Division

Manufacturing

Department

Formulation

Sub Department 1

Engineering - Formulation

Job Purpose The incumbent provides leadership to the“ 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; “ 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.
- 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 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 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 Å“Visible Felt Leadershipâ„¢ 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 Å“ZERO 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] Utility Operations Leadership “ 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.

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 ËœZeroâ„¢ 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 “ 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 Valuable 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 “ 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 “ 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 “ 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: 4-6, Team Size “ 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 “ 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