Head: Production and Packing Planner For OSD Manufacturing

Role & responsibilities

Objective:

To ensure efficient and optimized utilization of production and packing lines for Oral Solid Dosage (OSD) forms by coordinating machine loading, balancing workflows, and managing dependencies related to QC release, client schedules, and communication with department heads. The role also requires effective handling of rolling client forecasts to align production planning with firm POs and tentative demands.

Key Responsibilities:

1. Production and Packing Line Planning:

• Create and manage detailed production schedules, ensuring machine availability and minimal downtime.
• Ensure coordinated loading of production and packing lines to prevent bottlenecks.
• Maintain a daily and weekly machine utilization plan aligned with client requirements and delivery timelines.

2. Rolling Forecast Management:

• Receive and process rolling forecasts from clients, typically structured as:
• Month 1 & Month 2: Firm Purchase Orders (POs).
• Month 3: Tentative demand, subject to updates.
• Continuously update production schedules each month as forecasts are refined.
• Align resources and capacities with forecast changes to avoid production disruptions.

3. Client Coordination:

• Communicate with clients to confirm timelines, address changes in forecasts or priorities, and update them on batch statuses.
• Share reports on batch progress, planned timelines, and any delays with clients.
• Manage last-minute client changes (e.g., batch priority changes) with minimal disruption to operations.

4. Line Balancing:

• Assess and implement optimal product flows to avoid machine idling or overload.
• Allocate resources (manpower and materials) to match planned machine capacities.
• Balance tasks between multiple production and packing lines to minimize cycle time differences.

5. Coordination with Cross-Functional Teams:

• Quality Control (QC): Coordinate QC sampling, analysis, and release of materials and batches to avoid delays.
• Production and Packing Teams: Align schedules with department heads to ensure resource availability (e.g., operators, shift plans, changeover times).
• Quality Assurance (QA): Ensure IPQA approvals and validations are coordinated with the line schedule to avoid interruptions.

6. Machine Changeovers and Preventive Maintenance Coordination:

• Schedule production batches in line with planned maintenance activities to avoid clashes.
• Minimize changeover times between batches by optimizing machine cleaning and setup times.

7. Capacity Utilization Tracking and Reporting:

• Track and report machine utilization and downtime to identify areas for improvement.
• Generate reports on daily output vs. planned production and packing to management.
• Maintain data on batch adherence to TAT (Turnaround Time) targets.

8. Deviation Management:

• Handle deviations in production schedules due to QC delays, machine breakdowns, or manpower shortages by reworking loading plans.
• Communicate critical deviations to management and propose mitigation plans.

9. MIS (Management Information System) and Dashboard Reporting:

Key MIS Reports to be Generated:

• Daily Production Report: Shift-wise machine loading, batch progress, and QC release status.
• Rolling Forecast vs. Production Plan: Track alignment of monthly rolling forecasts against actual production.
• Weekly Planning Report: Consolidated report showing machine utilization, pending batches, and deviations.
• Monthly Summary: Total batches completed, machine uptime, changeover time analysis, and TAT compliance.
• Client Dashboard: Customized reports for clients showing batch status, expected release dates, and shipment timelines.
• Deviation and RCA Report: Summary of major deviations during the month with RCA (Root Cause Analysis) and CAPA (Corrective and Preventive Actions).

Key Dashboard Metrics:

• Production Metrics:
• Planned vs. Actual Batch Production
• Machine Utilization (%)
• Changeover Time (minutes per batch)
• QC Metrics:
• Sampling and Release TAT (Turnaround Time)
• Number of Pending QC Approvals
• Packing Metrics:
• Packing Line Utilization (%)
• Planned vs. Actual Output
• Deviation Metrics:
• Number of Line Downtimes
• Number of QC Holds and Reasons
• Client Metrics:
• Number of Client Deliverables Met On-Time (%)
• Pending Client Approvals

Dashboard Formats:

• Visual representation: Bar charts for machine utilization, pie charts for deviation categories, and timelines for TAT adherence.
• Real-time updates: Link data from the ERP/LIMS system to generate automatic daily updates.
• Drill-down options: Ability to view department-specific or batch-specific data for detailed analysis.

10. Regulatory Compliance and Documentation:

• Ensure production schedules are compliant with regulatory requirements.
• Maintain records of planned vs. actual production for regulatory inspections and internal audits.

Key Deliverables:

1. Daily Machine Loading Plans: Detailed loading plan for each shift, including batch allocation.

2. Rolling Forecast vs. Production Plan Reports: Comparison of client forecasts vs. actual production.

3. MIS Reports: A comprehensive set of production, QC, and client reports.

4. Dashboards: Visual, real-time summaries of production and packing status.

5. Deviation Analysis: Root cause analysis reports for any deviations from the production plan.

Educational Qualifications for Candidate Selection:

• Minimum Qualification: Bachelors Degree in Pharmacy (B.Pharm), Engineering (Mechanical, Industrial, or Production), or Science (B.Sc.).
• Preferred Qualification: Master’s in Pharmacy (M.Pharm), MBA in Operations, or certification in Production Planning (such as APICS, Lean Six Sigma, or SAP ERP certification).
• Experience:
• Essential: 5+ years of experience in pharmaceutical manufacturing/CMO operations, specifically in OSD production planning.
• Desirable: Experience in handling client coordination for rolling forecasts and managing ERP/MIS-based planning systems.

Additional Skills Required:

• Proficiency in Excel, ERP systems, and scheduling tools (SAP, Oracle, MES, etc.).
• Strong analytical and problem-solving abilities.
• Excellent communication skills for cross-functional coordination and client management.
• Proficiency in dashboard creation tools (Power BI, Tableau) for MIS reporting.
• Strong organizational and multitasking abilities to handle rolling changes in forecasts without compromising deadlines.

Perks and benefits