Manager PPIC

Key Responsibilities: 1. Production and Packing Line Planning: • Create and manage detailed production schedules, ensuring machine availability and minimal downtime. • Ensure coordinated loading of production and packing lines to prevent bottlenecks. • Maintain a daily and weekly machine utilization plan aligned with client requirements and delivery timelines. 2. Rolling Forecast Management: • Receive and process rolling forecasts from clients, typically structured as: • Month 1 & Month 2: Firm Purchase Orders (POs). • Month 3: Tentative demand, subject to updates. • Continuously update production schedules each month as forecasts are refined. • Align resources and capacities with forecast changes to avoid production disruptions. 3. Client Coordination: • Communicate with clients to confirm timelines, address changes in forecasts or priorities, and update them on batch statuses. • Share reports on batch progress, planned timelines, and any delays with clients. • Manage last-minute client changes (e.g., batch priority changes) with minimal disruption to operations. 4. Line Balancing: • Assess and implement optimal product flows to avoid machine idling or overload. • Allocate resources (manpower and materials) to match planned machine capacities. • Balance tasks between multiple production and packing lines to minimize cycle time differences. 5. Coordination with Cross-Functional Teams: • Quality Control (QC): Coordinate QC sampling, analysis, and release of materials and batches to avoid delays. • Production and Packing Teams: Align schedules with department heads to ensure resource availability (e.g., operators, shift plans, changeover times). • Quality Assurance (QA): Ensure IPQA approvals and validations are coordinated with the line schedule to avoid interruptions. 6. Machine Changeovers and Preventive Maintenance Coordination: • Schedule production batches in line with planned maintenance activities to avoid clashes. • Minimize changeover times between batches by optimizing machine cleaning and setup times. 7. Capacity Utilization Tracking and Reporting: • Track and report machine utilization and downtime to identify areas for improvement. • Generate reports on daily output vs. planned production and packing to management. • Maintain data on batch adherence to TAT (Turnaround Time) targets. 8. Deviation Management: • Handle deviations in production schedules due to QC delays, machine breakdowns, or manpower shortages by reworking loading plans. • Communicate critical deviations to management and propose mitigation plans. 9. MIS (Management Information System) and Dashboard Reporting: Key MIS Reports to be Generated: • Daily Production Report: Shift-wise machine loading, batch progress, and QC release status. • Rolling Forecast vs. Production Plan: Track alignment of monthly rolling forecasts against actual production. • Weekly Planning Report: Consolidated report showing machine utilization, pending batches, and deviations. • Monthly Summary: Total batches completed, machine uptime, changeover time analysis, and TAT compliance. • Client Dashboard: Customized reports for clients showing batch status, expected release dates, and shipment timelines. • Deviation and RCA Report: Summary of major deviations during the month with RCA (Root Cause Analysis) and CAPA (Corrective and Preventive Actions). Key Dashboard Metrics: • Production Metrics: • Planned vs. Actual Batch Production • Machine Utilization (%) • Changeover Time (minutes per batch) • QC Metrics: • Sampling and Release TAT (Turnaround Time) • Number of Pending QC Approvals • Packing Metrics: • Packing Line Utilization (%) • Planned vs. Actual Output • Deviation Metrics: • Number of Line Downtimes • Number of QC Holds and Reasons • Client Metrics: • Number of Client Deliverables Met On-Time (%) • Pending Client Approvals Dashboard Formats: • Visual representation: Bar charts for machine utilization, pie charts for deviation categories, and timelines for TAT adherence. • Real-time updates: Link data from the ERP/LIMS system to generate automatic daily updates. • Drill-down options: Ability to view department-specific or batch-specific data for detailed analysis. 10. Regulatory Compliance and Documentation: • Ensure production schedules are compliant with regulatory requirements. • Maintain records of planned vs. actual production for regulatory inspections and internal audits. Key Deliverables: 1. Daily Machine Loading Plans: Detailed loading plan for each shift, including batch allocation. 2. Rolling Forecast vs. Production Plan Reports: Comparison of client forecasts vs. actual production. 3. MIS Reports: A comprehensive set of production, QC, and client reports. 4. Dashboards: Visual, real-time summaries of production and packing status. 5. Deviation Analysis: Root cause analysis reports for any deviations from the production plan. Educational Qualifications for Candidate Selection: • Minimum Qualification: Bachelor’s Degree in Pharmacy (B.Pharm), Engineering (Mechanical, Industrial, or Production), or Science (B.Sc.). • Preferred Qualification: Master’s in Pharmacy (M.Pharm), MBA in Operations, or certification in Production Planning (such as APICS, Lean Six Sigma, or SAP ERP certification). • Experience: • Essential: 5+ years of experience in pharmaceutical manufacturing/CMO operations, specifically in OSD production planning. • Desirable: Experience in handling client coordination for rolling forecasts and managing ERP/MIS-based planning systems. Additional Skills Required: • Proficiency in Excel, ERP systems, and scheduling tools (SAP, Oracle, MES, etc.). • Strong analytical and problem-solving abilities. • Excellent communication skills for cross-functional coordination and client management. • Proficiency in dashboard creation tools (Power BI, Tableau) for MIS reporting. • Strong organizational and multitasking abilities to handle rolling changes in forecasts without compromising deadlines. Show more Show less