Division Manufacturing Department Formulation Sub Department 1 Engineering
- Formulation Job Purpose The incumbent provides leadership to theâ Unit Engineering Maintenance & Reliability Team and carries overall responsibility to:
• Manage Unit utility 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 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.
• 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;
• 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
• Turn Around Management: Ensure that Unit turnaround / shutdown are managed effectively with Åzero reworkÂ. 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 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 Key Accountabilities (1/6)
• 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
• 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 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 skilled 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 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
• administer the Master Services Agreement
• ensure utilities availability to meet production need
• 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 Key Accountabilities (3/6)
• [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
• %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 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
• 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 Utility 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 Utilities 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 Key Accountabilities (5/6) 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.
• [E] Functional Capability |Employee Connect | Rewards & Recognition Required ¢ 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 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
• OPEX
• CAPEX
• 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. Key Accountabilities (6/6) 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. Major Challenges
• CapEx and OpEx â Adherence to the budget
• 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 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 Key Interactions (2/2) Dimensions (1/2)
• Direct Reports: 4-6, Team Size â 11-15
• Utility Budget: 2-4 CR
• Capex Budget: Sustenance 10 CR
• Revenue of Baddi: 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 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 Key Decisions (2/2) Education Qualification BE / B Tech (Mechanical / Electrical) 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

📌 Head - Utility Operations (Medium Site) (Rangpo)
🏢 Cipla
📍 Rangpo