Assistant General Manager Job in CPL Pharmaceuticals Private Limited at Dahej

Job Purpose To lead and manage the complete Engineering Department of an API manufacturing plant, covering Mechanical Maintenance, Utilities, Electrical, Instrumentation & Automation, Projects, and Engineering Compliance. The role is responsible for ensuring maximum equipment reliability, uninterrupted plant operations, regulatory compliance, energy efficiency, cost optimization, and safe operation of all plant equipment and utility systems in accordance with cGMP, EHS, and applicable statutory requirements. 2. Key Responsibilities A. Mechanical Engineering & Maintenance Lead preventive, predictive, and breakdown maintenance of all mechanical equipment. Ensure reliable operation of reactors, centrifuges, ANFDs, dryers, condensers, heat exchangers, pumps, compressors, vacuum pumps, and agitators. Oversee maintenance of mechanical seals, gearboxes, bearings, valves, pipelines, and storage tanks. Manage equipment installation, alignment, overhauling, inspection, and commissioning. Develop preventive maintenance schedules, equipment history records, and critical spare-parts strategies. Conduct root-cause analysis of recurring breakdowns and implement CAPA. Coordinate statutory inspections and testing of applicable pressure vessels, boilers, lifting equipment, and other regulated systems. Ensure equipment integrity and compliance with relevant API, ASME, and other applicable engineering standards. B. Utilities Management Lead the operation, maintenance, and performance monitoring of all plant utility systems. Ensure uninterrupted supply of utilities to production and quality-control operations. Major utilities under responsibility: Boilers and thermic fluid heating systems. Chillers, cooling towers, and chilled-water systems. HVAC systems, including cleanroom and controlled-area ventilation where applicable. Compressed air systems and instrument air. Vacuum systems and liquid ring vacuum pumps. Nitrogen generation and distribution systems. Water treatment, DM water, purified water, and other process-water systems as applicable. Effluent treatment plant (ETP), solvent recovery utilities, and associated environmental systems. Fire protection systems and emergency utility arrangements. Monitor utility consumption, operating efficiency, capacity utilization, and energy costs. Ensure preventive maintenance, water quality monitoring, and required utility qualification and documentation. Drive energy conservation, water reduction, and utility cost optimization initiatives. C. Electrical Engineering Manage electrical maintenance and reliability of plant electrical infrastructure. Ensure operation and maintenance of HT/LT panels, transformers, switchgear, PCC/MCC panels, and distribution systems. Oversee DG sets, UPS systems, battery banks, emergency power supplies, and power distribution. Monitor electrical load, power factor, energy consumption, and electrical losses. Ensure preventive maintenance and thermography of electrical equipment. Coordinate statutory electrical inspections, earthing, lightning protection, and safety compliance. Ensure suitable electrical equipment selection for classified hazardous areas based on applicable standards. Manage electrical breakdowns, power failures, and preventive actions to avoid production interruptions. D. Instrumentation, Automation & Control Systems Lead maintenance and reliability of plant instrumentation and automation systems. Manage calibration and maintenance of pressure, temperature, flow, and level instruments. Oversee transmitters, control valves, weighing systems, load cells, sensors, and analytical instruments within engineering scope. Ensure reliable operation of PLC, SCADA, DCS, HMI, and associated control systems. Maintain interlocks, alarms, emergency shutdown functions, and safety-related control systems as applicable. Coordinate calibration schedules, instrument history records, and documentation in accordance with approved procedures. Ensure compliance with applicable requirements for computerized systems, audit trails, access controls, and data integrity in coordination with QA and IT. Support qualification, validation, change control, and periodic review of automated systems. E. Projects, Capex & Plant Expansion Lead engineering projects involving plant expansion, new API blocks, equipment installation, and utility upgrades. Prepare annual capital expenditure (CAPEX) budgets, cost estimates, and project execution plans. Review engineering drawings, P&IDs, equipment specifications, layouts, and vendor documents. Coordinate with process engineering, production, QA, QC, EHS, procurement, and external consultants. Manage equipment selection, technical bid evaluations, purchase orders, fabrication, erection, and commissioning. Ensure project execution within approved budgets, timelines, quality standards, and safety requirements. Lead design reviews, risk assessments, commissioning, and engineering handover. Ensure appropriate qualification and validation activities before equipment or systems are released for GMP use. F. GMP, Regulatory & Compliance Ensure engineering systems comply with applicable cGMP requirements and approved site procedures. Maintain engineering SOPs, preventive maintenance records, calibration records, equipment history files, and utility documentation. Support USFDA, EU GMP, WHO-GMP, customer, and internal audits as applicable to the site. Manage engineering deviations, change controls, CAPA, and audit observations in coordination with QA. Ensure critical utilities and equipment are qualified, maintained, and monitored according to approved procedures. Ensure calibration and maintenance activities are documented and completed within approved timelines. Maintain compliance with applicable environmental, electrical, boiler, fire, and factory safety regulations. G. EHS, Process Safety & Risk Management Ensure safe maintenance practices through permit-to-work, LOTO, confined-space entry, and hot-work controls. Coordinate HAZOP recommendations, engineering risk assessments, and process safety reviews. Ensure safe maintenance of equipment handling flammable solvents, corrosive chemicals, and hazardous process materials. Review mechanical integrity, pressure-system safety, fire protection, and emergency preparedness. Investigate engineering-related incidents and implement corrective and preventive actions. Promote a strong safety culture among employees, contractors, and service providers. H. Team Leadership & Cost Management Lead Mechanical, Utility, Electrical, Instrumentation, Automation, and Project Engineering teams. Establish departmental objectives, performance indicators, maintenance plans, and manpower requirements. Develop training programs and competency matrices for engineers, technicians, and contractors. Prepare annual OPEX and CAPEX budgets and monitor actual expenditure. Control maintenance costs, spare-parts inventory, contractor costs, and equipment lifecycle costs.