- Participate in New Product Development [NPD] meetings and represent Mfg /TEAG in NPD review meeting
- To obtain NPD briefs, convert product concept into feasible design, design end to end manufacturing process for productionising the product as per the agreed capacities.
- To identify suitable mfg equipment/vendors as per the mfg/process design for successfully delivering the volumes of NPD.
- To ensure installation & commissioning of facility ahead of the launch plan
- To deliver production volumes as per the launch plans as per agreed OEE, quality, safety, productivity, energy and manpower deployment norms/targets
- Identify high risk equipment / task in the project.
- After getting NPD project brief sizing the process, packaging with required utilities and Electrical & automation/digitization system
- Preparing end to end capex for the project.
- Preparing layout and aligning with operation safety, operation excellence teams.
- Preparing project network and closely monitoring the progress and updating the network regularly with status.
- Close monitoring of capex spent vrs budgeted for all equipment/ tasks
- 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 plot plans for NPD project with consideration to,
- Material and man movement
- Proximity of electricity and utilities to process and packaging areas
- RM storage near to Mfg, PM storage near Pkg,
- Maintaining minimum standard distance for change rooms and washrooms near Mfg/pkg area
- Utilizing existing utilities effectively
- 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.
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 in High-speed Flexible packaging machine like VFFS, HFFS, Flow wraps, Overwraps, Shrink wraps, Envelop wraps etc.
- Strong knowledge in various types of Laminates used in VFFS, HFFS, Flow wraps etc.
- Knowledge in High speed vertical, Horizontal , customized cartoners with leaflet and feeding etc.
- Knowledge in High speed Bottle unscrambler, filling, capping , labeling lines
- Knowledge in EOL equipment like Banding, collators, case packers, palletizers , stretch wrappers etc.
- Knowledge of industry practices in project and construction safety and Environment management
- Knowledge of Safety policies and procedures, statutory requirements
- 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.
