Lead - Reliability Analysis and Planning (Medium Site)

Division

Department

Sub Department 1

Job Purpose

Preface:  Cipla Manufacturing Assets are Aging with an average age of 20 Plus years and 75% of asset base >15 years of service and is degrading. 
Asset Management Processes work together to bring the balance of performance, risk, and cost to achieve an optimal solution. Asset Management is delivered by developing & implementing 12 processes viz. Maintenance Execution, Turnaround Management, Process safety, Ensure Safe Production, Pressure Equipment Integrity, Competency Framework, Electrical Equipment Integrity, Instrumented Protective Function, Site Management System, Contracting & Procurement, Reliability Centred Maintenance, Strategy & Asset Information Management. Asset management excellence is many things, done well. Asset Management excellence is achieved when a plant performs up to its design standards and equipment operates smoothly when needed. It™s maintenance costs tracking on budget, with reasonable capital investment. It™s high service levels and fast inventory turnover. The key is - how to balance the designing, maintenance, and replacement of assets throughout their life cycle with the costs to business “ in terms of finance, time, and resources. 
Reliability engineering is a sub-discipline of systems engineering that emphasizes the ability of equipment to function without failure. Reliability engineering deals with the prediction, prevention and management of high levels of "lifetime" engineering uncertainty and risks of failure.
The incumbent provides functional leadership to the “ Reliability Analytics & Planning and carries overall responsibility to:
1.    To drive introduction and implementation of asset management processes and systems at Goa.
2.    To champion Reliability Analysis & Maintenance Planning to drive continual improvement in asset integrity, process safety, reliability and operating efficiencies at Goa
 

Key Accountabilities (1/6)

I.    Maintain Deep Functional Knowledge as a SME to deliver the Reliability Analytics & Planning Services for the Site Operations
¢    Maintain deep functional knowledge of the Asset management processes, foundation standards & regulations such as 
o    ISO
o    IEC
o    OGP
o    API
o    OSHA
o    ASME
o    ANSI
o    ASTM
o    NACE
o    CCPS
II.    Asset Management
¢    Provide leadership in implementation of Asset management portfolio comprising of 12 asset management processes viz. Maintenance Execution, Turnaround Management, Process safety, Ensure Safe Production, Pressure Equipment Integrity, Competency Framework, Electrical Equipment Integrity, Instrumented Protective Function, Site Management System, Contracting & Procurement, Reliability Centred Maintenance, Strategy & Asset Information Management at all Goa-I units.
¢    Act as an integrator of Asset management processes and systems across Goa-I units. Provide direction to teams on steps for improving the maturity of the AME processes and systems across Goa-I units.
¢    Monitor the implementation of improvement plans for various Asset Management processes at Goa-I units.
¢    Maintain overview of portfolio of asset management tools in Goa-I units and drive improvement of existing and new AME tools across Goa-I units. Accountable for ensuring smooth operations of all asset management tools across Goa-I units within the agreed budgets. 
¢    Actively partner with various stakeholders like IT, Operations, Maintenance, HR, Procurement, LnD and vendors for ensuring the SLAs for various activities on Asset management process and tools implementation.
¢    Conduct quarterly health assessments of all 12 asset management processes for all units of Goa-I with the help of Site subject matter experts and site process owners & process focal points for all the 12 processes.
¢    Drive implementation and improvement in maturity of various software like SAP, RCM, RBI, IPF, RCA and AIM with respect to data completeness, standardized structures and competency of users across Goa-I units through various inhouse and external SMEs and focal points.
¢    Drive implementation of asset management strategies across Goa-I units for all the 12 asset management excellence processes through global SMEs & site focal points. Implement strategies for implementation of IT tools required for asset management implementation.
¢    Conducts process effectiveness reviews for various global asset management excellence process and sub processes such as reliability threats management, root cause analysis etc. based on specific requirements from time to time. Develop new and optimize existing processes through application of LEAN methodologies.
¢    Implement culture of benchmarking of processes & performance in Engineering and Projects organization. Support Central Engineering team in developing inhouse capabilities for conducting internal benchmarking.
 

Key Accountabilities (2/6)

III.    Embed the Asset Management Process in impact function
¢    Review Asset Register and ensure that asset management standards are duly embedded and the asset register is up dated.
¢    Support Central Engineering team in Conducting benchmarking studies for various asset management processes & implement the recommendations
¢    Support units in data collection for E&P monthly report & submit to Central Engineering team on time.
¢    Implement digital format - Engineering reports and KPIs
¢    Develop maintenance budget for Goa-I units in coordination with Unit E&MR heads & Monitor the same on monthly basis.
IV.    Implement Asset Integrity Management System: Data Adequacy & Integrity 
¢    Be the Focal Point for any changes in ERP data related to Asset Management System, working closely with Global and/or Central Data and Process design owners. 
¢    Ensure as Lead Reliability Analytics & Planning  
o    perform activities as a primary data engineer, subject matter expert, and/or lead engineer in maintenance, assurance, technical support, and standardization of technical data and documents of the operating unit, including any site engagements and leadership on technical and tools forums. 
o    Analyse technical data, documents, and processes for the business to align with AMS by working with engineering, maintenance, operations, and project teams and partners

Key Accountabilities (3/6)

V.    Reliability Engineering
¢    As Lead Reliability analytics & planning - maintain oversight of and Ensure that Reliability Engineering Program is being implemented in line with agreed timelines & priorities as per approved program for Goa I
¢    Support leadership to Unit E&MR teams in improving reliability of assets across Goa-I units.
¢    Support AI&R Team from a Planning & Project Management aspect  
o    plan & implement Reliability Management framework and tools for reliability management such as Proactive threat identification, to mitigate threats to availability, Root cause analysis, Reliability centred maintenance and technical integrity dashboard.
o    Drive implementation of the tools and reliability key performance indices across all units of Goa-I.
o    Develop competencies of Reliability Engineers through various inhouse and external training courses on both technical and asset management standards. Preference should be given to build the inhouse expertise on the subject.
o    Drive development and optimization of maintenance strategies through various discipline engineers and focal points. 
o    Monitor the health of various maintenance strategies across Goa-I units. 
o    Ensure simplification and standardization of maintenance strategies across Goa-I units. 
o    Inculcate risk-based culture and support discipline engineers in data based decision making processes. 
o    Introduce and implement the statistical tools and techniques such as Reliability modelling, predictive maintenance etc. Works with Project Engineering to ensure the reliability and maintainability of new and modified installations
¢    Drive generation of new ideas and suggestions for improvement of engineering designs to improve equipment reliability and efficiency of assets 
¢    Monitor risk to achieve the organization™s strategic objectives in the areas of environmental health and safety, asset capability, quality and production

Key Accountabilities (4/6)

VI.    Ensure that Asset integrity and Process Safety inspections & studies are conducted as per approved program
¢    As Lead Reliability analytics & planning - maintain oversight of and Ensure that Asset integrity and Process Safety inspections & studies are conducted as per approved program for Goa I
¢    Manage stakeholders/ representatives of various operating units through effective communication and identifying & resolving the bottlenecks for data analysis, maintaining issue logs, and use the same in implementing changes/improvements in the processes
¢    Ensure that recommendations from Asset integrity and Process Safety inspections & studies are built into the Asset Management Program and any CAPA tracked for completion. This includes
o    Recommendations from tools for AIPSM such as Risk Based Inspection, SAP, Inspection Data Management, Facility Status Reporting. Inspection Data Management
o    Leak detection & Repair Drive
o    Optimisation of inspection strategies and performance standards in SAP.
o    Health of hardware barriers in SAP.
o    Process Safety Studies recommendations
¢    Drive generation of new ideas and suggestions for implementation of new techniques and technologies for improving process safety of facilities.
VII.    Ensure that Reliability Centred Maintenance Studies are conducted as per approved program
¢    As Lead Reliability analytics & planning - maintain oversight of the Plant & Equipment covered under the RCM Studies program for Goa-I.
¢    Ensure that RCM studies are conducted as per the program agreed by the Asset Integrity & Reliability Team.
¢    Manage stakeholders/ representatives of various operating units through effective communication and identifying & resolving the bottlenecks for data analysis, maintaining issue logs, and use the same in implementing changes/improvements in the processes
¢    Ensure that recommendations from RCM studies are built into the Asset Management Program and any CAPA tracked for completion. This includes
o    RCM Findings in Plant Dossier
o    RCM Recommendations in Operations & Maintenance Strategy 
o    Review of Obsolescence & Retirals
o    Comments on significant life cycle events
 

Key Accountabilities (5/6)

VIII.    Ensure that Equipment Failures and Deficiencies are addressed
¢    As Lead Reliability analytics & planning - maintain oversight of the Plant & Equipment covered under the Reliability Engineering Program to ensure that Equipment Failures and Deficiencies are addressed on priority. 
¢    Ensure escalation where required.
IX.    Maintenance Planning
¢    Consolidation & Approval of the Comprehensive Maintenance Program for the Site to deliver the annual operating plan whilst complying with the Cipla Global Standards and Procedures [cGMP, EHS &ES, Tech Standards, Financial & HR Standards]
¢    Lead the communication of the CMP across all stakeholders including operations, quality, EHS, HR, Finance tec.
¢    Coordinate planned downtimes to reduce mean time between failures and minimize interference with production schedules. Minimize the number of interruptions once work begins.
¢    Provide technical assistance for supporting entire on-site maintenance activities
¢    Operationalize Maintenance Planning:
o    Prioritize incoming and backlog work
o    Develop and maintain the job plan library
o    Coordinate with the storeroom, material requirements
o    Facilitate appropriate scheduling meetings
o    Develop Schedules
o    Develop Shutdown Plans
o    Track Work Planning KPIs
¢    Be responsible for timely publishing of the comprehensive E&P MIS
X.    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 (6/6)

Major Challenges

• Aging Asset with high level of Asset Degradation
• Issues around Design & Installation “ high level of difficulty in doing Risk Based Inspections
• Challenges around capability & competence of personnel and service providers
• Working with multiple units.
• Working with multiple teams viz. unit engineering heads, Central engineering teams etc.
• Presentation skills
• Strategic thinking
• Data & document management
• Communication skills
• Proactiveness
• Analytical thinking

Key Interactions (1/2)

Internal
¢    Central Engineering Team “ Ensuring alignment with Global Engineering standards and procedures and best practices.
¢    Finance for Capex & Opex proposal approvals, analytics & MIS
¢    EHS for safe operations and near-misses 
¢    HR for Attrition, Recruitment, Training 
¢    Site head & Unit heads for Proposals, breakdowns and developments 
¢    Engineering DR for Guidance & Updates 
¢    Indirect purchase for Spares, scope, insurance and new vendors
¢    Central purchase for provide Technical inputs and clarifications for CAPEX 
¢    Global Leadership Team “ Guidance & Updates in TLT, Focus Calls & Reviews
¢    Corporate Affairs & Legal Team “ Guidance & Updates on Compliance matters
External
¢    OEMs for projects , automations, alternate vendor development , quality issues and maintenance 
¢    Facility maintenance contractors for Improve maintenance and quality standards 
¢    Industry Bodies “ Connect on external benchmarking & information on technology evolution
¢    Statutory Bodies “ Connect for Regulatory compliance

Key Interactions (2/2)

Dimensions (1/2)

• Direct Reports: NIL
• Maintenance + Utility Budget: 80-90 CR
• Capex Budget: Sustenance 50-60 CR Capacity Capex “ 100 -120 CR
• Revenue of Goa I: 1400 “ 1500 CR
• Current Replacement value of Assets Maintained: Net Block > 200 CR; CRV > 800 CR

Dimensions (2/2)

Key Decisions (1/2)

Decisions
¢    Optimisation of Maintenance & Operations Strategy 
¢    Optimisation of Maintenance cost
Recommendations
¢    Asset Management Software
¢    MRTA Technologies
¢    New Vendor addition 
¢    Asset management Processes Audits
¢    Hiring consultants 

Key Decisions (2/2)

Education Qualification

BE / B Tech (Mechanical)

Relevant Work Experience

¢    7-10 years of experience in engineering (Reliability, Maintenance, Operations and Projects). At least 3 years in Reliability Analytics & Planning SME role
¢    Exposure to Asset management Excellence Standards & Regulations
¢    Exposure to Asset Management tools like SAP, RBI, RCM, IPF, AIM etc.
¢    Exposure to Asset Integrity, Process Safety & efficiency standards
¢    Hands On experience on Reliability Engineering, analytics & planning of at least 3 years
¢     Ability to implement new techniques, deep understanding of manufacturing process, planning and organizational skills, prioritization multi-tasking, understanding of financial concepts 
¢    Good technical knowledge of Pharma / API machinery and utility requirements 
¢    Good knowledge and experience of data analysis 
¢    Knowledge of GMP and various regulatory requirements
¢    Good leadership skills and experience in industrial automation