Manager - Process and Utility

As Process and Utilities Manager, you will lead Internal and External Team in Designing, Procurement & Delivery of Process & Utilities equipment for Capacity / NPD projects from planning / capex preparation stage to operationalization.

Key Responsibilities:

• Designing and installing the process equipment and utilities, establishing their performance, monitoring their performance and providing post installation support to plant teams while productionizing new products or undertaking capacity expansion projects within the approved budget and timelines
• Improving performance of process equipment/utilities and reducing utility & mfg costs by proactively exploring and applying new methods/technology
• Taking responsibility in proving the performance of the selected solutions in coordination with suppliers and internal team
• Timely delivery and commissioning of process equipment/utilities for projects handled.
• Participate in department review meetings to understand the critical aspects of the project deliverables in terms of performance.
• Focus on process equipment solutions and proving the performance.
• Traveling and Operating from the factories at different parts of India (and abroad) on task/need basis to meet the objectives of end-to-end responsibility.
• Manage critical situations in project and remove constraints through possibility thinking.
• Scale up of new products from lab to plant scale.
• Collect data required to make improvement or modification in process.
• Generate technology transfer data from R & D Pilot Plant Scale for transferring technology to commercial plant.
• Floating the enquiry for all process, utilities.
• Completing Technical bid and coordinating with procurement team for commercial bid and closure of commercial discussion
• Approving equipment drawings and monitoring the equipment progress at supplier work with regular online/F2F meetings and communications.
• Attending FAT along with operation, quality operation excellence team
• Ensure machines /equipment are meeting min machine safety stds.
• Ensure selected equipment are energy efficient, reliable with better output and min rejections.
• Ensure IOT /Digital features are enables in selected equipment.
• Participate in execution to provide safety technical input for capital projects and ensure 100% compliance with the best safety standards.
• Follow up statutory approvals for the project with operations team
• Finalize civil, mechanical, piping consultants / contractors for execution, including sizing and selection of utilities like chillers, boilers, compressors, ETP,
• Prepare a project scoping document and create/finalize standards/specifications for various activities.
• Focus on meticulous planning with detailed tasks, timeline, dependency, etc. using software tools.
• Ensure that vendor/contractors and other service providers sign the NDA, provide the ABG, PBG etc as per the PO/contract terms
• Ensure safely, timely execution of the project within the approved budget and up to customer satisfaction.
• Ensure site safety conditions during project execution in line with the agreed safety standards.
• Periodically review with various contractors to monitor the progress completion of all actions on time.
• Verify invoices and bills raised by the contractors/service providers and ensure timely payments in coordination with the finance team as per the PO terms/URS
• Travel to factories at different parts of India on a task/need basis to meet the objectives of end-to-end responsibility.
• Manage critical situations in the project and remove constraints through possibility thinking.
• Conduct financial modeling and manage financial aspects, mainly related to the project like calculating ROI, Payback, Cost-Benefit analysis, etc.
• Take necessary steps to ensure process safety at the site and execution plan to mitigate process safety risks.
• Ensure the implementation of the latest technologies in the industry with suitably applicable IoT, Industry 4.0, and digitization.
• Finalize Technically Qualified User Required Specification (URS), Evaluate qualifying criteria for URS, and close observations with suppliers.
• Establish project teams, coordinate activities of multiple disciplines, and ensure the efficient, cost-effective utilization of staff.
• Coordinate with other team members (Operations, Quality, Projects) and ensure site readiness & facilitate installation of bulk mfg, utilities, filling, packing equipment at the site.
• Identify risk areas at an early stage and work to mitigate them
• Develop and implement a risk management plan to identify, assess, and mitigate potential risks throughout the project lifecycle.

Expected Delivery:

• Ensure "Zero Injury" at the project site.
• Finalize Layout plan for Manufacturing setups and Utility Equipment.
• Ensure compliance of contractors to various safety, statutory and other work standards
• Identifying Automation opportunities in existing process Mfg setups / mixers and selecting /finalizing / planning solution to minimize manpower.
• Evaluate the skill sets of contractors and their supervisors for respective jobs.
• Size and select BOQ for erection hardware like piping and accessories, insulation, Lifting and shifting of Mfg and Utility equipments etc.
• Ensure project design and implementation meet all legal compliance and GCPL safety standards
• Plan and implement a comprehensive quality control system for all aspects of the project
• Establish and maintain effective communication channels with all stakeholders, including contractors, vendors, team members, and management
• Identify and leverage opportunities to streamline processes, reduce costs, and improve project efficiency without compromising quality or safety
• Develop and maintain a risk management plan, identifying and addressing potential risks and developing contingency plans to mitigate those risks

Budget Responsibility:

• Create capital budget for process and Utilities equipment for Capacity and NPD projects.
• Identify and prepare any other budgetary requirements for other resources
• Always ensure project delivery within the approved project budget
• Anticipate budget over-run in advance and appraise relevant stakeholders proactively.

Who are we looking for

Education and Experience:

• Graduate in Engineering in Mechanical / Electrical Engineering with Project Experience
• More than 10 years of experience in Operation, Maintenance, Green and Brown field Project Management of Bulk mfg vessels, Utilities Commissioning in Medium to Large scale plants in FMCG, Pharma, Chemical industries
• Thorough knowledge in Project Management in setting up of small to medium facility from project planning to execution.
• Knowledge of industry practices in project and construction safety and Environment management
• String Knowledge in sizing and selection of Compressors, Boilers, Chillers, Cooling Towers AHUs etc.
• Operation and Maintenance knowledge in various types of boilers, Chillers, Compressors, Vacuum pumps etc.
• Knowledge in statutory requirements for IBR /Non-IBR boiler operations
• Knowledge of Safety policies and procedures, statutory requirements
• Strong Knowledge in energy audits and identifying energy saving projects, identifying solution and implementation.
• Digitization of Utility packages with CBMS, digital twin, UMS system etc.
• Digitization of Mfg process with auto batching, generating batch reports / shift report etc.
• Knowledge of IoT, Industry 4.0, Digitization, Data Capturing in Mfg and Utilities etc
• Knowledge of thumb-rule estimates for budgetary exercises such as costing of Utilities (steam, gas, compressed air, refrigeration & chilling etc.)
• Ability to plan in a structured way for smooth execution
• Ability to assess risks, plan mitigating actions and handle critical situations
• Proficiency in MS project, Zoho or similar planning software
• Knowledge in MS Office especially Excel, AutoCAD etc.

Key Skills:

• Create Business Solutions
• Exhibit a sense of urgency with lean thinking to optimize the men, machine, and material by using lean sigma tools for improving operational efficiency.
• Plan for new technologies to improve process capability and plant availability.
• Strong influencing skills at all levels (including senior levels)
• Ability to lead and deliver sustainable solutions
• Strong Communication skills
• Good inter-personal skills and effective communication skills
• Strong verbal & written communication / presentation skills including effective use of Powerpoint, Excel, Word, etc.
• Ability to lead people for smooth functioning with timely inputs.
• Ability to work with multiple supplier / contractors and service providers
• Coordinate with all cross functional teams to ensure completion of projects.
• Drive the change for implementing Smart Factory fundamentals.
• Ability to think innovatively /creatively.