Job Description

Position (designation): DGM- Manufacturing Grade: M3 Function / Department: Production Department Location: Any Plant Location The Role: Impact & Contribution • To produce high quality (as per internal set standards) Capsules and achieve Shift production Qty. (as per target budget) & ensure highest level of productivity & minimum downtime. • Ensures that Capsule specification, dimensions, process parameters and standards are understood clearly by all Operators / Fitters and charts for same are displayed on machine and are monitored & controlled to target value. Ensures calibration of all inspection & measuring equipment in Production Hall. • Ensures that immediate corrective actions are taken on the IQC and stage wise inspection reports. Keeps him informed regarding quality trend of capsules through FQC reports, customer visits & takes proper correctives in production areas in consultation with QC & Production head. • Strictly monitors the quality of the Capsules being produced and ensures that over 98% of the capsules produced met the capsules specifications. Ensures process loss does not exceed 2.0% on daily basis. • Educate subordinates regarding various m/c “basic” specification & standards to be maintained at time of m/c running or repair condition & product/process parameters on the machines wherever required. Job Responsibilities: 1. Achieve budgeted AF throughput along with planned growth (capacity optimization, new products). 2. Set benchmarks to meet customer expectation in order to achieve customer delight/ loyalty. 3. Continually develop organization health through good sustained systems and management practices. 4. To ensure discipline & good work culture on shop floor. 5. To develop & execute staffing strategies & build well composed team. 6. Ensure cost effectiveness 7. Promote achievement of the company OH&S and EMS aims and targets; drive compliance to company OH&S policies, principles, procedures and practices Key Activities to Be Performed: 1. Achieve budgeted AF throughput along with planned growth capacity optimization, new products) • Ensures that Capsule specification, dimensions, process parameters and standards are understood clearly by all Operators / Fitters and charts for same are displayed on machine and are monitored & controlled to target value. Ensures calibration of all inspection & measuring equipment in Production Hall. • Ensures that immediate corrective actions are taken on the IQC and stage wise inspection reports. Keeps himself informed regarding quality trend of capsules through FQC reports, customer visits & takes proper correctives in production areas in consultation with QC & Production head. • Strictly monitor the quality of the Capsules being produced and ensures that over 98% of the capsules produced met the capsules specifications. Ensures process loss does not exceed 2.0% on daily basis. • Educate subordinates regarding various m/c “basic” specification & standards to be maintained at time of m/c running or repair condition & product/process parameters on the machines wherever required. 2. Set benchmarks to meet customer expectation in order to achieve customer delight/ loyalty • Ensure defect free capsule manufacturing at shop floor • Ensure accurate quality control at ATS and up to final packing • Take immediate action for any defect reported at IQC as well as FQC level. No defect pass to next box • Maintain 100% compliance to customer requirements 3. Continually develop organization health through good sustained systems and management practices • Aligns himself and his team to meet the ISO 9001 - 2000 QMS, cGMP, TPM and USFDA requirements with proper records • Ensures that proper GMP is maintained around the machines, floor and in the other areas in the production halls including spillage prevention of gelatin, capsules, oil etc • Follows with administrative department / cleaning contractors for proper cleaning. Ensures proper floor condition in production hall & corridors. Ensures proper lighting on the machine & in the production hall • To have liaison with internal & external auditors as & when required 4. To ensure discipline & good work culture on shop floor • Handles day to day IR problem of the dept. Keeps management informed regarding any important feed backs received from the union • Ensures that proper discipline in the production department is maintained & the employees in the dept. are smartly dressed • Sets an example for his dept. through his own conducts & discipline. Motivates employees in the dept. to achieve desired goals of the organization To develop & execute staffing strategies & build well composed team • Identify person - job fits / misfits for next two levels • Develop & review training plans for next two levels • Ensure goal setting and performance appraisals for next two levels • Critique the performance for next two levels • Man power planning for next two levels • Exercise rewards and punishments to commensurate with performance • Periodic meetings and communication with all stake holders 6. Ensure cost effectiveness • Ensures optimum use of cutting blades without affecting quality(no uncut body) of the capsules produced • Monitor use of HPMC solution/ Gelatin and control wastage at the time of colour change or on running machine, immediately repairs the leaks etc • Ensure effective use of man power so that extra hours payments is well within control • Immediately acts upon the defects in the capsules to control HFX generation and control on sorting losses • Close control on malfunction of sorter, ATS and uncut device to keep process loss at its minimum 7. To ensure Compliance to OH&S and EMS Objectives • Promote achievement of the company OH&S aims and targets; drive compliance to company OH&S policies, principles, procedures and practices. Key Competencies Required: Functional: • Expertise capsule product, processes and business • Professional knowledge • Domain specific knowledge and skills a. HCM Operations and its working logic b. Understanding of capsule defects- its cause and effect c. Problem Solving Techniques/ Basic Chemistry of Gelatin/Viscosity and effect of temperature on viscosity / Knowledge of HVAC & Servo system d. Knowledge of colour pigments • Knowledge statutory/ Regulatory a. Viscosity and temperature of the feed tank should be within the specified norms b. To follow GMP norms c. Monitor GMP, ISO, FDA, internal audits and other such systems effectively and maintains records accordingly d. System up gradation and adherence, Follow SOP for TSE free/ preservative free production • IT skills Managerial: • Listening • Strategic thinking • Timely Decision Making • Cross Cultural Skills • Team and People development • Customer Focus • Drive for consistent results Performance Measurement • AFOE of operation • Dispatch targets achievement • Number of customer complaints • Overall 5S/ GMP scores of the department • New project/ development and KAIZEN projects Reporting Details The Team: Reporting to: GM – Manufacturing Points of Communication: Internal: a) Quality Assurance b) PFD c) Sales External: a) Customers / Authorities such as FDA etc. Authority: As per the authority limits decided by the organization Financial Others Skills, Knowledge & Experience 1) Knowledge: a) Sound knowledge of Capsule manufacturing machines, pharmaceutical machines, GMP practices, ISO standards. b) Sound knowledge about production activities, planning and controlling. c) Should be aware about EMS certification, knowledge about compliances in pharmaceutical industry. d) Sound knowledge about SAP, MIS. 2) Qualification: a) BE (Mechanical or Production), BE (Mech or Production) with MBA OPERATIONS preferred. 3) Experience: a) B.E with 12 to 15years of experience in Capsule / Pharma industry or any mass production process industry.
 
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