed AirMonitor actual consumption against design assumptions.Analyze deviations and implement improvement actions.Establish mass balance monitoring systems across manufacturing campaigns.4.



External Manufacturing Facility AssessmentConduct technical assessments of External Manufacturing facilities.Evaluate facility capabilities including:Reactor SizingDistillation SystemsUtility InfrastructureStorage FacilitiesMaterial Handling SystemsProcess Control SystemsVerify suitability of equipment for intended processes.Assess manufacturing readiness before commercialization.Conduct periodic technical audits of EM facilities.5. Site Readiness & CommissioningCoordinate with EM partners for readiness of equipment, manpower, utilities, and raw materials.Conduct pre-commissioning inspections and readiness reviews.Verify completion of engineering, safety, and operational requirements.Lead commissioning and start-up of commercial campaigns.Ensure smooth scale-up from pilot batch to commercial production.Support EM production teams during initial manufacturing campaigns.6. Production Campaign ManagementManage end-to-end manufacturing campaigns at toll manufacturing locations.Prepare batch execution plans and campaign schedules.Monitor:Production ProgressCampaign TimelinesBatch PerformanceYield AchievementResource UtilizationManufacturing EfficiencyTrack batch-wise production data and identify deviations.Publish weekly manufacturing reports and campaign performance updates.Prepare campaign closure reports and lessons learned documentation.7. Process Optimization & TroubleshootingProvide technical troubleshooting support for ongoing manufacturing operations.Coordinate with R&D; and T&D; teams to resolve process challenges.Perform root cause analysis for:Yield LossesProcess DeviationsQuality IssuesProduction InterruptionsIdentify opportunities for:Yield ImprovementUtility ReductionThroughput EnhancementCycle Time ReductionLead process optimization projects and continuous improvement initiatives.8. Yield, Cost & Performance ManagementMonitor manufacturing economics and process efficiencies.Analyze:Product YieldRaw Material ConsumptionSolvent RecoveryUtility ConsumptionConversion CostEstablish and monitor manufacturing performance benchmarks.Develop cost-saving proposals and value-improvement initiatives.Evaluate tolling cost structures and support commercial negotiations.9. SOP, Batch Card & Manufacturing DocumentationPrepare and Support to EM Partner:Standard Operating Procedures (SOPs)Batch CardsWork InstructionsProcess ManualsCleaning ProceduresManufacturing StandardsEnsure implementation and compliance at EM sites.Develop monitoring mechanisms for SOP compliance.Ensure proper documentation of production activities.Drive standardization across multiple manufacturing locations.10. Inventory,



Logistics & Reconciliation ManagementClosely track movement of:Raw Materials (RM)Packing MaterialsSemi-Finished Goods (SFG)Finished Goods (FG)Coordinate logistics between company sites and EM locations.Monitor inventory levels and prevent material shortages.Conduct periodic reconciliation of:Raw MaterialsSolventsIntermediatesFinished ProductsAnalyze inventory variances and take corrective actions.Coordinate with Supply Chain and Stores teams for inventory optimization.11. EHS & Regulatory ComplianceConduct EHS assessments of EM manufacturing facilities.Ensure implementation of recommendations arising from:Safety AuditsProcess Safety ReviewsJob Safety AnalysisEHS InspectionsVerify compliance with:Environmental RegulationsMonitor closure of EHS observations and recommendations.Promote a solid safety culture at EM sites.12. Stakeholder Management & Cross-Functional Coordination Internal CoordinationCoordinate extensively with:Research & Development (R&D;)Pilot PlantTechnology & Development (T&D;)ProductionQuality AssuranceQuality ControlSupply Chain ManagementProcurementLogisticsEHSCommercial & Finance TeamsExternal CoordinationCoordinate with:EM PartnerSCMCompany Logistic dept.13. Reporting & MISPrepare and present:Weekly Progress ReportsCampaign ReportsYield Analysis ReportsVariance ReportsCost Optimization ReportsCommercialization Status ReportsReview weekly production progress against plans.Report operational risks and delays to management.Develop dashboards and performance metrics for EM operations.Technical CompetenciesExternal Manufacturing ManagementTechnology Transfer & CommercializationProcess Scale-upBFD, PFD & P&ID; PreparationMaterial & Energy Balance CalculationsYield Optimization & Cost ManagementCampaign Planning & ExecutionContinuous Chemical Process OperationsProcess TroubleshootingRoot Cause Analysis (RCA)EHS & Process Safety ManagementInventory & Reconciliation ManagementLeadership CompetenciesProject ManagementVendor ManagementTeam LeadershipPlanning & OrganizingDecision MakingBehavioral CompetenciesStrong Analytical AbilityResult OrientationProblem Solving MindsetProactive ApproachOwnership & AccountabilityCollaboration & TeamworkEffective Communication Skills14.Qualifications & ExperienceQualificationBE / B. Tech – Chemical Experience12-18 years of experience in Chemical, Specialty Chemical, Agrochemical, Pharmaceutical, or MAH (Major Accident Hazard) Industries.Minimum 2-3 years of experience in External Manufacturing (EM) / Toll Manufacturing Operations preferred.Hands-on exposure to process scale-up, technology transfer, continuous improvement, and commercialization of chemical processes.Experience handling critical high-pressure and high-temperature reactions.

📌 Associate Director – External Manufacturing (Thrissur)
🏢 Navin Fluorine International
📍 Thrissur