Engineer - Instrumentation

Job Purpose

The incumbent is a team member of – Unit Engineering Maintenance & Reliability Team and carries overall responsibility to:
1.Execute the maintenance activities in the plant & ensure the minimum Instrumentation & Automation breakdown with maximum efficiency by following safety & GMP Standards
2.Support EM & R Senior Instrumentation Engineer in carrying out Functional EM&R Planning, Detailed Scheduling and Execution of CMP to- ensure continuity of availability of plant & equipment at optimal cost; achieve standard capacity; ensure overall plant & equipment integrity & reliability - in compliance with Cipla Policies, Standards & Procedures; Reporting of EM&R MIS, Incidents & Deviations @ SOP;
Instrumentation Engineer is responsible for executing maintenance tasks as assigned by Senior Engineer for his function in the Manufacturing & Packing Area.
Where outsourced, 3rd Party Instrumentation Engineer is accountable for the Service Floor / Technical Floor maintenance execution

Key Accountabilities (1/6)

I. Shift Maintenance Activity: Execute maintenance activities in a shift by managing available resources to achieve shift maintenance plan.
• Execute assigned tasks as per planned Instrumentation & Automation maintenance activity to meet maintenance targets for a shift
• Cater to machine maintenance requirements of Unit as a responsible member of the team with overall ownership of Unit Operations.
• Increase the efficiency of area by ensuring better utilization of equipment and by reducing downtime in manufacturing area
• Prepare and submit Instrumentation shift engineer report to ensure smooth shift handover
II. Comprehensive Maintenance Plan Execution: Give inputs for preparing & adhere to unique planner for planned preventive maintenance & instrument calibrations for effective maintenance and adherence to standards.
• Schedule shift activities in line with the CMP including PM, Calibration, and condition monitoring activities.
• Execute planned Instrumentation & Automation maintenance and update related documentation
o Preventive Maintenance
o Calibration
o Condition Monitoring
o Planned Corrective Actions
• Follow good Engineering practices during planned preventive activity.
• Perform validation, qualification and calibration as per schedule and update output of all activities in the systems
• Prepare new documents and update existing documents as per GMP requirement
• Update Metrics on Schedule compliance
III. Breakdown Maintenance: Handle breakdown maintenance to avoid recurrence and maintain continuous process operations
• Execute Instrumentation & Automation breakdown work expeditiously but safely and in compliance with cGMP.
• Receipt and tracking the job card for the break down activity
• Maintain critical Instrumentation & Automation spares inventory of all machines to reduce resolution time

Key Accountabilities (2/6)

IV. Efficient Equipment Operation: Operate the equipment efficiently without error and deviation as per SOP to meet shift targets
• Operate an equipment only when trained and authorized to do it.
• Perform unit operations as per SOP & unit processes as per work instructions
• Maintain equipment, facility and block premises as per SOP for audit readiness. Ensure equipment, facility and block premises are maintained as per regulatory compliance
• Ensure all operations are performed as per GMP & Safety norms by reviewing all processes and documents for compliance
• Maintain system integrity by updating documentations and deviations on CipDox while performing operations
V. New Technology / Capex: Use new technologies initiated by Management while adhering to CAPEX and OPEX targets to improve Machine/system performance
• Implement new technologies in the plant initiated by management
• Attend planned trainings and incorporate the learnings on the floor for improving machine performance
• Implement and close ideas generated through internal audits / Idea generation sessions
• Monitor present energy use of the plants to identify and report areas for energy conservation
• Implement Energy Conservation activities to improve the equipment efficiency, reduce error and reduce production cost
• Identify areas of improvement in instrumentation functoin for waste & work simplification
• Manage activities to operate within budget and to reduce operating expenses
• Verification of the contract invoices and making of the job orders as per estimates
VI. Spares Management: Perform Material and Spare management and issue Consumables, spares, materials, log books etc. to avoid delays due to unavailability of materials
• Issue required Instrumentation & Automation materials (spares and consumables) to the contractors from stores and make SAP entries for the receipts and issuance
• Maintain the inventory of critical spares and consumables by tracking consumption and monitoring of stocks
• Assess log book requirements, raise the request to QA and issue them within required timelines
• Classify the unused / spare / usable scrap materials or components and reuse the same where ever possible

Key Accountabilities (3/6)

VII. EHS Compliance: maintain high level of Safety during maintenance to avoid major breakdown and report accidents/ incidences
• Complete preplacement Safety Training before starting the work in any area.
• Monitor safe operations of the machine as per SOP and timely report any safety deviations
• Maintain proper procedures for safety permits in plant Ensure safety systems and procedures followed by the operators in the shift
• Issue work permits to contractual staff after verifying the safety aspects, monitoring and communicating safety hazards and safety near miss to the concern.
• Ensure availability and usage of PPEs in the shift by coordinating with EHS department for requirements and shift schedule; Ensure usage and maintenance of PPEs by self & other workmen during shifts
• Report any safety incident to the Shift In charge as well as the Senior Engineer for the following
o Near Miss
o Safety Incident
o Work Place Inspection
o Unsafe Act
o Unsafe Condition
• Attend safety meetings and ensure implementation of actions planned during departmental safety meeting at shop floor
• Ensure compliances to safety training targets by monthly reconciling attendance records
VIII. cGMP Compliance: Execute and update online documentation to meet cGMP requirements
• Complete preplacement cGMP Training before starting the work in any area.
• Monitor cGMP compliance in the impact domain and report any incident / cGMP deviation to the Shift In charge as well as the Senior Engineer.
• Maintain online instrumentation documentation and timely entries in all documents in cGMP environment and their supporting documents
• Check documentation before submission to ensure data integrity. In case of any deficiency or errors in documents and rectify them as per SOP
• Conduct training related to cGMP, equipment operation, safety and housekeeping for workmen
• Optimize the use of resources in housekeeping; Ensure good housekeeping and sanitisation as per the guidelines
• Operate software such as SAP, CipDox and QMS as required and basis training & certification.
• Execute CAPA as guided by the Instrumentation Senior Engineer.
• Prepare and maintain engineering documents wrt cGMP and Good Engineering Practices

Key Accountabilities (4/6)

IX. Continuous Improvements: Provide suggestions for optimization of processes to manufacture quality product
• Propose and implement new idea to enhance production, optimise the use of consumable goods and maximum utilization of resources
• Provide new ideas and simplify processes to reduce process cycle time and achieve new targets
• Participate in internal audits / Idea generation sessions to improve on deficiencies to verify GEP and GMP.
• Implement action plans for improving on deficiencies observed through internal / external audits
X. [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.

Key Accountabilities (5/6)

Key Accountabilities (6/6)

Major Challenges

• CapEx and OpEx – Adherence to the budget
• Cost vs performance trade off in equipment
• Ageing Asset leading to escalating OpEx Cost
• Challenges around capability & competence of personnel and service providers

Apply Link- Apply Link mentioned in below